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WORKING PROCEDURE FOR CNC CUTTING MACHINE
KAEFER KUWAIT
Prepared by
Navdeep Menon
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
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Introduction
This guide is an introduction to managing the risks associated with use of machinery and equipment in the workplace.
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
This presentation can be use for
Identify machinery and equipment hazards in the workplace Eliminate or reduce the risk of those hazards causing harm.
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CNC CUTTING SHOP
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ROBOR CNC machine has been projected and built for the cutting of insulating material and it can be used exclusively for this purpose. The machine is composed by a series of elements connected among them Frame
Bridge Portal
Arms carrying flywheels
Flywheels
Working bench
Hidden motorized roller conveyors
Remote running and programming
ROBOR CNC Cutting Machine
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Wintech CNC Cutting Machine
Wintechs Fast wire contour cutting machine consists of a fixed cutting table with horizontal linear bearings mounted along the two long sides. An aluminum gantry, housing the endless loop abrasive cutting wire, moves horizontally along the cutting table. Within the gantry, another system of linear bearings is used to control the vertical movement of the cutting wire. The Fast wire Motor, a direct drive electric motor, is mounted with the gantry assembly. The motor is controlled by an Inverter speed controller to operate 15mm/sec. The cutting wire rides on four wheels within the gantry, one wheel being directly driven by the Fast wire Motor. Vertical movement of the cutting wire and the horizontal movement of the gantry are controlled by stepper motors, mounted beneath the cutting table as part of the gantry carriage.
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CNC Concept
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
Concept of Working
CNC machine workers on 2D D (D= Dimension) concept
Wintech CNC works on 2D basis X Gantry with forward and backward moment & Y axis is a Cutting wire with up and down moment.
Robor CNC works on 2D basis X axis is a conveyor table with forward and backward moment, Y axis is a cutting wire with up and down motion.
Y axis Cutting Wire
X axis Table Y axis Cutting Wire
X axis Conveyor
Wintech CNC Robor CNC
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Outline
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
Danger and Risk
Safety- Acceptable Risk Level
What is CNC
Usage of CNC machines
Advantages of CNC machines
Mechanical
Electrical
Software
Personnel Safety
Cautions
Reminder
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Most people have a misunderstanding between danger / hazard and risk. A danger is ever present whereas risk is the possibility of that
danger happening.
Consider the following two statements:
A running CNC is dangerous
A running CNC is risky
A Running CNC is dangerous, but it is only a risk if it is in your vicinity.
We can avoid or reduce risk by bounding danger
(Run the CNC machine by providing proper fencing, guards, barrication and follow all safety procedure, so the risk of accident
will be very low)
Risks are events or conditions that may occur, and whose
occurrence, if it does take place, has a harmful or negative
effect.
Danger and Risk
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Safety - Acceptable Risk Level
Risk 0 does not exist but it must be reduced up to an acceptable
level
Safety is the absence of risks which could cause injury or damage
the health of persons.
Its one of the machine designer job to reduce all risks to a value
lower than the acceptable risk.
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Safety must be taken into account:
already in the design phase
and must be kept in place throughout all stages of a machines life cycle: Transportation
Installation
Adjustment
Operation, Production
Maintenance
Dismantling
Safety is necessary to obtain Safe Working Man-hours
Machine Safety as Global Concept
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What is CNC ?
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
CNC means Computer Numerical Control.
This means a computer converts the design produced by Computer Aided Design software (CAD), into numerals. The numerals can be
considered to be the coordinates of a graph and they control the
movement of the cutter. In this way the computer controls the cutting
and shaping of the material.
The numerical data required to produce a part is provided to a machine in the form of a program, called part program or CNC
program.
The program is translated into the appropriate electrical signals for input to motors that run the machine.
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Advantages of CNC
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
CNC use for PIR (polyurethane/ polyisocyanurate) foam cutting different size and design.
Low waste generation. High part to part accuracy and consistency. Less time and effort required. Easier to work without human effort. Easier to program Easy storage of existing programs Easy to change a program Avoids human errors CNC machines are safe to operate Complex geometry is produced as cheaply as simple ones Usually generates closer tolerances than manual machines
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CNC Machine Safety Measures
Mechanical hazards that cannot be eliminated must be controlled to prevent harm.
Non-mechanical hazards that cannot be eliminated must be controlled to prevent harmful exposure.
Access hazards that cannot be eliminated must be controlled to provide safe access (for operation, maintenance, repair, installation, service, cleaning or
decommissioning).
Risk associated with CNC
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CNC Machine Safety Measures
All moving parts of the machine are adequately protected with proper guards to avoid grab into incident.
The arms carrying flywheels is closed with protection panels equipped of entering doors with screw locking.
The operation area of the machine is particularly fenced with safety panels or otherwise barricated with external barrication.
The opening of the barriers is allowed only if the machines movements are stopped and it causes automatically the safety block of all the machines movement.
Fixed protection or by protections with locks can be accessible only from qualified maintenance personnel.
Machinery and equipment with moving parts that can be reached by people.
Mechanical
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Common mechanical hazards and associated risks for machinery and equipment are
Hazard Risk
Rotating shafts, pullies, sprockets and
gears Entanglement
Hard surfaces moving together Crushing
Wire or shear action Severing
Sharp edge moving or stationary Cutting or puncturing
Cable or hose connections Slips, trips and falls
MECHANICAL
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The Fast wire machine is primarily designed to cut computer-drawn and nested shapes (complex and simple) from a range of flexible and rigid PIR foams.
Flywheels used for the tensioning and the rotation of the cutting wire.
In case when wire get break or damaged, the flywheel will automatically get it inside the protection door which saves other to get in contact with fast wire
Dont
Do not start cutting while protection doors are open
Avoid touching flywheels while machine in operation
MECHANICAL
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Protection Door
Dos Protection door of cutting wire shall
always be closed while machine in
operation
Always use barrication to avoid
unwanted entrance
MECHANICAL
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Separation is a simple and effective machinery and equipment risk control. Separation may be achieved by distance, barrier or time. Distance separation means a person cannot reach the hazard due to distance. Barrier separation means an effective barrier or guard denies access and controls ejection of parts, products or waste.
Time separation means at the time of access, the machinery or equipment is disabled.
Risk Control of Mechanical Hazards
Guarding A guard can perform several functions: it can deny bodily access, contain ejected parts, tools, off-cuts or swath, prevent emissions escaping or form part of a safe working platform.
A fixed guard can be permanently applied by bonding agent, welding or secured with one-way screws. If access is generally not required, a permanently fixed barrier is the preferred option.
Adjustable guarding incorporates movable sections or panels of the guard and allows for material or parts to be fed into the guarded area while still preventing bodily contact.
MECHANICAL
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A dust collection system is an air quality improvement system used in CNC to improve breathable air quality and safety by removing particulate matter from the air and environment. Dust collection systems work on the basic formula of capture, convey and collect.
Dos Use dust mask to avoid inhalation of PIR dust
Use dust free shield goggles
to avoid dust to come in
contact with eye.
MECHANICAL
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First, the dust must be captured which is accomplished with devices such as capture hoods to catch dust at its source of origin
Second, the dust must be conveyed which is done via a ducting system, properly sized and manifold to maintain a consistent minimum air velocity required to keep the dust in suspension for conveyance to the collection device.
Finally, the dust is collected in a dust extractor bag
Dont
Do not remove dust extractor bag
while machine in operation
Avoid come in contact with dust
suction hood while machine in
operation
MECHANICAL
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Roller conveyor is a conveyor that consists of a series of parallel rotating bars that move goods along to their end destination.
The design of a roller conveyor consists of a series of tubes mounted at set intervals. The tubes rotate at the same rate and in the same direction to push objects along the top of the conveyor.
Maintenance of roller conveyors requires periodically cleaning the bearings used for rotation to ensure that the rollers are smooth, and checking for signs of leaks and soiling on the bars themselves.
MECHANICAL
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Conveyor motor and chain guard safe us from getting in contact with the rotating
parts.
MECHANICAL
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CNC Remote Handset enables the operator to manually control movement of the
cutting wire position. In this the operator can start, cancel and pause cutting jobs as well as control the cutting speed .
MECHANICAL
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Safety Stand
Emergency stop button. It
allows the emergency stop of
the machine. It is push and
pull type.
Conveyor chain movement.
Conveyor front roller
movement controller
Conveyor back roller
movement controller
MECHANICAL
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The immediate safety control is the emergency button placed on the main control panel and on the safety barriers locking column.
If the operator is not able to act immediately to press emergency, the machine is able to intervene to avoid dangerous for the personnel's life or for the machine integrity.
All the operations made inside of the electric control panel must be executed by qualified and authorized personnel.
ELECTRICAL
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Circuit breaker lockout system is an important safety
procedure that involves shutting of the power supply
of the machine during maintenance or repair. This
procedure protects employees from risk caused
by power sources. Used properly in conjunction with
the well planned lockout process, this safety lock
helps ensure that the
employee will not inadvertently activate the
piece of machine while someone is working on it.
ELECTRICAL
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Emergency stop is a safety mechanism used to shut off a device in an emergency
situation in which it cannot be shut down
in the usual manner.
It is designed and configured to
a) Completely and as quickly as possible
abort the operation, even if this damages
equipment and
b) Be operable in a manner that is quick,
simple
c) Emergency switches feature a
removable barrier or other protection
against accidental activation.
ELECTRICAL
http://en.wikipedia.org/wiki/Safety
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Emergency stop & Emergency switching off
What is an emergency stop operation
Is an emergency operation intended to stop a process or a movement that has become hazardous
is part of the emergency stop function system of the machine
What is an emergency switching off operation
Is an emergency operation intended to switch off the supply of electrical energy to all or part of an installation where a risk of electric shock or another risk
of electrical origin is involved
is directly linked to risk of electrical origin, related to the machine or not
ELECTRICAL
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Emergency Stop or Emergency Switching Off
Emergency Switching Off
Eliminate the risk induced by the
machine operation
- Safety risk assessment -
Eliminate the risk of electrical shock
by switching off the electrical supply
Safety of machinery
Emergency Stop Equipment
Machinery
TRIGGER
Emergency Stop
ELECTRICAL
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EMERGENCY BUTTON
In emergency situation, that may
become dangerous for the people or
for the machine elements, the
operator must push one of the
emergency buttons.
1st Emergency stop button on back
side column of CNC machine.
2nd Emergency stop button on front
side column of CNC machine
3rd Emergency stop button on
operating Panel board of CNC
machine
ELECTRICAL
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CNC Control Panel
9 monochromatic display allows the dialogue between the operator and the numerical control during the management of the CNC machine functionality
Green lighting lamp is activated when the general switch is ON, and it has the function to indicate the electrical control panel is under tension.
ELECTRICAL
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Wintech CNC Emergency stop button and other control switches on
panel board.
ELECTRICAL
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Wintech dust extractor (collector) bag switch.
Power ON & OFF button.
ELECTRICAL
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Homing system Homing system is a pre-check type system which allows system to
check all the electrical and mechanical connection step wise and shows the defects in panel monitor while switch on the machine.
Until the defects or any maintenance is balance, the machine will not start its operation.
Auto defect display system which show the particular defect in
machine which makes the repair easier.
SOFTWARE
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The control cabinet contains the
positioning control electronics. The
electronics module responsible for
controlling the motion of the machine is
called the Indexer. The Indexer
connects to Input and Output boards,
which take inputs from the machine
and controls outputs to the machine.
Cable ducts carry all control and power
wires from the machine to the control
cabinet. This cabinet also contains the
Fast wire Saw Motor control.
Wintech CNC machine operating
cabin. The cutting design shall be
selected and commanded from computer and accordingly that machine
will cut the blocks.
SOFTWARE
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Protect People and Increase Productivity
Investing in machine safety Health & safety for all personnel
Cut costs associated with: Physical injuries
Insurance premiums Lost production, penalties
Increased productivity due to the prevention of accidents Better failure detection Worker confident at work Improving maintenance efficiency
PERSONNEL SAFETY
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Fencing to avoid any
unwanted entrance while machine in operation
PERSONNEL SAFETY
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Barrications to avoid
entrance while machine is under operation
PERSONNEL SAFETY
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Safety Sign to aware others from not
getting into incident.
PERSONNEL SAFETY
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Personnel safety.. Dust free Shield glass and dust mass to be wear as mandatory PPE while working with CNC PIR cutting Machine
PERSONNEL SAFETY
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Cautions displayed in CNC operating cabin.
Authorized CNC operator name mentioned
Emergency Evacuation plan displayed on the CNC operating cabin.
PERSONNEL SAFETY
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Safety Precautions
WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON
Do not use the machine to cut material other than that specified. Ensure that all guards and safety devices are in position and secured. Shut off the CNC machine for any electrical and mechanical maintenance. Do not enter any exterior person or unauthorized person when the CNC is under function. The clothes which we are wearing should not have any fluttering parts that can cause handhold to eventually organs of the machinery. Adjust the dust collector shroud (where fitted) correctly for maximum efficiency Do not use bracelets, necklaces or other objects that could remain caught in the moving parts of the machinery. The working on the electric equipment must be realized only by a qualified electrician. Do not enter inside the fence and barricaded area while machine is in running condition. Do not load or unload the material before getting instructions from operator. All people should aware of emergency button location. Do not stand on the conveyor or inside the safety barrier when the CNC machine is operating. Do not operate the machine when the personnel are in the immediate vicinity of the machine. The wires supplied are very sharp. Use caution while replacing the cutting wires. Only trained and certified person shall operate the machine. Isolate the machine before any maintenance or service work is carried out and maintenance should be carried out by suitable qualified person. Do not operate the machine without the safety barriers in place and should be ensure that they are closed during operation. Do not touch the wires when the machine is operating. Avoid contact with moving assemblies. Check the machinery parts and safety devices on daily basis before starting the operation. Shut off the machine in emergency situation. Always follow the operator instructions, Do Not Avoid.
CAUTIONS
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Safety glasses must be worn at all
times in work areas.
Long and loose hair must be
contained or restrained.
Appropriate protective footwear with
substantial uppers must be worn.
Close fitting, protective clothing or
a workshop apron is encouraged.
Rings and jewellery must not be worn. A mask must be worn when
excessive airborne dust is created.
HOUSEKEEPING
On completion, isolate all switches. Leave machine and floor in a safe, clean and tidy state.
POTENTIAL HAZARDS
Entanglement & entrapment
Pinch, crush & squash points
Dusts and fumes
Eye Injury Electrical Components
Manual Handling
CAUTIONS
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The safety precautions protects your personnel, material and increases your
productivity
Safety must be taken into account from the design stage to end of the life of
your installation
DO NOT AVOID SAFETY
CAUTIONS
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Thank You
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