Mechanical Power Presses

Mechanical power presses

OSHA 1910.217 is the vertical regulation OSHA 1910.212, general requirement; 1910.219 MPTA ANSI B11.1 - 1998 for best safety practices 350,000 in the U.S.
Full revolution clutch since 1857 Part revolution clutch since 1927
2

Full Revolution Clutch

Part Revolution Clutch

Capacity
1/4 to bench-top to 5000 lbs. Smaller one likely to be Gap (C) Frame If inclinable, OBI, if not incliniable, OBS Larger ones tend to be straight side frame 4 columns from bed (bottom) to crown (top) Distinctive features: flywheel, crankshaft, clutch, brake, ram (slide) goes up and down

Part revolution bench top press

Bench top press (contd)

Light Curtain
7

Full vs. Part Revolution Clutch?

Is an air line going to the clutch? If yes, its a part revolution clutch press If no, then look for an operating rod coming down the side of machine to identify it as a full revolution clutch

Part revolution clutch

Full revolution clutch

10

Hydraulic Power Presses

OSHA 1910.212, general requirements, 1910.219 MPTA ANSI B11.2 - 1995 for best safety practices

11

Hydraulic Press

Light curtain

Foot control

12

Power Press Brakes

OSHA 1910.212, general requirements, 1910.219 MPTA ANSI B11.4 - 1993 for best safety practices

13

Press Brake

14

Modes of operation for mechanical power press

Inch: Short hops of ram used for setup, maintenance, but not for production Single stroke: Often hand fed, sometimes with H.I.D. feeding. Safeguarding Devices most common Continuous: Makes many cycles without stopping using an automatic feed & coil stock. Sging: Guards 15 most common

Modes of Operation, Control Selector inch, single stroke, continuous

Emergency stop button

16

Primary operations
Automatics or blankers Coil stock with automatic feeds Payoff reels or cradles to unwind Continuous mode
17

Secondary operations?
Single-stroke mode of operation Manually fed - one at a time Often use Hands-in-Die Feeding Hand feeding tools are the BSP Cycle initiation can be hand or foot Ergonomic issues if high repetition

18

Types of mechanical presses

Two general frame configurations
C frame
Used for maximum rated forces up 300 tons Similar to C clamp in appearance Three subcategories
OBI (Open Back Inclinable) Gap Press (OBS) Horn Press

19

Open Back Inclinable Press

Hand operated inclining mechanism on OBI. Turning hand crank rotates screw to tilt press back to desired position.

20

Open Back Stationery Press

Flywheel is located at the rear of the press frame on front-to-back presses, eliminating obstruction around the die frame.

21

Horn Press

22

General frame configurations

(contd)

Straight side frame

Used on most presses that can develop a maximum rated tonnage of 20 tons or more
Consist of bed with a four corner post arrangement called uprights.

23

Part Revolution Straight-Side Press - Left Side View

Main Drive Air Surge Drive Air Releasing Brake Dual Solenoid Valve Air Pressure Switch for Clutch/Brake Air Pressure Switch for Counterbalance Air Pressure-Gauge & Lubricator Assembly for Clutch/Brake Upright or Column Lubricator Operators Station Lifting Lug

Crown

Side Guard Bed Filter-Regulator-Gauge for Die Cushion 24

Air Counterbalance Tie Rod Nut Belts Tie Rod Sheave Main Gear Crankshaft Flywheel Air Friction Clutch Connection (Pitman) Side Adjusting Mechanism Side (Ram) Gib

Cover Rotating Limit Switch Assembly Knockout bracket Knockout Rod Knockout Bar

Run Buttons Top-Stop Buttons Bolster

Control panel with Starter and Disconnect Switch Emergency-Stop Button 25

Straight Side- Front View

Full Revolution - Left Side View

Motor Cam and Limit Switch Motor Starter Disconnect Switch Control Box Knockout Knockout Bracket Inclining Mechanism Operators Station Slide (Ram) Knockout Bar Drag Brake

Frame (Body)

Side Barriers Leg 26

Full Revolution - Front View

Belts Limit Switch Crankshaft Flywheel Clutch Area Connection (Pitman) Lubricator Die Clamp Rear Barrier Bolster Run Buttons (Two-Hand Trip) Gib Air Cylinder (Solenoid Valve, & Filter-Regulator-Gauge and Lubricator Assembly Not Shown) Bed Leg Tie Rod 27 Cover Side Adjusting Screw Sheave Lifting Bolt

Leg Bolts

Foot Control

Types of mechanical power presses (contd)

Functional type Operating characteristics
Full revolution clutch Part revolution clutch
Electric motor is primary drive source Motor drives press flywheel, which generates energy thats applied by way of the crankshaft and ram to the lower dies.
28

Full revolution clutch

Uses keys, pins, or jaws to engage crankshaft to flywheel Once engaged, clutch drags crankshaft through one complete revolution before it can be disengaged Uses friction brake that is always applied to hold slide stationery when clutch is not engaged Will not stop until it has completed one full stroke

29

Clutch Pin

30

Clutch pin

31

Clutch Pin

32

Jaw type
Striking plate on flywheel Rotary air seal

Sliding sleeve with multiple engaging jaws

Direct-acting pneumatic chamber

33

Friction Brake

34

Part revolution clutch

Engaged and disengaged at any point in slide Engaged with air pressure/released with absence of air pressure A friction brake that is air released and spring applied is used to stop and hold slide in position when clutch is not engaged Can be stopped at any point in

35

Air line for clutch engagement. Engaged with air pressure, released with absence of air pressure.

Part revolution clutch

36

Part revolution brake

Air released and spring applied

37

Mechanical power presses and their controls - (full revolution clutch)

Machines using full revolution clutches
Will incorporate single stroke mechanism Single stroke mechanism dependent on spring action Springs will be compression type operating on a rod or guide within a hole or tube Designed to prevent interleaving of spring coils in event of breakage

38

Single stroke mechanism

Compression spring operating on a rod or guided within a hole or tube.

39

Methods of initiating press cycle

Foot pedals - treadle
Protected to prevent unintended operation from falling or moving objects. Pad with nonslip contact area firmly attached to pedal Pedal return springs will be compression type If counterweights are provided, path of travel of weight will be enclosed
Enclose the weights path of travel to prevent interference with its movement
40

Foot treadle

Canopy guard

Removable foot pedal

Treadle
41

Foot Control
Protection from unintended objects Manufactures Specifications

Compression type spring

Applicable Safety Warnings

42

Hand operated levers

Will be equipped with a spring latch on the operating lever to prevent premature and accidental tripping Operating levers, if provided are required for each operator, and require concurrent operation

43

Two-Hand trips
Protected against unintentional operation Requires both hands, concurrent operation, and provided for all operators

44

Two-Hand Trips/Controls

Note: Red stop button normally not present

45

Two-Hand Trips/Controls

46

Two-Hand Trip/Controls
Prior Action Button

Two Hand Control Top Stop

Emergency Stop

47

Part revolution clutches

Machines using part revolution clutches
Clutch release and brake will be applied when external clutch engaging means is removed, deactivated or de-energized Stop control
Red stop control, required at each station Top stop, if provided, will be yellow

Stop control will override any other control

48

Part revolution clutches (contd)

Press stroking selector
A means of selecting off, inch, single stroke and continuous will be available. Means capable of being supervised

Inch Operation
Designed to prevent exposure of workers hands by:
Requiring concurrent use of both hands Being a single control protected against accidental actuation Will not be used for production (ANSI)

49

Part revolution clutches (contd)

Multiple operating stations
Control station for each operator capable of being supervised

Continuous
Will be supervised, and require prior action or decision by the operator in addition to the selection of the continuous mode

Hand-foot selection
If provided, selection method for foot control will be separate from stroking selector Will be supervised by employer
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Part revolution clutches

(contd)

Foot control
Protected against unintentional operation

Clutch/brake air valve failure

Control of air-clutch machines will be designed to prevent significant increase in normal stopping time due to a failure within the operating valve mechanism, and to inhibit further operation if such failure does occur.

51

Part revolution clutches

(contd)

Press drive motor interlock

Clutch/brake control should not initiate the press stroke unless the drive motor is in the forward direction

Engaging method failure

Clutch/brake control will automatically deactivate in event of power failure or pressure supply for the clutch engaging means Reactivation will require restoration of 52 normal supply and the use of the tripping mechanism

Part revolution clutches

(contd)

Air counterbalance supply

Clutch/brake control will automatically deactivate in event of failure of the counterbalance air supply Reactivation of the clutch will require restoration of normal air supply and use of the tripping mechanism

Turnover bar operation

Selection of bar operation will be by means capable of being supervised by the employer

53

Part revolution clutches control reliability

When required, control system will be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent initiation of a successive stroke until the failure is detected Failure will be detectable by a simple 54 test, or indicated by the control system

Part revolution clutches control reliability (contd)

Dual-air valves Air-filter regulator Air Pressure switch Rotating cam switch assembly

55

Dual-Air Valve Single-Air Valve

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57

Rotating Cam Switch Assembly

Belt Assembly

Rotating Cam Switches

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Part revolution clutches brake monitoring

Be constructed to automatically prevent the activation of a successive stroke if stopping time or braking distance deteriorates to a point where the safety distance being utilized does not meet the requirements Used with the Type B gate or movable barrier device, will be 59 installed to detect slide top-stop

Solid State Diagnostic Display Panel

60

Part revolution clutches brake monitoring (contd)

Be installed so indicates when performance of the braking system has deteriorated Be constructed and installed to monitor brake system performance on each stroke
61

Part revolution clutch - top stop overrun brake monitors

Top stop brake monitor checks the crankshaft position at the end of each stroke, and will not let the operator initiate another stroke if the crankshaft is too far past top dead center.

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Other safety requirements - electrical

Control circuit
All clutch/brake control circuits will incorporate features to minimize unintended stroke in event of control component failure

Disconnects
Main power disconnect capable of being locked only in the Off position

Starters
Protect against accidental operation Drive motor with a magnetic motor restart function
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Other safety requirements - electrical

(contd)

Transformer
Used to reduce voltage of operator controls

Ground
Electrical circuits shall be protected against an accidental grounding
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Disconnect switch capable of being locked in off position

Motor starter control panel start/stop switch

65

Disconnect Switch, turns to locked position

Solid control panel

66

Motor starter and fused disconnect switches

SWITCH TURNS TO LOCKED POSITION

MOTOR START SWITCH

MOTOR START STOP CONTROL

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Solid state control panel

Light curtain switch

Control selector

Motor stop button

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Other safety requirements (contd)

Counterbalance
Air counterbalance system with adequate capacity that will hold slide and attachments

Hydraulic equipment
Maximum working pressure will not exceed working pressure rating of any components

Air controlling equipment

Protected against foreign material and water entering pneumatic system

Pressure vessels
Must meet ANSI/ASME code for pressure vessels, 1968 edition

69

Point of operation safeguarding - Two-Hand Trip

Point of operation devices - will protect operator by
Preventing and/or stopping normal stroking of the press if the operators hands are placed I n the point of operation Preventing the operator from reaching into the point of operation, or withdrawing his hands if they are inadvertently located in the point of operation as the dies close

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Point of operation safeguarding - Two-Hand Trip

(contd)

Preventing the operator from reaching into the point of operation at all times Requiring application of both of the operators hands to machine operating controls and locating such controls at a safe distance from the point of operation that the slide completes the downward travel or 71 stops before the operator can reach

Point of operation safeguarding - Two-Hand Trip

(contd)

Enclosing the point of operation before a press stroke can be initiated, and maintaining this closed condition until the motion of the slide has ceased Enclosing the point of operation before a press stroke can be initiated so as to prevent an operator from reaching into the point of operation prior to die closure or prior to cessation of slide motion during the downward stroke 72

Point of operation safeguarding - Two-Hand Trips

Require use of both operators hands Located at safe distance from P.O.O. Provided for each operator Require concurrent application Incorporate antirepeat feature Fixed so only a supervisor is capable of relocating the trips
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Point of operation safeguarding Two-Hand Trips (contd)

Incorporate antirepeat feature Fixed in position so only a supervisor is capable of relocating the trips Safety distance calculation
Tm = 1/2 + 1 X Time necessary to # of engaging complete one 74 points per revolution

Two-Hand controls - part revolution only

Require use of both operators hands Located a safe distance from P.O.O. Provided for each operator Require concurrent application Protected against unintentional operation Incorporate antirepeat feature

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Two-Hand Controls

Key Selector capable of being supervised

Top Stop

Emergency Stop

Indicator Light
76

Two-Hand Controls - part revolution only (contd)

Fixed in position so only a supervisor is capable of relocating the controls Safety distance
Ds = 63 inches/second x Ts; where Ds = minimum safety distance (inches) 63 inches/second = hand speed constant; and Ts = stopping time of the press measured at

77

Presence sensing device

Device will be interlocked into control circuit to prevent or stop slide motion if the operators hand or other part of his/her body is within the sensing field of the device during the downstroke of the press slide

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Presence sensing device

(contd)

May not be used on machines using full revolution clutches May not be used as a tripping means to initiate slide motion Will be constructed so failure within system does not prevent the normal stopping action from being applied to press when required, but does prevent initiation of a successive stroke until the failure is corrected Muting (bypassing) of protective function of such device during the upstroke of press 79 slide is permitted

Presence sensing device

(contd)

Guards will be used to protect all areas of entry to the P.O.O. not protected by the presence sensing device Safety distance from sensing field to P.O.O. will be greater than the distance determined by the following formula:
Ds = 63 inches/second X Ts where: Ds = minimum safety distance (inches) 63 inches/seconds = hand speed constant; and Ts = stopping time of the press measured at approximately 90 degree position of crankshaft rotation (seconds)

80

Light Curtain - Presence Sensing Device

Features * Meets industry standards * Self-checking circuitry * Strobe-light and weld flash immunity without increasing response time * Detects objects 1 or larger * Channel blanking * 50 max operating range
Control box 20 Cables
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Receiver

Transmitter

Light Curtain - Flex Systems Applications

Receivers

Transmitters
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Presence sensing device

Control box

Light curtain

83

Presence sensing device

Top guard assembly

Light curtain

84

Horizontal mounted light curtain

Presence sensing devices light curtain

Vertical mounted light curtain

85

Pullback s
Device will include attachments for each operators hands
Attachments will be connected to and operated only by the press slide or upper die Attachments will be adjusted to prevent operator from reaching into P.O.O. A separate pull-out device will be provided for each operator

86

Arm-Type Pullback

87

Overhead Type Pullback

88

Two-Man Operation

89

Two-Man Operation

Side Guard Panel

Pullbacks

Light Curtain

90

Wristlets and Cables

91

Point-of Operation Devices Protect Hands

Ram Up - Die Open

Ram Descending - Die Closing

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Point-of-Operation Devices Protect Hands (contd)

Ram Down - Die is Closed

93

Pullbacks (contd)
Inspected, checked and adjusted at start of each operators shift, following a new die setup, and when operators are changed Necessary maintenance, repair or both will be performed and completed before press is operated Records of adjustments, inspections and maintenance will be kept in accordance with paragraph (e) of this section Sweep device may not be used for point- 94 of-operation safeguarding after December

Restraint Devices
Device will include attachments for each operators hands Attachments will be securely anchored and adjusted so that operator is restrained from reaching into P.O.O. Separate set of restraints will be provided for each operator if more than one operator is required on a press Records of adjustments, inspection and maintenance will be kept in accordance with paragraph (e) of this section
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Two-person sliding restraint

96

Gates
A gate or movable device will protect the operator as follows:
Type A gate or movable barrier device will protect the operator as specified in paragraph (c)(3)(I)(f) Type B gate or movable barrier device will protect the operator as specified in paragraph (c)(3)(I)(g)
97

Guards
Every point-of-operation guard will meet the following design, construction, application and adjustment requirements:
Prevent entry of hands/fingers into P.O.O. by reaching through, over, under or around guard Conform to the maximum permissible openings of Table 0-10 Create no pinch point between guard 98 and moving machine parts

Guards (contd)
Utilize fasteners not readily removable by the operator
Exception: Electrical interlock switch

Facilitate its inspection Offer maximum visibility of the point of operation consistent with the other requirements
99

Guards (contd)
A die enclosure guard will be attached to the die shoe or stripper in a fixed position
Good for one particular press

A fixed barrier guard will be secured to the frame of the press or to the bolster plate
No openings
100

Guards (contd)
An interlocked press barrier guard will be attached to the press frame or bolster plates, and will be interlocked with the press clutch control The adjustable barrier guard will be securely attached to the press bed, bolster plate, or die shoe, and will be adjusted and operated in conformity with Table 0-10
A point-of-operation enclosure which does not meet the requirements of Table 0-10 will be used only in conjunction with P.O.O. devices
101

Front Guard

Interlock switch

102

Side Guard

Fixed Panel

Adjustable guard

103

Barrier Guard

Fixed panel in back of machine

104

Expanded metal lexan guarding materials

Adjustable guarding sections

105

Various Guards

106

Various guards (contd)

107

Various guards (contd)

108

Various guards (contd)

109

Spring lift guard

Mechanical motor springs

Black square mesh Adjustable hairpins

110

Spring lift guard

Air cylinders

Linear bearing assembly Nonadjustable portion of panel with black mesh

Adjustable hairpins

Key-operated control station

111

Design, setting and feeding of dies

Die setting
Establish die setting procedures Provide and require use of hand tools for removing scrap pieces

Scrap handling
Provide means for handling scrap material

Guide post hazard

Hazard created by a guide post when separated from its bushing
112

Design, setting and feeding of dies (contd)

Unitized tooling
Opening between top of the punch holder and face of the slide, or striking pad will be guarded

Tonnage, stroke and weight designation

All dies will be:
Stamped with the tonnage and stroke requirements Stamped to indicate upper die weight Stamped to indicate complete die weight

113

Tonnage, stroke and weight designation

Model number

Tonnage

Stroke

114

Tonnage, stroke and weight designation

Model number

Tonnage

Stroke

115

Design, setting and feeding of dies (contd)

Die fastening
Securely mount die to bolster plate and slide When clamp caps or setscrews are used in conjunction with punch stems, additional means of securing the upper shoes to the slide will be used

Die handling
Handling equipment attach points will be provided on all dies requiring mechanical handling
116

Design, setting and feeding of dies (contd)

Die setting
Employer will establish a die setting procedure that will enhance compliance with paragraph (c) of this section
Provide spring loaded turnover bars Provide die stops, or other means to prevent losing control of the die while setting or removing dies Provide and enforce the use of safety blocks Provide brushes, swabs, lubricating rolls, and automatic/manual pressure guns so operators and die setters will not be

117

Spring loaded turnover bar

Vinyl-coated yellow handle

Made of high tensile steel

Fully enclosed spring

118

Design, setting and feeding of dies (contd)

Inspection and maintenance records
Periodic and regular inspections of all presses and safeguards Inspected and tested no less than weekly; clutch/brake, antirepeat, and single stroke mechanism

Modifications
Establish new or changed guidelines for care and use
119

Sample Press Inspection Report

Parts Inspected Frame/Motor Flywheel/Gears Crankshaft Clutch/Brake Connection and slide adjusting screw Slide and Gibs Slide counterbalance Air/Electrical system Foot switch P.O.O. safeguarding Guards and presence sensing devices Pullbacks/Restraints A or B Gate/ Two Hand Trip or Control 120 OK Defective Condition Corrective Action Date Repaired

Guide for inspecting mechanical power presses

Frame
Cracks, broken or loose parts

Motor
Clean, and lubricated

Flywheel
Rotates in correct direction, free running

Gears
Loose, broken/cracked teeth, excess noise?

Crankshaft
Cracks, bent, proper clearance in

121

Guide for inspecting mechanical power presses

(contd)

Clutch
Full revolution
single stroke capability, loose or worn parts, weak or broken springs

Part revolution
Air or oil leaks, proper alignment, disengagement, stopping position, worn clutch lining, weak or broken springs

Brake
Linings worn, properly adjusted, does it stop slide quickly
122

Guide for inspecting mechanical power presses

(contd)

Slide and gibs

Face of slide parallel to bolster, proper gib clearance, any scoring

Connection & slide adjusting screw

Proper bearing and ball seat clearance, screw turns freely

Slide counterbalance
Spring type
Proper adjustment, broken springs or loose nuts

Pneumatic type
Air leakage, proper pressure, loose connection to slide
123

Guide for inspecting mechanical power presses

(contd)

Air system
Proper air pressure, valve operation, pressure gauges, leaks

Electrical system
Can main power switch be locked only in off position, grounding, condition of wiring

Foot switch
Nonslip pad on contact area, shielded from accidental operation
124

Guide for inspecting mechanical power presses

(contd)

Point-of-operation safeguarding
Guard
Barrier that prevents entry of operators hands or fingers into point-of-operation area

Presence sensing
Reliable design and proper electrical tie-in to control Fixed at proper distance

Pullback
Enough or too muck pull on cables Is adjustment being made for change of operator, die, shift Records of inspection/maintenance

125

Guide for inspecting mechanical power presses

(contd)

Point-of-operation-safeguarding
A or B Gate
Point of operation enclosed before press cycle can be initiated

Restraint
Adjusted so operators fingers cannot reach into dies Securely anchored Adjusted for each operator

Two-hand Trip or Control

Shielded against unintended operation Concurrent antirepeat Fixed at proper safety distance from pinpoint
126

Design, setting and feeding of dies (contd)

Instructions to operators
Training shall be provided for press operators

Work area
Adequate clearance between machines for movement of operator Ample room for cleaning, and material handling Floors kept in good condition 127

Design, setting and feeding of dies (contd)

Overloading
Operate presses within manufacturer specifications

Report of injuries
Report injuries within 30 days

128

Bellows safety shield

129

Die set shields

Bellows safety shield

Bellows safety shield

130

Hand feeding and retrieving tools

131

Die safety block accessories

Two-piece aluminum safety wedges Adjustable screw device

132

Die safety block accessories (contd)

Safety plug is disconnected. Press is inoperable.

Block in use
133

Die safety block accessories (contd)

Electric safety plug is connected. Control circuit is made and press can be operated

Block in storage
134

Die safety block accessories (contd)

Interlock must be interfaced into the control system so that when plug is pulled, power to the main drive motor is disconnected.

135

Die safety block accessories (contd)

Electrical power cut-off system

Die safety block

Wedges

Die safety block holder

136

Types of Press brakes

Press brakes are machines that have a long narrow bed and slide, usually supported by C form frames on the ends of the bed and slide
Part revolution clutch - mechanical friction Part revolution clutch - air Hydraulic Hydra-Mechanical
137

Two-speed air-clutch press brake

Light curtain on floor stands

Custom control box

Two operator stations

Barriers

138

Hydraulic press brake

Control box Light curtain

Interface box

Side guards and mounting brackets

Foot switch

139

Hydramechanical press brake

Control box

Hydraulic valve

Light curtain

140

141

142

Press brake

Light curtain Side shield

143

Press brake

Light curtain Side shield

144

Application of press brakes

Press brakes are used to perform a variety of operations on sheet, plate, and other metals
The primary application of a press brake is to bend sheet metal at an angle to form flanges, boxes, channels, etc.

145

Press brake bending metal

146

Safeguarding point of operation (guards)

Barrier guards Adjustable guards Self-adjusting guards Interlock guards
147

Safeguarding point of operation (devices)

Two-Hand controls Restraints/Pullbacks Presence sensing devices Gates
148

Safeguarding standards
29 CFR 1910.212(a)(3)(ii) Section 5(a)(1) ANSI B11.3
149

Table 0 -10
Danger Line Clearance Line Guarding must extend from some point on clearance line to some point on opening line Minimum Guarding Line Typical guard locations 1/2 2-1/8 5/8 3/8 1/4 1/2 3/4 7/8 1-1/4 1-1/2 1-7/8 6 Maximum

Table 0 -10 Distance of opening from P.O.O. hazard 1/2 to 1-1/2 1-/12/ to 2-1/2 2-1/2 to 3-1/2 3-1/2 to 5-1/2 5-1/2 to 6-1/2 6-1/2 to 7-1/2 7-1/2 to 12 -1/2 12-1/2 to15 -1/2 15-1/2 to 17-1/2 17-1/2 to 31 -1/2 Max width of opening 1/4 3/8 1/2 5/8 3/4 7/8 1-1/4 1-1/2 1-7/8 2-1/8

1-1/2

14

17-1/2

At distances over 31-1/2 use 6 as maximum opening

Travel Stock Line

150