Guidelines for the Comprehensive Safety Standards of Machinery (2007)

Up Date : 2008.03.26

Attached Table 2 Inherently safe design measures

Ensure that all parts that a worker may touch are avoided sharp edges and corners, protruding parts, etc.
To protect workers from being caught, cause the machinery shape, dimensions, etc. and machinery drive force, etc. to comply with the following:
- (1) Crushing and shearing hazards are avoided by reducing the gap so that no part of the body can enter it, or by increasing the minimum gap between the moving parts, such that the part of the body under consideration can enter the gap safely.
- (2) The actuating force is limited to a sufficiently low value so that the actuated part does not generate a mechanical hazard.
- (3) The mass and/or velocity of the movable elements, and hence their kinetic energy is limited to a sufficiently low value so that the movable elements does not generate a mechanical hazard, when the elements collide to workers.
Enable work to be conducted outside the region where the moving parts of the machinery move or at a location away from hazards without entering that region or approaching the hazards.For example, mechanization and automation of machine loading / unloading operations and more generally of handling operations (of workpieces, materials, substances ) limit the risk generated by these operations by reducing the exposure of parsons to hazards at the operation point.
To protect machinery from damage, etc., make the machinery strength, etc. comply with the following:
- (1) Perform correct strength calculations, etc. to limit stresses generated in the various parts of the machinery.
- (2) Use pressure-limiting valves and other overload protection mechanisms to limit stresses generated in the various parts of the machinery.
- (3) Select the appropriate materials in consideration of corrosion, ageing, abrasion and wear, etc. that may be generated on the machinery.
To prevent machinery from overturn, etc., consider the kinetic energy of the machinery itself and the external forces, etc. to ensure stability of machinery.
To protect against electric shocks, provide the electrical equipments in machinery with a means of protection against electric shocks due to direct contact and indirect contact.
Adopt a method that will not generate noise, vibration, or excessive heat or a method that will reduce these at source.
Limit radiation outputs from ionizing radiation, laser beams, etc. (hereinafter referred to as "radiation, etc.") to the minimum level at which the machinery functions.
Refrain from using, or use only a little, matter that may cause a fire or explosion. Moreover, if a fire or explosion may occur due to a flammable gas, liquid, etc., prevent the machine from overheating, prevent the atmosphere from reaching a concentration that may cause explosion, use explosion-proof electromechanical equipment, and/or take other measures.
Use harmless or low-harm substances.
Take into account ergonomic principles in designing machinery to reduce physical stress and strain ofworkers, and to avoid the occurrence of error-operations, etc., as specified below:
- (1) Enable the machinery to be adjusted according to the size, etc. of the bodies of workers and set a work position and work moves to a level that will not overstrain the workers.
- (2) For the action period of the machinery and the frequency of tasks, set them to a level that will not overstrain the workers.
- (3) If the luminous intensity in a normal work environment is not sufficient, provide lighting equipment to allow for a luminous intensity required for work.
To prevent risks due to an inappropriate design, etc. in the control system, the control system shall comply with the following:
- (1) Starting of machinery shall be by a shift from a low to a high energy state of a control signal.Moreover, Stopping of machinery shall be by a shift from a high to a low energy state of a control signal.
- (2) Starting of an internal power source or switching on an external power supply shall not result in starting working parts.
- (3) If the machinery stops due to an interruption of the power supply from power source of the machinery or due to activation, etc. of the protective device, that machinery shall not start to run unless in response to a restarting operation even after restored to an operable state.
- (4) For programmable controllers, they shall not be easily re-programmable on purpose or on mistake by the user .
- (5) Provision shall be made to prevent the machinery from malfunctioning due to electromagnetic noise or other electromagnetic interference and to prevent radiation of unnecessary electromagnetic energy that may cause other machinery to malfunction.
To prevent risks due to a breakdown, etc. in a sensitive mechanism or control system, use reliable parts and components for the relevant mechanism and control system.Moreover, in designing that mechanism and control system, use components of “oriented failure mode”, make components redundant, use automatic monitoring, and carry out other measures.
To prevent risks due to error-operation, take the following measures for manual controls (actuators), etc.:
- (1) The controls , etc. shall be to comply with the following:
  - a) Facilitate selection, etc. of starting, stopping, and operation control modes. In considering (1), note(2) and (3) of the G for RA.
  - b) Attach clearly identifiable, appropriate labels as necessary in such cases as when there is a possibility that some parts or actions will be confused.
  - c)Match the direction of operation to the direction of action of the moving parts of the machinery.
  - d) Match the amount of operation and the resistance of operation to the amount of action to be executed by the operation.
  - e) For the moving parts of the machinery that may cause hazards, make them impossible to operate unless intentionally.
  - f) For operation devices capable of moving the moving parts of the machinery only when a control is operated, ensure that stopping the operation by means such as releasing the control will stop the moving part of the machinery, with the relevant control going back to its neutral position immediately.
  - g) For operations where the control and operation are not on a 1-to-1 basis as in keyboard-induced operations, ensure that operations to be executed are displayed clearly on the display, etc. and that an operation can be canceled as necessary before it is executed.
  - h) If protective gloves, protective shoes, or other personal protective equipment needs to be used, or if the use thereof is foreseeable, the operational constraints due to the use thereof shall be taken into account.
  - i) Actuators for the emergency stop function and other controls shall be strong enough to withstand foreseeable loads when operated.
  - j) Display devices required to ensure appropriate operations shall be installed in locations where they can be clearly visible from the locations where the controls are operated.
  - k) They shall be arranged in locations where they can be operated quickly, securely, and safely.
  - l) Manual controls shall be located out of reach of the hazard zone, except for certain controls where, of necessity, they are located within a hazard zone, such as emergency stop or teach pendant.
- (2) For starting devices, make them comply with the following:
  - a) Ensure that the machinery can be started only when the starting device is intentionally operated.
  - b) For machinery equipped with more than one starting device and where operating either starting devices when more than one worker is doing work may cause a risk to other workers, provision shall be made to prevent such risks by means such as limiting the parts to be started by operating one starting device.
  - c) They shall be installed in locations where the operator is able to observe that no worker is inside the hazard zone.If visibility is insufficient, shape the machinery so as to reduce the dead angle range, provide a means of visually recognizing the relevant zone indirectly by means of a mirror, etc., or take other similar measures.
- (3) For operation control modes of the machinery, make them comply with the following:
  - a) For machinery to be used in more than one operation control mode with different protection measures or work procedures, ensure that they can be fixed at the positions of individual operation control modes and are equipped with a mode switch that uses a key switch, password, etc. to prevent changeover of mode without intentional operation.
  - b) Where, for setting, teaching, process changeover, fault-finding, cleaning or maintenance of machinery, a guard has to be displaced or removed or a protective device has to be disabled, and where it is necessary for the purpose of these operations for the machinery to be put in operation, safety of the operator shall be achieved using a specific control mode equipped with all the following functions:
    - (a) All control modes other than the one selected shall be disabled.
    - (b) Moving parts that may cause hazards shall be permitted only by continuous actuation of an enabling device, a hold-to-run control device, or tow-hand control device.
    - (c) If an operation needs to continue, the operation of any moving part that may cause hazards shall be permitted only in reduced risk conditions (e.g. reduced speed, reduced power/force, step-by-step operation, e.g. with a limited movement control device) .
- (4)For devices for normal stoppage, make them comply with the following:
  - a) The stop command shall come before any operation command.
  - b) Machinery consisting of a combination of two or more machines which are interlocked for operation shall be so designed that stopping either machine will simultaneously stop the other machines that may increase the risk if the operation continues.
  - c) The machinery shall be equipped, in each control, with a switch designed to stop a part or a whole of the machinery.
To prevent risks stemming from maintenance and inspection, take the following measures:
- (1) Of the machinery parts and components, those which need inspection at appropriate periods for safety, those which must be replaced according to the nature of the task involved, or those which readily become worn or deteriorated shall be made safe and easy to maintain and inspect.
- (2) Ensure that maintenance and inspection can be conducted according to the following priorities:
  - a) Ensure that it can be conducted without removing the guard, resetting the protective device, or entering the hazard zone.
  - b) Ensure that it can be conducted with the machinery stopped if it is necessary to remove the guard, reset the protective device, or enter the hazard zone .
  - c) If it cannot be conducted with the machinery stopped, take the measures set forth in 14 (3) b).

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Guidelines for the Comprehensive Safety Standards of Machinery (2007) Up Date : 2008.03.26 Attached Table 2 Inherently safe design measures Ensure that all parts that a worker may touch are avoided sharp edges and corners, protruding parts, etc. To protect workers from being caught, cause the machinery shape, dimensions, etc. and machinery drive force, etc. to comply with the following: (1) Crushing and shearing hazards are avoided by reducing the gap so that no part of the body can enter it, or by increasing the minimum gap between the moving parts, such that the part of the body under consideration can enter the gap safely. (2) The actuating force is limited to a sufficiently low value so that the actuated part does not generate a mechanical hazard. (3) The mass and/or velocity of the movable elements, and hence their kinetic energy is limited to a sufficiently low value so that the movable elements does not generate a mechanical hazard, when the elements collide to workers. Enable work to be conducted outside the region where the moving parts of the machinery move or at a location away from hazards without entering that region or approaching the hazards.For example, mechanization and automation of machine loading / unloading operations and more generally of handling operations (of workpieces, materials, substances ) limit the risk generated by these operations by reducing the exposure of parsons to hazards at the operation point. To protect machinery from damage, etc., make the machinery strength, etc. comply with the following: (1) Perform correct strength calculations, etc. to limit stresses generated in the various parts of the machinery. (2) Use pressure-limiting valves and other overload protection mechanisms to limit stresses generated in the various parts of the machinery. (3) Select the appropriate materials in consideration of corrosion, ageing, abrasion and wear, etc. that may be generated on the machinery. To prevent machinery from overturn, etc., consider the kinetic energy of the machinery itself and the external forces, etc. to ensure stability of machinery. To protect against electric shocks, provide the electrical equipments in machinery with a means of protection against electric shocks due to direct contact and indirect contact. Adopt a method that will not generate noise, vibration, or excessive heat or a method that will reduce these at source. Limit radiation outputs from ionizing radiation, laser beams, etc. (hereinafter referred to as "radiation, etc.") to the minimum level at which the machinery functions. Refrain from using, or use only a little, matter that may cause a fire or explosion. Moreover, if a fire or explosion may occur due to a flammable gas, liquid, etc., prevent the machine from overheating, prevent the atmosphere from reaching a concentration that may cause explosion, use explosion-proof electromechanical equipment, and/or take other measures. Use harmless or low-harm substances. Take into account ergonomic principles in designing machinery to reduce physical stress and strain ofworkers, and to avoid the occurrence of error-operations, etc., as specified below: (1) Enable the machinery to be adjusted according to the size, etc. of the bodies of workers and set a work position and work moves to a level that will not overstrain the workers. (2) For the action period of the machinery and the frequency of tasks, set them to a level that will not overstrain the workers. (3) If the luminous intensity in a normal work environment is not sufficient, provide lighting equipment to allow for a luminous intensity required for work. To prevent risks due to an inappropriate design, etc. in the control system, the control system shall comply with the following: (1) Starting of machinery shall be by a shift from a low to a high energy state of a control signal.Moreover, Stopping of machinery shall be by a shift from a high to a low energy state of a control signal. (2) Starting of an internal power source or switching on an external power supply shall not result in starting working parts. (3) If the machinery stops due to an interruption of the power supply from power source of the machinery or due to activation, etc. of the protective device, that machinery shall not start to run unless in response to a restarting operation even after restored to an operable state. (4) For programmable controllers, they shall not be easily re-programmable on purpose or on mistake by the user . (5) Provision shall be made to prevent the machinery from malfunctioning due to electromagnetic noise or other electromagnetic interference and to prevent radiation of unnecessary electromagnetic energy that may cause other machinery to malfunction. To prevent risks due to a breakdown, etc. in a sensitive mechanism or control system, use reliable parts and components for the relevant mechanism and control system.Moreover, in designing that mechanism and control system, use components of “oriented failure mode”, make components redundant, use automatic monitoring, and carry out other measures. To prevent risks due to error-operation, take the following measures for manual controls (actuators), etc.: (1) The controls , etc. shall be to comply with the following: a) Facilitate selection, etc. of starting, stopping, and operation control modes. In considering (1), note(2) and (3) of the G for RA. b) Attach clearly identifiable, appropriate labels as necessary in such cases as when there is a possibility that some parts or actions will be confused. c)Match the direction of operation to the direction of action of the moving parts of the machinery. d) Match the amount of operation and the resistance of operation to the amount of action to be executed by the operation. e) For the moving parts of the machinery that may cause hazards, make them impossible to operate unless intentionally. f) For operation devices capable of moving the moving parts of the machinery only when a control is operated, ensure that stopping the operation by means such as releasing the control will stop the moving part of the machinery, with the relevant control going back to its neutral position immediately. g) For operations where the control and operation are not on a 1-to-1 basis as in keyboard-induced operations, ensure that operations to be executed are displayed clearly on the display, etc. and that an operation can be canceled as necessary before it is executed. h) If protective gloves, protective shoes, or other personal protective equipment needs to be used, or if the use thereof is foreseeable, the operational constraints due to the use thereof shall be taken into account. i) Actuators for the emergency stop function and other controls shall be strong enough to withstand foreseeable loads when operated. j) Display devices required to ensure appropriate operations shall be installed in locations where they can be clearly visible from the locations where the controls are operated. k) They shall be arranged in locations where they can be operated quickly, securely, and safely. l) Manual controls shall be located out of reach of the hazard zone, except for certain controls where, of necessity, they are located within a hazard zone, such as emergency stop or teach pendant. (2) For starting devices, make them comply with the following: a) Ensure that the machinery can be started only when the starting device is intentionally operated. b) For machinery equipped with more than one starting device and where operating either starting devices when more than one worker is doing work may cause a risk to other workers, provision shall be made to prevent such risks by means such as limiting the parts to be started by operating one starting device. c) They shall be installed in locations where the operator is able to observe that no worker is inside the hazard zone.If visibility is insufficient, shape the machinery so as to reduce the dead angle range, provide a means of visually recognizing the relevant zone indirectly by means of a mirror, etc., or take other similar measures. (3) For operation control modes of the machinery, make them comply with the following: a) For machinery to be used in more than one operation control mode with different protection measures or work procedures, ensure that they can be fixed at the positions of individual operation control modes and are equipped with a mode switch that uses a key switch, password, etc. to prevent changeover of mode without intentional operation. b) Where, for setting, teaching, process changeover, fault-finding, cleaning or maintenance of machinery, a guard has to be displaced or removed or a protective device has to be disabled, and where it is necessary for the purpose of these operations for the machinery to be put in operation, safety of the operator shall be achieved using a specific control mode equipped with all the following functions: (a) All control modes other than the one selected shall be disabled. (b) Moving parts that may cause hazards shall be permitted only by continuous actuation of an enabling device, a hold-to-run control device, or tow-hand control device. (c) If an operation needs to continue, the operation of any moving part that may cause hazards shall be permitted only in reduced risk conditions (e.g. reduced speed, reduced power/force, step-by-step operation, e.g. with a limited movement control device) . (4)For devices for normal stoppage, make them comply with the following: a) The stop command shall come before any operation command. b) Machinery consisting of a combination of two or more machines which are interlocked for operation shall be so designed that stopping either machine will simultaneously stop the other machines that may increase the risk if the operation continues. c) The machinery shall be equipped, in each control, with a switch designed to stop a part or a whole of the machinery. To prevent risks stemming from maintenance and inspection, take the following measures: (1) Of the machinery parts and components, those which need inspection at appropriate periods for safety, those which must be replaced according to the nature of the task involved, or those which readily become worn or deteriorated shall be made safe and easy to maintain and inspect. (2) Ensure that maintenance and inspection can be conducted according to the following priorities: a) Ensure that it can be conducted without removing the guard, resetting the protective device, or entering the hazard zone. b) Ensure that it can be conducted with the machinery stopped if it is necessary to remove the guard, reset the protective device, or enter the hazard zone . c) If it cannot be conducted with the machinery stopped, take the measures set forth in 14 (3) b). このページの先頭へホーム \|国際会議案内 \|交通案内 \|サイトマップ \|FAQ \|免責事項 Copyright (C) 1999- JICOSH All Right Reserved.