Machine Safeguarding. Released. Engaged. ANSI B Part Rev ANSI B Full Rev. Top and side protection

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1 Machine Safeguarding 5 concerns on any machine Point of Operation Safeguarding - guard, device, method Controls - control reliability Disconnect and other LOTO devices Starter - magnetic (drop-out protection) Covers - rotating components covered to (7 feet - OSHA) from floor/working platform (8 feet - ANSI) (10 feet European Stds.) OSHA Rotating Component Covers Emergency-Stop Buttons Red in color One per press minimum Mushroom-shaped Labeled (E-Stop) Readily Accessible Yellow background Manual latch feature Engaged Released Older ones; momentary switch Foot controls shall be protected to prevent operation from falling or moving objects or from unintended operation by accidental stepping onto foot control OSHA (b)(10) Top and side protection ANSI B Part Rev ANSI B Full Rev Follow Ross procedures for Function-testing each both valves and for cleaning or replacing the muffler Keep spare mufflers for brake faults Self-check back to control Dual self-checking Solenoid Air Valve provides (pneumatic) Control Reliability Dual Solenoid Air Valve is by far the easiest to identify indicator of Control Reliability 1

2 OSHA 29 CFR (b)(8)(i) NFPA These Disconnects are lockable only in the OFF position Specific voltage is identified NFPA Center of the grip of operating handle to be no more than 6 7 (2M) above floor, platform, stair or ladder Magnetic-type Motor Starter This is 480 volts and must be transformed down to 120vac to meet NFPA-79 Start Button protected and spring-loaded Electrical REVIEW Disconnect (lockable OFF only) Starter (drop-out protection required) Transformer (120 volt a.c. maximum) Ground (to prevent false operation) Category 0 Stop Control (NFPA 79) ANSI / NFPA Electrical Standard for Industrial Machinery ANSI B11 Standards use this for Electrical Items Point of Operation Safeguarding OSHA (c)(1) Methods of Safeguarding the Point of Operation - General Requirements It shall be the responsibility of the employer to provide and insure the usage of point of operation guards or properly applied and adjusted point of operation devices on every operation performed on a mechanical power press ANSI B Point of Operation Hazards The user shall have the responsibility to provide and ensure that point of operation guards or devices are used, checked, maintained, and where applicable, adjusted on every operation performed on a press production system for every individual exposed to a point of operation hazard ¼ die opening with press at TDC Safe Opening? Hand Feeding Tools are secondary safeguarding only made of soft material to prevent shattering sufficient length and configuration to keep hands outside of hazard area ergonomic design to minimize stress to hand, wrist, arm, and shoulder OSHA (c)(1)(ii) ANSI B OSHA (c)(4) ANSI B hand tools may allow inadvertent entry of hands or fingers into the Point of Operation 2

3 Point of Operation Safeguarding for Mechanical Power Presses Guards prevent - Devices control access to point of operation hazards Guards 1 - die enclosure 2 - fixed 3 - interlocked 4 - adjustable Safe Opening Devices 1 - PSSD Light Curtains 2 - pullbacks 3 - restraints 4 - gates ("A" or "B") 5 - two-hand control 6 - two-hand trip ANSI B OSHA (c)(3) Point of Operation Devices a) Presence Sensing Safeguarding Devices (electro-optical IR light curtains are most common) b) Pullback (Pullout) Device c) Restraint (Holdout) Device d) Two Hand Actuating Devices e) Type A Gate (movable barrier device) f) Type B Gate (movable barrier device) g) Safe Opening Wire covers Ring Guards To Prevent Unintended Operation Double Side Wings Single Side Wings Fabricated Shields Safety Distance: Light Curtain and 2HC rockfordsystems.com 16 Two-Hand Control on a part revolution clutch press To be a SAFEGUARDING DEVICE: Protect from unintended operation, Anti-Repeat, Concurrent ½ sec max, Holding-time, Interrupted-stroke Anchored at Safety Distance, etc. OSHA Safety Distance Formula for a Two-Hand Control or Presence Sensing Device Stopping Time in seconds at 90 CS position x 63 inches per second (hand speed constant) = minimum safety distance in inches.200 x 63 = 12.6 Safety Distance OSHA (c)(3)(vii)(c) and (c)(3)(iii)(e) OSHA (b)(7)(v) ANSI B

4 Portable Stop-Time Measurement Device Meter Sensor Safety Distance Leader Pin Bushing Actuator Separated Die Leader Pins and Bushings are the closest point of operation hazard Function-testing 2-hand Control before every Operating Shift Light Curtain Presence Sensing Devices Prevent initiation if sensing field is obstructed prior to cycle initiation and Stop hazardous motion ANSI B a) and PSSD OSHA (c)(3)(iii) if sensing field is obstructed after cycle initiation Full Revolution Clutch Press with Light Curtain 2-box Light Curtain 3-box Light Curtain PROHIBITED BY OSHA (c)(3)(iii)(a) MPPS top of page 21 4

5 Muting (c)(3)(iii)(d) TDC Bypasses output 360 signal of P.S.D. P.S.D. Active on upstroke on downstroke Muting used for: 1) parts ejection 2) circuit checking 3) material feeding Muting done in timing circuit of press control Crankshaft 270 Rotation P.S.D. Muted on upstroke /4 die opening Channel Blanking on Light Curtains (fixed or floating) Blanking turns off a small portion of the sensing field so an object can block a channel(s) without detection. Blanking is controlled in the light curtain (or its 3rd box) Fixed Blanking must be limited to a small area and be carefully supervised Fixed Blanking Blankers Light Curtain Blankers allow for conveyor Too many Light Curtain Blankers ANSI B MOS Identified... Don t Blank too many Don t Mute too early Don t leave Blanking keys in Light Curtain selectors Unless all the key does is Reset the Light Curtain after being interrupted 5

6 Front-surface mirrors reduce range about 12% 3-sided Light Curtain includes the coil feed ANSI B E Stainless-steel mirrors about 18% - shatterproof Blankers increase Safety Distance One Example Red: obstructed Amber: blanking Green: clear Safety Distance for Light Curtain ANSI B E8.6.3 (16) Safety Distance for a Light Curtain Presence Sensing Device ( ) x = T s press and T c press control T r light curtain (tag or flag) T bm added for brake monitor K hand speed constant D pf penetration depth factor Ds = K (Ts + Tc + Tr + Tbm) + Dpf D s Minimum Safety Distance Safety Distance for Presence Sensing Devices BSP: mount light curtain far enough so it protects all tooling set-ups using largest die as reference point Check stopping time before installing light curtain and on a periodic and regular basis thereafter ANSI B A stopping performance test of the press shall be made a part of the periodic inspection and maintenance program. STM FLAG NOT interrupting Light Curtain STM FLAG interrupting Light Curtain 6

7 Safety Distance for vertical Light Curtain is measured from the separated Die Leader Pins and Bushings Light Curtains see nothing below the dotted lines Bushing Leader Pin Light Curtains should be only be installed, checked out, and maintained by a Qualified Person a person or persons who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work. ANSI B Point of Operation Guards used with: Continuous (walk-away - unattended) Continuous (maintained - attended) Continuous on Demand Automatic Single Stroke Single Stroke (strip feeding) Light Curtain Function Testing Procedure ANSI B Guards and devices must be checked... Point of Operation Guard Requirements OSHA and ANSI ANSI OSHA (c)(2) and ANSI B (8)(5) can t reach through, over, under, around meets Table 0-10 for openings and distances no pinch points between guard & moving parts good visibility into the point of operation fasteners not readily removable (tool required) *materials strong enough to protect people *free from sharp edges that could injure people Point of Operation Guard on OBI Mechanical Power Press O.U.T.A. Over, Under, Around, Through? 7

8 ANSI B Figure C.8 Location of Guard Openings and Distances is similar to this but is based on a smaller hand size OSHA TABLE 0-10 Liberty Mutual & ANSI Standard writing committee OSHA Guard Opening Scale Front: American measurements Back is blank Back: Metric measurements Front: American measurements A guard opening scale can be used to measure guard openings and distances from the P.O.O. ANSI Guard Opening Scale Liberty Mutual & ANSI Standard writing committee Guard Opening Scale Comparison OSHA ANSI OSHA s Four Categories of Point of Operation Guards on Mechanical Power Presses (ii) Die Enclosure OSHA ANSI (iii) Fixed (iv)(v) Interlocked (vi) Adjustable ANSI B OSHA (c)(2)(ii) ANSI B OSHA (c)(2)(iii) Die Enclosure becomes part of one specific die Fixed may have openings but not adjustable 8

9 ANSI B , OSHA (c)(2)(iv)(v) ANSI B OSHA (c)(2)(vi) Interlocked prevents or stops motion when opened Adjustable allows for a variety of material sizes What does OSHA say about hinged/movable guard sections? Hold shut with a fastener that requires a tool OR Use an electrical interlock no specific type What does ANSI say about hinged/movable guard sections? Must have electrical interlock for that section using Up-to-date technology for Best Safety Practice Simple Guard Interlock Switches can be easily defeated (cheated) Newer Guard Interlock Switches KEY geometry makes it difficult to defeat KEY forces a make/break of electrical contacts Guard Closed Guard Open KEY Interlock Switch KEY Part-Revolution Mechanical Press Interlocked Guard 9

10 SICK Incorporated Safety Interlocks Defeating Electrical Interlocks Taping down (spring-loaded) actuator Wiring down the (spring-loaded) actuator Removing actuator from the guard and connecting it to switch (with wire or tape) Internally tampering with the actuator itself Jumpering-out interlock inside control box Function Testing Point of operation Guard 2 Reasons to Function-test Guard Interlocks: 1) to make sure the interlock WORKS 2) to make sure it has NOT been CHEATED EN Safety Related Parts of Control Systems Category B Category 1 Category 2 Category 3 Category 4 safety-related parts of machine and safeguards components withstand environment well tried safety components and principles components monitored before machine start-up and periodically dual/monitored system of critical components single fault does not lead to loss of safety function dual/monitored system with all foreseeable faults detected DETECTION of faults PREVENTION of faults Latching Interlocked Guard with a latching motion sensor Request for access button is pushed - Safety relay then looks for motion or time-out. Guard can be opened when solenoid inside the switch is energized. Expanded Metal Guarding with Black Mesh for visibility 10

11 Yellow T-Slot Covers (ANSI Z535.1 Color Coding) Guard over the in-going feed rolls Side Window Guard 3 reasons for Combo: Impact Noise Coolant Guard / Light Curtain Combination NHID to Lubricate Materials & Dies Aluminum tool prying stuck piece from die The user shall furnish and enforce the use of hand tools for freeing and removing material workpieces, or scrap stuck in the die OSHA (d)(1)(ii) ANSI B Manual Strip Lubrication Spray Bottle Lubrication OSHA(d)(9)(5) ANSI B Automated Coil Lubrication Separated Leader Pins and Bushings - POO Hazard Die Set Shield Leader Pin Bushing Guide Posts (Leader Pins) OSHA (d)(4) ANSI B Telescopic SS Sleeve Bushing Leader Pin ANSI B similar pinch points between the slide or dies... shall be considered the same as a point of operation hazard for safeguarding Pinch Point Point of Operation OSHA (d)(5) Unitized Tooling Two possible ways to eliminate this POO hazard 11

12 Die Identification OSHA (d)(6) Tonnage, Stroke, Weight Designation Stamped or records available: TONNAGE and STROKE Stamped: UPPER die weight Stamped: COMPLETE die weight ANSI B adds Shut Height to this list (SDAU) (measured at press stroke DOWN slide adjustment UP) Press Tonnage Press Stroke Upper Die Weight Complete Die Weight Stem can break or work loose from ram Bolts through ears of ram Punch Stem Slide Cavity Clamp Cap Additional means to support upper die shoe for dies with punch stems and clamp caps ANSI B b) OSHA (d)(7) Safe Die Handling Die Change Lift Table Ergonomics OSHA (d)(9) Die Setting ANSI B Procedures Material Handling Risk of Strain Injuries is very high 12

13 Die Handling ANSI B ) Employer shall provide die stops or other means to prevent losing control of the die while setting dies into or removing dies in presses which are inclined OSHA (d)(9)(iii) Die Setting Light Curtain on hinged mount for easier die changes Tail-out Guard Turnover Bars ANSI B OSHA (d)(9)(ii)... provide means to ensure removal of the turnover bar... Awareness Barriers a) spring-action on bar b) interlocked storage pocket for the bar c) interlock on the barring slot cover Safety Blocks OSHA (d)(9)(iv) for dies being adjusted or repaired while in the press ANSI B : Die adjustment, cleaning, repair...while die is in the press and hands or other body parts are in point of operation for repair or for adjustment and cleaning not integral to the production process, provide means to prevent initiation of hazardous movements... Safety Blocks or other slide/die support means to either: a)... hold full working force... via built-in Slide Locks Interlocked Safety Block b)... be interlocked... hold maximum anticipated load 13

14 Either of these take up the space above the Safety Block Octagon-shaped Safety Blocks Adjustable Screw-Jack Triangular Wedges Adjustable Interlocked Safety Block on hinged retractable arm Interlocked Safety block on hinged arm OSHA (e)(1)(i) ANSI B Periodic and Regular Inspection of MPP Quarterly? Monthly? or according to press usage Applies to ALL presses - no exceptions What to inspect: All press parts - Auxiliary Equipment - Safeguards Hinged Interlocked Safety Block What to document: Date of inspection Signature of Inspector Press Serial Number OSHA (e)(1)(i) Periodic + Regular Inspections for MPP Weekly Press Inspections OSHA (e)(1)(ii) (ALL Full Revolution Presses require weekly inspections) What to Inspect: Clutch / Brake Mechanism Anti-repeat feature FR or PR Single Stroke Mechanism (or Single Stroke Trip System) FR or PR FR only List Press Auxiliary Equipment here Exception: What to Certify: PR Press with (b)(13) and (b)(14) (Control Reliability & Brake Monitoring) Date of Inspection Signature of Inspector Press or serial number 14

15 Training OSHA (e)(3),(f)(2) employer must train those who care for - inspect - maintain operate mechanical power presses ANSI B Training Requirements All associated with press production systems Operators, Die Setters, Maintenance, Supervisors. Training must include Lockout/Tagout Reporting Injuries on mechanical power presses OSHA (g) POINT OF OPERATION INJURIES requiring more than simple first aid must be reported to State or Federal OSHA within 30 days of occurrence Reporting Point of Operation Injuries (i) employer's name, address, location of workplace (ii) employee's name, injury sustained, task being performed (operation, setup, maintenance) (iii) type of clutch used on the press, (full, part, direct) (iv) type of safeguard being used on the press (v) cause of the accident (e.g. repeat, no safeguard) (vi) type of feeding (manual, automatic, HID, HOOD) (vii) means used to actuate press stroke (hand, foot) (viii) number of operators required and number provided with controls and safeguards American National Standard ANSI B Hydraulic and Pneumatic Power Presses OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards; (fixed, adjustable, interlocked), Presence-sensing devices, Pullbacks, Restraints, Two-hand trip, Two-hand control, Type-A gates, Type-B gates, Safe Opening Hydraulic Press with Light Curtain, two-hand control, and side barriers PSDI Control Light Curtain and side barriers swung open Hydraulic Presses 15

16 Hydraulic Press American National Standard ANSI B Power Press Brakes Slide Up Button Hydraulic Pressure Gauge NO ROTATING components (flywheels, gears, crankshafts, sprockets) ALL LINEAR motion instead OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards; (fixed, adjustable, interlocked), Type-A gates, Type-B gates, Presence-sensing devices, Pullbacks, Restraints, Two-hand control, Single control (hand or foot), Safe Distance Press Brake Tooling Press Brake Safeguarding ANSI B (guards) and 8.7 (devices) 8.6 Guards (fixed, adjustable, interlocked) Movable Barriers (A or B type Gates) Light Curtain or Radio Frequency Pullback Restraint Two-Hand Control Single Control (hand or foot) Close proximity POO AOPD (laser) 8.8 Safe Speed Safeguarding 8.9 Distance (six conditions) Light Curtain bending operation on a Mechanical Press Brake Overhead Restraint - large part 16

17 Robotically-fed Press Brake with Perimeter Light Curtain Down-acting Hydraulic Press Brake with Light Curtain Up-acting Hydraulic Press Brake with Light Curtain Interlocked Perimeter Guard Press Brake Safeguarding 2-hand down / foot-through sequence (hand supports piecepart - safe opening ) 2-hand single-stroke (fixture piecepart mechanically, magnetically, vacuum) 2-hand down / 2-hand through sequence (requires piecepart fixturing) Foot switch single stroke (safeguarding: light curtain, pullback, restraint Foot down / foot-through sequence (with light curtain, pullback, restraint) Two-hand down Foot- through Sequence Blanking required No Blanking required Foot-down Foot-through Sequence with Light Curtain Small Part Feed line height Can reach over or under LC Feed line height adjustable height table Can t reach over or under LC 17

18 3-sided Light Curtain on Hydraulic Press Brake Muting Light Curtain ignores the changing profile of a workpiece as it bends up through the sensing field Feed line height ANSI B Light Curtain mutes just before upper die touches the workpiece Laser Safeguarding Devices for Hydraulic Press-Brakes AKAS III - Fiessler Electronik - (Bystronic PB s) Laser Device hand-holding small parts BendGuard - (Trumpf Tru-Bend PB s) Laser Sentry - Metal Tech Controls V SICK Automation Lazer Safe - Rockford Systems LLC Laser Beam - Zakron DSF ANSI B Close Proximity Point-of-Operation AOPD Active Optical Protective Devices Laser Device for parts with tall side-legs LazerSafe Safeguarding System for Hydraulic Press Brakes Close Proximity Point-of-Operation Active-Optical Protective Device (AOPD) LazerSafe for Hydraulic PB s is mounted at ZERO Safety Distance 18

19 Safe Speed Safeguarding ANSI B This method of safeguarding only applies to bending operations on press brake production systems... acceptable when the following conditions are met: a) Safe speed is a ram speed of 10mm/sec (0.39 inches/second) or less... using a three-position hold-to-run control b) If a press brake is capable of exceeding this speed, one of the following methods of monitoring is required... i) if the control of safe speed is through non-variable means, then continuous monitoring of the control devices is required ii) if the control of safe speed is through the use of variable parameters, then continuous monitoring of the speed of the ram is required. A stop shall occur if the safe speed is exceeded. Two-Hand Control and up/down foot switches but no Light Curtain Two-Hand Control Two Foot Switches Mechanical Press Brake with Type-B Gate Device Guidelines for P.O.O. Guarding on Press Brakes OSHA Instruction CPL Feb. 14, 1997 D5... safeguarding by maintaining a safe distance from the point of operation may be acceptable but only when safeguarding by physical barriers/devices is not feasible... D6b... limited to one-time only fabrication of made-to-order or custom-made piece parts... applies to small quantity runs in a job shop or model shop... meaning more than one of the same piecepart over a continuous timeframe of no more than four hours per month... D6c... employer has a safety program including safe work procedures, training, and supervision... D6d... employer has a workplace history of operating power press brakes safely by maintaining safe distance... E... employer must have and be prepared to demonstrate to OSHA an effective program... which includes exposure prevention procedures and training/enforcement of these procedures... D7... Operator and Helpers must not approach closer than 4 inches to the P.O.O. measured from the exterior point of contact of the power press brake die closest to the employee... Shields help prevent access to pinch points Unitized Tooling 19

20 OK Backs of two Press Brakes Grab-wire E-stop Cables Danger Signs Not OK Both with Awareness Barriers Interlocked Guards on the backs of Press Brakes American National Standard ANSI B Shears OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards; (fixed, adjustable, interlocked), Presence-sensing devices, Pullbacks, Twohand control, Single control (hand or foot), Awareness devices, barriers, signals, signs, gap (throat) guard Older shears are usually mechanical with either full or part revolution clutch Newer shears are often hydraulic. Most shears are actuated with foot control Rotating Component Covers Point-of-Operation (Comb) Guard Hold-down Guards Spring-returned Foot Treadle Throat-gap Guard Full Rev Shear When shears are used for single-stroke, they shall incorporated an anti-repeat feature 2 3 Point of Operation Hazards on Shears: 1. Shear Blade 2. Hold Downs 3. Hand Slot 3 1 Pinch-point 20

21 Awareness Barrier Rings HAND-TOOLS and TRAINING for small part placement Three-sided Interlocked Guard on back of a Shears American National Standard ANSI B (R07) Manual Turning Machines OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards; (fixed, movable, interlocked), Presence-sensing devices, Two-hand control, Awareness barriers and devices, Chip/coolant shields Manual Engine Lathe #1 Hazard - starting lathe with key in chuck Spring Loaded Chuck-Wrench 330,000 Manual Metalcutting Lathes in USA to prevent wrench from being left in chuck 21

22 Edge Lip Boot Tray GUARDS prevent intentional entry into hazardous areas SHIELDS prevent inadvertent entry into hazardous areas Hazard Exposure? Hinged Lexan Chuck Shield Interlock built-in to the hinged mounting bracket Boot Tray Hinged Lexan Chuck Shields Hinged Steel Chuck Shields Chip/Coolant Hazards Chips/coolant shall be controlled from being thrown or splashed onto operator, aisle, or assigned work area using a SHIELD or other means 22

23 Kick-Plate coast-down brake Telescopic stainless-steel sleeves cover horizontal rotating components American National Standard ANSI B (R07) Drilling Milling Boring Manual machines with or without Automatic Control OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards; (fixed, movable, interlocked), Presence-sensing devices, Two-hand control, Awareness barriers and devices, Chip/coolant shields Unsafe Practice Spring-loaded Chuck Keys Down position Releasing and Lifting Telescopic Chuck Shield Movable Guards shall provide access to hazard areas without the use of tools Universal swing-away Shields One section locked up Up position 23

24 Interlocked Chip Shield Magnetic Shield Universal Swing-away Shield knocks down chips and coolant Reversing Magnetic Motor Starter with Cat 0 Stop Control Updated Electrical Point of operation Shield Vise must be anchored to table on drills and mills Chip containment Shield Grinder Safety If rotating wheel breaks, fragments can hit Operator Ring Test Wheels before mounting and carefully follow mounting procedures OSHA (9)(d)(i) requires Ring-Testing ANSI B has same procedures Never adjust work-rest with wheel in motion Grinding Wheel Handling Storage 24

25 ANSI B Abrasive Wheels ANSI B Grinding Machines 1/4 maximum opening Tongue Guard to wheel /4 Work Rest Direction Arrow Self-closing Guard Floor Standing 24 or larger wheels 1/8 maximum opening for Work Rest #1 OSHA Machine Safeguarding violation-every state in the U.S.A. ANSI B OSHA (a)(4) 1/8 Tongue Guard Rotating shaft hazard Belt-Sanding/Grinding Polishing Wheels Scotchbrite soft Wheels Shields Rubber cap over end nut 4 not mentioned OSHA Polishing Wheels Soft Grinding Wheels Scratch (Wire) Brushes Sanders Face-Sanding/Grinding Metalcutting Saws ANSI B Band Saws: horizontal and vertical (moving frame or moving table) Circular Saws: vertical, horizontal, swing, chop, radial Hack Saws: vertical and horizontal OEM Blade Guards 25

26 Needs blade guard under table Unused portion of the Saw Blade is exposed User-fabricated Blade Guard replaces original Lower Blade Guard to table when not in use Blade must also be guarded UNDER the table Band Saw Shield Universal Swing-Away Chip Shield American National Standard ANSI B Rollformers & Rollbenders OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards; (fixed, adjustable, interlocked), Presence sensing devices, Two-hand control, Awareness barriers, devices, signals, Safe work practices Guards on a long Rollforming Line 26

27 Grab-wire E-stop Cable Rollformer Point of Operation Guards Rollformer Sectional Guarding Bradbury Co. - Moundridge, KS Light Curtains on Rollformers Awareness Barrier Chains on Rollformers Rollbenders ANSI B rolls that form sheet or plate into a circular shape Common on Rollbenders: E-Stop Devices such as: cable, kick plate, body bar, button Hold-to-run foot switch Pendant with 2-hand control Personal protective equipment Additional Safety can be provided by: Operator Training, Safe Work Practices Warning Signs, Color Coding 3-Roll (Pyramid) Roll Bender 27

28 E-Stop cable 3-Roll Bender Point of Operation Guard Grab-wire E-stop Cable FMA s Journal of the Fabricator Precision Rollbending Three-roll Plate Bender Wind Towers Courtesy of ROUNDO Legs are made on Three-roll benders Emergency Stop shall not be used as an alternative for proper safeguarding Two-hand Control on floor pedestal L-shaped Mats on a Tube Bender 28

29 Tube Bender with AB Railings and Mats Horizontal Tube Bender with Area Laser Scanner American National Standard ANSI B Performance Criteria for Safeguarding Safe Operator Location OSHA General Requirements for All Machines OSHA Mechanical Power Transmission Apparatus NFPA Electrical Standard for Industrial Machinery Point of Operation Safeguarding: Guards (all types), Devices (all types), Distance (Safe holding), Operator location, Safe Opening Coil Slitting Lines Light Curtain Presence Sensing Devices can only be used on machines that can stop consistently and immediately anywhere in their stroke or cycle without damaging: machine - tooling work or creating another hazard Point of Operation Perimeter (Area) Point of Operation Light Curtain for Hand and Finger protection Perimeter Light Curtain for Torso protection Light Curtains on Cardboard box corrugator 29

30 Manual Gate and Two-hand Control Perimeter Light Curtains Light Curtain and a Manual Gate Light Curtain and Two-hand Control Two for One Light Beams 200 Range 2-sided Perimeter Light Curtain Railings protect the Light Beams and Mirrors Two Light Beams with corner mirrors for three-sided protection Safeguarding of Personnel & Equipment Welding robot cells Automatic assembly machines Packaging machines Tire Manufacturing Forklifts, Towmotors, Lift Trucks Tube-bending machines Press/bolster guarding Automatic Storage & Retrieval Systems (ASRS) Complex material handling processes Shrink-wrap machines Palletizing robots ANSI / ASME B Guided Industrial Vehicles Carton-making machines Automatically Guided Vehicles (AGV s) General safety mat replacement Area Laser Scanner SICK Incorporated 30

31 Mat Function Indicators ANSI B Large enough No sneak between Anchored to floor Capable of being supervised Pressure-sensitive Mats YES Pressure-sensitive Mats and Perimeter Guard - CNC Turret Punching Machine NO Radio Frequency Antenna capacitive PSSD s with adjustable sensitivity Mats must be fastened to floor to prevent moving them too close to the hazard area Drop-Probe Devices Ring-drop Devices Halo Devices ANSI B Also see ANSI B Rivet Setting Equipment The probe detection device shall not, in or of itself, create a hazard Mechanically verifies the absence of hand or fingers in Point of Operation Riveters, Spot Welders, Staplers, Stakers Eyeletters, Terminators, Dinkers, Clickers Riveters with Drop-Probes 31

32 Drop Probe Device on a Spot Welder Stack Lights Light Curtain and Two- hand Control Drop distance must be carefully monitored Different probes for different parts? - possibly Probe moves quickly - excellent productivity Visual or Audible Awareness Signals ANSI B NFPA Machine Indicator Lights Red Danger Blue Action Green Safe Yellow Warning Rope Pull Cable type of E-Stop requires reset when tripped Latching Pull-switch Cable runs longer than 20 may need a switch on BOTH ends 90 Grab-wire E-stop cable Cross-over Stairs with Grab-wire E-stop cable Laser Cutting Center Telescopic Antenna Safety Trip Switch reprinted with permission Scientific Technologies Inc. Laser Standards *American National Standards Institute (ANSI Z136) (applies to the use of lasers) American National Standards Institute (ANSI B11.21) (Machine Tools Using Lasers) State Standards in: Alaska, Arizona, Arkansas, California, Florida, Georgia, Illinois, Massachusetts, New York, Ohio, Texas, Washington 32

33 Machine Tools using Lasers ANSI B Protection during operation Laser Radiation Safeguarding One or more guards (or safeguarding like floor mats or light curtains) shall prevent human exposure during operation to levels of laser radiation higher than the MPE Maximum Permissible Exposure as determined by Laser Safety Officer A hazard analysis shall be performed to determine which type of safeguarding shall be used. Local protection vs. Peripheral protection ANSI B11.21 Machine Tools using Lasers for processing materials - REVIEW Local vs. Peripheral protection Presence sensing devices Interlocked Doors Hold-to-run controls PPE (Eyewear is critical) Laser Safety Officer per ANSI Z136 (Rockwell Laser Industries) Laser Institute of America VTL s CNC Lathe with sliding interlocked door Always stand off to SIDE running high RPM Vertical Turret Lathes with semi-circular Guard Rails Interlocked Enclosure Guards Fasteners Removed Interlock Cheated 33

34 Door Interlock is ON - Key is removed while machine is running a piecepart Danger and Warning Signs 34