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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