GUDEL CP 3-5 V2, Руководство по эксплуатации

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Hazard analysis / Risk analysis
Customer:
Machine type: CP with/without control system
Project no.:
Document no.:
Risk assessment / safety goals / protective measures / residual risks
1)
Solution suggested to the customer (cursive, Times New Roman)
Güdel solution (Arial)
1.14 x x x x x x x x x x x Risk of injury (cutting,
crushing) gearbox, racks Technician,
commissioning
technician,
forwarding agent
Carelessness Cutting injuries, crush injuries x x 1 1/b Cutting and crush injuries occur Wearing proper protective clothing Application-specific protective measures Y
1.15 x x x x x x Rotating parts All Contact with rotating parts Persons are injured x x 10 3/d Injuries occur Attach protective cover or warning symbol Wearing protective clothing x Y
1.16 x x x Manual workstations Operators Automatic movements at the
manual workstation Someone is surprised by the
automation, body parts are crushed
and injuries result. x x 20 3/d Operating personnel or third
parties are injured during the
manual insertion or ejection of
the workpieces.
Insertion or ejection axes may only be moved in jog mode or with two-hand
operation. The drive configuration is such that only a slow axis speed is achieved
at maximum speed of the drive motor. The operating elements for insertion and
ejection must be configured so that the operator has a clear view of the movement
and cannot be endangered. Areas where body parts could be crushed are to be
prevented with design measures to the greatest possible extent. Extra attention is required of the operator at manual
workstations.
Only perform movements if no other person is in the danger area
and none of your own body parts are in the line of danger of the
corresponding axis x Y
1.17 x x x x x x x x x x x x Hot surfaces. All During normal operation,
touching hot surfaces. Person is injured by hot surface. x x 8 2/c Persons suffer burns. Hot surfaces are covered by mechanical protective devices or marked by the
operator. None
x Y
1.18 x x x x x x x x x x x x x x Hot oil squirted out due to
high pressure at the gearbox All Overload or non-compliance with
the intended use Burns or eye injuries x x 10 3/d Oil comes out. Use of the product within the defined parameters. Wearing protective clothing, in particular helmet, goggles, and
shoes x Y
1.19 x x x x x No, wrong, or insufficient
oil Technicians,
Maintenance
personnel
Improper oil change Failure of the transfer function as well
as increased temperature, resulting in
damage and injuries x x 10 3/d Consequential damage occurs,
with injuries
Maintenance instructions must be observed None x Y
1.20 x x x x x x x x x x x Oil running out due to leaks all Failure of the gasket Environmental damage, slipping
hazard as well as consequential
damage due to the insufficient oil (see
1.18) x x 10 3/d The occurrence of
consequential damage with
injuries and environmental
damage
Maintenance intervals must be maintained Application-specific protective measures x Y
1.21 x x x x x x x Wear (tooth breakage)
gearbox all Tooth breakage Transfer function fails, resulting in
consequential damage with injuries x x 10 3/d Consequential damage occurs,
with injuries
Maintenance intervals must be maintained Application-specific protective measures x Y
1.22 x x x x x Noise all Overload or non-compliance with
the intended parameters Unpleasant noise level, difficult
communication x x 2 1/b Excessive noise level occurs Use of the product within the defined parameters. Vibrations and resonances must
be prevented. None Y
1.23 x x x x x x x Malfunction of protection
measures Operators,
Maintenance
personnel
Aging, fatigue fracture, failure due
to vibration or overloading Someone is surprised by the
unexpected situation and injured as a
result x x 10 3/d A preventable hazard occurs. The system is equipped with emergency off devices that trigger an emergency off of
the system. A lock-out (overview of the switch off locations) draws attention to the
switch-off devices. Do not walk under suspended workpieces or vertical axes. Only
possible in setup mode. Permanent workstations are not
permitted in the direction of movement of the axes. x Y
1.24 x x x x x x x x x x Slipping All Inattention and/or careless
operation Persons are injured x x 4 2/c Injuries occur For the option of walkable drive axes, use anti-slip plates.
Otherwise, walking on the drive axis is contrary to intended use.
None x Y
1.25 x x x x x x x x x x x Danger of tripping All Inattention and/or careless
operation Persons are injured x x 4 2/c Injuries occur Customer must provide for sufficient protection in accordance with the ambient
conditions. None x Y
1.26 x x x x Faulty assembly All Incorrectly assembled system Someone is surprised by the
unexpected situation and injured as a
result x x 10 3/d The module is mounted
incorrectly.
The content of the operating manual is known to the technicians.
Before a Güdel device is transported to the operation site, unpacked, assembled,
and commissioned, the operating manual must first be read and understood. None x Y
1.27 x x x x Loss of stability All Inattention and/or careless
operation Machine/System tips over x x 10 3/d It is possible for the module to
tip or equipment to fall down.
Equipment without base supports:
To connect to customer supports, the specified screw configuration according to
the Güdel layout has to be used with the corresponding screws.
Equipment with base supports:
The supplied screws for assembly have to be used. For the connection of the
uprights to the floor, the anchoring suggestion according to the Güdel layout
needs to be taken into consideration.
Fall protection has to be mounted for area gantries.
The operating manual must be read and understood. Check the connections that are responsible for the stability of the
device before starting the system. x Y
1.28 x x x Improper disposal can cause
environmental damage. All Disposal regulations are not
observed Environmental hazard x x 10 3/d The device and its
consumables are not disposed
of properly at the end of their
service life.
National regulations regarding disposal of the system must be observed. None x Y
1.29 x x x Malfunction of the control
system Setters Failure of control unit components Someone is surprised by the
unexpected movement and injured as
a result x x 10 3/d The risk of potential hazards
becomes too high.
Only drive systems are used that comply with the state of the art and the standards
referenced in the machine directive. Work in this condition requires a high level of individual
responsibility from the operator/setter.
There is no way to completely ensure that a malfunction of the
control system does not create a hazard by movement the axes.
The operator must therefore try to never be in the possible
direction of travel of the axes and ensure that no third parties
are in the possible danger zones. x Y
1.30 x x x Malfunction of the control
system Operators,
Maintenance
personnel
Failure of control unit components Someone is surprised by the
unexpected movement and injured as
a result x x 10 3/d The effects of a control system
malfunction endanger the
operator or third parties.
The areas of movement are to be enclosed by mechanical safety fences, light
curtains and light grids so that it is not possible to enter this area from any side.
Movements must transition to static states as quickly as possible. In normal operation, all protective hoods must be closed,
removable protective hoods must be screwed securely.
Required conduct: Inspect the protective hoods before starting
normal operation. x Y
1.31 x x x x x x x x x Electrical hazard Operators,
Maintenance
personnel,
Technicians
Touching the machine
Defective insulation
Improper el. installation
Unsuitable components Someone suffers an electric shock and
is injured or killed as a result. x x 10 3/d Operating personnel or third
parties are injured by direct or
indirect electrical contact.
Only contact-protected components are to be used.
Before working on electrical installations, always disconnect the system (plug/main
switch) and double check.
Work on electrical installations, switch cabinets and devices may only be
performed by authorized technicians.
Control cabinet fuses Work on electrical installations requires expertise and extra
care. x Y
1.32 x x x Disruption of the energy
supply Operators,
Maintenance
personnel
Power failure, lightning, interrupted
compressed air supply Someone is surprised by the
unexpected movement and injured as
a result x x 10 3/d The effects of a power failure
endanger the operator or third
parties.
The movement of the drives is mechanically limited in case the supply voltage fails
(mechanical limit stops and holding brakes).
The movement of the drives is braked if the supply voltage fails. The operator and
third parties are outside the danger area. After a crash, defective elements of the mechanical limit stops
cannot necessarily be recognized immediately. The entire
bumper unit must always be replaced. x Y
1.33 x x x x Disruption of the energy
supply Setters Power failure, lightning, interrupted
compressed air supply Someone is surprised by the
unexpected situation and injured as a
result x x 10 3/d The effects of a power failure
endanger the operator or third
parties.
The movement of the drives is limited by mechanical limit stops in case the supply
voltage fails. The drives have already been switched off in case of a power failure
(safety shutdown situation). The movement of the drives is braked in case of supply
voltage failure by the motor brake or holding brake in the drive train. After a crash, defective elements of the mechanical limit stops
cannot necessarily be recognized immediately. The entire
bumper unit must always be replaced.
x Y
1.34 x x x x x x x x Falling or flung out parts Operators,
Maintenance
personnel,
Setters,
Commissioning
technicians
Forced fracture of components or
mounting elements if the X-carrier -
with Y-axis not retracted - runs
against a different carriage or
against an obstacle (crash) in the
end position damper. Persons are injured or killed by falling
or flung about parts. x x 10 3/d In case of a crash, falling or
ejected parts can injure or kill
persons.
Mechanical guards are available against parts that could fall or fly away.
The protective equipment is inspected by means of calculation and trial. The gantry can no longer be operated safety following a crash.
The gantry must be taken out of operation and contact be made
with Güdel before putting it back into operation.
After a crash, defective elements cannot be detected easily. In
any case, a general inspection in the sense of a fine check must
be carried out. x Y
1.35 x x x x x x x x Falling or flung out parts Operators,
Maintenance
personnel,
Setters,
Commissioning
technicians
Forced fracture of components or
fastening elements due to overload
at e-stop or crash with extended Y-
and/or Z-axis. Persons are injured or killed by falling
or flung about parts. x x 10 3/d In case of a crash or an e-stop,
falling or ejected parts can
injure or kill persons.
The axes are protected against separation from the rest of the system by a fall
protection device.
Mechanical guards are available against parts that could fall or fly away.
The protective equipment is inspected by means of calculation and trial.
To protect against mechanical overload, the drive torques for all operating modes
must be limited in accordance with the operating manual
=> Reference to torque limitation of the module configurator
The gantry can no longer be operated safety following an
overload. The gantry must be taken out of operation and contact
be made with Güdel before putting it back into operation.
After an overload, defective elements cannot be detected easily.
In any case, a general inspection in the sense of a fine check
must be carried out. x Y
Author: Alain Thurner
Created: 11.12.2009 Process owner: Michael Marti
Approved: 11.06.2019 / Version 01
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Risikobeurteilung_Module CP_2019_06_11_EN.xlsx