Cnc working procedure

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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.


This presentation can be use for

Identify machinery and equipment hazards in the workplace Eliminate or reduce the risk of those hazards causing harm.

3 WORKING PROCEDURE FOR CNC CUTTING MACHINE - NAVDEEP MENON

CNC CUTTING SHOP


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


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


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


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


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


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.


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 ?


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


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


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


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


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


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


Protection Door

Dos Protection door of cutting wire shall

always be closed while machine in

operation

Always use barrication to avoid

unwanted entrance

MECHANICAL


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


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


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


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


Conveyor motor and chain guard safe us from getting in contact with the rotating

parts.

MECHANICAL


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


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


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


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


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


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


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


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


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


Wintech CNC Emergency stop button and other control switches on

panel board.

ELECTRICAL


Wintech dust extractor (collector) bag switch.

Power ON & OFF button.

ELECTRICAL


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


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


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


Fencing to avoid any

unwanted entrance while machine in operation

PERSONNEL SAFETY


Barrications to avoid

entrance while machine is under operation

PERSONNEL SAFETY


Safety Sign to aware others from not

getting into incident.

PERSONNEL SAFETY


Personnel safety.. Dust free Shield glass and dust mass to be wear as mandatory PPE while working with CNC PIR cutting Machine

PERSONNEL SAFETY


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


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


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


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


Thank You

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Cnc working procedure