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Safety by design: Hard Guarding

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How and why to assess risks, identify hazards, design, fabricate and install hard guarding. (Bosch Rexroth) Drive for Technology 2010 presentation

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Safety by design: Hard Guarding

  1. 1. SAFETY BY DESIGN HARD GUARDING BOSCH REXROTH PAUL KOZICZYNSKI
  2. 2. Safety by Design – Hard Guarding  Agenda  Why Guard? y  Guarding Process  Question 2
  3. 3. Why Guard?  Adhere to laws  OSHA 1910.212 (a)(3)(iii) ( )( )( )  The point of operation of machines whose operation exposes an employee to injury, shall be guarded. 3
  4. 4. Why Guard? 4
  5. 5. Why Guard?  Questions to ask yourself  Would you be comfortable working on this equipment?  What if someone I cared about was working on this machine?  Typical Excuses  “Someone would have to be stupid to stick their hand in there!” Someone there! 5
  6. 6. Guarding Process  Risk Assessment  Design g  Fabricate  Install  Risk Assessment 6
  7. 7. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Identify Hazards  Identify every hazard on the machine  Hard Guards • Visible Hazards – Cutting g – Pressing – Crushing – Shearingg – Flying Objects  ANSI Standards • Specific to type of machine 7
  8. 8. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Assign a risk level  High Risk • High Probability • High Cost – Redundant ( hard and soft guarding ) – Redundant controls – Constant monitoring  Low Risk • Less Likely • Not as tragic – Single Solution g – Cost Effective Solution 8
  9. 9. Risk Assessment - Design - Fabricate - Install - Risk Assessment Hard Guarding - General Applications  Fixed Point guards  Machine guards (4’x4’ panels & smaller), removable panels, doors - 30x30  Larger guards (panels larger than 4’x4’), freestanding guards, guard/frame combinations - 45x45 & larger  Perimeter guards - EcoSafe or 45x45 & larger 9
  10. 10. Risk Assessment - Design - Fabricate - Install - Risk Assessment Hard Guarding – Fixed Point/Machine Guarding  Fixed Point/Machine guards  Permanent part of the machine  Not dependent upon moving parts to perform its intended function  Constructed of sheet metal, screen, wire cloth, bars plastic or other substantial material  Usually preferable to all other types because of its relative simplicity and permanence 10
  11. 11. Risk Assessment - Design - Fabricate - Install - Risk Assessment Hard Guarding – Fixed Point/Machine Guarding  Fixed Point/Machine guards  On the machine  Integrated into the process  Stand alone automation  Types  Very small to very large  Barriers from Mesh to Glass  Require Access  For Production  For Maintenance  Space and Function 11
  12. 12. Risk Assessment - Design - Fabricate - Install - Risk Assessment Hard Guarding – Fixed Point/Machine Guarding  Fixed Point/Machine guards  How do I design a guard?  Focus on framing solution 12
  13. 13. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels - Connector  Connector - Connection Screw  M12x30, M8x25, M6x16 - self tapping  M12x30 standard screw  M16x100 standard screw  Advantages g  Does not obscure the t-slot. No need to trim panels to fit around connector.  Inexpensive (especially self tapping versions)  Torx head version available  Disadvantage  Machining required  Not easy to reconfigure 13
  14. 14. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels - Connector  Connector - Inside to Inside/Outside Gussets  For 8mm and 10mm t-slots  Advantages  Does not obscure the t-slot. No need to trim panels to fit around connector.  No machining required  Easy to reconfigure  Disadvantages  Not as strong as the connection screw 14
  15. 15. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels - Inserts  Panel Suppo t Inserts - Hold pa e s a e Support se ts o d panels in position in t-slot.  For 6mm, 8mm, 10mm t-slots  Advantages  Accommodate a variety of panel widths  Prevent “panel rattle”  Heavy duty panel support available for 6mm (nominal 1/4”) panels l  Disadvantages  Di Disassembly required t bl i d to change panels 15
  16. 16. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels - Inserts  Removable Panel Support Inserts - H ld panels i position. Hold l in iti  For 8mm and 10mm t-slots  Ad t Advantages  Accommodate a variety of panel widths  Prevent “panel rattle” panel rattle  Panels may be removed without disassembly  Panels may be installed after frame/guard assembly is complete  Disadvantages  Glazing strip splits after repeated removal 16
  17. 17. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels - Inserts  Flush Mount Removable Panel Suppo t Inserts - us ou t e o ab e a e Support se ts Hold panels in position.  For 8mm and 10mm t-slots  Advantages  Suitable for clean room applications  Accommodate a variety of panel widths y p  Prevent “panel rattle”  Removed without disassembly  Installed after frame/guard assembly g y completed  Disadvantages  For 45 & 90 Series 17
  18. 18. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels – Glazing Strips  Glazing Strip - Hold panels in position.  For 6mm, 8mm and 10mm t-slots  Advantages  Easy installation  Prevents panel rattle p  Inexpensive  Disadvantages g  None 18
  19. 19. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Panels – Panel Clips  Variofix Panel Mounting Fasteners g  For 8mm and 10mm t-slots  Advantages g  Accommodate a variety of panel widths  Prevent “panel rattle”  Panels may be removed without disassembly  Panels may be installed after frame/guard assembly is complete  Available in version without plastic clips p p  Extremely fast installation  Nut provided for OSHA “compliance”  Disadvantage  Leaves gap around panel 19
  20. 20. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Wire Mesh – Frame Profile  Wire Mesh Frame and Corner Connectors  For 10mm t-slot  May be mounted to the side of 6mm and 8mm t-slots  Advantages  Deep se ated s ot holds wire mesh e e eep serrated slot o ds e es even when panels are large  Inside and Outside Corners accommodate odd panel shapes  May be used for removable panels  Disadvantage  None 20
  21. 21. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards with Wire Mesh - Accessories  Clamp Bushing  For 8mm or 10mm t-slots  Advantages  Use only number necessary for application  Can install after frame/guard assembly  Inexpensive  Independent of wire mesh gage 21
  22. 22. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Swinging Doors  Hinges  For 6mm, 8mm, and 10mm (20 series, 30series, 40 series, 45 series, 50 series, and 60 series profiles)  Advantage  All hinges have alignment tabs (for 8mm and 10mm t-slots, tab orientation is done by the customer)  Packaged in pairs with appropriate hardware  Hinge hasp sized to profile 22
  23. 23. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Swinging Doors  Clean Room Hinges  For 6mm, 8mm, and 10mm (20 series, 30series, 40 series, 45 series, 50 series, and 60 series profiles)  Ad t Advantages  Hinges have alignment tabs  Packaged in pairs with appropriate hardware 23
  24. 24. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Swinging Doors  Lift-Off Hinges  For 8mm, and 10mm (30 series, 45 series, and 60 series profiles) p )  Advantages  All hinges have alignment tabs g g  Packaged in pairs with appropriate hardware  Can be reconfigured for 4 hinge mounting options  Disadvantages  • Not available for 40/50 Series 24
  25. 25. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Swinging Doors, EcoSafe  Hinge Lift Off Hinge, Lift-Off  For 45x45 profiles used with EcoSafe profiles  Advantages  Adjustability  High strength T Block mounting strength, T-Block  Disadvantages  Mounts with T blocks 25
  26. 26. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Sliding Doors  Aluminum Sliding Door Guide Profile g  Available for 8mm and 10mm t-slots (aluminum for 10mm only)  Advantages  Available in either aluminum structural version or polypropylene snap-in version i  Lift out door possible with insert  Panel spacer available to eliminate rattle  End Stops and End Caps available  Disadvantages  Aluminum version must be milled to make a butt joint 26
  27. 27. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Guillotine Doors  Counterbalance  Designed for use with 45x45 profile  Advantages  No springs  Simple, robust mechanics p ,  Disadvantage  Counterweight not supplied g pp 27
  28. 28. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Folding Doors  Folding Door Kit  For 8mm and 10mm t-slots  Advantages  Guide pin position selectable on assembly  50k cycle lifetime  Use on 30, 40, and 45 Series 28
  29. 29. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guarding Accessories - Folding Doors  Universal Ball Detent Latch  For 10mm t-slots MMounts t 40 45 and 50 series profiles t to 40, 45, d i fil  Advantages  Cl Clean d i design  Ease of installation 29
  30. 30. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guarding Accessories - Folding Doors  Detent Latch  For 6, 8, and 10mm t-slots  Mounts directly to door material  Advantages  Clean design  Ease of installation  Clean room suitable 30
  31. 31. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guarding Accessories - Folding Doors  Magnetic Latch g  For 6, 8, and 10mm t-slots  Mounts directly to door material  Advantages  Clean design  Ease of installation  20 & 40N versions available  Clean room suitable 31
  32. 32. Risk Assessment - Design - Fabricate - Install - Risk Assessment Door Accessories - Locks  Locks for Swinging or Sliding Doors  For 30 series and 45 series profiles  Advantages  One lock for either sliding or swinging doors  Left and right hand locks available  Disadvantages  Single key for multiple units not possible 32
  33. 33. Risk Assessment - Design - Fabricate - Install - Risk Assessment Door Accessories - Locks  Compact Lock  For 40 series and 45 series profiles  Advantages  One lock for either sliding or swinging doors  Left and right hand locks available  Heavy steel construction  Low profile  Universal key version available  Disadvantages 33
  34. 34. Risk Assessment - Design - Fabricate - Install - Risk Assessment Door Accessories - Locks  Locks for Heavy Swinging Doors  For 45x45 profile  Advantages  Esthetically pleasing  Mechanism reversible for left or right hand g doors  Disadvantages  Milling required to install  Lock barrel not supplied  Relatively expensive 34
  35. 35. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guard Access - Removable Panels  Removable Frame Brackets  For 8mm or 10mm t-slots  Ad t Advantages  Locks panel in position with screws for OSHA compliance  Panel remains hanging when screws are removed 35
  36. 36. Risk Assessment - Design - Fabricate - Install - Risk Assessment Guards - Floor to Guard Elements  Base Plates Floor Guard Foot Anchor Bolts  Foot Plates Foundation Brackets  Leveling Feet 36
  37. 37. Risk Assessment - Design - Fabricate - Install - Risk Assessment Door Accessories - Other  Handles  For 6mm, 8mm, and 10mm t-slots  Strap and Bar types available  Stops  For 8mm and 10mm t-slots  Latches  For 6mm, 8mm, 10mm t-slots  Handle Adapter, EcoSafe 37
  38. 38. Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding  Perimeter Guarding g  Automated Process  Stand Alone – not mounted to machine  Limited Access during production  Large in Size  Integrated 38
  39. 39. Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding - Ecosafe Guarding System The especially economical p y protective barrier system only a few items to order standard and custom sizes immediately deliverable pre-constructed assemblies EcoSafe panels EcoSafe suspension bracket EcoSafe door frame quick installation accessories for sliding doors. rigid wire mesh attachment easily reconfigured universal fastening t-slot attractive design EcoSafe Door locks Wire mesh handle Footplate Hinges profiles adapter 39
  40. 40. ECOSAFE GUARDING BENEFITS Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding - Ecosafe Guarding System  PRECISION ENGINEERED  Strength • Maximum engagement of extrusion profile • Publish technical data  Appearance • Clean smooth aluminum finish • Rugged and industrial 40
  41. 41. Guards - EcoSafe  Pre-Assembled Support Posts  2000mm or custom 350mm to 2300mm  Available in 45x45 or 45x90 support pp 41
  42. 42. Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding - Ecosafe Guarding Benefits  EASY INSTALLATION  Easy to align and pre-install posts pre install • Installs ON SITE in less than 1/2 the time • Easy to re-configure & modify 42
  43. 43. Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding - Ecosafe Guarding System  Hook -n- Hang brackets  Hook -n- hang concept • Easy installation y • Easy removal • Multi-angle 43
  44. 44. ECOSAFE GUARDING BENEFITS Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding – Ecosafe Guarding System  FLEXIBILITY  Works for all types of configurations – Straight runs – Angled corners  Custom panel options available – Lexan – Other 44
  45. 45. Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding – EcoSafe Guarding System  Sliding Door Kit with Overhead Trolley  Available in 1000mm & 1500mm widths  No trip hazard at bottom of door  Mounts on standard Support Posts  Easy sliding Delrin® bearings  V-block stop 45
  46. 46. Risk Assessment - Design - Fabricate - Install - Risk Assessment Perimeter Guarding – EcoSafe Guarding System  Sliding Door Kit with Lower Roller Guide  Available in 1000mm & 1500mm widths  No overhead guide to obstruct fork trucks  No trip hazard at bottom of door  Mounts on standard Support Posts  Easy sliding Delrin® bearings  V-block stop 46
  47. 47. ECOSAFE GUARDING
  48. 48. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Design (Hard Guarding)  Internal Capabilities • Evaluate Competence • Evaluate Resources • Determine Costs  External Resources at CMA/Flodyne/Hydradyne 48
  49. 49. Risk Assessment - Design - Fabricate - Install - Risk Assessment  External Resources: CMA/ Flodyne/Hydradyne  Design • Dedicated Engineering – Turnkey solutions » From Drawings » On-site measurements » CAD Capabilities  Integrated Solutions g • Hard and Soft Guarding Solutions 49
  50. 50. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Fabrication (Hard Guarding)  Frame Material • Aluminum Profile  Fabrication Required • Cut • Machine  Equipment Required q p q • Saw • Machining Center (drill, tap, mill etc.) 50
  51. 51. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Fabrication (Hard Guarding)  Barrier Material • Wire Mesh • Pl i l Plexiglass or E i l t Equivalent – Clear, Smoked • Aluminum and sheet metal • Glass  Fabrication Required • Cut • Machine holes  Equipment Required • Panel Saw and Shear • Drill 51
  52. 52. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Fabrication (Hard Guarding)  Internal Capabilities • Evaluate Competence • Evaluate Equipment • Determine Costs  External Resources at CMA/Flodyne/Hydradyne 52
  53. 53. Risk Assessment - Design - Fabricate - Install - Risk Assessment  External Resources: CMA/ Flodyne/Hydradyne  Fabrication • Dedicated Assembly Team • Framing Machining Fabrication – Cutting – Drilling g – Tapping • Barrier Fabrication – Shearing Mesh – Panel Saw for Plexiglass  Integrated Solutions • Hard and Soft Guarding Solutions 53
  54. 54. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Installation (Hard Guarding)  Internal Capabilities • Evaluate Competence • Evaluate Equipment • Determine Costs  External Resources at CMA/Flodyne/Hydradyne 54
  55. 55. Risk Assessment - Design - Fabricate - Install - Risk Assessment  External Resources: CMA/ Flodyne/ Hydradyne  Installation • Dedicated Installation Team • Multiple levels of service – Raw Material – Kits – Turnkey solutions • On-site Installation  Integrated Solutions • Hard and Soft Guarding Solutions 55
  56. 56. Risk Assessment - Design - Fabricate - Install - Risk Assessment  Did you eliminate the identified hazards?  Evaluate the new guarding  Document Completion p  Identify New Hazards  Were new hazards created?  Repeat process as necessary 56
  57. 57. APPLICATIONS 57
  58. 58. APPLICATIONS 58
  59. 59. APPLICATIONS 59

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