AS 1219-1994

1 - AS 1219-1994 POWER PRESSES - SAFETY REQUIREMENTS
4 - PREFACE
5 - CONTENTS
7 - SECTION 1 SCOPE AND GENERAL
7 - 1.1 SCOPE
7 - 1.2 OBJECTIVE
7 - 1.3 APPLICATION
7 - 1.4 REFERENCED DOCUMENTS
8 - 1.5 DEFINITIONS
8 - 1.5.1 Accompanying documents
8 - 1.5.2 Ancillary equipment
8 - 1.5.3 Arrester brake
8 - 1.5.4 Competent person
8 - 1.5.5 Die safety block
8 - 1.5.6 Extractor
8 - 1.5.7 Guards
8 - 1.5.8 Hazardous area
9 - 1.5.9 Inching
9 - 1.5.10 Muting
9 - 1.5.11 Nip point
9 - 1.5.12 Overrun or fall-back
9 - 1.5.13 Power presses
9 - 1.5.14 Regulatory authority
9 - 1.5.15 Safe distance
9 - 1.5.16 Shall
9 - 1.5.17 Should
9 - 1.5.18 Shear
9 - 1.5.19 Shear point
9 - 1.5.20 Self-monitoring
9 - 1.5.21 Stops
9 - 1.5.22 Stroke
11 - SECTION 2 DESIGN AND CONSTRUCTION GENERAL REQUIREMENTS
11 - 2.1 GENERAL
11 - 2.2 PROTECTION OF PEOPLE
11 - 2.3 RAM COUNTERBALANCE
11 - 2.4 SECONDARY RETENTION OF ELECTRIC MOTORS
11 - 2.5 FLYWHEEL BRAKE
11 - 2.6 ILLUMINATION OF THE DIE SPACE
12 - 2.7 FEEDING AND EJECTION METHODS
12 - 2.8 INITIATING CONTROLS FOR DRIVE MOTOR
12 - 2.8.1 Control design
12 - 2.8.2 Start and stop controls
12 - 2.8.3 Mechanical strength
12 - 2.8.4 Protection of controls
12 - 2.8.5 Emergency stop controls
12 - 2.9 RAM-OPERATING SYSTEMS
12 - 2.9.1 General
12 - 2.9.2 Stroke-initiating controls
12 - 2.9.3 Hand-operated controls
13 - 2.9.4 Foot-operated controls
13 - 2.9.5 Ram adjustment
13 - 2.10 SELECTOR CONTROLS
13 - 2.10.1 General
13 - 2.10.2 Locking-in prevention
13 - 2.10.3 Prevention of operation
13 - 2.10.4 Stroke-initiating control
13 - 2.10.5 Multiple initiating controls
13 - 2.11 ARRESTER BRAKES
13 - 2.12 HAZARDOUS AREA
13 - 2.12.1 Unsafe access
14 - 2.12.2 Elimination of risk
14 - 2.12.3 Access to hazardous areas
14 - 2.12.4 Safety blocks
14 - 2.13 MONITORING DEVICES
14 - 2.14 HYDRAULIC PRESSES
14 - 2.14.1 General
14 - 2.14.2 Anti-repeat device
14 - 2.15 PNEUMATIC PRESSES
14 - 2.15.1 General
15 - 2.15.2 Use of air
16 - SECTION 3 DESIGN AND CONSTRUCTION - ELECTRICAL, AIR AND HYDRAULIC CONTROL SYSTEMS
16 - 3.1 ELECTRICAL CONTROL EQUIPMENT
16 - 3.1.1 General
16 - 3.1.2 Independent circuits
16 - 3.1.3 Independent safety devices
16 - 3.1.4 Solenoids
16 - 3.1.5 Manual reset
16 - 3.2 AIR CONTROL EQUIPMENT
16 - 3.2.1 General
16 - 3.2.2 Supply lines
16 - 3.2.3 Installation
17 - 3.2.4 Filters
17 - 3.2.5 Lubrication
17 - 3.2.6 Control valves
17 - 3.3 HYDRAULIC CONTROL EQUIPMENT
17 - 3.3.1 General
17 - 3.3.2 Supply lines
17 - 3.3.3 Removable parts
17 - 3.3.4 Draining
17 - 3.3.5 Piping
18 - 3.3.6 Filters
18 - 3.3.7 Reservoirs
18 - 3.3.8 Pumps
18 - 3.3.9 Hydraulic systems
19 - 3.3.10 Control valves
20 - SECTION 4 DESIGN AND CONSTRUCTION - CLUTCH AND BRAKE SYSTEMS
20 - 4.1 POSITIVE CLUTCHES
20 - 4.1.1 General requirements
20 - 4.1.2 Prevention of overrun or fall-back
20 - 4.1.3 Extractor
21 - 4.2 COMBINATION FRICTION CLUTCH AND BRAKE SYSTEMS
21 - 4.2.1 General
22 - 4.2.2 Air operation of clutch or brake
22 - 4.2.3 Use of springs
22 - 4.2.4 Clutch/brake monitoring system
22 - 4.2.5 Single-stroke device
22 - 4.2.6 Anti-repeat device
23 - 4.2.7 Rotary limit-switch drive
23 - 4.2.8 Prevention of overrun and fall-back
23 - 4.2.9 Control of driving motor
23 - 4.3 EDDY-CURRENT CLUTCHES
23 - 4.3.1 Clutch circuit
23 - 4.3.2 Anti-repeat device
23 - 4.3.3 Rotary limit-switch drive
24 - SECTION 5 INSTALLATION OF POWER PRESSES
24 - 5.1 GENERAL
24 - 5.2 PLANNING
24 - 5.3 LAYOUT
25 - SECTION 6 GUARDING
25 - 6.1 GENERAL
25 - 6.2 GUARDING AT OTHER THAN THE POINT OF OPERATION
25 - 6.2.1 General requirements
25 - 6.2.2 Projecting parts on control elements
25 - 6.2.3 Guarding of moving parts
25 - 6.3 GUARDING OF THE POINT OF OPERATION
26 - 6.4 REMOVAL OF GUARDS
26 - 6.4.1 General
26 - 6.4.2 Power stamping press
26 - 6.4.3 Brake presses
27 - 6.5 SELF-ACTUATING GUARDS
27 - 6.5.1 General
27 - 6.5.2 Preferred application
27 - 6.5.3 Use of automatic guards
28 - 6.5.4 Design and construction
28 - 6.5.5 Installation
28 - 6.5.6 Specific requirements
28 - 6.5.7 Additional safety guards
29 - 6.6 STROKE ACTUATING GUARDS
29 - 6.7 MICROPROCESSING AND PROGRAMMABLE LOGIC CONTROLS
29 - 6.8 SUPERVISORY CIRCUITS
30 - SECTION 7 INSTRUCTIONS FOR OPERATING AND MAINTENANCE
30 - 7.1 GENERAL
30 - 7.2 SYNOPSIS OF PLANT
30 - 7.3 OPERATING INSTRUCTIONS
30 - 7.4 MAINTENANCE INSTRUCTIONS
30 - 7.5 INSPECTION AND MAINTENANCE PROGRAM
30 - 7.6 REGULAR INSPECTION OF GUARDS AND SAFETY DEVICES
31 - 7.7 PERIODIC EXAMINATION OF GUARDS
31 - 7.8 PERIODIC EXAMINATION OF POWER PRESSES
32 - SECTION 8 TRAINING AND SUPERVISION OF OPERATORS
32 - 8.1 SAFE WORKING GUIDELINES
32 - 8.2 TRAINING
32 - 8.3 SUPERVISION
32 - 8.4 OPERATING PROCEDURES
33 - 8.5 RECORDS
34 - SECTION 9 TOOLS AND DIES
34 - 9.1 GENERAL
34 - 9.2 DIE DESIGN
34 - 9.2.1 Relevant factors
34 - 9.2.2 Guides
34 - 9.2.3 Safety block
34 - 9.2.4 Die mounting
34 - 9.2.5 Noise reduction
34 - 9.2.6 Die design check sheet
34 - 9.2.7 Die marking
35 - 9.3 LUBRICATION
35 - 9.4 PROVING OF TOOLS
35 - 9.5 DIE-SETTING
35 - 9.5.1 Personnel
35 - 9.5.2 Disconnection of power
35 - 9.5.3 Die-setting
35 - 9.5.4 Setting bar as lever
35 - 9.5.5 Equipment check
35 - 9.5.6 Trial pressings
35 - 9.5.7 Entry to the hazardous area
35 - 9.5.8 Unattended press
35 - 9.6 DIE MAINTENANCE
35 - 9.6.1 Personnel
35 - 9.6.2 Dies in press
36 - 9.6.3 Safety blocks to be inserted
36 - 9.6.4 Checkof safety devices
36 - 9.7 DIE HANDLING AND STORAGE
37 - SECTION 10 MATERIALS HANDLING
37 - 10.1 GENERAL
37 - 10.2 INCOMING MATERIAL
37 - 10.3 OUTGOING MATERIAL
37 - 10.4 PRESS-FEEDING METHODS
37 - 10.5 DISPOSAL OF PARTS
37 - 10.6 PRESS KNOCKOUTS AND LOWER LIFT-OUTS
38 - 10.7 GRAVITY EJECTION
38 - 10.8 ANCILLARY EQUIPMENT
38 - 10.8.1 General
38 - 10.8.2 Coil-feeding equipment
38 - 10.8.3 Die-loading facilities
38 - 10.8.4 Interpress handling
38 - 10.9 MANUAL HANDLING
39 - SECTION 11 SAFE SYSTEMS OF WORK
39 - 11.1 GENERAL
39 - 11.2 HIERARCHY OF CONTROL MEASURES
39 - 11.3 DEVELOPMENT OF SAFE SYSTEMS OF WORK
40 - 11.4 MAINTENANCE AND REPAIR OPERATIONS (INCLUDING APPROPRIATE ISOLATION PROCEDURES)
41 - APPENDIX A - POWER PRESS GUARDS
59 - APPENDIX B - TYPICAL DAILY INSPECTION SHEET FOR POWER PRESS GUARD
60 - APPENDIX C - EXAMPLE OF A POWER PRESS INSPECTION REPORT

Specifies safety requirements for the design, construction, operation and maintenance of power stamping presses and brake presses. It incorporates the details for the safeguarding of power presses, die design and die setting, and provides appropriate recommendations for the operation, inspection and maintenance of presses, and the training and supervision of operators.

This Standard specifies particular safety requirements for the design, construction, operation and maintenance of power stamping presses and brake presses. It incorporates the details for safeguarding, die design and die-setting, and provides appropriate recommendations for operation, inspection, and maintenance of presses, and training and supervision of operators. This Standard does not cover hot-metal presses, guillotines, shearing machines, roll-forming machines, forge hammers or forge presses, bulldozers, upsetters, injection moulding or die-casting equipment.

First published as AS CZ8-1959.Revised and redesignated as AS 1219-1972.Second edition 1988.Third edition 1994. First published as AS CZ8-1959. Revised and redesignated as AS 1219-1972. Second edition 1988. Third edition 1994.