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1、 AS 4024.30022009 Australian Standard Safety of machinery Part 3002: Materials forming and shearingHydraulic power presses AS 4024.30022009 This Australian Standard was prepared by Committee SF-008, Guarding of Power Presses. It was approved on behalf of the Council of Standards Australia on 16 Marc
2、h 2009. This Standard was published on 18 May 2009. The following are represented on Committee SF-008: Australian Chamber of Commerce and Industry Australian Council of Trade Unions Australian Industry Group Department of the Premier and Cabinet, SA Federal Chamber of Automotive Industries Safety In
3、stitute of Australia WorkCover New South Wales This Standard was issued in draft form for comment as DR 04138. Standards Australia wishes to acknowledge the participation of the expert individuals that contributed to the development of this Standard through their representation on the Committee and
4、through the public comment period. Keeping Standards up-to-date Keeping Standards up-to-date Australian Standards are living documents that reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Betwee
5、n editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments that may have been published since the Standard was published. Detailed information about Australian Standards,
6、 drafts, amendments and new projects can be found by visiting www.standards.org.auwww.standards.org.au Standards Australia welcomes suggestions for improvements, and encourages readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at mailstandards.org.aum
7、ailstandards.org.au, or write to Standards Australia, GPO Box 476, Sydney, NSW 2001. The Standard is downloaded from Standard Sharing AS 4024.30022009 Australian Standard Safety of machinery Part 3002: Materials forming and shearingHydraulic power presses Originated as part of AS CZ81959. Previous
8、edition part of AS 12191994. Revised in part and redesignated as AS 4024.30022009. COPYRIGHT Standards Australia All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of
9、the publisher. Published by Standards Australia GPO Box 476, Sydney, NSW 2001, Australia ISBN 0 7337 9151 4 AS 4024.30022009 2 PREFACE This Standard was prepared by the Standards Australia Committee SF-008 Guarding of Power Presses to supersede, in part, AS 12191994, Power pressesSafety requirements
10、. The Standard is one of a series dealing with the safety of power presses. It is based upon but not equivalent to EN 693:2001, Machine toolsSafetyHydraulic presses in order to maintain consistency with AS 4024.1, Safety of machinery series of Standards. The terms normative and informative have been
11、 used in this Standard to define the application of the appendix to which they apply. A normative appendix is an integral part of a Standard, whereas an informative appendix is only for information and guidance. The Standard is downloaded from Standard Sharing 3 AS 4024.30022009 CONTENTS Page SECTI
12、ON 1 SCOPE AND GENERAL 1.1 SCOPE 4 1.2 OBJECTIVE4 1.3 REFERENCED DOCUMENTS 5 1.4 DEFINITIONS 6 SECTION 2 HAZARDS 2.1 GENERAL 11 2.2 RISK ASSESSMENT 11 SECTION 3 SAFETY REQUIREMENTS AND MEASURES 3.1 INTRODUCTION. 13 3.2 BASIC DESIGN CONSIDERATIONS . 13 3.3 MECHANICAL HAZARDS IN THE TOOLS AREA. 17 3.4
13、 CONTROL AND MONITORING SYSTEM. 21 3.5 TOOLSETTING, TRIAL STROKES, MAINTENANCE AND LUBRICATION . 25 3.6 OTHER MECHANICAL HAZARDS . 26 3.7 SLIPS, TRIPS AND FALLS 26 3.8 PROTECTION AGAINST OTHER HAZARDS. 27 SECTION 4 USER INFORMATION 4.1 MARKING 33 4.2 INSTRUCTION HANDBOOK 33 APPENDICES A CLOSED TOOLS
14、 35 B INTERLOCKING DEVICES ASSOCIATED WITH GUARDS. 36 C ELECTRO-SENSITIVE PROTECTIVE EQUIPMENT 39 D CALCULATION OF MINIMUM SAFETY DISTANCES 40 E CONDITIONS FOR NOISE MEASUREMENT OF HYDRAULIC PRESSES. 42 F RESPONSE TIME OF THE HYDRAULIC SYSTEM 44 G CONNECTION OF STOPPING TIME MEASUREMENT EQUIPMENT 45
15、 AS 4024.30022009 4 Standards Australia www.standards.org.au STANDARDS AUSTRALIA Australian Standard Safety of machinery Part 3002: Materials forming and shearingHydraulic power presses S E C T I O N 1 S C O P E A N D G E N E R A L 1.1 SCOPE This Standard specifies technical safety requirements and
16、measures for hydraulic presses that are intended to work cold metal or material partly of cold metal. In operations involving hot working and the use of tongs during the machine cycle, the principles given in AS 4024.1 should be considered, but may not be capable of being fully applied. This Standar
17、d should be read in conjunction with AS 4024.1 (series). This Standard also covers presses whose primary intended use is to work cold metal, but are also used in a similar way to work other sheet materials (e.g. cardboard, plastic, rubber or leather), and metal powder. The requirements in this Stand
18、ard take account of the intended use of the power press. This Standard presumes access to the press from all directions, deals with the hazards (described in Section 2) and specifies safety measures for both the operator and other exposed persons. The Standard also applies to ancillary devices that
19、are integral to the press. NOTE: For the safeguarding of integrated manufacturing systems using presses, see also ISO 11161. This Standard does not cover machines whose principal designed purpose is (a) sheet metal or paper cutting by guillotine (see AS 1893); (b) attaching a fastener, e.g. riveting
20、, stapling or stitching; (c) bending or folding by brake presses; (d) straightening; (e) turret punch pressing; (f) extruding; (g) drop forging, hot forging or drop stamping; (h) compaction of metal powder; (i) single purpose punching machines designed exclusively for profiles, e.g. for the construc
21、tion industry; or (j) printing presses. 1.2 OBJECTIVE The objective of this Standard is to enable designers, manufacturers, suppliers, employers and users of hydraulic power presses to reduce the risks to the safety of persons working with or near hydraulic power presses. The Standard is downloaded
22、from Standard Sharing 5 AS 4024.30022009 www.standards.org.au Standards Australia 1.3 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1657 Fixed platforms, walkways, stairways and laddersDesign, construction and installation 1893 Code of practice for the guarding a
23、nd safe use of metal and paper cutting guillotines 2671 Hydraulic fluid powerGeneral requirements for systems (ISO 4413:1998, MOD) 2788 Pneumatic fluid powerGeneral requirements for systems (ISO 4414:1998, MOD) 4024.1 Safety of machinery (series) 4024.1201 Part 1201:General principlesBasic terminolo
24、gy and methodology 4024.1202 Part 1202:General principlesTechnical principles 4024.1301 Part 1301:Risk assessmentPrinciples of risk assessment 4024.1501 Part 1501:Design of safety related parts of control systemsGeneral principles for design 4024.1502 Part 1502:Design of safety related parts of cont
25、rol systemsValidation 4024.1601 Part 1601:Design of controls, interlocks and guardingGuardsGeneral requirements for the design and construction of fixed and movable guards 4024.1602 Part 1602:Design of controls, interlocks and guardingInterlocking devices associated with guardsPrinciples for design
26、and selection 4024.1603 Part 1603:Design of controls, interlocks and guardingPrevention of unexpected start-up 4024.1801 Part 1801:Safety distances to prevent danger zones being reached by the upper limbs 4024.1803 Part 1803:Safety distances and gapsMinimum gaps to prevent crushing of parts of the h
27、uman body 4024.2601 Part 2601:Design of controls, interlocks and guardingTwo-hand control devicesFunctional aspects and design principles 4024.2801 Part 2801:Safety distances and gapsPositioning of protective equipment with respect to the approach speed of parts of the human body 60204 Safety of mac
28、hineryElectrical equipment of industrial machines 60204.1 Part 1: General requirements (IEC 60204-1, Ed.5 (FDIS) MOD) 60529 Degrees of protection provided by enclosures (IP Code) 62061 Safety of machineryFunctional safety of safety-related electrical, electronic and programmable electronic control s
29、ystems AS/NZS 3000 Electrical installations (known as the Australian/New Zealand Wiring Rules) 4586 Slip resistance classification of new pedestrian surface materials ISO 3746 AcousticsDetermination of sound power levels of noise sources using sound pressureSurvey method using an enveloping measurem
30、ent surface over a reflecting plane 11161 Safety of machineryIntegrated manufacturing systemsBasic requirements 11202 AcousticsNoise emitted by machinery and equipmentMeasurement of emission sound pressure levels at a work station and at other specified positionsSurvey method in situ AS 4024.3002200
31、9 6 Standards Australia www.standards.org.au ISO/TR 11688 AcousticsRecommended practice for the design of low-noise machinery and equipment 11688-1 Part 1: Planning 11688-2 Part 2: Introduction to the physics of low-noise design IEC 61496 Safety of machineryElectro-sensitive protective equipment 614
32、96-1 Part 1: General requirements and tests 61496-2 Part 2: Particular requirements for equipment using active opto-electronic protective devices (AOPDs) 1.4 DEFINITIONS For the purpose of this Standard, the following definitions apply. 1.4.1 Ancillary device Any device intended for use with the pre
33、ss tools and integrated with the press, e.g. devices for lubrication, feed and ejection. 1.4.2 Cycle 1.4.2.1 Automatic Operating mode where the slide or ram repeats continuously or intermittently, all functions achieved without manual intervention into the danger zone after initiation. 1.4.2.2 Opera
34、ting Movement of the slide or ram from the cycle start position (normally the top dead centre) to the bottom dead centre and back to the cycle stop position (normally the top dead centre). The operating cycle includes all operations carried out during this movement. 1.4.2.3 Single Operating mode whe
35、re each operating cycle of the slide or ram has to be positively actuated by the operator. 1.4.3 Dead centres Points at which the tool, during its travel, is either (a) nearest to the die (generally it corresponds to the end of the closing stroke), known as the bottom dead centre (BDC); or (b) furth
36、est from the die (generally it corresponds to the end of the opening stroke), known as the top dead centre (TDC). 1.4.4 Die The fixed part of the tools used in a press. 1.4.5 Die cushion Accessory for a die that accumulates and releases, or absorbs, force as required in some press operations. 1.4.6
37、Early opening interlocking guard Guard associated with an interlocking device which, if opened when any dangerous movement in the tools area has ceased, does not interrupt the operating cycle. 1.4.7 Guard locking device Mechanical device to maintain an interlocking guard gate in the closed and locke
38、d position until the risk of injury from the hazardous machine functions has passed. The Standard is downloaded from Standard Sharing 7 AS 4024.30022009 www.standards.org.au Standards Australia 1.4.8 Hydraulic press Machine designed or intended to transmit energy by linear movement between closing
39、tools by hydraulic means for the purpose of the working (e.g. forming or shaping) of cold metal or material partly of cold metal between the tools. Such energy is produced by the effects of hydrostatic pressure (see Figures 1.1 and 1.2). 1.4.9 Limited movement control device (inching device) Control
40、 device whose actuation permits only a limited amount of travel of a machine element, thus minimizing risk as far as possible; further movement is precluded until there is a subsequent and separate actuation of the control. 1.4.10 Monitoring (M) Safety function which ensures that a safety measure is
41、 initiated if the ability of a component of an element to perform its function is reduced, or if the process conditions are changed in such a way that hazards are generated. 1.4.11 Muting Temporary automatic suspension of a safety function(s) by safety related parts of the control system during othe
42、rwise safe conditions in the operation of a machine. 1.4.12 Overall system stopping performance (overall response time) Time occurring from the actuation of the sensing function to the cessation of hazardous motion, or to the machine assuming a safe condition. 1.4.13 Part detector Device that detect
43、s the workpiece or the correct position of the workpiece and which permits or prevents the initiation of the stroke. 1.4.14 Position switch Switch that is operated by a moving part of the machine when this part reaches or leaves a predetermined position. 1.4.15 Redundancy (R) Application of more tha
44、n one device or system, or part of a device or a system, to ensure that, in the event of one failing to perform its function, another is available to perform that function. NOTE: Where the term redundant is used, provision of a redundancy feature or element is implied. 1.4.16 Restraint valve Device
45、that protects against a gravity fall of the slide or ram. 1.4.17 Single stroke function Feature used to limit the motion of the tool to one operating cycle (single cycle) even if the stroke initiating means (e.g. a pedal) is held in the operating position. 1.4.18 Slide or ram Main reciprocating pres
46、s member that holds the tools. 1.4.19 Tool The moving part of the tools used in a press. 1.4.20 Tool protective device Device that protects the tool against damage by stopping the stroke or by preventing its start. AS 4024.30022009 8 Standards Australia www.standards.org.au 1.4.21 Tools Term for the
47、 combination of tool and die. 1.4.22 Toolsclosed Tools designed and constructed to be inherently safe. NOTE: An example of a closed tool is given in Appendix A. 1.4.23 Up-stroking press Vertical press in which the press table moves upwards during the closing stroke (reciprocal to a down-stroking pre
48、ss). The Standard is downloaded from Standard Sharing 9 AS 4024.30022009 www.standards.org.au Standards Australia NOTE: Tools area safeguards not shown. FIGURE 1.1 EXAMPLE OF BOX FRAME TYPE HYDRAULIC PRESS AS 4024.30022009 10 Standards Australia www.standards.org.au NOTE: Tools area safeguards not
49、shown. FIGURE 1.2 EXAMPLE OF OPEN FRONT PRESS The Standard is downloaded from Standard Sharing 11 AS 4024.30022009 www.standards.org.au Standards Australia S E C T I O N 2 H A Z A R D S 2.1 GENERAL Table 2.1 lists significant hazards and their related danger zones normally associated with a hydraulic power press. It is derived from a risk assessment of hydraulic presses c