FORD U-KZ003X-1987 MACHINE AND EQUIPMENT GUARDS DESIGN AND REFERENCE DATA《机器和设备护罩的设计和参考数据》.pdf

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1、* This document has been reproduced from the best hardcopy available * 4!lil!m Manufacturing Standards Ia MACHINE and EQUIPMENT GUARDS DESIGN and REFERENCE DATA ! . , ff!. Manufacturing MACHINE and EQUIPMENT GUARDS Administration DESIGN and REFERENCE DATA U+XKUX :PlAi 1337. Page 01 , _, MACHINE and

2、EQUIPMENT GUARDS 1. CONTENTS TITLE Scope . Application Exclusions 4 03 Legal Requirements 5 03 Definitions 6 04 References 7 05 SECTION PAGE 2 03 3 03 Machine Design 8 06 Safeguards Required -Extent Y 07 Guarding Layout a ( Guard Types atid Selection I 10 08 $ 11 08 Guard Design and Construction 12

3、09 Guard Material 13 10 Safety Interlock Systems -Selection 14 11 Safety Interlock Design 15 13 Types of Safety Interlocks App l/2 16/17 Guarding Illustration Fig A/B 18 MACHINE and EQUIPMENT GUARDS DESIGN and REFERENCE DATA u-Rzoo3x. IW 1987. Page 02 m 9009l,b0 004b47b 3b3 m MACHINE and EQUIPMENT G

4、UARDS 2 SCOPE To provide for the design of equipment for adequate protection in conformity with National Law, at minimum costs, with minimum restrictions on machine output capability, tool changing and maintenance accessibility. 3 APPLICATION All Ford manufacturing plants located within European Aut

5、omotive Operations. This standard applies to machinery and equipment used for the manufacture of Production or Service Parts or during Tryout, Repair or other such operations. 4 EXCLUSIONS This Standard will not apply in the following circumstances: a) specialised machine/equipment covered by specif

6、ic Ford Standards for safety requirements, e.g.: I Power Pre%ses - U-DROlO (Body and A MANUAL LOAD/UNLOAD GATE:- moveable guard interlocked to the machine control system * to allow access to the lnachine danger areas only when these dangerous movements are prevented. 6.8 AUTOMATIC GUARD:- a guard as

7、sociated with, and dependant upon, the mechanism of the machine, operating so as to safely remove from the danger area any part of a person exposed to danger. clp 6.9 ADJUSTABLE GUARD:-!:a guard which provides for an adjustable size opening . through which material can be fed. 6.lU SELF-ADJUSTING GU

8、ARD:- a guard which is opened by the passage of a workpiece and returns automatically to the safe position on completion. 6.11 TIMING/LOCKING DEVICE:- a device (e.g. shot-bolt) used in conjunction with a guard, which is designed to prevent access to dangerous parts which are moving after the power s

9、upply has been interrupted, until movement of the parts has ceased, so as to prevent danger. 6.12 TWO-HAND CONTROL DEVICE:- . a device which requires both hands simultaneously to operate machinery controls thus affording a measure of protection from danger to the machine operator only. 6.13 SENSING

10、DEVICE:- a device which ensures that an approach to a danger point beyond a safe limit causes the dangerous movement to retract or stop before injury can be inflicted, e.g. Light Curtain, Pressure Sensitive Mat, Capacitance T,oop, Pressure Sensitive Strip. MACHINE and EQUIPMENT GUARDS DESIGN and REF

11、RRRNCE DATA U-KZ003X imY 1937.i Page 04 7 REFERENCES 7.1 Ford European Manufacturing Standards having particular reference to Health and Safety on Machinery and Equipment include: U - EXOOl Electrical Standard for Industrial Equipment. U - Fax005 Two-hand Control Devices. U - Fix001 Hydraulic Standa

12、rd for Industrial Equipment. U - NxOOl Pneumatic Standard for Industrial Equipment. U- SXOOl-2 Noise Control - Noise emission levels, Machines and Equip. U - sxoo3 Control of Exposure to Mineral and Oil Mist. 7.2 STATUTORY ACTS include the following non-exhanstive list:- BRITAIN - Health and Safety

13、at Work Act 1914. - Factories Acts 1961 and associated regulations. GERMANY - Technical Equipment Act (Gesetz uber Technische Arbeitsmittel) - Unfallverhuetungsvorschriften (UVV). FRANCE - Code Du Travail Page 05 8 MACHINE DESIGN. 8.1 MACHINE DESIGN, wherever reasonably practicable shall: 8.1.1 - en

14、sure that all aspects including tooling and controls/systems are fail-safe, i.e. provide safe conditions upon failure. 8.1.2 - avoid exposure of dangerous operating conditions to personnel and minimise the need for safeguards. e.g. position pairs of work stations of a transfer machine adjacent to ea

15、ch other to avoid the need for interposing guards if access between them is not required (see Fig A) 8.1.3 - minimise the extent and complexity of safeguards to: facilitate setting, production and maintenance minimise stoppages and work content achieve specified output. e.g. covered slideways to eli

16、minate trapping, avoid further guards and provide safe access to feed drives (see Pig A) 8.1.4 - permit all non-hazardous routine adjustments, cleaning, lubrication and maintenance without: a) remaval of safeguards +? b) entering prohibited areas c) dismantling machinery. 8.1.5 * - prevent danger in

17、 the event of power supply interruption. e.g. positively locked clamp/chuck to prevent accidental ejection of workpieces. 8.1.6 - prevent danger from incorrect clamping of workpieces. 8.1.7 - prevent uncontrolled emission of oil, coolant, swarf, fume and excessive noise (see Ford Standards U-SXOOl-1

18、 and U-SXOOl-2). 8.1.8 - prevent dangerous unguarded trapping between machine parts and between nnchine and other installations. 8.2 MACHINERY and EQUIPMENT PARTS requiring removal according to the vendors : recommended maintenance schedule and of a weight too heavy for safe manual lifting, shall be

19、 clearly marked with the weight of the part - see Ford Standard U-XG003 - and be designed and constructed to enable the safe use of lifting equipment. Maintenance manuals should also show these weights. MACHINE and EQUIPMENT GUARDS DESIGN and REFERENCE DATA u-Rzoo3x HAY 1387. Page 06 9 9.1 9;2 9.3 9

20、.4 9.5 9.6 9.7 GRINDING MACHlNES: SAFEGUARDS REQUIRED -EXTENT: ADEQUATE SAFEGUARDS are required where it is not reasonably practicable for the machine design to eliminate danger to persons. Such safeguards cannot be expected to protect persons who deliberately abuse/misuse the safety facilities prov

21、ided or ignore the safe system of work laid down. CLIMBING ON MACHINERY: It is only necessary to guard for the possibility of climbing on machinery if it is reasonably foreseeable that: a) operators would do so to perform their duties (e.g.toolchanEe; filling of hoppers or feed chutes etc.). In this

22、 instance, where necessary, machines should have suitable, safe platforms or ladders and appropriate guarding to provide safe access. b) access will be necessary to the danger area with the machine/ equipment in operation, eg for viewing operation (viewing panels should be incorporated in guards). c

23、) the machine shape forms a convenient stairway to danger points. SAFE ZONES do not require guards unless necessary for other reasons, such as to contain coolant or noise. i.e. where adequate guarding has been provided for localised hazards on the machine, creating SAFE ZONES (see Fig.A), it is not

24、necessary to use additional guarding to Fully enclose the machine. : e GUARD SIZES to be no larger than necessary for safety and good engineering unless necessary for other reasons (e.g. to contain coolant or noise or to provide sufficient access in the case of an access gate) - see section 12.2.1.

25、ADDITIONAL PRECAUTIONS, e.g. restricted area floor markings, may be necessary to avoid dangerous traps being created between normally safe, moving parts of machinery/equipment (e.g. conveyor) and portable objects (e.g. stockbins). OTHER HAZARDS: Additionally to preventing access t.o danger points, s

26、afeguards shall, where necessary, contain coolant, swarf,noise, chemicals, dust, gases, vapours, flying particles (chips, welding sparks) and harmful radiations and protect against temperature, pressure, vacuum, and electrical hazards. Protection integrated with safety guarding and/or local to the s

27、ources of these emissions is preferred to enclosure of the complete machine. 9.7.1 - to have wheelguards in accordance with the Federation of European Producers of Abrasive Products (FEPA) European Safety Code for the Use, Care and Protection of Abrasive Wheels. 9.7.2 - to have special consideration

28、 for wheel burst protection where wheel surface speeds above 45 metres/second are employed. MACHINE and EQUIPMENT GUARDS DESIGN and REFERENCE DATA U-KZ003X IdAY 1987. Page 07 10 GUARDING LAYOUT 1U.l CLOSE PROXIMITY GUARDING shall: 10.1.1 - be used wherever required for observation of the machine or

29、process or for environmental reasons (e.g. to contain coolant, swarf, or noise) and is normally applied in machining areas. 10.1.2 - follow the contour of the machine sufficiently close, or be otherwise .adapted so far as reasonably practfcable , as to prevent the presence of personnel between the g

30、uard and the danger point with gates closed. 10.2 PERIMETER FENCING shall: 10.2.1 - be used where necessary because of movements of machine parts or workpieces, setting or maintenance access , and is normally applied to metal stamping and body construction/assembly equipment. 111.2.2 - be at suffici

31、ent distance from the machine to permit operator or maintenance access. 10.2.3 - prevent dangerous trapping between the guard and machine (refer to National Statutes -see Section 7 References). 10.2.4 - not require entry of fencing to operate main operator control console or for any manual operation

32、 performed every cycle, e.g. load/unload. I s 11 GUARD TYPES AND SELECTION: Vendors shall determine the need and type of guards in accordance with the following (in order of precedence): a) the legal requirements of the user country b) the order requirements and specifications c) the requirements of

33、 this standard where applicable subject to the approval of Ford specifing engineers and safety engineers. 11.1 FIXED GUARDS should be selected for all danger zones not requiring access by production operator and requiring only non-routine maintenance access. 11.2 DISTANCE GUARDS. Selection: as 11.1

34、when a simpler solution than close guarding would result, and access/visibility is acceptable to Ford, distance- guards should be used. These must prevent the presence of personnel between the guard and the danger point. See Fig B. 11.3 INTERLOCKED SAFEGUARDS to be selected for all danger zones requ

35、iring operator access, frequent maintenance or routine servicing, e.g. oiling. Wherever practicable, all routine servicing should be remote from danger zones to avoid the necessity for additional access gates: e.g. Pipe oil fillers away from danger zones outside of fixed guards. MACHINE and EQUIPMEN

36、T GUARDS DESIGN and REFERENCE DATA U-KZOO3X IIAY 1357. Page 08 11.4 11.5 11.6 12 12.1 12.2 MANUAL LOAD/UNLOAD OPENINGS: For continuous manual load/unload openings, low effort, fast operating safeguards initiating the cycle should be used, i.e. light-beam screens; rising or sliding doors - power oper

37、ated with pressure-sensitive strip, where necessary or cost effective. SENSING DEVICES: may be used as described in 11.4 or where other safeguards are not reasonably practicable. ADJUSTABLE GUARDS: shall only be used when other safeguards are not reasona.bly, practicable, e.g. drilling machine for r

38、epair production. GUARD DESIGN AND CONSTRUCTION: DRAWINGS: Vendors shall submit an outline guard plan on the machine layout, and concept sketches with basic dimensions, for approval of Ford speciting engineers and Ford safety engineers prior to proceeding. GUARDING DESIGN AND CONSTRUCTION shall: 12.

39、2.1 - be such that personnel cannot endanger themselves by reaching through, around, under or over barriers without climbing. The minimum overall height from the working position for fencing shall be to Section 3.1.2 of DIN 31001 but not less than 1.4 metres. 150-400mm floor clearance should be prov

40、ided for cleaning under remote fences. : s 12.2.2 - not present a hazard such as trapping or shear points, splinters, rough or sharp edges, or other sources likely to cause injury. 12.2.3 - cope with the environmental hazard to which it is likely to be exposed. e.g. heat, welding sparks, hot swarf,

41、etc. 12.2.4 - effectively protect against splash, and spillage of cutting fluid, e.g. sheet metal guards to the extent necessary to contain cutting fluid with means to return drips when gates are open. Local protection against splash is preferred to full enclosures. 12.2.5 - allow access for cleanin

42、g of machinery where necessary. 12.2.6 - provide adequate strength in relation to the machine function without excessive weight. 12.3 FIXED GUARDING wherever possible shall be sectionalised such that each section can be opened or removed by one person (with the aid of a tool - see Definition 6.5.).

43、- For normal working heights, panels hinged to swing open by gravity (using offset hinges) secured by one fixing, are recommended. MACHINE and EQUIPMENT GUARDS DESIGN and REFERENCE DATA U-KZ003X MAY 1987 Page 09 12.4 12.5 12.6 12.7 12.8 12.9 13 13.1 13.2 GUARD MOUNTING strength shall be compatible w

44、ith guards without impctling access. Fixed top frames should be avoided to provide headroom anti crane access, e.g. by using twin bottom tracks for sliding gates. See Fig A. Where a top frame has to be used to provide guard stability over inter- locked doors the top frame height should be at a minim

45、um of 2000 mm. GAPS between supports and/or guards shall not exceed those shown in section 3.1.4.1.1. of DIN 31OUl. GUARD FIXINGS e.g. bolts, shall be the minimum number necessary, and be captive and accessible from the outside of the guard wherever possible. STANDARDISED GUARD CONSTRUCTION is encou

46、raged as a means to reduce costs provided machine design or access is not compromised. GUARDING COLOUR: shall be the same as the machine unless otherwise specified, e.g. to improve visibility - mesh may be black. VISIBILITY shall be adequate to observe the machine functioning and : should be provide

47、d by the guard material or by suitable viewing panels. GUARD MATERIAL -to be selected according to application, subject to the approval of Ford Specifing Engineers and Ford Safety Engineers, as follows: CLEAN/DRY OPERfTIONS and areas where swar Ila or coolant will not escape: - welded or interwoven

48、wire mesh panels should be used (for visibility). - Mesh openings to be to DIN 31001 Dee 1976 Section 3.1.4.2.1. SWARF/COOLANT escape-prone areas or where specified noise levels could not otherwise be met: - solid panels to be used but adequate cooling to be allowed for. Where required for visibilit

49、y of the machine functioning, suitable means of observation shall be provided, e.g. an impact- resistant transparent plastic screen of sufficient strength so as to withstand all associated process hazards, this to be designed and sited to avoid being permanently obscured by cutting fluid, swarf or dust in production. MACHINE and EQUIPMENT GUARDS DESIGN and REFERENCE DATA u-KZOO3X MAY 1987 Page 10 14 SAFETY INTERLOCK SYSTEMS - SELECTION: In addition to the main isolator lock-off system for Maintenance use (see Ford.Manufacturing Standard U-EXOOl ), where access gates are necessary