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AS 4024.3001-2009

AS 4024.3001-2009

Safety of machinery Materials forming and shearing - Mechanical power presses

Standards Australia

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Table of Contents

<toc>
<bookmarktable>
<bookmark index=&apos;0&apos;>
<pageno>1</pageno>
<text>AS 4024.3001-2009 SAFETY OF MACHINERY - MATERIALS FORMING AND SHEARING-MECHANICAL POWER PRESSES</text>
<bookmark index=&apos;1&apos;>
<pageno>4</pageno>
<text>PREFACE</text>
</bookmark>
<bookmark index=&apos;2&apos;>
<pageno>5</pageno>
<text>CONTENTS</text>
</bookmark>
<bookmark index=&apos;3&apos;>
<pageno>6</pageno>
<text>SECTION 1 SCOPE AND GENERAL</text>
<bookmark index=&apos;4&apos;>
<pageno>6</pageno>
<text>1.1 SCOPE</text>
</bookmark>
<bookmark index=&apos;5&apos;>
<pageno>6</pageno>
<text>1.2 OBJECTIVE</text>
</bookmark>
<bookmark index=&apos;6&apos;>
<pageno>7</pageno>
<text>1.3 REFERENCED DOCUMENTS</text>
</bookmark>
<bookmark index=&apos;7&apos;>
<pageno>8</pageno>
<text>1.4 DEFINITIONS</text>
<bookmark index=&apos;8&apos;>
<pageno>8</pageno>
<text>1.4.1 Band brake</text>
</bookmark>
<bookmark index=&apos;9&apos;>
<pageno>8</pageno>
<text>1.4.2 Brake</text>
</bookmark>
<bookmark index=&apos;10&apos;>
<pageno>8</pageno>
<text>1.4.3 Clutch</text>
</bookmark>
<bookmark index=&apos;11&apos;>
<pageno>8</pageno>
<text>1.4.4 Clutch-full revolution</text>
</bookmark>
<bookmark index=&apos;12&apos;>
<pageno>8</pageno>
<text>1.4.5 Clutch-part revolution</text>
</bookmark>
<bookmark index=&apos;13&apos;>
<pageno>8</pageno>
<text>1.4.6 Cycle</text>
</bookmark>
<bookmark index=&apos;14&apos;>
<pageno>8</pageno>
<text>1.4.7 Dead centres</text>
</bookmark>
<bookmark index=&apos;15&apos;>
<pageno>8</pageno>
<text>1.4.8 Die</text>
</bookmark>
<bookmark index=&apos;16&apos;>
<pageno>8</pageno>
<text>1.4.9 Die cushion</text>
</bookmark>
<bookmark index=&apos;17&apos;>
<pageno>9</pageno>
<text>1.4.10 Direct drive</text>
</bookmark>
<bookmark index=&apos;18&apos;>
<pageno>9</pageno>
<text>1.4.11 Early opening interlocking guard</text>
</bookmark>
<bookmark index=&apos;19&apos;>
<pageno>9</pageno>
<text>1.4.12 Extractor</text>
</bookmark>
<bookmark index=&apos;20&apos;>
<pageno>9</pageno>
<text>1.4.13 Guard locking device</text>
</bookmark>
<bookmark index=&apos;21&apos;>
<pageno>9</pageno>
<text>1.4.14 Limited movement control device</text>
</bookmark>
<bookmark index=&apos;22&apos;>
<pageno>9</pageno>
<text>1.4.15 Mechanical press</text>
</bookmark>
<bookmark index=&apos;23&apos;>
<pageno>10</pageno>
<text>1.4.16 Monitoring</text>
</bookmark>
<bookmark index=&apos;24&apos;>
<pageno>10</pageno>
<text>1.4.17 Muting</text>
</bookmark>
<bookmark index=&apos;25&apos;>
<pageno>10</pageno>
<text>1.4.18 Overall system stopping performance</text>
</bookmark>
<bookmark index=&apos;26&apos;>
<pageno>11</pageno>
<text>1.4.19 Overrun</text>
</bookmark>
<bookmark index=&apos;27&apos;>
<pageno>11</pageno>
<text>1.4.20 Overrun monitoring device</text>
</bookmark>
<bookmark index=&apos;28&apos;>
<pageno>11</pageno>
<text>1.4.21 Position switch</text>
</bookmark>
<bookmark index=&apos;29&apos;>
<pageno>11</pageno>
<text>1.4.22 Redundancy</text>
</bookmark>
<bookmark index=&apos;30&apos;>
<pageno>11</pageno>
<text>1.4.23 Shut height</text>
</bookmark>
<bookmark index=&apos;31&apos;>
<pageno>11</pageno>
<text>1.4.24 Single stroke function</text>
</bookmark>
<bookmark index=&apos;32&apos;>
<pageno>11</pageno>
<text>1.4.25 Slide</text>
</bookmark>
<bookmark index=&apos;33&apos;>
<pageno>11</pageno>
<text>1.4.26 Tool</text>
</bookmark>
<bookmark index=&apos;34&apos;>
<pageno>11</pageno>
<text>1.4.27 Tools</text>
</bookmark>
<bookmark index=&apos;35&apos;>
<pageno>11</pageno>
<text>1.4.28 Tools-closed</text>
</bookmark>
</bookmark>
</bookmark>
<bookmark index=&apos;36&apos;>
<pageno>13</pageno>
<text>SECTION 2 HAZARDS</text>
<bookmark index=&apos;37&apos;>
<pageno>13</pageno>
<text>2.1 GENERAL</text>
</bookmark>
<bookmark index=&apos;38&apos;>
<pageno>13</pageno>
<text>2.2 RISK ASSESSMENT</text>
</bookmark>
</bookmark>
<bookmark index=&apos;39&apos;>
<pageno>15</pageno>
<text>SECTION 3 SAFETY REQUIREMENTS AND MEASURES</text>
<bookmark index=&apos;40&apos;>
<pageno>15</pageno>
<text>3.1 INTRODUCTION</text>
</bookmark>
<bookmark index=&apos;41&apos;>
<pageno>15</pageno>
<text>3.2 BASIC DESIGN CONSIDERATIONS</text>
<bookmark index=&apos;42&apos;>
<pageno>15</pageno>
<text>3.2.1 Brakes and clutches</text>
</bookmark>
<bookmark index=&apos;43&apos;>
<pageno>16</pageno>
<text>3.2.2 Presses with part revolution clutches (friction clutches)</text>
</bookmark>
<bookmark index=&apos;44&apos;>
<pageno>16</pageno>
<text>3.2.3 Presses with full revolution clutches</text>
</bookmark>
<bookmark index=&apos;45&apos;>
<pageno>17</pageno>
<text>3.2.4 Hydraulic and pneumatic systems-common features</text>
</bookmark>
<bookmark index=&apos;46&apos;>
<pageno>18</pageno>
<text>3.2.5 Pneumatic systems</text>
</bookmark>
<bookmark index=&apos;47&apos;>
<pageno>18</pageno>
<text>3.2.6 Hydraulic systems</text>
</bookmark>
<bookmark index=&apos;48&apos;>
<pageno>19</pageno>
<text>3.2.7 Slide adjustment and stroke adjustment</text>
</bookmark>
<bookmark index=&apos;49&apos;>
<pageno>19</pageno>
<text>3.2.8 Electrical systems</text>
</bookmark>
</bookmark>
<bookmark index=&apos;50&apos;>
<pageno>19</pageno>
<text>3.3 MECHANICAL HAZARDS IN THE TOOLS AREA</text>
<bookmark index=&apos;51&apos;>
<pageno>19</pageno>
<text>3.3.1 General</text>
</bookmark>
<bookmark index=&apos;52&apos;>
<pageno>20</pageno>
<text>3.3.2 Safeguarding measures</text>
</bookmark>
<bookmark index=&apos;53&apos;>
<pageno>20</pageno>
<text>3.3.3 Limits of protection</text>
</bookmark>
<bookmark index=&apos;54&apos;>
<pageno>20</pageno>
<text>3.3.4 Control system category</text>
</bookmark>
<bookmark index=&apos;55&apos;>
<pageno>26</pageno>
<text>3.3.5 Access required to more than one side</text>
</bookmark>
<bookmark index=&apos;56&apos;>
<pageno>26</pageno>
<text>3.3.6 Safe methods of work</text>
</bookmark>
<bookmark index=&apos;57&apos;>
<pageno>26</pageno>
<text>3.3.7 Closed tools</text>
</bookmark>
<bookmark index=&apos;58&apos;>
<pageno>26</pageno>
<text>3.3.8 Fixed enclosing guards</text>
</bookmark>
<bookmark index=&apos;59&apos;>
<pageno>26</pageno>
<text>3.3.9 Interlocking guards</text>
</bookmark>
<bookmark index=&apos;60&apos;>
<pageno>26</pageno>
<text>3.3.10 Control guards</text>
</bookmark>
<bookmark index=&apos;61&apos;>
<pageno>26</pageno>
<text>3.3.11 Early opening guards</text>
</bookmark>
<bookmark index=&apos;62&apos;>
<pageno>27</pageno>
<text>3.3.12 Presence sensing systems</text>
</bookmark>
<bookmark index=&apos;63&apos;>
<pageno>28</pageno>
<text>3.3.13 Preset time</text>
</bookmark>
<bookmark index=&apos;64&apos;>
<pageno>28</pageno>
<text>3.3.14 Two-hand controls</text>
</bookmark>
<bookmark index=&apos;65&apos;>
<pageno>29</pageno>
<text>3.3.15 Early opening guards</text>
</bookmark>
<bookmark index=&apos;66&apos;>
<pageno>29</pageno>
<text>3.3.16 Conditions of interlocking the motor and the clutch</text>
</bookmark>
<bookmark index=&apos;67&apos;>
<pageno>29</pageno>
<text>3.3.17 Single stroke devices</text>
</bookmark>
<bookmark index=&apos;68&apos;>
<pageno>29</pageno>
<text>3.3.18 Mechanical restraint devices</text>
</bookmark>
<bookmark index=&apos;69&apos;>
<pageno>29</pageno>
<text>3.3.19 Other requirements</text>
</bookmark>
</bookmark>
<bookmark index=&apos;70&apos;>
<pageno>30</pageno>
<text>3.4 CONTROL AND MONITORING SYSTEM</text>
<bookmark index=&apos;71&apos;>
<pageno>30</pageno>
<text>3.4.1 Control and monitoring functions</text>
</bookmark>
<bookmark index=&apos;72&apos;>
<pageno>31</pageno>
<text>3.4.2 Part revolution clutch presses: Redundancy and monitoring of clutch/brake control systems, and overrun monitoring...</text>
</bookmark>
<bookmark index=&apos;73&apos;>
<pageno>33</pageno>
<text>3.4.3 Muting</text>
</bookmark>
<bookmark index=&apos;74&apos;>
<pageno>33</pageno>
<text>3.4.4 Programmable electronic systems (PES), programmable pneumatic systems (PPS) and safety related functions</text>
</bookmark>
<bookmark index=&apos;75&apos;>
<pageno>34</pageno>
<text>3.4.5 Selector switches</text>
</bookmark>
<bookmark index=&apos;76&apos;>
<pageno>34</pageno>
<text>3.4.6 Isolation switch</text>
</bookmark>
<bookmark index=&apos;77&apos;>
<pageno>34</pageno>
<text>3.4.7 Position switches</text>
</bookmark>
<bookmark index=&apos;78&apos;>
<pageno>35</pageno>
<text>3.4.8 Control devices</text>
</bookmark>
<bookmark index=&apos;79&apos;>
<pageno>35</pageno>
<text>3.4.9 Valves</text>
</bookmark>
</bookmark>
<bookmark index=&apos;80&apos;>
<pageno>35</pageno>
<text>3.5 TOOLSETTING, TRIAL STROKES, MAINTENANCE AND LUBRICATION</text>
<bookmark index=&apos;81&apos;>
<pageno>35</pageno>
<text>3.5.1 General</text>
</bookmark>
<bookmark index=&apos;82&apos;>
<pageno>35</pageno>
<text>3.5.2 Guarding</text>
</bookmark>
<bookmark index=&apos;83&apos;>
<pageno>36</pageno>
<text>3.5.3 Trial strokes</text>
</bookmark>
<bookmark index=&apos;84&apos;>
<pageno>36</pageno>
<text>3.5.4 Feeder devices</text>
</bookmark>
<bookmark index=&apos;85&apos;>
<pageno>36</pageno>
<text>3.5.5 Manual rotation of the crankshaft</text>
</bookmark>
<bookmark index=&apos;86&apos;>
<pageno>36</pageno>
<text>3.5.6 Additional control devices</text>
</bookmark>
<bookmark index=&apos;87&apos;>
<pageno>36</pageno>
<text>3.5.7 Opening movable guards</text>
</bookmark>
<bookmark index=&apos;88&apos;>
<pageno>36</pageno>
<text>3.5.8 Two-hand controls</text>
</bookmark>
<bookmark index=&apos;89&apos;>
<pageno>36</pageno>
<text>3.5.9 Limited movement devices</text>
</bookmark>
<bookmark index=&apos;90&apos;>
<pageno>37</pageno>
<text>3.5.10 Devices provided for toolsetting</text>
</bookmark>
<bookmark index=&apos;91&apos;>
<pageno>37</pageno>
<text>3.5.11 Interfaces</text>
</bookmark>
</bookmark>
<bookmark index=&apos;92&apos;>
<pageno>37</pageno>
<text>3.6 OTHER MECHANICAL HAZARDS</text>
<bookmark index=&apos;93&apos;>
<pageno>37</pageno>
<text>3.6.1 Safeguarding drive and transmission machinery</text>
</bookmark>
<bookmark index=&apos;94&apos;>
<pageno>37</pageno>
<text>3.6.2 Safeguarding ancillary devices</text>
</bookmark>
<bookmark index=&apos;95&apos;>
<pageno>37</pageno>
<text>3.6.3 Ejection hazards</text>
</bookmark>
</bookmark>
<bookmark index=&apos;96&apos;>
<pageno>37</pageno>
<text>3.7 SLIPS, TRIPS AND FALLS</text>
</bookmark>
<bookmark index=&apos;97&apos;>
<pageno>37</pageno>
<text>3.8 PROTECTION AGAINST OTHER HAZARDS</text>
<bookmark index=&apos;98&apos;>
<pageno>37</pageno>
<text>3.8.1 Electrical hazards</text>
</bookmark>
<bookmark index=&apos;99&apos;>
<pageno>38</pageno>
<text>3.8.2 Thermal hazards</text>
</bookmark>
<bookmark index=&apos;100&apos;>
<pageno>38</pageno>
<text>3.8.3 High pressure fluid ejection hazards</text>
</bookmark>
<bookmark index=&apos;101&apos;>
<pageno>38</pageno>
<text>3.8.4 Hazards generated by noise</text>
</bookmark>
<bookmark index=&apos;102&apos;>
<pageno>38</pageno>
<text>3.8.5 Hazards generated by vibration</text>
</bookmark>
<bookmark index=&apos;103&apos;>
<pageno>38</pageno>
<text>3.8.6 Hazards generated by materials and substances</text>
</bookmark>
<bookmark index=&apos;104&apos;>
<pageno>39</pageno>
<text>3.8.7 Hazards generated by neglecting ergonomic principles</text>
</bookmark>
</bookmark>
</bookmark>
<bookmark index=&apos;105&apos;>
<pageno>40</pageno>
<text>SECTION 4 INFORMATION FOR USE</text>
<bookmark index=&apos;106&apos;>
<pageno>40</pageno>
<text>4.1 MARKING</text>
</bookmark>
<bookmark index=&apos;107&apos;>
<pageno>40</pageno>
<text>4.2 INSTRUCTION HANDBOOK</text>
</bookmark>
</bookmark>
<bookmark index=&apos;108&apos;>
<pageno>42</pageno>
<text>APPENDIX A - PRESSES WITH FULL REVOLUTION CLUTCHES-DESIGN REQUIREMENTS</text>
<bookmark index=&apos;109&apos;>
<pageno>42</pageno>
<text>A1 EXTRACTOR DESIGN</text>
<bookmark index=&apos;110&apos;>
<pageno>42</pageno>
<text>A1.1 Clutch engagement</text>
</bookmark>
<bookmark index=&apos;111&apos;>
<pageno>42</pageno>
<text>A1.2 Movement limitation</text>
</bookmark>
<bookmark index=&apos;112&apos;>
<pageno>42</pageno>
<text>A1.3 Mechanical interlocking</text>
</bookmark>
<bookmark index=&apos;113&apos;>
<pageno>42</pageno>
<text>A1.4 Rolling key clutch</text>
</bookmark>
</bookmark>
<bookmark index=&apos;114&apos;>
<pageno>42</pageno>
<text>A2 PREVENTION OF OVERRUN AND FALL-BACK</text>
<bookmark index=&apos;115&apos;>
<pageno>42</pageno>
<text>A2.1 General</text>
</bookmark>
<bookmark index=&apos;116&apos;>
<pageno>42</pageno>
<text>A2.2 Interlocking guards</text>
</bookmark>
</bookmark>
</bookmark>
<bookmark index=&apos;117&apos;>
<pageno>43</pageno>
<text>APPENDIX B - INTERLOCKING GUARDS</text>
<bookmark index=&apos;118&apos;>
<pageno>43</pageno>
<text>B1 PRESSES WITH FULL REVOLUTION CLUTCHES</text>
<bookmark index=&apos;119&apos;>
<pageno>43</pageno>
<text>B1.1 Guard gate</text>
</bookmark>
<bookmark index=&apos;120&apos;>
<pageno>43</pageno>
<text>B1.2 Guard performance</text>
</bookmark>
<bookmark index=&apos;121&apos;>
<pageno>43</pageno>
<text>B1.3 Extractor interlocking device</text>
</bookmark>
<bookmark index=&apos;122&apos;>
<pageno>43</pageno>
<text>B1.4 Guard to extractor linkage</text>
</bookmark>
</bookmark>
<bookmark index=&apos;123&apos;>
<pageno>44</pageno>
<text>B2 PRESSES WITH PART REVOLUTION CLUTCHES</text>
<bookmark index=&apos;124&apos;>
<pageno>44</pageno>
<text>B2.1 Hand fed press</text>
</bookmark>
<bookmark index=&apos;125&apos;>
<pageno>44</pageno>
<text>B2.2 Early opening guard</text>
</bookmark>
<bookmark index=&apos;126&apos;>
<pageno>44</pageno>
<text>B2.3 Automatic feed</text>
</bookmark>
</bookmark>
</bookmark>
<bookmark index=&apos;127&apos;>
<pageno>46</pageno>
<text>APPENDIX C - CALCULATION OF MINIMUM SAFETY DISTANCES</text>
<bookmark index=&apos;128&apos;>
<pageno>46</pageno>
<text>C1 SAFETY DISTANCE</text>
</bookmark>
<bookmark index=&apos;129&apos;>
<pageno>46</pageno>
<text>C2 DETERMINATION OF K</text>
</bookmark>
<bookmark index=&apos;130&apos;>
<pageno>46</pageno>
<text>C3 DETERMINATION OF C</text>
</bookmark>
<bookmark index=&apos;131&apos;>
<pageno>46</pageno>
<text>C4 SYSTEM STOPPING PERFORMANCE</text>
</bookmark>
<bookmark index=&apos;132&apos;>
<pageno>47</pageno>
<text>C5 POSITION OF PROTECTIVE DEVICES</text>
</bookmark>
<bookmark index=&apos;133&apos;>
<pageno>47</pageno>
<text>C6 DETERMINATION OF C</text>
</bookmark>
</bookmark>
<bookmark index=&apos;134&apos;>
<pageno>48</pageno>
<text>APPENDIX D - SETTING OF THE ROTARY CAM ARRANGEMENT</text>
<bookmark index=&apos;135&apos;>
<pageno>48</pageno>
<text>D1 BASIC FEATURES OF THE ECCENTRIC ADJUSTMENT AND ROTARY CAM ARRANGEMENT</text>
</bookmark>
<bookmark index=&apos;136&apos;>
<pageno>53</pageno>
<text>D2 DETERMINATION OF THE POSITION WHERE MUTING BEGINS</text>
</bookmark>
</bookmark>
<bookmark index=&apos;137&apos;>
<pageno>56</pageno>
<text>APPENDIX E - DETERMINATION OF OVERALL RESPONSE TIME</text>
<bookmark index=&apos;138&apos;>
<pageno>56</pageno>
<text>E1 SCOPE</text>
</bookmark>
<bookmark index=&apos;139&apos;>
<pageno>56</pageno>
<text>E2 RESPONSE TIME</text>
</bookmark>
<bookmark index=&apos;140&apos;>
<pageno>56</pageno>
<text>E3 DETERMINATION OF t1</text>
</bookmark>
<bookmark index=&apos;141&apos;>
<pageno>56</pageno>
<text>E4 DETERMINATION OF t2</text>
</bookmark>
<bookmark index=&apos;142&apos;>
<pageno>57</pageno>
<text>E5 DETERMINATION OF t3</text>
</bookmark>
<bookmark index=&apos;143&apos;>
<pageno>59</pageno>
<text>E6 COMMENTARY ON FIGURES E3 AND E4</text>
</bookmark>
</bookmark>
</bookmark>
</bookmarktable>
</toc>

Abstract

Sets out requirements for mechanical power presses that are intended to work cold metal or material partly of cold metal. Does not apply to guillotines, brake presses, straighteners, turret punch presses, extruders, forging presses, compaction of metal powder or printing presses.

Scope

This Standard specifies technical safety requirements and measures for the design, manufacture and supply of mechanical 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 (series) should be considered, but may not be capable of being fully applied. This Standard 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 which are used in a similar way to work other materials (e.g. cardboard, plastic, rubber or leather), and metal powder.
The requirements in this Standard take account of intended use. This Standard presumes access to the press from all directions and specifies the safety measures for both the operator and other exposed persons.
This Standard also applies to ancillary devices that are integral parts of the press. 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, stapling or stitching;
(c) bending or folding by brake presses;
(d) straightening;
(e) turret punch pressing;
(f) extruding;
(g) drop forging or drop stamping;
(h) compaction of metal powder;
(i) single purpose punching machines designed exclusively for profiles, e.g. for the construction industry; or
(j) printing presses.

General Product Information

Document Type Standard
Status Current
Publisher Standards Australia
Committee SF-008
Supersedes
  • AS 1219-1994
  • DR 04137

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