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First International Seminar, SAFE 99, on Safety & Fire Engineering, Cochin, India, November 24-26, 1999
PRINCIPLES OF MACHINE GUARDING
M.N. Vinodkumar and A.B. Bhasi
Department of Mechanical Engineering,
Cochin University of Science and Technology, Cochin ~ 22.
SYNOPSIS
While working on machines accidents may occur due to different reasons including
human negligence. To avoid accidents the machines can be guarded using different types of
‘guards preventing persons from reaching the unsafe area while the machine is running. This
paper describes the different types of machine guarding techniques used in recent times.
INTRODUCTION
Machines are dangerous because they are designed to change the shape and form of
materials which human bodies cannot do. Whenever man and machine meet, the possibility
of accidents is always there. To safe guard workers who operate and maintain machines, it
is necessary to make the machines safe.
‘Accidents occur when a person is in danger area where a dangerous part of machinery is
in motion. If a barrier is brought in between these two it can ensure that a person or his
clothing is not coming in contact with the dangerous parts of the machinery.
Human failure is the main cause of industrial accidents. Human nature is unpredictable
and we cannot entirely rely upon the skill and experience of the operator working on the
machine. Physical, mental and emotional differences cause different people to perform
guard the dangerous part before the machine can be operated.
> stay closed until the dangerous part is at rest
> prevent operation of the machine if the interlocking device fails.
Automatic guards
“There are used where neither a fixed guards nor an interlocking guard is practicable. Such
‘4 guard must prevent the operator from coming in contract with the dangerous part of the
machine while it is in motion, ot must be able to stop the machine in case of danger.
‘An automatic guard is usually operated by the machine itself through a system of linkages
or through levers, and there are many variations, such as a swing guard, a sweep guard or a
pull back guard.
415 ‘Trip guards
When the person or his hands comes to the danger area the power is cut off with the help
of an electric eye. It also brakes the machine quickly to stop it or prevent it's starting.
Two hand trip
‘This ensures that the operator is away from the danger zone of the machine as both hands
are to be simultaneously used to start the machine. They may press two electric switch buttons
6 operate two control valves or mechanical levers to start the machine.
Photo electric guard
In this type a light curtain is provided instead of mechanical barriers. A light source and
a photo-cell receiver is provided across the danger area. The photo cells control the operation
of a relay system which inturn controls the running of the machine. If the light curtain is
interrupted, the machine comes to a stop.
Point of operation guards
Special types of guards are necessary at the point of operation of various machines
depending upon the specific operation and nature of feeding.
In presses individual die guards prevent operators from placing their hands between the
die and the punch. Fixed barrier guards are also used especially in automatic presses where
the point of operation must be occasionally exposed so that jams can be relieved,
In machine tools splash guards, shields and the means of guarding may be used to prevent,
the exposure of the workers to cutting oils which may cause skin irritation especially if
contaminated.
Im boring and drilling machines a simple sleeve guard or other barrier that protects the
operator from the spindle can be used.
Providing guards for machines will not always keep accidents away. The employees who
works around mechanical equipments or the operator of a machinery must maintain a healthy
respect for safe guards. The following practices must be always maintained for safety.
> No guard should be adjusted or removed for any reason by anyone unless
specific permission is given by the supervisor
the person concerned i
machine adjustment is considered a normal part of his job
46 v
No machine should be started unless the guards are in place and in good condition,
‘When guards or devices are removed for any reason, the power for the equipment should
be tumed off and the main switch locked and tagged.
No employees should be permitted to work on or around mechanical equipment while
wearing loose clothes or jewelry.
Inspection and maintenance of guards should be carried out regularly as a part of
maintenance schedule,
Safety devices
When guards come in between the machine and the operator preventing his unnecessary
or careless movement near the danger area, there are some incidental safety devices, which can
help to avoid accidents. The examples are:
>
>
>
>
Belt shifters used for shifting belts from one pulley to another.
Use of magnetic fingers, suction cups, tongs and similar special tools in presses and
broaching machines.
's on a power press, Which does not permit another stroke to occur even
Non repeat devi
if the pedal is kept depressed,
Emergency switches at the close proximity of the worker.
DESIGN AND CONSTRUCTION OF GUARDS
‘The following aspects must be considered in designing and construction of guards to serve
it’s purpose effectively.
>
vvvy
vvy
It should provide positive protection and prevent all access to the danger zone during
operation, It is not enough for the guard to give only a warning signal or an alarm to the
operator.
It should not cause discomfort or inconvenience to the operator.
It should not unnecessarily interfere with the production,
It should work with minimum effort
It should be best suited for the job and machine,
It should not weaken the structure of the machine.
It should require minimum maintenance
It should be durable and resist normal wear and shock during the operation of the
machine
It should not constitute hazards by itself.
an CONCLUSION
Good maintenance of machines and guards is very important for safe working and
efficient production. Machines should always be used within their rated capabilities as
otherwise some form of defect or mechanical failure can occur which may c nt. It
is most essential that every management must procure equipments of highest standards and
maintain fool-proof safety system in order to reduce serious accidents, down time, loss of
se accel
production and maintenance cost
In addition to making the machines safe, the supervisors and persons working on
machines must be trained and educated about the importance of safety.
REFERENCES
1, Indian Factories Act and Rules thereunder
2. Accident Prevention Manual for Industrial Operations published by the National Safety
Council of America (6 Edition), USA.
3. Heinrich, H.W., “Industrial Accident Prevention”, Me Graw Hill Book Co., USA.
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