GUARDING of

CARDING MACHINES

Important Note: All the publications in the Publications Archive contain the best guidance available at the time of publishing. However, you should consider the effect of any changes to the law since then. You should also check that the Standards referred to are still current.

Published by Occupational Safety and Health A Service of the Department of Labour ISBN 0-477-03442 -X

CONTENTS
Introduction Background and Future Developments Hazards Legal Requirements Guarding Requirements Woollen carding machine Worsted carding machine Guard Construction Material Type Support Deadlock/Padlock System Trapped Key Interlock System Solenoid-Operated Bolt System Appendices (photographs) Sliding panel guards with trapped key interlock on a carding machine Hinged panel guards with trapped key interlock on a carding machine Fixed guards with hinged panel doors locked by solenoid bolt Further Information 4 5 7 8 9 9 11 12 12 12 12 17 21 24

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INTRODUCTION
This booklet sets minimum requirements for the guarding of carding machines in order to establish a uniform guarding standard in the industry. It has been discussed and agreed with the industry. The Department of Labour requires all owners of carding machines, whether they are in the woollen industries or own non-woven machinery, to comply with these requirements. Guidelines are given on different systems of locking and interlocking the guard panels, which have been implemented successfully by some owners of carding machines. As a guide, technical outlines are also included to assist machine owners to upgrade and interlock guards for their machines. Carding machines are used in both worsted and woollen yarn production. They are also used in the production of most other staple yarns. In all cases, the design of the carding machine is arranged to suit the product to be carded, but the basic principle of guarding these machines is the same. The principles and examples given in this booklet do not exhaust all the possibilities. Any other system of guarding which is equally effective or better will be acceptable to the Department of Labour.

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BACKGROUND AND FUTURE DEVELOPMENTS

The requirements for guarding of carding machines, developed many years ago, were that sliding gates or hinged panels should be provided to enclose the perimeter of the machine. There was no demand for locking or interlocking of the guards. However, accident statistics for carding machines in recent years have proved that the provision of sliding or hinged guards without any locking system is inadequate to prevent accidents on these machines. This is mainly due to the fact that operators can easily gain access to moving parts of the machine without isolating the machine first, or waiting until the overrun has completed. Guards can also be left open during operation and therefore defeat their purpose. This does not strictly comply with the requirements of sections 15, 16 and 17 of the Machinery Act 1950. The objective of the Department of Labour and the industry is to improve the guarding standards of carding machines, to ensure a safe working environment, and to minimise loss of production and costs due to accidents. A number of firms have developed and implemented different approaches to lock or interlock their guards by the following systems: Guards are locked by padlocks and keys held by a responsible person. Guards are interlocked to the motion of the machine by a trapped key interlock system incorporated with a time delay unit. Guards are interlocked to the motion of the machine by a solenoid-operated bolt system, which will only release the locking bolts when a

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rotation-sensing device has detected that the machine is at a complete standstill. The departments requirements for guarding of carding machines are that the perimeter of the machine shall be enclosed by barrier guards of appropriate height to prevent reach to dangerous parts, with restricted access allowed through sliding or hinged gates. These gates shall be locked by padlocks or deadlocks and the keys held by a responsible person. The use of padlocks or deadlocks to lock guards will be effective only in firms which have: A good record of training and supervision of personnel. Restricted access for unauthorised personnel to the machine. Whenever possible, it is strongly recommended that carding machine owners interlock their guards, in order to eliminate the possibility of accidents.

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HAZARDS

A carding machine consists of a large number of transmissions, rollers, belts, pulleys, chains and gear wheels. It can be very dangerous if not adequately guarded. Fingers, hands, feet or loose clothing can easily get caught between the in-running nips and trapping points created by moving parts of the machine and cause severe injuries like fractures, amputation or even death. The main areas of hazards are: The in-running nips and trapping points at the transmission and rollers which have overrun after the power has been isolated. At the tape condenser of a woollen carding machine, as broken threads have to be put back on the appropriate tapes where there are nip hazards with the machine running. Around the scotch feed or broad band area, where there are some transmission and trapping hazards between moving and stationary parts.

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LEGAL REQUIREMENTS
Sections 15, 16 and 17 of the Machinery Act 1950 require moving parts of any prime movers, every part of transmission machinery and every dangerous part of any machinery to be securely fenced, unless parts are in such a position or of such construction as to be safe to every person employed or working on the premises, as they would be if securely fenced. These requirements can be met in respect of carding machines by: Complete enclosure of the moving parts of the prime mover transmission by means of barrier guards, with restricted access allowed through sliding or hinged gates which are locked or interlocked. This includes shafts, belts, pulleys, rollers and all other transmission components, unless they are beyond reach by any person. Secure fencing of all dangerous parts to prevent access while they are in motion.

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IVE CH carding machine ARWoollen

Scribbler

GUARDING REQUIREMENTS

A woollen carding machine has three parts: the first is the scribbler, the second is the intermediate scribbler (broad band or scotch feed) and the third is the carder or condenser card.

This area is to be enclosed by barrier guards of appropriate height, with restricted access allowed through sliding or hinged gates which are locked or interlocked to the motion of the machine.

Scotch feed or broad band

This area can be left as a walk-through area, but all the transmission and trapping hazards associated with the overhead lattice and traversing carriage are to be guarded. Scotch feed or broad band transmissions are to be enclosed if they are within reach. All dangerous parts within reach are to be guarded locally or by means of barrier guards.

Carder
The sides of the carding section and the condenser are to be enclosed by barrier guards of appropriate height, with restricted access allowed through sliding or hinged gates which are locked, or interlocked, to the motion of the machines.

Condenser
If it is necessary to repair the wool threads at the top of the tape condenser while the machine is in motion, an access ladder and a walkway with proper handrails and platforms are to be constructed across this

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area to enable the operator to carry out work safely. The transmission and dangerous parts at each side of the rollers at the condenser section must be enclosed by guards if they are within reach during access to the top of the condenser. This is to apply even when gates are fitted to this area. An air tool or a stick must be used to repair the wool thread. Using hands for such a task is prohibited. A trip wire or bar or similar device shall be provided in the area at a readily accessible location, for stopping the machine in the event of an emergency. When gates near the condenser area are open, access to other parts of the carder must be blocked off, so that the operator cannot use these gates for access to an area other than the tape condenser area. For interlock gates, access to the condenser can be controlled by provision of a separate lockable gate to this area, with the key held by a responsible person other than the operator. If the trapped key interlock system is used, this provision may not be necessary. A spare key can be held by the responsible person for overriding the interlock to allow access for the purpose of repairing wool thread at the condenser while the machine is in motion. The entry gate to the pit to the rear of the condenser must also be locked or interlocked. Access to the bottom of the condenser area for repairing wool thread shall also be controlled in the same way as required at the top of the condenser. The transmission and dangerous parts at each side of the condenser tape rollers which are within reach shall be guarded as far as is practicable. A trip wire or bar or similar device for stopping the machine during an emergency shall also be fitted in this area where repairing of wool thread is required.

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The underside of the carder must be fenced off to prevent the operator from going beyond the condenser area. A gate, which can be locked or interlocked, shall be provided to limit access to areas beyond the condenser area.

Machine adjustment
Where possible, machine adjustments are to be made with the machine stopped. Any adjustment to the machine which is necessary while the machine is in operation, shall, where practicable, be carried out with the guards in position. Where it is not practicable for the guards to be in position while adjustment is made to the machine in motion, only a responsible person like a supervisor or carding engineer may have access to the area, and then only while the necessary adjustments are being made.

Worsted carding machine

The worsted carding machine has only one part and is therefore about half the length of a woollen carding machine, or smaller. The guarding of the worsted carding machine shall meet the relevant requirements for the woollen carding machine.

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IVE CH ARMaterial

GUARD CONSTRUCTION
The barrier guard must be soundly constructed of suitable materials, which can be solid or perforated. The perforation or the mesh wire shall be such that fingers cannot reach the dangerous parts. Mesh sizes and minimum distance between a guard and a dangerous part can be established from the departments booklet The Ergonomics of Machine Guarding. Where a guard made of sheet metal or mesh would obstruct visibility of areas required to be under observation during the operation, a screen of shatterresistant transparent material made, for example, of toughened glass or Perspex, should be provided.

Type
If there is a constraint of space between machines, sliding panels are appropriate for access through guards along the sides of the machine. Guards with hinged panels for access or contour guards usually occupy more space and, hence, they are to be used only where there is ample space between machines. In this case, the number of gates can be reduced by installing the fixed barrier guards along the sides of the machine, with hinged panels at each corner for access. Figures 1, 2 and 3 show the different types of guarding used for carding machines.

Support
Guards must be securely fixed to independent supports or to the machine frame. They are to be of sufficient strength to prevent deflection which would allow access to the dangerous parts. The sliding type

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should be hung from overhead tracks and fitted with bottom rails to ensure stability and smooth sliding of the gates.

Where necessary, there can be clearance under the guards for cleaning purposes, provided this clearance does not allow reach to the danger zone. Openings, clearances and gaps in guards must not exceed those as determined from the booklet The Ergonomics of Machine Guarding.

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(b) Carder

Gate within interlock sliding panel for access to condenser and locked by deadlock

Figure 1. Guards with sliding panels

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(a) Scribbler

(b) Carder

Figure 2. Guards with hinged panels

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Figure 3a. Fixed guards at sides with hinged door at each corner

Figure 3b. Contour guard

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DEADLOCK/PADLOCK SYSTEM
To prevent guards from being left open during operation, it is essential that all gates for access to the moving parts of the machine shall be locked by deadlocks or padlocks. Locks must be of robust construction and keys held by a responsible person (the foreman or plant manager) and, if necessary, this responsibility can be shared between two persons other than the operator. The person in charge of keys must ensure that the machine power has been isolated and the machine overrun has completed, before he unlocks any lock. A convenient and cost-effective way of locking gates, which will also minimise human error, is by locking a series of panels for: Sliding gates by means of a long pipe or rod fitted with bars or pins, which slot into holes in panels and lock them together by using one lock at the end of the rod, as shown in figure 4. Hinged gates by using a long bar which can hinge down when all gates are closed, and locked by a deadlock at the end of the bar, as shown in figure 5. Gates shall be designed to prevent the locking bar from hinging down when any gate is open. Stops must be fitted to prevent gates from being pushed inward. In both cases, the locking rod or bar and components shall be of robust construction, with sufficient strength to withstand any external force likely to be imposed on them. If systems as illustrated in figures 4 and 5 are used for locking gates, a normally closed limit switch can be fitted at the end of the locking rod or plate, to ensure that the machine cannot be started, unless all
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the gates are shut. Where guards are of the hinged panel type, a photoelectric light beam can also be installed to detect whether gates are shut. If one gate is opened, the light beam will be interrupted and the machine cannot be switched on.

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Round with hole for lock bolt is fitted to the rid or pipe Deadlock or interlock deadlock

Rod or pipe Turning lever for locking and unlocking of panels Pin slots into hole and locks panel

Sliding panel (a) Gate for access to condenser and locks by a deadlock (for interlock system only)

(b)

Figure 4. A series of sliding panels locked by a rod fitted with pins which slot into holes in the panels

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Locking bar at open position

(a)

Locking bar attached to circular plate Deadlock or interlock deadlock at locking position Circular plate for locking

(b)

Figure 5. A series of hinged panels locked by a hinged bar with a deadlock at one end

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TRAPPED KEY INTERLOCK SYSTEM

The sliding or hinged gates can be interlocked to the motion of the machine by using a trapped key interlock (key exchange) system, which works on the principle that the master key, which controls the power supply to the machine through a switch at the master key box, has to be turned off before keys for individual guards can be released. A typical trapped key interlock system is illustrated in figure 6. When the machine is operating, key A is trapped in the power supply interlock and all access points are locked closed. A time delay unit or a rotation-sensing unit can be used to monitor the residual motion or overrun of the machine after the power has been switched off. To open the access gates, the steps are: Power is isolated and key A can be released. Key A is inserted and kept captive in the time delay unit (or rotation-sensing unit). The unit ensures that there is a specific time interval which has to be greater than the time of overrun (or the unit detects that the motion in the machine has stopped) before key B is released. Key B is inserted in the key exchange box and kept captive. Key C can then be released for opening gates and kept captive in each lock. Only by reversing this key transfer sequence can normal operation of the machine resume. Instead of locking each individual gate by a lock, the system of locking a series of gates together by using

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one lock, as mentioned previously and shown in figures 4 and 5, is recommended. This will reduce the number of keys in the key exchange box and hence reduce the time for locking and unlocking. It also significantly reduces the cost of installation. A small individual gate can be provided at the guard near the condenser, to control access to the top of the condenser for repairing wool threads, if necessary, during machine operation. This gate can be locked by an ordinary deadlock and opened only by a responsible person other than the operator. This interlock-based safety control system is a convenient and cost-effective way of eliminating human error and providing positive protection for person and machine.

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Machine Power Supply

ON-key trapped

LOCKED OFF - key free

Rotation-sensing or time delay unit

Access keys locked Key B free

Access keys released Key B trapped

Access gates locked

Access gates open - keys trapped

Machine running

Machine stopped

Figure 6. Diagrammatic arrangement of a trapped key interlock system

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SOLENOID-OPERATED BOLT SYSTEM

The solenoid-operated bolt system, which incorporates a rotation-sensing device or a time delay unit, is another method of interlocking gate guards. Each gate is locked by means of an interlock deadlock, fitted with a solenoid to prevent withdrawal of the lock bolt until an electrical signal is received from the rotation sensing or time delay unit. To open gates, the following sequences are followed: First motion of the key in the power control box switches off the power to the machine. The rotation-sensing unit detects that the machine is completely at a standstill or the time delay unit monitoring the time is at the end of the predetermined period. Key can then be turned to the second position and solenoids activated. Lock bolts are withdrawn and gates are opened. Normally closed limit switches shall be fitted to gates so that the solenoid cannot be activated to lock the bolt unless all gates are closed. When the solenoidoperated bolts have locked all gates, an electrical signal is transmitted to the power control box and the machine can be switched on. Electrical limit switches used for guard interlocking shall be arranged so that the actuator is released when the guard is fully closed allowing the machine to start. When the gate is opened the switch contacts are positively opened by the cam and the machine cannot be started. Details of this preferred method of fitting limit switches are set out in the departments booklet Electrical Interlocking of Machinery Guards. These are

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also shown in figure 7 for hinged gates and figure 8 for sliding gates. Gates shall be constructed in such a way or fitted with a device to prevent them from being shut unintentionally. For this purpose, a spring may be used to act against the closing of a gate. A latch which is operated manually can be used to hold the gate in position temporarily, so that the solenoid-operated lock bolt can be engaged.

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(a) Gate open

(a) Gate closed

Figure 7. Normally closed limit switch used for hinged gate

Sliding gate closed

Sliding gate open

(a) INCORRECT

Sliding gate closed

Sliding gate open

(a) CORRECT

Figure 8. Mounting of limit switches for sliding gates

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APPENDIX 1: SLIDING PANEL GUARDS WITH TRAPPED KEY INTERLOCK ON A CARDING MACHINE

(Photographs courtesy of Feltex Carpets of New Zealand)

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APPENDIX 2: HINGED PANEL GUARDS WITH TRAPPED KEY INTERLOCK ON A CARDING MACHINE

(Photographs courtesy of UEB Carding Ltd.) 28 Guarding of Carding Machines

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APPENDIX 3: FIXED GUARDS WITH HINGED PANEL DOORS LOCKED BY SOLENOID BOLT

(Photograph courtesy of Capston Printing Works Ltd.)

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FURTHER INFORMATION
Further information on guarding of carding machines and other machinery can be obtained from your nearest Department of Labour, Occupational Safety and Health area office. Offices are located at: Whangarei New Plymouth North Harbour Napier Penrose Lower Hutt West Auckland Wellington Manukau Nelson Rotorua Christchurch Tauranga Dunedin Palmerston North Invercargill

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