MACHINE SAFETY Sate, Quick Jam Clearing Interlocked barrier guards provide an alternative to lengthy lockout/ ark NenrRors Omren ST Machine Senviooe tagaut procedur Siege ios a ube mated woodcutting machinery i 10 Beg ceeere thee Jrms gly without exposure to potentially haz nas machine motion. Simply ofening up the machine o clear ajar runs the risk that stored electrical or hydraulic tnergy might caus the machin to mave, On the other nand, performing a lckouttagout oper tion tu pet ie aun ino way sole ate tales 1 considerable smoutt of time. To devel op = saw gunrding eyetnn, Haske Marines fn Soddy Daisy, TN, worked with Omron Machine Services, maker of machine and process safe guarding preducts based in Arabeim, CA, The result was a relay based system that automat Cally shuts down snd locks out the Hasko FSM Metchester flooring machine in sppronimately iSenatarinlthegepch enon SRE stock for woodcutting machinery. cone minute 9 1, "The machine has a series of buttons that can the pished to open guards on various parts for fast access. But even after the machine is pow- ered down, there isthe small chance that poten- tial energy in the hydraulic or electrical power systems might expose the operator to hazardous motion. A typical lock out/ag out procesure involves tuning off the power at the control ppancl and puting @ padlock on the ewiteh to prevent it from being turned on until work is romrleted This procedure takes abeut 15 min- ‘utesmany times longer then clearing the actual jam, Hasko determined that clearing out the ‘machine falls under the OSHA lockoutitegout exception (OSHA 29 CER 1910,147(ajn))) that ‘makes it possible 1 ullze alternative measures te provide 0 cafeguard. Ga unique zero speed sensor, compatible with an inverter used on Hasko machine motors, eliminates the need for external hardware such ae motion detection senears ‘The Hasto FSM MawhMMaster cam produce more then 20,000 linear feet of tongue and {groove herdwact Booring por chift, The machina features directly oppesed sidebeads, built in top ‘and bottom jointers. programmable loxic con- troller (PLC) and electric motor breaking Periodically, it's necessary for the operator to stop the machine and remove a jammed board, ‘make a machine adjustment, or perform a simi- lar task. So Hasko has developed a unique pro- ‘cess for clearing ajam anywhere in the machine (ad Feotitieg eo counted bo cnack position te Meeting sefety standards Hasko set out to developed a machine control system that srould maintain the epeod af i quick-clear method while incorporating safe- suards and circuits that meet the alternative ‘measure standards as described in ANSUASSE 2244,1-2003, particularly clause 5.4.3.2 where levels of control circuit integrity are deserited. ‘We decided to partner with Omron Machine ‘Serves on this projet” wick provides prod ‘ucts and system integration services, explains Mingus Abus) techie opeations iasngerfor Pasko. A zero speed sensor compatible with fn inverter used to contral the machine's motor, says Abstan, eliminsting the need for external hardware such as motion detection sensors.” Hasko and Omron Machine Services engi neers worked together to develop a method for patting the machine in a safe mode within eeténde op the ,qpenater. auld sent a, jem. in less than & minate The new guarding sys- tem includes interlocked barrier guards using an Omron ST! dual cbanael monitoring relay (model SR2O8AD). ‘Three SR122 expansion ardseg mei deal humecd anaitatig of the six Omron STI locking interlock switches {model 714019). Five Omron STI stop-motion SRIZ5SMS monitoring relays are used, one for ‘each motor drive. When the operator presses the stop signal, the monitoring relay detecss the beck electromagnetic force (EMF) of the motor ‘Once the drives have decelerated the motors and stopped the cutler heads, the delayed out [puts of the SRZOBAD relays are used to remove power from the cutier head drives. The relay then signals the guard locking evitch te wnlock the guard, allowing safe access to the mackine Abston says this dual channel with monitor: ing cizcuit for locking interiocked barrier guards ‘complies with ANS! BI1.19 and ANSUINFPA T9for imeslocked guards, where the hazardous motion can have excessive coast down time and the operator could reach the hazard prior tn cos sation of motion, Depressurtzing hydraulic system ‘The hydraulic civcuit also employs an ANSI biecking sclenoid valve that dumpe precsure from the main supply manifold to the tank when it is not energized. This value has spool position ‘monitoring wired into the safety circuit monitor ing loop to ensare that the hydraulic feed motors sad eds ace Tnclatedl ees Iiydiic gps: during safery end emergency stops as required According to Abston. iydraulic valve redun- ‘ancy with monitoring ofthe coil position com- plies with the intent of ANSI B11.19 for single component failure for the rydrautie components that have direct control of pointof-operation ‘The emergency stop circuit includes an (Omen STI dusl channe) monitoring relay model ‘SR208AD that provides dual channel monitor of all emergency stop pushbuttons. The circuit provides contacts from dual channel force mui i vcage ati tored by the relay Contacts are then interfaced to the PLC. All PLC outpats are Interrupted, with the ‘exception of those that fre necesary 16 allow for opening the machine feed rolls to clear jammed stock, Use of redundant monitored interlock circuits means that al single faults are detected io. the oafety control system, ith no loss of the safety Fumetion, says Abston ‘The new integrated safety system increases safety and production over existing machines, Absion says. Hasko is providing the new machine Safeguarding as an optlon thet costs approx! mately 58 of the total cost of the machine, The reduction in the time ta clear jams—frars more than 15 minutes to less than 1 minute~pays back the additional cost of the of the safety fea tures in less than one year. ‘the time to perform. ‘ther common operations, such as checking the height of the bottom hand, bas been reduced by a similar amount, Abston adds. Collaboration among the customer, system integrator, resulted in a “system thal provides substantial improvements in both productivity aud salety," Abston cascades, “Phe sew safety tystem hae been eo sucosssful that we are incor. porating its features into other machines. such as a new ripsaw that we have just developed. The new safety system gives us a considerable advan tage over our compentors” e@ ‘Mark Nekriorn is the Safety Integration Divi (an snanogor for Cnn STY Scie Ser eok For moze information, vist: wivw.haskomachines.com worn sti.com wan. sumacmeserices.con Engineers worked together to develop a ‘method for putting the ‘machina in 9 safe mode jn a mattor of seconds ‘sothe operator could clear a jam i ess than a mew. images courtesy of ask ONLINE wa controteng.com/ drehive: ‘Sata Motion Choiens ‘March 2007 and Safety, July 2006 ‘Also search machine at wwwosha.gov ‘wovw.controlong.com + CONTROL ENGINEERING 1ULY 2007 « 77