AS 4024.3001-2009

1 - AS 4024.3001-2009 SAFETY OF MACHINERY - MATERIALS FORMING AND SHEARING-MECHANICAL POWER PRESSES
4 - PREFACE
5 - CONTENTS
6 - SECTION 1 SCOPE AND GENERAL
6 - 1.1 SCOPE
6 - 1.2 OBJECTIVE
7 - 1.3 REFERENCED DOCUMENTS
8 - 1.4 DEFINITIONS
8 - 1.4.1 Band brake
8 - 1.4.2 Brake
8 - 1.4.3 Clutch
8 - 1.4.4 Clutch-full revolution
8 - 1.4.5 Clutch-part revolution
8 - 1.4.6 Cycle
8 - 1.4.7 Dead centres
8 - 1.4.8 Die
8 - 1.4.9 Die cushion
9 - 1.4.10 Direct drive
9 - 1.4.11 Early opening interlocking guard
9 - 1.4.12 Extractor
9 - 1.4.13 Guard locking device
9 - 1.4.14 Limited movement control device
9 - 1.4.15 Mechanical press
10 - 1.4.16 Monitoring
10 - 1.4.17 Muting
10 - 1.4.18 Overall system stopping performance
11 - 1.4.19 Overrun
11 - 1.4.20 Overrun monitoring device
11 - 1.4.21 Position switch
11 - 1.4.22 Redundancy
11 - 1.4.23 Shut height
11 - 1.4.24 Single stroke function
11 - 1.4.25 Slide
11 - 1.4.26 Tool
11 - 1.4.27 Tools
11 - 1.4.28 Tools-closed
13 - SECTION 2 HAZARDS
13 - 2.1 GENERAL
13 - 2.2 RISK ASSESSMENT
15 - SECTION 3 SAFETY REQUIREMENTS AND MEASURES
15 - 3.1 INTRODUCTION
15 - 3.2 BASIC DESIGN CONSIDERATIONS
15 - 3.2.1 Brakes and clutches
16 - 3.2.2 Presses with part revolution clutches (friction clutches)
16 - 3.2.3 Presses with full revolution clutches
17 - 3.2.4 Hydraulic and pneumatic systems-common features
18 - 3.2.5 Pneumatic systems
18 - 3.2.6 Hydraulic systems
19 - 3.2.7 Slide adjustment and stroke adjustment
19 - 3.2.8 Electrical systems
19 - 3.3 MECHANICAL HAZARDS IN THE TOOLS AREA
19 - 3.3.1 General
20 - 3.3.2 Safeguarding measures
20 - 3.3.3 Limits of protection
20 - 3.3.4 Control system category
26 - 3.3.5 Access required to more than one side
26 - 3.3.6 Safe methods of work
26 - 3.3.7 Closed tools
26 - 3.3.8 Fixed enclosing guards
26 - 3.3.9 Interlocking guards
26 - 3.3.10 Control guards
26 - 3.3.11 Early opening guards
27 - 3.3.12 Presence sensing systems
28 - 3.3.13 Preset time
28 - 3.3.14 Two-hand controls
29 - 3.3.15 Early opening guards
29 - 3.3.16 Conditions of interlocking the motor and the clutch
29 - 3.3.17 Single stroke devices
29 - 3.3.18 Mechanical restraint devices
29 - 3.3.19 Other requirements
30 - 3.4 CONTROL AND MONITORING SYSTEM
30 - 3.4.1 Control and monitoring functions
31 - 3.4.2 Part revolution clutch presses: Redundancy and monitoring of clutch/brake control systems, and overrun monitoring...
33 - 3.4.3 Muting
33 - 3.4.4 Programmable electronic systems (PES), programmable pneumatic systems (PPS) and safety related functions
34 - 3.4.5 Selector switches
34 - 3.4.6 Isolation switch
34 - 3.4.7 Position switches
35 - 3.4.8 Control devices
35 - 3.4.9 Valves
35 - 3.5 TOOLSETTING, TRIAL STROKES, MAINTENANCE AND LUBRICATION
35 - 3.5.1 General
35 - 3.5.2 Guarding
36 - 3.5.3 Trial strokes
36 - 3.5.4 Feeder devices
36 - 3.5.5 Manual rotation of the crankshaft
36 - 3.5.6 Additional control devices
36 - 3.5.7 Opening movable guards
36 - 3.5.8 Two-hand controls
36 - 3.5.9 Limited movement devices
37 - 3.5.10 Devices provided for toolsetting
37 - 3.5.11 Interfaces
37 - 3.6 OTHER MECHANICAL HAZARDS
37 - 3.6.1 Safeguarding drive and transmission machinery
37 - 3.6.2 Safeguarding ancillary devices
37 - 3.6.3 Ejection hazards
37 - 3.7 SLIPS, TRIPS AND FALLS
37 - 3.8 PROTECTION AGAINST OTHER HAZARDS
37 - 3.8.1 Electrical hazards
38 - 3.8.2 Thermal hazards
38 - 3.8.3 High pressure fluid ejection hazards
38 - 3.8.4 Hazards generated by noise
38 - 3.8.5 Hazards generated by vibration
38 - 3.8.6 Hazards generated by materials and substances
39 - 3.8.7 Hazards generated by neglecting ergonomic principles
40 - SECTION 4 INFORMATION FOR USE
40 - 4.1 MARKING
40 - 4.2 INSTRUCTION HANDBOOK
42 - APPENDIX A - PRESSES WITH FULL REVOLUTION CLUTCHES-DESIGN REQUIREMENTS
42 - A1 EXTRACTOR DESIGN
42 - A1.1 Clutch engagement
42 - A1.2 Movement limitation
42 - A1.3 Mechanical interlocking
42 - A1.4 Rolling key clutch
42 - A2 PREVENTION OF OVERRUN AND FALL-BACK
42 - A2.1 General
42 - A2.2 Interlocking guards
43 - APPENDIX B - INTERLOCKING GUARDS
43 - B1 PRESSES WITH FULL REVOLUTION CLUTCHES
43 - B1.1 Guard gate
43 - B1.2 Guard performance
43 - B1.3 Extractor interlocking device
43 - B1.4 Guard to extractor linkage
44 - B2 PRESSES WITH PART REVOLUTION CLUTCHES
44 - B2.1 Hand fed press
44 - B2.2 Early opening guard
44 - B2.3 Automatic feed
46 - APPENDIX C - CALCULATION OF MINIMUM SAFETY DISTANCES
46 - C1 SAFETY DISTANCE
46 - C2 DETERMINATION OF K
46 - C3 DETERMINATION OF C
46 - C4 SYSTEM STOPPING PERFORMANCE
47 - C5 POSITION OF PROTECTIVE DEVICES
47 - C6 DETERMINATION OF C
48 - APPENDIX D - SETTING OF THE ROTARY CAM ARRANGEMENT
48 - D1 BASIC FEATURES OF THE ECCENTRIC ADJUSTMENT AND ROTARY CAM ARRANGEMENT
53 - D2 DETERMINATION OF THE POSITION WHERE MUTING BEGINS
56 - APPENDIX E - DETERMINATION OF OVERALL RESPONSE TIME
56 - E1 SCOPE
56 - E2 RESPONSE TIME
56 - E3 DETERMINATION OF t1
56 - E4 DETERMINATION OF t2
57 - E5 DETERMINATION OF t3
59 - E6 COMMENTARY ON FIGURES E3 AND E4

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.

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.

Originated as part of AS CZ8-1959.
Previous edition part of AS 1219-1994.
Revised in
part and redesigned as AS 4024.3001-2009.