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GB 27607-2011: Mechanical press -- Safety requirements
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GB 27607-2011: Mechanical press -- Safety requirements

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Mechanical press - Safety requirements ICS 25.120.10 J62 National Standards of People's Republic of China Mechanical presses - Safety requirements Issued on. 2011-12-05 2012-10-01 implementation Administration of Quality Supervision, Inspection and Quarantine of People's Republic of China Standardization Administration of China released

Table of Contents

Introduction Ⅲ 1 Scope 1 2 Normative references 1 3 Terms, definitions and abbreviations 2 3.1 Terms and definitions 2 3.2 Acronyms 6 4 serious risk 6 4.1 Risk assessment 6 4.2 Risk Assessment Results 6 5 Safety requirements and (or) measures 7 5.1 General 7 5.2 Basic design requirements 8 5.3 Working hazardous area (area within the mold) of mechanical hazards 10 Control and monitoring systems 14 5.4 5.5 mold adjustment, commissioning, maintenance and lubrication 17 5.6 Other mechanical hazards 18 5.7 slip, trip and fall hazard 18 18 5.8 Other hazards 6 Safety requirements and testing (or) measures 21 6.1 Test Method 21 6.2 Safety requirements and testing (or) measures 21 7 information 29 7.1 marks 29 7.2 Manual 29 Appendix A (normative) interlocking guard 31 Appendix B (normative) minimum safety distance 33 Annex C (informative) Installation example 35 photoelectric protection device Annex D (informative) closed mold 36

Foreword

The standard Chapter 3, Chapter 4 are recommended, the rest are mandatory. Accordance with the standards GB/T 1.1-2009. Drafting Rules "Standardization Guide Part 1 standard structure and preparation of" given. The standard proposed by China Machinery Industry Federation. This standard by the National Forging Machinery Standardization Technical Committee (SAC/TC220) centralized. This standard is drafted by. Jinan Foundry and Metalforming Machinery Research Institute Co., Ltd., Jinan Machine Tool Group Co., Ltd., Nanjing Eston Digital Technology Co., Ltd., a high density forging Machinery Co., Ltd., Jiangsu Yang Li Group Co., Ltd. The main drafters of this standard. Ma Liqiang, He Qing, Li, Wu Bo, Qi-liter, Zhongtai Sheng, exhibition Xiujuan. Mechanical presses - Safety requirements

1 Scope

This standard specifies the mechanical press products (hereinafter referred to as the press) the design, manufacture, alteration, terms and definitions used in serious danger Insurance, safety requirements and (or) measures, testing and use of information. This standard applies to the press and as the design, manufacture, modification and use of the press part of the auxiliary equipment, but also for integration To automated production line equipment. This standard does not apply to machinery for the following purposes. --- Shears; --- Mechanical connection of the machine, such as riveting machines; --- Bending or folding machine; --- Corrected machine; --- Turret press; --- Extruder; --- Hammer or hot forging presses; --- Metal powder press; --- Punching steel profile processing machinery; --- Screw press; --- Punching profiles (such as steel) designed for special punching machine.

2 Normative references

The following documents for the application of this document is essential. For dated references, only the dated version suitable for use herein Member. For undated references, the latest edition (including any amendments) applies to this document. GB 150 steel pressure vessels GB/T 1251.2 Ergonomics - Visual danger signals - General requirements, design and testing GB/T 2893.2 Graphical symbols - Safety colors and safety signs - Part 2. Design principles for product safety labels GB 2894 Safety Signs and use guidelines GB/T 3766 Hydraulic System General technical conditions GB 4584 presses photoelectric protection device technology Security Technical Requirements GB 5091 presses GB 5093 press held electromagnetic sucker technical conditions GB 5226.1-2008 Safety of machinery - Electrical machinery and electrical equipment - Part 1. General requirements GB/T 7932 General technical conditions of pneumatic systems GB/T 8196-2003 mechanical safety devices fixed and movable guards General requirements for the design and manufacture GB/T 9969 General Instructions industrial products GB 12265.3-1997 Safety of machinery to avoid crushing of parts of the human body minimum spacing GB/T 15706.1-2007 Safety of machinery - Basic concepts, general principles for design - Part 1. Basic terminology, methodology (ISO 12100-1.2003, IDT) GB/T 15706.2-2007 Safety of machinery - Basic concepts, general principles for design - Part 2. Technical principles (ISO 12100-2.2003, IDT) GB 16754-2008 Safety of machinery - Emergency stop design principles (ISO 13850.2006, IDT) GB/T 16855.1-2008 Safety of machinery safety related control system components - Part 1. General principles for design (ISO 13849-1.2006, IDT) GB/T 16856.1-2008 Safety of machinery - Risk assessment - Part 1. Principles (ISO 14121-1.2007, IDT) GB 17120 Metalforming machinery - Safety requirements GB 17888.1 Safety of machinery stationary facilities - Part 1. Choice of fixed means of access between two levels (ISO 14122-1) GB 17888.2 Safety of machinery stationary facilities - Part 2. Working platforms and channels (ISO 14122-2) GB 17888.3 Safety of machinery stationary facilities - Part 3. Stairs, steps and guardrails (ISO 14122-3) GB 17888.4 Safety of machinery stationary facilities - Part 4. Fixed ladders (ISO 14122-4) GB/T 18153 Safety of machinery - accessible surface temperature Ergonomics data to establish temperature limit values for hot surfaces GB/T 18569.1 Safety of machinery decreased from hazardous substances emitted by machinery health risk - Part 1. Machinery Manufacturers for the principles and norms GB/T 18569.2 Safety of machinery decreased from hazardous substances emitted by machinery - Part 2 Health risks. the method of generating verification procedures Device design and selection principles interlock GB/T 18831-2010 mechanical belt guards GB/T 19671-2005 Safety of machinery - hands control devices - Functional aspects and design principles GB/T 19876-2005 Safety of machinery and parts of the body close to the speed of the positioning of protective equipment GB 23821 Safety of machinery - Safety distances to prevent danger zones being reached on the lower limbs GB 26483 mechanical presses noise limits 3 Terms, definitions and abbreviations GB/T 15706.1, GB/T 15706.2 and GB 17120 and as defined in the following terms, definitions and abbreviations apply to this document. 3.1 Terms and Definitions 3.1.1 Band brake bandbrake A brake cylinder mounted on a friction plate and laying flexible belt for braking. 3.1.2 Brakes brake When the clutch is disengaged, the slider stop and remain stopped to make a state agency (usually by friction brake). 3.1.3 Clutch clutch Power to control the movement of the slider is set binding. 3.1.4 Full revolution clutch clutch-fulrevolution Once engaged or operation, after the completion of a full stroke slider to disengage the clutch, such as key clutch. Also included only in the working stroke To a certain position in order to disengage the clutch. 3.1.5 Sub-turn clutch clutch-partrevolution At any position on the slide stroke can engage and disengage the clutch. Such as a friction clutch. 3.1.6 Automatic cycle (continuous stroke) cycle-automatic A mode of operation without manual operation can be completed according to the slider movement start instruction continuously or intermittently repetitive motion. 3.1.7 Duty cycle cycle-operating Working stroke from the starting point (usually top dead center) to the lower dead point and return to the starting point of the working stroke of the slide motion. Duty cycle comprising All processes of the movement. 3.1.8 Single cycle (single stroke) cyclesingle A mode of operation, each working stroke slide actuated by the operator. Each time the clutch is engaged, the slider moves only a job stroke. 3.1.9 Dead deadcentres Mold on which the limit point slide movement. --- From the lower die recently, generally refers to the closed end of travel, known as the bottom dead center (BDC); --- Furthest away from the lower mold, usually open stroke end, known as the top dead center (TDC). 3.1.10 Lower mold die Fixed mold presses the stationary part. 3.1.11 Drawing pad diecushion Lower mold support device, is for some forming process, savings, release or absorb energy needs. 3.1.12 Direct Drive directdrive One type of drive, the slider movement without using the clutch but by turning on and off the motor to complete. 3.1.13 Advance Open interlocking guard earlyopeninginterlockingguard Guards with interlocking device, working in the danger zone after the end of all the dangerous movement open guard, without interrupting the operation stroke. 3.1.14 Guard locking device guardlockingdevice When using hazardous machinery functions possible danger that the protective door interlock guards maintain a closed and locked state Machinery. When the guard is closed and locked the machine to operate, and when the risk has not been eliminated guards remain locked status. 3.1.15 Limited movement control devices (inching devices) limitedmovementcontroldevice; inchingdevice Its operation can only slider or machine part motion control device defining a distance, before the control means re-operation execution, the machine unit Member can further movement. 3.1.16 Mechanical presses mechanicalpress Metallic or non-metallic material is performed by cold forming machine between mold is passed from the host to the energy transmission between the dies Mechanically to complete. This energy transfer can be performed by the flywheel and clutch or direct drive mechanism, shown in Figure 1. 3.1.17 Surveillance monitoring A security feature if a part or component is no longer able to exercise its function due to changes in processing conditions or re-work process It will produce dangerous, issue safety information. Explanation. 1 --- flywheel cover; 2 --- clutch; 3 --- flywheel; 4 --- motor shaft; 5 --- belt; 6 --- slider; 7 --- slider bottom plane; 8 --- work surface; . 9 --- table; 10 --- foot switch. Example 1 FIG Presses (safety device unillustrated mold area) 3.1.18 Inhibition muting When the machine is in the normal operation of other safety conditions, by the control system relating to safety components temporarily stop automatically one or more security Features. 3.1.19 The total response time to stop overalsystemstoppingperformance; overalresponestime Security devices to start or end the dangerous movement to achieve a safe state the time spent. 3.1.20 Overtravel (offside) overrun Crank movement beyond a predetermined stop position, such as beyond the top dead center. 3.1.21 Overtravel monitoring device overrunmonitoringdevice If offside exceeds a predetermined limit, a restraint device continues to boot the machine signals. 3.1.22 Position switch positionswitch When certain moving parts of the machine arrives or leaves a predetermined position of the switching operation. 3.1.23 Redundancy redundancy Using more than one device or system to ensure that when a device or system failure, another device or system to complete the specified function. 3.1.24 Maximum Die height maximumdiesetheight When the slider is adjusted to the maximum stroke and Die height adjustment mechanism is in the upper limit position and the slider is in the bottom dead center position, the slider plane To the table on the distance between the plane plate. 3.1.25 Slider slide Is the major press reciprocating member to press the body to guide, on which the mold. 3.1.26 The upper mold tool Moving part of the mold. 3.1.27 Mold tools A combination of upper and lower molds collectively. 3.1.28 Closing the mold tools-closed Mold has its own security features (see Figure D.1). 3.1.29 Disengaging mechanism extractor; latch Disengage the clutch the entire transfer device. 3.1.30 Emergency brake emergencybrakingdevice It refers to the press in order to achieve full revolution clutch at a certain position within a crank angle range disengaged immediately, in order to achieve fast brake slide Stop means; the device should be intrinsically safe. 3.1.31 Brake corner brakingangle Refers to the press (emergency) stop button to start to slide stop running period, the corresponding angle turned eccentric system. 3.1.32 Monitoring system monitoringsystem Implement monitoring systems. The system has been constituted as a complete device, the monitoring device is called. 3.1.33 Safe operation of the accessory back-upsafetytool It refers to the press outside the host for the safe operation of the user's hand to provide additional operational tools. Including hand pliers, hook, tweezers, all kinds of suckers (Electromagnetic, vacuum) and process-specific tools. 3.1.34 JHA area operatingdangerzone After installation refers to the press ram die (slider), die (slider) of the vertical plane of projection range. 3.2 Acronyms The meaning of this standard abbreviations represented as follows. M --- monitoring; R --- redundancy; S --- single channel; BDC --- bottom dead center; TDC --- top dead center; PES --- programmable electronic systems; PPS --- programmable pneumatic system; AOPD --- photoelectric protection device; EI --- electrical.

4 serious risk

4.1 Risk Assessment Should be predictable in all aspects of evaluation, including overtravel, unintended and unconscious start working stroke or slide under the action of gravity Accidental fall. In all possible dangers listed in the press a predetermined period of life and should be given of the operation may enter the danger zone And other personnel to generate describe risk. Risk assessment should also include a control system failure impact analysis. The use of standards Who, as the designer, manufacturer, supplier or user, risk assessment should be carried out according to GB/T 16856.1. With particular attention to the following. --- Use of the press, including maintenance, adjustments and cleaning as well as foreseeable misuse; --- Grave danger presses. 4.2 Risk Assessment Results Table 1 lists the project is an important risk for all types of presses according to GB/T 16856.1-2008 this standard include the use of The results of risk assessment. Chapters 5 and 7 and Appendices A, B, C and Appendix D Appendix measures and the use of information technology Risk assessment is based on an important risk listed in Table 1, and by eliminating the hazard or reduce the risk of making dangerous under control. Press Serious danger, danger zone, protective measures are shown in Table 1. As part of the risk assessment, the designer should be recognized for the pressure listed in Table 1 Dangerous machine is complete and accurate. Table 1 grave danger, danger zone, protective measures Danger area Protective measures The relevant clauses of this standard GB/T 15706.1-2007 Related reg Mechanical hazards. - Risk of crushing - Cut dangerous - Cutting or severing hazard - The risk of wound - Or inhalation hazard involved Mould Area. - Die motion area - Slide movement area - Pulling the pad motion area - Workpiece ejection region - Protective zones 5.3,5.4,5.5 4.2.1 Impact, risk of collision Mobile electrical, hydraulic and pneumatic devices part; Electrical and mechanical drive means; Mechanical feeder device; Installation, adjustment and maintenance 5.6.1,5.6.2,5.6.3 4.2.1 Table 1 (continued) Danger area Protective measures The relevant clauses of this standard GB/T 15706.1-2007 Related reg Part thrown danger Machinery parts and components; Workpiece and die 5.6.4 4.2.1 High pressure fluid ejection hazard 5.8.3 Hydraulic System 4.2.1 Slip, trip and fall hazard Work at height; The floor area around the press 5.7 4.10 Electrical Hazard. - Direct contact with dangerous - Non-direct contact with dangerous - Heat radiation (burns) Dangerous Electrical Equipment; Electrical equipment failure so that the charged parts 5.8.1 4.3 Thermal hazards. - Human contact may produce burning Wounds and burns Brakes, clutches, hydraulic systems 4.4 Parts 5.8.2 Dangerous Noise. - Induced hearing loss (deafness) Noise hazard area around the press 5.8.4 4.5 Vibration hazard. - Possible human disorders Vibration-prone part of the press, such as exercise Workstation 5.8.5 4.6 Hazardous materials and substances produced by. - Machining, use and discharge of Materials and substances, such as by contact or inhalation Hazardous liquids, gases, fumes and dust are Danger caused; - Fire or explosion hazard Hydraulic system, pneumatic system and control Member, toxic workpiece material; Exhaust ventilation and dust collection equipment 5.8.6 4.8 Ignore the principles of ergonomics Ergonomic generated Danger. - Machinery and human traits and capacities Lack of coordination, such as unhealthy working postures, Excessive or repetitive force, etc. Working position and operational control and maintenance Retaining space 5.8.7 4.9 5 Safety requirements and (or) measures 5.1 General 5.1.1 Presses category Press the clutch structure can be divided according to sub-transfer clutch presses, full revolution clutch presses. 5.1.2 Technical measures to reduce the risks to be taken Presses should be consistent with GB 17120 and provisions of this standard. Methods and measures to eliminate the serious danger in Table 1, to reduce the risk Technical measures to be taken are as follows. --- Basic requirements of major components and system design (see 5.2); --- In different operating modes, operating the danger zone and prevent mechanical hazards of the relevant regional security precautions (see 5.3, Table 2, Tables 3 and 4); --- Prevent and dangerous protective measures (see 5.4) control and monitoring systems or control device failure; --- Mold installation and adjustment, commissioning, maintenance, safety precautions and dangers that may arise when lubricating taken (see 5.5); --- Security measures taken for other mechanical hazards may occur (see 5.6 to 5.8). 5.1.3 security features Security features should have effective security performance, and performance and reliability tests conducted by a nationally recognized testing agencies; security Features of life, life, safe conditions of use, maintenance, use and other measures should be specified. It should adopt performance and reliability tests Safety devices, safety features include clutches and brakes, emergency brakes, double safety valve, electronic protective devices and safety aids loading Home and other safety-related components. 5.1.4 Removal and Reconstruction All safety-related part of the user on the press shall not be demolished, to be modified risk assessment should be, after the transformation shall meet the standard Provisions. 5.2 Basic design requirements 5.2.1 brakes and clutches 5.2.1.1 does not allow the use of hydraulic or pneumatic means to manipulate the brake, also not allowed to manipulate the brake diaphragm. 5.2.1.2 should be designed to ensure that. a) the use of a compression spring clutch is disengaged and the brake combination; b) the use of multiple sets of spring; c) all spring on the size, mass, stiffness should be consistent; d) when the compression spring adjustment, clamping device should be locked to prevent the relaxation of the spring; e) of the spring guide grooves and the guide pin should minimize the constraints, so that the spring retractable. 5.2.1.3 clutch and brake combination and disengagement should not affect its security features should be avoided clutch and brake can be combined Possibilities. NOTE. Usually should clutch - brake combination structure to minimize the possibility of simultaneous binding. 5.2.1.4 brake and clutch parts should be designed to ensure that any failure (such as energy transfer or bolt) can not make the other parts of the production fast Students dangerous chain failure. 5.2.1.5 heat generated if they can be dangerous, cooling measures should be taken. 5.2.1.6 brake design should take effective measures to prevent lubricant immersed brake friction surface. 5.2.1.7 clutch and brake shall be designed to ensure the destruction or erosion of the sealing material (such as seals, gaskets) water vapor, dust, or Lubricant will not adversely affect the required functions, such as clogged air line or other adverse effects. 5.2.1.8 shall be designed to ensure that dust, liquids, or the accumulation of particles is reduced to a minimum to avoid the accumulation of Growth with brake Performance so damaged or loose parts thus causing brake failure. 5.2.1.9 prohibit the use of the band brake to stop the slide in mechanical press. 5.2.2 transfer clutch (friction clutch) Presses 5.2.2.1 should ensure clutch engagement and disengagement in the correct position on the itinerary, at full load temperature rise should be specified. 5.2.2.2 should retain sufficient work space, to ensure that does not occur due to friction and the slider malfunction. 5.2.2.3 clutch should be able to prevent the accumulation of debris on the surface of the friction clutch affect performance and should be able to effectively eliminate the incoming debris. 5.2.2.4 clutch and its control system should be designed to ensure that in the case of pneumatic, hydraulic and electrical failure, can immediately disengage the clutch, the system Brake actuator immediately. 5.2.2.5 If the diaphragm in the clutch system, measures should be taken to avoid damage due to sharp edges or rough cut surface wear caused by not Permission is granted to film relaxation (as a result of material fatigue) impede the exhaust. 5.2.2.6 clutch and brake interlock control action should be sensitive and reliable, mutual interference does not occur. 5.2.2.7 clutch operation should double safety valve, should have the monitoring system, and should be specified. 5.2.3 General requirements for hydraulic and pneumatic systems 5.2.3.1 Hydraulic and pneumatic systems should be designed in line with GB T 3766 and GB/T requirements/7932's. 5.2.3.2 should be installed filters, pressure regulators and disconnect. 5.2.3.3 should be installed to ensure that the working pressure remains within the permissible range of devices. 5.2.3.4 glass and plastic containers should be installed guards without affecting observe the situation, to prevent danger caused by flying debris. 5.2.3.5 All piping, fittings, channel balance or reservoir, core drill holes or no burr, foreign bodies, burrs and foreign matter may cause the valve, Damage to the clutch and brake moving parts. 5.2.3.6 should take measures to prevent pipeline damage due to thermal expansion caused; fixed line spacing should be consistent with the provisions and fixed firmly to avoid Vibration or movement. Measures should be taken to prevent the piping hose kinking may result in clogging, especially in the clutch and brake lines. 5.2.3.7 When the pressure drop may lead to unintended dangerous motion slider, you should not use a hose, tubing and pipe connections should prevent accidental loss Pressure should not be used sleeve joints, bonding and sealing ring or the like, should be through an interference fit or by welding. 5.2.3.8 work should not be relied pipeline valve support, in order to avoid the effects of vibration on the valves and piping. 5.2.3.9 working valve should be designed to ensure that the non-working state leaked to the inlet pressure fluid can drain away freely, avoid working in the clutch As a pressure cylinder. 5.2.3.10 work should be designed to ensure that the valve inlet and drain port can not be closed simultaneously. Outlet pipe diameter 5.2.3.11 and clutch cylinder and the valve between should be large enough to ensure the prompt release of the clutch cylinder can flow body. The drain valve work port large enough diameter, avoiding the formation of residual pressure in the cylinder. Correct selection control valves, clutches and brakes Pressure ratio between. 5.2.3.12 work control valves and other components (such as regulator and pressure gauge) should be installed in a position easy to operate and can prevent the damage. 5.2.3.13 or need to manually (ie, non-electrical) the pilot control valve is reset to mechanically at the end of stroke position in the clutch is disengaged Set should be mandatory (for example, after the release of the force on the valve spool should be automatically moved to a safe location). 5.2.3.14 Pressure Vessels shall comply with the provisions of GB 150. 5.2.4 pneumatic system 5.2.4.1 When the pressure control valve or other system components require lubrication,... ...