CSE376 SAFETY TECHNOLOGY
Lecture 5 - Machine Guarding
Learning Objectives
To understand the need for safeguarding.
To identify machinery hazards and apply the principles of
safeguarding.
To suggest the appropriate use of fixed guard, interlock
guard, automatic trip guard, fluid power systems.
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Section 1
Need for Machine Guarding
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INTRODUCTION
Once upon a time, safety legislation were made due to
machinery accidents.
Definition of machine: apparatus for applying power, having
fixed and moving parts, each with definite functions.
The prime mover of machines is often an electric motor.
The transmission transfer the motive power to the
processing parts.
Moving parts of machines can cause very serious accidents.
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REGULATIONS
F&IUO – general duties of proprietors
F&IUO – general duties of persons employed
F&IU (guarding and operation of machinery)R
F&IU (Woodworking machinery) R
F&IU (Abrasive Wheels)R
F&IU (Cartridge operated fixing tools)R
F&IU (Blasting by abrasive)R
F&IU (Noise at Work)R 4
PRIME MOVER
There is a duty to securely fence the following
Moving parts of prime movers and flywheel.
Turbines.
Every part of electric generators, motors,
electric converters and flywheels connected to
them.
TRANSMISSION
There is a duty to securely fence the following
Shafts, wheels, drums, chains, gear, pulley systems,
couplings, clutches, driving belts and other
device which facilitates the transfer of power.
Also has to be securely fenced by means of
construction or position.
Efficient devices have to be provided to isolate
transmission machinery from the power source.
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DANGEROUS PARTS OF MACHINERY
The legislation does not recognize a machine as a
whole to be dangerous.
Only those parts of the machinery that are
considered dangerous have to be guarded.
A part of the machine is considered dangerous if it
might be a reasonably foreseeable cause of injury,
to anybody acting in a way in which a human being
may be reasonably expected to act, in
circumstances which may be reasonably expected
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to occur.
DANGEROUS PARTS OF MACHINERY
The fencing must be secure enough to protect not
only the prudent, alert and skilled workers but also
the careless, inattentive and lazy workers.
Prevent the workers from coming into contact
with dangerous parts.
Fixed guard is to be used as far as possible.
Dangerous parts and guards must be tested,
inspected and maintained regularly by competent
persons.
During cleaning and repair, the dangerous parts in
not considered in motion. 8
Where there is a risk of exposure to
dangerous parts during
operation
examination
lubrication
adjustment
maintenance,
that risk must be eliminated, or, where it cannot be
eliminated, minimised.
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Section 2
Machine Hazards
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MACHINE HAZARDS
Hazard arise from motions:
Rotating motions
Sliding motions
Oscillating motions
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MACHINE HAZARDS
BS5304
a. Entanglement
b. Traps
c. Contact danger
d. Entanglement
e. Impact danger
f. Ejection danger
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MACHINE HAZARDS
Traps
Being trapped between the machinery and any
material in or at the machinery or any fixed
structure, limbs are drawn into an in-running
nibs or trap by a closing or passing movement.
Contact danger
Come into contact with the moving parts of the
machinery, sharp, abrasive, hot, cold, electrically
live
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MACHINE HAZARDS
Entanglement
Become entangled by parts of moving machinery,
hair, gloves, clothing, necklace, rings.
Impact danger
Being struck by parts of machinery in motion
Ejection danger
Being struck by parts of machinery or material
ejected from the machinery
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TRAPS
Where rotary items contact other rotary items or
tangentially moving parts, the danger of an in-running nip is
created.
Rollers, gear wheels, pulley belt, conveyor or drive belts,
chains and sprockets.
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Rollers belt and pulley rack and pinion
TRAPS
Another type is traps is between moving and fixed
parts
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CONTACTS
rotary designed to abrade or cut. eg abrasive wheel,
circular saws, milling machines, router, moulders,
meat slicing machines, vertical band saws
Vertical Milling Horizontal Milling Band saw
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ENTANGLEMENT
The contact friction with
even a slowly moving
rotating part can be
sufficient to pull and wrap a
person’s clothing or limb
around the part.
Projections such as set
screws, cotter pins, keys
and so are liable to catch
clothing or jewelry.
Between rotating parts and 19
rollers.
EJECTION DANGERS
Materials and workpieces can be ejectecd, e.g.
molten metal from spot welders and diecasters.
Circular saw can throw timber back violently if
knots are encountered.
Parts of machine can be thrown out, e.g. during
explosion.
Abrasive wheels can burst through over-speeding.
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MULTIPLE DANGERS
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SPOT THE HAZARDS
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MORE MACHINERY HAZARDS
Noise
Vibration
Pressure
Electricity
Temperature
Ionizing radiation
Non-ionizing radiation
Dusts
Chemicals 23
Explosives
Section 3
Machine guards
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CONTROL OF MACHINERY HAZARDS
Hardware and technology – technical procedures
Technical design
Machine design, reduce need for access
Guard design, reduce ease of access
Ergonomic layout of controls to reduce human errors
Organization behavior – procedural procedures
Planned maintenance and inspection of machines and guards,
System of work
Permit-to-work
Individual behavior – behavioral procedures
Training, basic skills
Systems and procedures 25
Instruction and supervision
CONTROL METHODOLOGY
Guards
Put up barriers to prevent the entry of body or clothing.
Also prevent materials shoot out.
Devices
Control or attachments that inhibit normal operation of
a machine.
Distance
Out of reach
Location
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Put dangerous parts at remote position and out of reach.
CONTROL OF MACHINERY HAZARDS
Guard must be properly:
Designed
Constructed
Tested
Examined
Adequate information about its correct use is
supplied. 27
4 TYPES OF MACHINE GUARDS
1. Fixed guards
2. Interlock guards
3. Automatic guards
4. Trip guards
Listed according to priority
Fixed guard is the first choice whenever it is
practical. Other guarding device have lower priority.
It should be rule that all prime movers and
transmission machinery are totally enclosed by
fixed guarding. 28
FIXED GUARD
A permanent and complete
barrier between human
parts and dangerous machine
parts.
It has no moving parts.
It is either welded in position
or attached by substantial
bolts.
Can be opened only with the
aid of tools. Fixings that can
be undone by hand are
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unacceptable.
FIXED GUARDS
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FIXED GUARD
Could be solid or wire mesh.
Solid material block view but openings in mesh create
danger.
Should allow sufficient gap between the guard and the
moving parts so as not to create trapping points.
Should have adequate:
Strength, sturdy
Stiffness
Durability
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Reliability
PROS AND CONS OF FIXED GUARD
No need to use power.
Many fixed guards have openings (material feed,
product exit, removal of jammed workpieces),
when there is no work, the opening allow entry
of limbs.
Guard made of transparent plastic soon become
dirty and tempt the operator to move the guard
out of purpose.
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INTERLOCK GUARD
An Interlock is a safety device that interconnects a
guard with the control system or power system of
the machinery to which it is fitted.
Interlock guards are normally the next choice after
fixed guards, but may sometimes be preferred to
them.
It is used when access is required on a regular basis.
A combination of fixed guard and interlock guard is
common. 33
INTERLOCK GUARD
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INTERLOCK GUARD
Should be designed, installed and adjusted so that:
Until the guard is closed the interlock prevents the
machinery from operating by interrupting the
power medium.
Either the guard remained locked closed until the
risk of injury from the hazard has passed, or
opening the guard causes the hazard to be
eliminated before access is possible.
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ADVANTAGES OF INTERLOCK GUARDING
Efficiency less dependent on human behavior.
Do not represent the last line of defense.
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AUTOMATIC GUARDS
Considered as less effective guards.
Automatic guards move into position by the
machine itself, thereby removing any part of the
person from the dangerous area.
Usually operate by pushing the operator out of the
danger area before the dangerous parts move.
It does not prevent the operator from coming into
contact with the dangerous parts. Interlock guard
does.
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Push away guards
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AUTOMATIC GUARDS
The movable part of the guard is positively actuated
by the movement of the dangerous part of the
machinery.
The guard is securely fixed to the machinery so
that it cannot be adjusted or detached without the
use of special tools.
Speed of guard movement is limited.
Sufficient clearance around the operator.
Common on power presses, guillotines, heavy and
slow moving machines. 39
ADVANTAGES OF AUTOMATIC GUARDS
It removes persons or parts of body away from
danger area every time it is started.
Reliable and lesser component failure.
Disadvantage is the possibility of causing impact
injury when the guard strike the worker.
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TRIP GUARDS
It causes the machine to stop or become safe
when a person approaches a danger point.
Device located around the
perimeter of or near the
danger area
Operator must be able to
reach the cable to stop the
machine
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PROS AND CONS OF TRIP GUARDS
Allow frequent access to danger points.
But trips can be defeated easily.
Trips represent only a last line of defense.
Often, it only serve to limit injury.
At worse, they offer no protection at all.
Fixed guard, interlock should be used whenever
it is possible.
Essential to check and inspect everyday.
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TWO HANDS CONTROL
Machine can only start when both buttons are
actuated.
It make sure the both hands are away from danger43
zones.
TWO
HANDS
CONTROL
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PROS AND CONS OF 2 HANDS DEVICES
Pros
Allow rapid manual maneuvering of the workpiece.
Good for low risk operations.
Good for sole operators work.
Cons
Protect hands only.
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EMERGENCY STOP BUTTON
Intended to be actuated
deliberately in an emergency.
Additional on guarding device.
Should not be confused with trip
devices.
It is not a guarding device.
Protect equipment damage rather
than save lives.
Good for person trapping. 46
NEED FOR REGULAR INSPECTION
Constantly maintained
Continually in a state of effective operation
Check for secure fastenings
No access is possible to danger point
Check for secondary trapping points
Check openings in the fixed guards.
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Section 4
Risk asessment
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THE RISK PRIORITY CHART
PROBABILITY: CONSEQUENCE: how severely could it hurt someone?
what is the CATASTROPHIC MAJOR MINOR
likelihood of it kills, disables, significantly injures, first aid only, no
happening? permanently NOT permanently work time lost
injures
VERY LIKELY: it
could happen 1 2 3
LIKELY: it could
happen 2 3 4
occasionally
UNLIKELY: it could
happen, although 3 4 5
uncommon
VERY UNLIKELY:
it could happen, 4 5 6
although probably
never will
• If you score a 1 or 2, do something NOW.
• If you score a 3 or 4, plan to do something soon. 49
• If you score a 5 or 6, plan to review the risk in the future.
CONCLUSION
You should have learnt :
Machine hazards
Machine guarding.
How to control machine hazard.
How to advise others in safe use of machines.
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