• AS 4024.3001-2009

    Superseded A superseded Standard is one, which is fully replaced by another Standard, which is a new edition of the same Standard.

    Safety of machinery Materials forming and shearing - Mechanical power presses

    Available format(s):  Hardcopy, PDF 1 User, PDF 3 Users, PDF 5 Users, PDF 9 Users

    Superseded date:  24-08-2021

    Language(s):  English

    Published date:  17-05-2009

    Publisher:  Standards Australia

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    Table of Contents - (Show below) - (Hide below)

    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

    Abstract - (Show below) - (Hide below)

    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 - (Show below) - (Hide below)

    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 - (Show below) - (Hide below)

    Committee SF-008
    Development Note Standard has been given Pending Revision status. Under Revision by DR AS 4024.3001:2021.
    Document Type Standard
    Product Note Pending Revision indicates that as a result of the Aged Standards review process, the document needs updating. If no project proposal, meeting the quality criteria, is received within the 12 month timeframe, the document shall be withdrawn.
    Publisher Standards Australia
    Status Superseded
    Superseded By
    Supersedes
    Under Revision

    History - (Show below) - (Hide below)

    First published as AS CZ8-1959.Revised and redesignated as AS 1219-1972.Second edition 1988.Third edition 1994.Revised in part and redesigned as AS 4024.3001-2009. Originated as part of AS CZ8-1959. Previous edition part of AS 1219-1994. Revised inpart and redesigned as AS 4024.3001-2009.

    Standards Referenced By This Book - (Show below) - (Hide below)

    AS 62061-2006 Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems
    AS 4024.1502-2006 Safety of machinery Design of safety related parts of control systems - Validation (Reconfirmed 2014)
    AS 4024.1803-2006 Safety of machinery Safety distances and safety gaps - Minimum gaps to prevent crushing of parts of the human body
    AS 60529-2004 Degrees of protection provided by enclosures (IP Code) (Reconfirmed 2018)
    AS 4024.1501-2006 Safety of machinery Design of safety related parts of control systems - General principles for design (Reconfirmed 2014)
    AS 4024.1202-2006 Safety of machinery General principles - Technical principles
    AS 2671-2002 Hydraulic fluid power - General requirements for systems (ISO 4413:1998, MOD)
    AS 60204.1-2005 Safety of machinery - Electrical equipment of machines General requirements (IEC 60204-1, Ed. 5 (FDIS) MOD)
    AS 1893-1977 Code of practice for the guarding and safe use of metal and paper cutting guillotines
    AS/NZS 4024.1:2006 Series Safety of machinery Safety of machinery series
    AS 2788-2002 Pneumatic fluid power - General requirements for systems (ISO 4414:1998, MOD)
    AS 4024.1601-2006 Safety of machinery Design of controls, interlocks and guarding - Guards - General requirements for the design and construction of fixed and movable guards
    AS 4024.1602-2006 Safety of machinery Interlocking devices associated with guards - Principles for design and selection
    AS 1657-1992 Fixed platforms, walkways, stairways and ladders - Design, construction and installation
    AS 4024.1907-2006 Safety of machinery Displays, controls, actuators and signals - System of auditory and visual danger and information signals
    AS 4024.2601-2008 Safety of machinery Design of controls, interlocks and guarding - Two-hand control devices - Functional aspects and design principles
    AS 4024.1603-2006 Safety of machinery Design of controls, interlocks and guards - Prevention of unexpected start-up (Reconfirmed 2014)
    AS 4024.2801-2008 Safety of machinery Safety distances and safety gaps - Positioning of protective equipment with respect to the approach speed of parts of the human body
    AS 4024.1301-2006 Safety of machinery Risk assessment - Principles of risk assessment
    AS 4024.1801-2006 Safety of machinery Safety distances to prevent danger zones being reached by the upper limbs

    Standards Referencing This Book - (Show below) - (Hide below)

    AS/NZS 4240.2:2009 Remote control systems for mining equipment Operation and maintenance for underground metalliferous mining (Reconfirmed 2021)
    AS/NZS 4240.3:2013 Remote control systems for mining equipment Operation and maintenance for underground coal mining
    AS 1210-2010 Pressure vessels (Reconfirmed 2021)
    AS 4431:2019 Safe working on new lift installations in new constructions
    AS/NZS 3584.3:2012 Diesel engine systems for underground coal mines Maintenance
    AS/NZS 3007:2013 Electrical equipment in mines and quarries - Surface installations and associated processing plant
    AS 4233.2:2013 High pressure water jetting systems Construction and performance
    AS 3533.4.4:2018 Amusement rides and devices Specific requirements - Hire go-karts
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