Safety Devices
Machine Access
Personnel are protected from the work area of the cell with a combination of safety features including fencing, interlocked safety gates, and guards.
The fencing and its associated interlocking are provided to protect the operator and other persons from the following hazards:
- Robot working zones.
- Welding operations.
- Failure of energy supplies.
Failure to properly operate and maintain the cells safety features will increase risk of injury to the operator and all other persons adjacent to the machine.
Access to the cell components is limited due to fencing, guarding, etc. As such, special precautions must be taken when entering the cell to access the equipment.
- Remove guarding only when necessary
- Replace all guarding completely before returning machine to production
- Repair or replace any defects before restarting machine
- Never defeat safety devices and guards
Follow Lockout / Tagout (LOTO) before removing guarding to work on the system.
Never operate this machine unless all guarding is in place and undamaged.
Ensure that guarding is handled properly. When servicing machine, ensure guarding is placed in a safe place, away from moving parts.
Disregarding these safety precautions can result in machine damage, injury, or death.
Safety Gates
Use normal shutdown procedures to stop the machine and lockout the gate being accessed before entering a safety gate. Lockout any applicable energy sources before performing any work within the gated area.
When a safety gate has been opened, it can be locked out by placing the lockout device through the sliding handle to prevent the handle pin from sliding back into the receiver. If more than one person is to enter the cell, each person must place a locking device on the gate handle. Lock out the safety gate BEFORE entering into the cell.
Emergency Stops (E-Stop)
Emergency Stop (E-Stop) buttons, when pressed, shut down the entire cell for safety purposes. The E-Stops are located on the Main Operator Panel (MOP), Secondary Operator Panel (SOPs), Robot FlexPendants, safety gates, laser cutting booth door, laser resonator, and fencing.
Main Disconnect
The Main Disconnect switches are located on the Power Distribution Panel (PDPs). To remove main power from the machine, open the Main Electrical Disconnect switch following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
If more than one person is to perform work on the machine, each employee must place a personal lock on the energy source using a multiple lockout device (scissor lock). The main electrical disconnect will shut off the main power to the operation. Verify power is removed by indication on the MOP screen and attempt to start the machine before beginning maintenance.
PLC Lighting Rotary Disconnect Switch
The Programmable Logic Controller (PLC) electrical power circuits that are wired above the main electrical disconnect are not de-energized by the Main Disconnect switch. The PLC Lighting Rotary Disconnect switch (also known as E-2, or Hot Power) is located inside the Power Distribution Panel. The PLC Lighting Rotary Disconnect switch controls the power to 120VAC Power Supply circuits, powering the operation lighting and PLC. The PLC Lighting Rotary Disconnect Switch features provisions for placing a personal padlock to lockout and prevent personnel from switching the power back to the "ON" position.
Before performing any maintenance or repair work, ensure to follow all Lockout / Tagout (LOTO) procedures.
VFD Controller
The Variable Frequency Drive (VFD) Disconnect switch is located on the Weiss VFD Control Panel. To remove power from the turntable, open the Weiss VFD electrical disconnect switch following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
If more than one person is to perform work on the machine, each employee must place a personal lock on the energy source using a multiple lockout device (scissor lock). The VFD electrical disconnect will shut off the power to the turntable and its drive system. Verify power is removed by indication on the Main Operator Panel (MOP) screen and attempt to operate the turntable. The turntable must not be able to move.
Robot Controllers
The ABB IRC5 Robot Controller Main Disconnect switch is located on the ABB IRC5 Robot Controller. Each robot controller features a Main Disconnect switch. There are twelve (12) located in this cell, each controlling the a specific ABB robot.
To remove power from a robot, place the electrical disconnect in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
Weld Controllers
The ABB Weld Controller Disconnect switches are located on the ABB Weld Controllers, each located above the ABB Robot Controllers. There are twelve (12) located in this cell, each controlling the spot weld guns on a different ABB robot.
To remove power from a robot spot welder, place the electrical disconnect in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
Atlas Copco Sealer Controller
The Atlas Copco Sealer Controller receives 480VAC power and has a rotary type disconnect. To remove power from the Atlas Copco Sealer Controller, place the rotary electrical disconnect switch in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
ABB Integrated Dispensing Connector (IDC)
The ABB Integrated Dispensing Connector (IDC) receives 480VAC power and has two (2) rotary type disconnects. The top disconnect switch controls the power from the Main and the lower disconnect switch controls power to the heating system. The IDC is located directly above the ABB IRC5 Robot Controller that it is associated with.
To remove power from the ABB IDC, place the rotary electrical disconnect switch in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
ABB Transformer Neutral Panel
The ABB Transformer Neutral Panel receives 480VAC power and sends 480VAC to the IDC power supply. There is one controller for ABB IDC.
To remove power from the ABB Transformer Neutral Panel and IDC power supply, place the rotary electrical disconnect switch in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures including arc flash safety and apply a personal lock.
Cap Changers
The Brauer Systemtechnik Cap Changer Disconnect switches are located next to each of their associated ABB IB Weld Robots. There are multiple cap changers located in this cell, each controlling power to the specific Brauer Tip Changer. Power should always be removed from the specific tip changer before doing any maintenance on or around the tip changer.
To remove power from a robot tip changer, place the electrical disconnect in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures and apply a personal lock.
Tip Dressers
The ABB Tip Dresser Disconnect switches are located next to each of their associated ABB IB Weld Robots. There are multiple ABB Tip Dressers located in this cell, each controlling power to the specific ABB Tip Dresser. Power should always be removed from the specific tip dresser before doing any maintenance on or around the tip dresser.
To remove power from a robot tip dresser, place the electrical disconnect in the "OFF" position following the proper Lockout / Tagout (LOTO) procedures and apply a personal lock.
The operating handle may be padlocked in the "OFF" position with up to three (3) padlocks. When locked, the enclosure door is interlocked and can not be opened. All padlocks must be removed to gain entry to the enclosure.
Water Shut-Offs
There are four (4) ball valves that control the main water system to the cell. These four (4) valves are for "Plant Water Out", "Plant Water In", "To Header", and "From Header". Closing these ball valves will remove water from any of these four systems.
Each of the three (3) Robot Weld Controllers also have two (2) ball valves that control water to and from the header.
The IPG Photonics Laser Chiller located outside of the laser cutting booth also has multiple ball valves that control water to and from the header.
When doing maintenance on the robots and any of their associated equipment, close the water valves to stop water pressure to the equipment.
Main Air
The main air lockout valve is located on the fencing. Turn the main air supply manual shut off valve to the "OFF" position and apply a padlock following all Lockout / Tagout (LOTO) procedures. Verify there is a zero pressure reading on the air pressure gauge before starting any maintenance work on the air system or machine.
Some pneumatic circuits trap air. Check the pneumatic drawings for any possible trapped air circuits and relieve any trapped air before performing any maintenance on the system.
Ancillary Air
The ancillary equipment has individual shutoff valves allowing for pneumatic shutoff for a specific piece of equipment without removing air from the entire cell. Each of these shutoff valves are found in different locations throughout the cell. Air shutoff valves are used for following ancillary components:
- Turntables
- Fixtures
- Robots
- Lift Assist
- Laser Cutting Booth
- Laser Cutting Booth Adsorption Dryer
Turntable shutoff is located on the fencing, near the main air shutoff. Each robot has an air shutoff located on the sides of the individual robot controllers. Turn the ancillary air supply manual shut off valve to the "OFF" position and apply a padlock, following all Lockout / Tagpout (LOTO) procedures. Verify there is a zero pressure reading on the air pressure gauge before starting any maintenance work on the the specific equipment.
Before locking out the air supply, secure any machine parts that could move when the air pressure is removed.
Light Screens
Safety light screens, or light curtains are used in front of the turntable. Safety light screens protect personnel from injury and machines from damage by guarding points of operation, access, areas, and perimeters. Banner EZ-SCREEN is a two-piece ("two-box") system - comprising an emitter and a receiver. Emitters have a row of synchronized modulated infrared (invisible) Light Emitting Diodes (LEDs) in a compact rectangular metal housing. Receivers have a corresponding row of synchronized photo-detectors. The dimensions of the light screen created by the emitter and receiver are called the "defined area"; its width and height are determined by the length of the sensor pair and the distance between them.
In typical operation, if any part of an operator's (or any opaque objects) of more than a predetermined cross section is detected, the Output Signal Switching Device (OSSD) solid-state safety outputs will turn off. These safety outputs are connected to the guarded machine's Final Switching Devices (FSDs) that control the Machine Primary Control Slemens (MPCEs), which immediately stop the motion of the guarded machine.
Safety Lockout Pins
Station equipment with inclined or vertical units use safety pins to lock the units from sliding or falling during maintenance, or repair work. The safety pins reside in holders mounted next to the pin insertion point. ALWAYS ensure the pins are returned to their holders after work is completed.
Fencing
When the machine is in operation, all safety guards must be in place on the equipment and safety gates and doors closed and latched. There are three (3) interlocked safety gates located near the robot controllers on this cell as shown in the figure. All fencing must be undamaged and in place before operating machinery
There are also sets of light screens located in the front of the machine by the turntable, laser cutting fixtures, and load table fixtures. The light screens must be clear before the machine can be placed in automatic mode.