BRITISH STANDARD BS EN 13985 2003 Machine tools — Safety — Guillotine shears ICS 25 120 10 ��������� � ���� ���������������������������������������������� ����� +A1 2009 BRITISH STANDARD BSEN 15985 20[.]
Terms and definitions
This European Standard utilizes the terms and definitions outlined in EN 1070:1998, along with additional definitions found in relevant A and B standards, as well as annex A of EN 292-2:1991/A1:1995.
3.1.1 ancillary device device intended for use with the guillotine shear and integrated with it (e.g devices for lubrication, feed, ejection)
3.1.2 beam main reciprocating guillotine shear member holding the top blade The top blade can be guided either by direct slide (vertically up and down) or swinging beam
3.1.3 clamp part of the machine which holds the sheet material in position on the work table during the cutting stroke Also called hold-down or jack
Crocodile shears operate similarly to scissors, utilizing a shearing action The power is applied at an angle around the pivot, with the blade movement being solely guided by this pivot point.
The operating cycle refers to the movement of the moving parts from the starting position, typically the top dead center, to the bottom dead center and back to the top dead center This cycle encompasses all operations performed during this movement.
Dead centers refer to specific points in the travel of a moving blade These points include the bottom dead center (BDC), which occurs at the end of the closing stroke, and the top dead center (TDC), which is reached at the end of the opening stroke.
Guillotine shears, often referred to simply as guillotines or shears, are machines designed with side frames connected by a work table This setup includes a fixed bottom blade and a movable upper beam equipped with top blade(s) The blades can be configured at either a fixed or variable angle, determining the angular relationship between the top and bottom blades.
An inching device is a limited movement control mechanism that allows only a restricted amount of travel for a machine element, significantly reducing risk Further movement is prevented until there is a subsequent and separate actuation of the control, as outlined in section 3.23.8 of EN 292-1:1991.
The monitoring safety function is crucial for initiating protective measures when a component's ability to perform its function is compromised or when process conditions change, potentially leading to hazards This aligns with the guidelines outlined in section 3.7.6 of EN 292-2:1991.
3.1.10 muting temporary automatic suspension of a safety function(s) by safety related parts of the control system (see 3.7 of
3.1.11 overall system stopping performance; overall response time time occurring from actuating the protective device to the cessation of hazardous motion, or to the machine assuming a safe condition
Redundancy involves the use of multiple devices, systems, or components to ensure that if one fails, another is ready to take over its function This approach enhances reliability and performance in critical applications.
Abbreviations
3.2.4 BDC Bottom dead centre (see 3.1.6)
3.2.5 TDC Top dead centre (see 3.1.6)
3.2.8 AOPD Active opto-electronic protective devices
3.2.9 ESPE Electro-sensitive protective equipment
The hazards listed in Table 1 stem from a thorough hazard identification process, highlighting associated danger zones and referencing protective measures for guillotine shears as outlined in this standard The safety requirements and protective measures detailed in clauses 5 and 7 are derived from a risk assessment, addressing the identified hazards by either eliminating them or mitigating the risks they pose.
The risk assessment considers potential access from all directions, including unexpected incidents such as strokes or falls due to gravity It identifies risks to both operators and individuals who may enter danger zones, accounting for hazards that could arise during various stages of intended use, including commissioning, setting, production, maintenance, repair, decommissioning, and dismantling.
EN 292-1:1991) during the life of the machine The assessment includes an analysis of the effect of failure in the control system
The user of this standard, including designers, manufacturers, and suppliers, must ensure that the list of significant hazards in Table 1 is comprehensive for the specific machine being assessed If additional hazards are identified, the user is required to analyze and evaluate the associated risks in accordance with EN 1050, paying special attention to the machine's intended uses such as commissioning, setting, production, maintenance, repair, decommissioning, and dismantling, as well as any reasonably foreseeable misuse.
Table 1 — Significant hazards, danger zones, protective measures
No Hazards Danger zone Relevant clauses in
Protective measures: relevant clauses in this standard
Generated by machine parts or work-pieces Blades and associated area:
Generated by accumulation of energy inside the machinery caused, for example, by:
– liquids and gases under pressure
– between the moving blade and the work-piece
– between the moving blade and the fixed blade
– between moving and fixed parts of guillotine shear – between the table and work- piece
– between the clamps and work-piece or table – between fixtures/positioning devices and work-piece – at power operated gauges – moving work-pieces,
1.1 Crushing hazard – ejection or falling of work- pieces at the rear of guillotine shear,
1.2 Shearing hazard – rear moving sheet supports,
– rear sheet conveyor, – sheet stacking unit
1.3 Cutting of severing hazard From the hazardous event of falling objects 1.4 Entanglement hazard
1.5 Drawing-in or trapping hazard
1.6 Impact hazard Moving parts of electrical, hydraulic and pneumatic equipment
Motor and drive machinery – moving flywheels, belts, pulleys and other motor driven parts
1.9 High pressure fluid injection or ejection hazard
No Hazards Danger zone Relevant clauses in
Protective measures: relevant clauses in this standard
2.1 Contact of persons with live parts (direct contact)
2.2 Contact of persons with parts which have become live under faulty conditions
3.1 Thermal hazards resulting in burns and scalds, by a possible contact of persons
Parts of the hydraulic system 1.5.5, 1.5.6,
(e.g loss of balance, loss of awareness) hearing losses
Falling of work-pieces at the rear of guillotine shear
6.5 Lasers Any area at the guillotine shear where there is a risk due to laser beam
7.0 Hazards generated by materials and substances processed or used by machinery, for example:
7.1 Hazards from contact with or inhalation of harmful fluids, gases, mists, fumes and dusts
Toxic materials used in the construction and intended use of the guillotine shear
8.0 Hazards generated by neglecting ergonomic principles in machinery design, as e.g from:
8.1 Unhealthy postures or excessive effort
8.2 Inadequate consideration of hand-arm or foot-leg anatomy
No Hazards Danger zone Relevant clauses in
Protective measures: relevant clauses in this standard
8.7 Inadequate design, location or identification of manual controls
8.8 Inadequate design or location of visual display units
10 Unexpected start-up, unexpected overrun/ over speed
10.1 Failure/disorder of the control system Blades and associated area:
10.2 Restoration of the energy supply after an interruption
– between the moving blade and the work-piece
– between the moving blade and the fixed blade
– between the table and work- piece
– between the clamps and work-piece or table – between fixtures/positioning devices and work-piece – safeguarding – at power operated gauges
No Hazards Danger zone Relevant clauses in
Protective measures: relevant clauses in this standard
10.3 External influences on electrical equipment
– ejection or falling of work- pieces at the rear of guillotine shear
– rear sheet conveyor, – sheet stacking unit
10.6 Errors made by the operator
(due to mismatch of machin- ery with human character- istics and abilities, see 8.6)
13 Failure of the power supply see 10 1.2.6 5.2.1.12
14 Failure of the control circuit 1.2.1, 1.2.3,
16 Break-up during operation Mechanical, electrical, hydrau- lic, and pneumatic equipment
17 Falling or ejected objects or fluids
Machine components Work-pieces and blades
18 Loss of stability/ overturning of machinery
Floor area around the guillotine shear
19 Slip, trip and fall of persons
All access and/or work at heights
Floor area around the guillotine shear
5 Safety requirements and/or protective measures
General
The guillotine shears covered by this standard range in size from small to large machines with a single operator or several operators
The methods or measures to be implemented to eliminate the significant hazards or reduce their associated risks are detailed in this clause in the following manner:
⎯ basic design considerations for major guillotine components or systems (see 5.2);
⎯ safeguarding against mechanical hazards in the blade area under different modes of production (see 5.3);
⎯ protection against hazards due to control system or control component failures (see 5.4);
⎯ safeguarding against hazards which can occur during setting, trial strokes, maintenance and lubrication (see
⎯ safeguarding against other hazards (see 5.6 to 5.8)
In addition, the machine shall be designed according to the principles of EN 292 for hazards relevant but not significant which are not dealt with by this standard.
Basic design considerations
Fluid or air pressure must not be utilized for brake application unless there are mechanisms in place to maintain brake integrity and disengage the clutch in case of pressure loss Additionally, diaphragms are prohibited for brake application.
The designer must ensure that the compression springs used for the brake and clutch disengagement are reliable and well-tested components It is essential to utilize multiple assemblies, ensuring that all springs are uniform in dimensions, quality, and rating The loading mechanisms for the springs should allow for secure locking of the spring anchorages to prevent slackening Additionally, the design of the spring housing, guiding arrangements, and guide pins should minimize binding Importantly, the brake system must remain functional even if 50% of the spring assembly fails.
5.2.1.3 The arrangement provided for engagement and disengagement of the clutch and brake shall not affect their safe function
NOTE Combined clutch and brake units are recommended so as to reduce the possibility of the overlapping of their engagement
The design of the clutch and brake must ensure that any failure of components, such as power transmission elements or screws, does not hinder the disengagement of the clutch or the application of the brake.
5.2.1.5 Any heat generated which can cause a hazardous situation shall be dissipated
5.2.1.6 Effective arrangements shall be made to prevent reduction of braking performance due to penetration of lubricants to the brake friction surfaces
The design of the clutch and brake must minimize the accumulation of dust, fluid, or debris that could impair their performance Additionally, any moisture, dust, or lubricating oil that may damage packaging materials, such as gaskets and seals, should not adversely affect their functionality by obstructing air channels or reducing efficiency.
5.2.1.8 Band brakes shall not be used on guillotine shears for the purpose of stopping the beam
5.2.1.9 Clutches shall be of a capacity capable of engaging and disengaging the intended stroke, without excessive temperature rise, under conditions of maximum use of the guillotine shears
5.2.1.10 Sufficient working clearances shall be provided so as to ensure that, under the severest conditions of operation and temperature, no undesired movement of the driven members shall take place
To ensure optimal clutch performance, it is essential to implement measures that prevent the buildup of debris from frictional surfaces in critical areas and facilitate its effective dispersal.
The design of the clutch and brake control system must ensure that, in case of a failure in the pneumatic, hydraulic, or electrical supply, the clutch will disengage and the brake will be applied immediately.
In clutch systems utilizing diaphragms, it is essential to implement protective measures against potential damage caused by sharp edges and rough surfaces Additionally, it is crucial to ensure that air evacuation is not hindered by diaphragm slackening, which may occur due to material fatigue.
5.2.2 Hydraulic and pneumatic systems - Common features
5.2.2.1 The general requirements in EN 982 and EN 983 shall be applied in designing hydraulic and pneumatic systems These systems shall also comply with the particular requirements in 5.2.2, 5.2.3 and 5.2.4
5.2.2.2 Filters and pressure regulators shall be provided
5.2.2.3 Devices shall be provided to ensure that the permitted range of working pressure is maintained
5.2.2.4 Pressurised transparent bowls (e.g glass, plastic) shall be protected to prevent injury from flying particles without affecting visibility
All piping, pipe fittings, passages, surge or storage tanks, and cored or drilled holes must be free from burrs or foreign matter to prevent potential damage to valves and clutch and brake operating components, as outlined in EN 982:1996 and EN 983:1996.
Piping runs should be continuous between apparatus whenever possible, with precautions in place to mitigate damage from thermal expansion Additionally, rigid piping must be securely supported at regular intervals to prevent vibration and movement.
To prevent fluid traps, it is essential to avoid kinking flexible pipes, especially those supplying the running joint of the clutch and brake Kinking can obstruct fluid flow, leading to operational issues.
To prevent unintended dangerous motion of the beam due to a drop in pressure, it is essential to select pipes and pipe connections that mitigate this risk Flanged or welded connections should be utilized to ensure a secure and reliable system.
5.2.2.8 The support of operating valves shall not depend only on the connected piping This is to avoid undesirable effects from vibration which might affect both valves and piping
Operating valves for the clutch and brake must be designed to allow any leakage past the inlet valve to escape freely when in the non-operating position, preventing pressure build-up in the clutch-operating cylinder.
Operating valves for the clutch and brake must be designed to ensure that both the inlet and exhaust ports cannot be closed simultaneously.
Exhaust ports and piping connecting clutch operating cylinders and valves must be chosen to facilitate the quick release of fluid from the cylinders It is essential to implement measures that prevent residual pressure in the cylinder through the exhaust ports of the operating valves Additionally, the selection of the valve should ensure that the pressure ratio between the clutch and brake prevents excessive residual pressure in the event of a valve malfunction.
NOTE Normally, a ratio of at least 3.5 to 1 between spring pressure in the brake and residual pressure in the cylinder is satisfactory
5.2.2.12 Control valves and other control components (e.g regulators, pressure gauges) shall be mounted in positions which provide accessibility and protection against damage
When valves are operated manually or mechanically, it is essential that the mechanisms for restoring the valves are positive This means that upon releasing the actuator, the valve should automatically return to a safe position For further details, refer to section 5.4.6.
Any unintended movement due dissipation shall be avoided of stored energy according to EN 1037
NOTE The safety position can be the open or closed position of a valve, depending upon the well-tried principles in the hydraulic or pneumatic circuit
Mechanical hazards in the blade and associated area
The primary hazard zone in guillotine shears is the blade and its surrounding area, necessitating protective measures to address these risks This section outlines the required safeguards for the blade and its vicinity However, if the gap between the closing surfaces is limited to a maximum of 6 mm, no additional safeguarding is necessary.
NOTE See Table 2 for values of A and B
Figure 2 — Feed opening in a fixed guard at the front side of a guillotine shear
Table 2 — Height of feed openings and minimum related safety distances
(mm) B – Minimum related safety distance (mm)
NOTE See Figure 2 for understanding of A and B
For guillotine shears with height of feed opening A exceeding 38 mm safeguarding by interlocking guards or ESPE using AOPD is recommended
3a - Example of safeguarding using fixed guards
3b - Example of safeguarding using light curtain Figure 3 — Guards fitted to guillotine shears to prevent front and side access
According to EN 292, EN 953, and relevant sections, it is essential to implement guards and devices to protect individuals in cutting areas Designers, manufacturers, and suppliers should prioritize fixed guards to limit access to moving parts If fixed guarding is not feasible, alternative safeguarding methods must be chosen to minimize risks, focusing on principal hazards and production modes Recommended methods include interlocking guards and electro-sensitive protective devices.
The chosen safeguarding methods will ensure the protection of all individuals who may enter the danger zone during operations, setup, maintenance, cleaning, and inspection activities, as outlined in section 4.2.
The guards and protective devices must be integrated with the guillotine shear's control system, ensuring they meet the same category requirements for safety and compliance.
The machine front table extension shall exceed the front safeguarded area
The relationship between the dimension of the feed opening and the distance to the nearest danger point (plate clamps/cutting line) shall follow Table 2 (see also Figure 2.)
A fixed guard must be installed to block access to the danger zone in front of guillotine shears, specifically protecting against the moving blade and plate clamps These fixed guards are required to meet the standards set by EN 292.
According to EN 953 and sections 5.3.2, 5.3.5, and 5.3.6.1, safety guards must be securely attached to the machine Additionally, the access openings to danger zones and the corresponding safety distances of the fixed guard must adhere to the specifications outlined in Table 4 of EN 294:1992.
The design of the fixed guard shall allow good visibility of the cutting line
Access shall be prevented to the danger zone via slots or grooves cut in the surface of the work table (see also Table 2)
5.3.3.3 Interlocking guards without guard locking
Interlocking guards without guard locking must adhere to EN 953 standards to prevent access to danger zones during hazardous movements, in conjunction with fixed guards The stroke initiation should be blocked until the guard gate is securely closed, and the interlocking devices must comply with EN 1088, designed according to section 6.2.2 of EN 1088:1995 The guillotine shear's control system should meet category 4 requirements of EN 954-1:1996 Additionally, these interlocking guards should be positioned to ensure that operators cannot reach the danger zone before hazardous movements cease, with safety distance calculations based on the guillotine shear's stopping response time and the operator's movement speed, as outlined in EN 999 and annex A.
5.3.3.4 ESPE using AOPDs in the form light curtains
ESPE must ensure that AOPDs, specifically light curtains, comply with type 4 standards as per EN 61496-1:1997 and are designed according to pr EN 61496-2:1997 The control system for the guillotine shear must meet category 4 requirements of EN 954-1:1996, and access to the danger zone should only occur through the light curtain's detection zone, with additional safeguards to prevent access from other directions The design must ensure that the feed table prevents individuals from standing between the light curtain and the danger zone, adhering to specified safety distances Hazardous movements must not be initiated if any part of the body interrupts the light curtain, and reset controls should be positioned for a clear view of the danger zone, with only one reset control device allowed per detection zone If back AOPDs are used, a reset control device must be present for each detection zone.
To ensure operator safety, ESPE utilizing AOPDs as light curtains must be strategically positioned to prevent operators from reaching the danger zone before hazardous tool movements stop The safety distance calculation should consider the guillotine shear's overall response time and the operator's movement speed, in accordance with EN 999 and annex A Importantly, the minimum safety distance must always be at least 100 mm.
The minimum safety distances, denoted as S and S*, must always be at least 100 mm Additionally, the detection capability and the gap between the front light beam and the table should not exceed 100 mm.
6 Point of danger ( reference for calculation of S ;S' )
Figure 4 — Examples of safeguarding using light curtain
When a guillotine shear is equipped with adjustable work-piece supports and back gauges, the design of these back gauges must ensure that they cannot be adjusted by reaching between the tools, even if rear work-piece supports are present.
Back gauges and rear work-piece supports must be designed to prevent any adjustments from being made by reaching under the blade, ensuring safety and compliance in operation.
Fixed guards shall prevent access to the danger areas created by the blades and clamps from the sides of the machine (see Figure 3)
To ensure safety, access to the moving blade and powered back gauges, as well as auxiliary devices from the rear, must be restricted This can be achieved through various methods, including the use of fixed guards, interlocking guards, or a combination of interlocking and fixed guards Additionally, the implementation of an Electro-Sensitive Protective Equipment (ESPE) using Active Opto-electronic Protective Devices (AOPDs) is recommended.
Where it is not possible to operate with a fixed guard, an interlocking guard or an ESPE using AOPD may be provided
Fixed guards must be installed at the rear of the machine to prevent access to the blades and powered back gauges, ensuring that cut sheet metal is safely discharged The design of the guard, including the opening beneath it and the distance to the nearest danger point, must comply with the safety distances outlined in EN 294 Additionally, the openings in fixed guards should adhere to the safety distances specified in EN 294:1992 Table 4 and EN 811.
5.3.6.3 Interlocking guards or interlocking guards in conjunction with fixed guards
When an interlocking guard is opened, all dangerous movements must cease, ensuring that the blade, powered back gauges, and ancillary devices remain inactive until the guard is securely closed, in compliance with EN 1088 If full body access is possible within the guarded area, a separate reset control is necessary The reset and interlocking functions must meet at least the S & M (single channel and monitored) standard, utilizing a positive opening type switch linked to redundant relays Additionally, the reset device should be positioned outside the guarded area while providing a clear view of it.
The control and monitoring system
This sub-clause pertains to all safety components that control or monitor the operation of the guillotine shear and its tools Compliance with EN 60204-1 is required for the design of electrical systems, while EN 954-1 must be followed for the safety-related aspects of electrical, hydraulic, pneumatic, and mechanical systems.
Control systems must incorporate safety functions that require reactivation of controls for the guillotine shear to execute a stroke This reactivation is necessary after any change in the mode of control or operation, the closure of an interlocking guard, a manual reset of the safety system, an operating power failure, or a primary pressure failure.
In cases where a safety system intervention occurs, such as with an interlocking guard or an ESPE utilizing an AOPD, it is essential to implement separate manual reset functions to restore normal operation This is necessary if a person can access the danger zone through the interlocking guard, if the ESPE is interrupted during any hazardous movement, or if the ESPE protects the sides of the guillotine shear that are not in operation.
The reset control must be positioned within sight of the danger zone while remaining out of reach Additionally, the reset functions should include at least one channel with monitoring capabilities, as specified in section 5.4 of EN 954-1:1996.
5.4.1.3 This sub-clause applies to guillotine shears fitted on the operator's side with protective devices of the following types, namely:
⎯ interlocking guards without guard locking
For machines fitted with these protective devices at a non-operator's side 5.3.6.2 and 5.3.6.3 apply
In the event of a fault in the safety-related components of protective devices or control systems, it is crucial that unintended start-ups are prevented, the safety functionality of the protective device is preserved, and the machine can be halted during hazardous movements Additionally, the control system must immediately stop the machine during dangerous phases of operation, or at the end of the operating cycle at the latest Furthermore, the control system should ensure that no new production cycle can begin until the fault has been resolved.
The start and stop functions of interlocking guards or ESPE utilizing AOPD in the safety-related components of the guillotine shear control system must be redundant and monitored, aligning with category 4 standards.
According to EN 954-1:1996, the start and stop functions in electrical systems must be hardwired In a pneumatic guillotine shear control system, it is essential to monitor the valve state through pressure signals, position detection, or an inherent monitoring system that reveals any valve failures automatically.
In situations where a redundant and monitored control system is necessary, it must function within two distinct operating systems Each system must independently halt hazardous movements, regardless of the status of the other Any failure in either system should be identified through monitoring, preventing another closing stroke If a system's failure is self-evident—meaning that the loss of its function stops the next operating cycle—additional monitoring for that system is not needed.
5.4.1.5 The control system of the programmable back gauges and powered work-piece supports shall conform at least to category B of EN 954-1:1996
5.4.2 Programmable electronic systems (PES), programmable pneumatic systems (PPS) and safety related functions
5.4.2.1 The use of PES and PPS shall not reduce any level of safety laid down in this standard
5.4.2.2 Where a guillotine shear is controlled by a PES or a PPS, the safety related part of the control system shall not rely solely on the PES or PPS
5.4.2.3 Monitoring functions may be achieved by a PES or a PPS
In situations where multiple modes of operation are available for the guillotine shear's cycle initiation or safety system, such as setting mode, single cycle, or automatic cycle, it is essential to include selector switches The control system must be designed to prevent start-up when the selector switch is engaged.
When a single selector switch is available, it must be used to choose the appropriate safeguarding mode, which may involve multiple guards or protective devices If multiple selector switches are present and linked to the control system, the selected mode of operation will automatically correspond to the relevant safeguarding mode, such as interlocking guards with guard locking during automatic cycles and light curtains in single cycles Importantly, the selector switch must not bypass any safeguarding measures of the guillotine shear unless additional safeguards, like perimeter fencing, are implemented.
5.4.3.3 If the guillotine shear is designed to be operated also by more than one operator, the level of protection shall be the same for each operator
Electrical selector switches must comply with section 9.2.3 of EN 60204-1:1997 Their design should guarantee complete isolation of circuits for any unused position through positively operated contacts or redundant, monitored hardware Additionally, if the switch is in an intermediate position, no operation should be allowed.
5.4.3.5 The selector switch shall give a clear indication and be key operated (e.g key switch, password)
In a two-channel control system, faults can occur in one channel while the other remains functional, ensuring continued operation Additionally, faults may arise during non-hazardous phases of the closing stroke, further minimizing risk.
The design of the switch and its operation must ensure that, once positioned, they maintain their correct alignment with the operating cam and the stroke For electrical position switches, refer to section 10.1.4 of EN 60204-1:1997 The same standards apply when utilizing a pneumatic valve as a position switch.
Overrun detection is essential for machines with ESPE utilizing AOPD and/or interlocking guards If the crankshaft exceeds its designated stopping position as defined by the manufacturer, an immediate stopping signal will be triggered, halting the machine at the top dead center (TDC) Additionally, no new cycle can be initiated during this condition.
Control devices, including push buttons and foot switches, must be shrouded to avoid accidental activation Foot switches should allow access from only one direction and be operated by a single foot, while the use of treadles is prohibited.
Tool-setting, trial strokes, maintenance and lubrication
The guillotine shear must be designed to ensure safe blade changing, maintenance, and lubrication Access and manual intervention during these processes should be minimized, potentially utilizing an automatic system or remote application for lubrication.
The guillotine must be designed to allow all maintenance tasks to be performed with the power turned off, except when adjustments to machine parts under power are essential It should include features that enable the movement of the blade, beam, and back gauges during maintenance and lubrication while keeping guards and protective devices in place and functional If this is not feasible, at least one of the following controls must be available at the setter position: a hold-to-run control device or an inching device.
For tool setting the devices in a) or b) above shall be positioned at the tool setter position (front or back) and only movements of the blade shall be possible
5.5.3 Hold-to-run control devices and inching devices shall be hardwired and the safety related parts of the control system shall conform to category 1 of EN 954-1:1996
5.5.4 The slide/ram movement shall not exceed 6 mm per inching step
When using a bar or device to manually rotate the crankshaft while the main motor is off, safety measures must be in place to prevent clutch re-engagement until the flywheel has completely stopped This can be achieved through a motion detector, with the control system adhering to category 1 of EN 954-1, or by employing an electrical drive control system with integrated speed monitoring that meets category 3 of EN 954-1:1996 Additionally, it should be impossible to accidentally leave the bar in position during normal operation, and at least part of the flywheel must be visible to confirm that it is stationary.
To adjust the blade gap, it is essential that feeler gauges cannot be inserted between the blades at the cross-over point while moving along the blade's length, unless the beam is operated under controlled conditions.
Mechanical hazards - Other
Access to danger zones in guillotine shears and their ancillary devices must be restricted through various safety measures Fixed guards are suitable when access is needed infrequently, while movable guards that are interlocked with the control system are required for more frequent access In cases where dangerous movements do not stop before reaching the danger zone, interlocking guards with locking and delayed unlocking mechanisms must be implemented, controlled by timers or motion detectors Additionally, the use of electro-sensitive protective equipment (ESPE) with active optoelectronic protective devices (AOPDs) is recommended for enhanced safety For information on safeguarding the rear side of a guillotine shear, refer to section 5.3.6.3.
Safety distances for fixed or interlocking guards against reaching over, under, around, and through openings must comply with EN 294:1992 Specifically, for reaching over physical barriers, these distances should align with Table 2 of EN 294:1992 Additionally, when using an Active Optoelectronic Protective Device (AOPD) for reaching through, the minimum safety distances must be calculated according to EN 999.
5.6.2 Interlocking devices shall conform to the requirements of EN 1088 and their control circuit(s) to at least category 1 of EN 954-1
Ancillary devices not governed by the guillotine shear must be interlocked with the guillotine shear control system to prevent any hazardous situations during maintenance or intervention.
Slips, trips and falls
Raised work stations equipped with guillotine shears must include sufficient guardrails and toe-boards Additionally, safe access to these work stations should be ensured in accordance with safety regulations.
NOTE Adjustment during tool setting, daily inspections and lubrication on raised workstations require a platform and a permanent access For repair only, no platform is required
The design and construction of the operator's position at guillotine shears must prioritize safety by minimizing the risk of slips, trips, and falls This can be achieved by incorporating features such as profiled slip-resistant flooring in areas integral to the guillotine shear.
Protection against other hazards
All electrical equipment shall be designed and constructed to prevent electrical hazards (e.g shock) see
To prevent burns from accessible parts of the guillotine shear, such as the metal components of the hydraulic system that can exceed temperatures of 64°C within a contact duration of 4 seconds, appropriate measures like shielding and insulation must be implemented, in accordance with EN 563 standards.
5.8.3 High pressure fluid ejection hazards
Additional shielding, e.g screens, shall be provided to flexible piping installed adjacent to an operator´s working position to reduce the risk resulting from a failure in the flexible piping system
5.8.4 Loss of stability/overturning of machinery
The designer of a guillotine shear shall ensure stability including work loads, either by design or by provision of fixing points to allow connection to the floor/foundation (see 7.2.2 d))
The guillotine shear must be designed and built to minimize airborne noise emissions, prioritizing the latest technological advancements and available noise reduction methods, especially at the source.
When designing a guillotine shear, the information and technical measure to control noise at source given in
EN ISO 11688-1:1998 and EN ISO 11688-2:1998 shall be followed
The design must consider noise from all sources, implementing effective technical measures to reduce noise from the guillotine shear's main sound sources Key strategies include utilizing fluid transmission damping facilities, installing acoustic panels for motors and pumps, employing anti-vibration mounts, incorporating damping facilities for transmission noise through flywheels and gearwheels, using pneumatic exhaust silencers, and applying acoustic panels to power generation sources.
To reduce noise in hydraulic units, it is essential to implement damping facilities at the clamps and blades areas Additionally, incorporating damping solutions for falling workpieces and acoustic enclosures for feeding and transfer systems can significantly minimize noise levels Furthermore, utilizing anti-vibration machine mounts can effectively address structurally transmitted noise.
Alternative methods that provide equal or greater noise reduction efficiency can be implemented Ultimately, the declared noise emission values serve as the key criterion for assessing the noise output of a specific machine.
5.8.5.3 The measurement of noise emission values shall be made according to EN ISO 11202 and, if required, to
EN ISO 3746 For very large machines where EN ISO 3746 is not applicable, the determination of sound pressure level shall be done at least:
⎯ located 1,6 m above the reflecting plane;
⎯ at a distance of 1 m from the machine (e.g in front of the control panel)
The measurement shall be made during idling and 3 work cycles
The minimum information to be provided in the test report concerning the measurement of airborne noise emissions is the following:
When documenting machine data for a guillotine shear, it is essential to include key details such as the manufacturer's identification, the year of construction, and the specific series or type designation Additionally, the serial or prototype number of the guillotine shear being tested should be recorded, along with its nominal capacity, which encompasses the thickness and material specifications Finally, the maximum number of strokes per minute must also be noted to ensure comprehensive machine data documentation.
During measurement, it is essential to consider the operating conditions, including strokes per minute, installation mounting, and work cycle descriptions (refer to annex D: D.1, D.2, D.3, D.5) Additionally, the force applied in kilonewtons (kN) and the specifications of the material used during operation must be documented Lastly, test conditions should also include idle running scenarios without load.
The article outlines the essential measurements for testing the guillotine shear, including its location relative to the reflecting plane, the measurement procedure, and the applicable noise emission standards It also details the positions of microphones, workstations, and other specified locations, along with the measurement duration For further information, please refer to annex D.
The article presents key results regarding sound measurements, including the background sound pressure levels and the necessary correction factors It highlights the equivalent continuous A-weighted sound pressure level at the operator's position, the peak C-weighted instantaneous sound pressure level in the same location, and notes that sound power is emitted when the equivalent continuous A-weighted sound pressure level exceeds 80 dB (A).
NOTE Information on the conditions for noise measurement of guillotine shears is given in annex D
If the guillotine shear is fitted with a laser (e.g to indicate the cutting line), the laser shall be of category III A or lower category in accordance with EN 60825-1
5.8.7 Hazards generated by materials and substances
5.8.7.1 Asbestos linings for clutch and brake shall not be used
5.8.7.2 Adequate means shall be provided to prevent the formation of aerosols and respirable oil mists in unhealthy concentration, e.g from oil used to lubricate pneumatic systems
5.8.8 Hazards generated by neglecting ergonomic principles
5.8.8.1 The guillotine shear and its controls shall be designed to provide a good work posture which is not fatiguing
5.8.8.2 The positioning, labelling and illumination of control devices, and facilities for materials and tool set handling shall be in accordance with ergonomic principles
To ensure safety and visibility on the guillotine shear, it is essential that workstations and areas containing control devices, guards, and protective equipment are adequately illuminated This lighting must be sufficient to allow for clear visibility of all work equipment and materials, while also preventing eye strain Specifically, the tools area should achieve a minimum illumination level of 300 lux.
Guillotine shear components weighing over 25 kg must be equipped with appropriate attachments for lifting devices, in compliance with prEN 1005-2 standards.
5.8.8.5 Tanks containing hydraulic fluid shall be placed or oriented in such a way that the filler and drainpipes can be easily reached
5.8.8.6 Further guidance on ergonomic principles shall be as given in EN 60204-1, EN 614-1,
Table 3 — Requirements for safeguarding from the front side for different modes of operation - Single cycle or automatic cycle, manual feed
Start and stop function (note 2)
Interlocking guard without guard locking
Any other than the guard itself
ESPE using the AOPD Any other than the protective device itself
Use of appropriate safety distance
SYMBOLS a) El = electrical b) Hydr = hydraulic c) Pneu = pneumatic (e.g valve) d) M = monitoring (see 3.1.9) e) R = redundancy (see 3.1.12) f) S = single channel
NOTE 1 For tool setting, see 5.5
NOTE 2 See 5.4.1 for the objectives of the control system.
Table 4 — Requirements for safeguarding from the front side for different modes of operation - automatic cycle, solely automatic feed
Start and stop function (note 2)
Interlocking guard without guard locking
Any other than the guard itself
ESPE using the AOPD Any other than the protective device itself
Use of appropriate safety distance
SYMBOLS a) El = electrical b) Hydr = hydraulic c)
= pneumatic (e.g valve) d) M = monitoring (see 3.1.9) e) R = redundancy (see 3.1.12) f) S = single channel
NOTE 1 For tool setting, see 5.5
NOTE 2 See 5.4.1 for the objectives of the control system.
6 Verification of the safety requirements and/or protective measures
Table 5 highlights the verification methods for the safety requirements and measures outlined in clause 5, along with references to the relevant sub-clauses in this standard.
Table 5 — Means of verification of the safety requirements and/or protective measures
Sub-clause Safety requirements and/or protective measures
Calculations (note 4) 5.2 BASIC DESIGN CONSIDERATIONS
5.2.1.2 a) Compression springs in the brake x x
Compression springs in the clutch x x
5.2.1.11 Accumulation and dispersal of debris x x x
5.2.1.13 Sharp edges and rough surfaces x x x
5.2.2 Hydraulic and subsidiary pneumatic systems - Common Features
Sub-clause Safety requirements and/or protective measures
5.2.2.10 Inlet port and exhaust ports x x
5.2.5.2 Emergency stop, category 0 stop, see 5.4.5.2 x x x
5.2.5.3 Protection for operator interface IP 54 x x
5.2.5.4 Protection of control gear IP 54 x x
5.2.5.6 Prevention of an unexpected start-up x x
5.2.6 Prevention of unintended gravity fall
5.3 MECHANICAL HAZARDS IN THE BLADE AND ASSOCIATED AREA
Sub-clause Safety requirements and/or protective measures
Calculations (note 4) 5.3.3 Access from the front
5.3.3.2 Interlocking guard with guard locking x x x
5.3.3.3 Interlocking guard without guard locking x x x x
5.3.4 Adjustable work-piece supports and back gauges x x x
5.3.10 Access from more than one side, operators protection x x x
5.3.13.1 Blades fitted not by friction only x x
5.4 THE CONTROL AND MONITORING SYSTEM
Sub-clause Safety requirements and/or protective measures
5.4.1.3 Fail-safe condition, redundant and monitored functions x x x
5.4.1.5 Programmable gauges and work-piece supports, category B x x
5.4.2 Programmable systems and safety related functions
5.4.3.3 Same protection for each operator x x x
5.4.5.2 Emergency stop of all hazardous movements, category 0 x x x
Tools for manual override of other valves x x x
Sub-clause Safety requirements and/or protective measures
No manual override on restraint valves x 5.5 TOOLSETTING, TRIAL STROKES, MAINTENANCE, LUBRICATION
5.5.2 Movement of the beam with guards and protective devices operational according to 5.3.2 x x
5.5.2 a) Hold-to-run control in conjunction with slow speed x x x x
5.5.3 Hold to run and inching hard wired x x
5.5.5 a) Prevention of clutch re-engagement x x x
5.6.1 c) Interlocking guards with guard locking x x x x
5.7.1 Guard rails and toe-boards x x x
5.8 PROTECTION AGAINST OTHER HAZARDS FROM:
Sub-clause Safety requirements and/or protective measures
5.8.7 Hazards generated by materials and substances
Marking
NOTE 1 Visual inspection will be used to verify the features necessary for the requirement by visual examination of the components supplied
NOTE 2 A performance check/test will verify that the features provided perform their function in such a way that the requirement is met
NOTE 3 Measurement will verify by the use of instruments that requirements are met, to the specified limits
NOTE 4 Drawings/calculations will verify that the design characteristics of the components provided meet the requirements
7.1.1 The general requirements laid down in 5.4 of EN 292-2:1991 and 1.7.3 of annex A of EN 292-2/A1:1995 shall be followed and EN 61310-2 shall be taken into consideration
The guillotine shear must be clearly marked with essential information, including the manufacturer's name and address, the year of construction, and the machinery designation along with its series or type Additionally, it should display the serial number, the mass of the guillotine shear without ancillary devices, and the mass of major parts and ancillary devices intended for removal with lifting equipment Important specifications such as the maximum cutting capacity, nominal cutting length, supply data for electrical and pneumatic systems, and overall response time with corresponding safety distances must also be included.
Instruction handbook
7.2.1 The requirements laid down in 5.5 of EN 292-2:1991 and 1.7.4 of annex A of EN 292-2/A1:1995 shall be followed
The instruction handbook for the guillotine shear must encompass essential information, including a reiteration of the marking details (refer to section 7.1.2), a reference to applicable standards, and copies of EC certification documents along with pressure vessel or control system test reports from the Technical Construction File It should provide guidelines for safe transportation and installation, addressing floor conditions, foundations, fixing points, services, anti-vibration mountings, and lighting Additionally, the handbook must outline procedures for the initial testing and examination of the guillotine shear and its safeguarding system prior to first use Instructions on control systems should include circuit diagrams for electrical, hydraulic, and pneumatic systems, clearly illustrating the interface between any hardwired components and the PES or PPS Lastly, a declaration regarding airborne noise emissions must be included as stipulated by A.1.7.4 f).
The EN 292-2/A1:1995 standard specifies that measurements must be conducted according to the methods outlined in section 5.8.5.3 and annex D, utilizing the dual-number form as defined in EN ISO 4871 Accompanying the declaration, a statement detailing the measuring method and the operating conditions during the test is required, along with the values of the uncertainties Kp (A) and Kw (A) presented in the dual-number format in accordance with EN ISO 4871:1996.
4 dB when using EN ISO 3746:1995;
5 dB when using EN ISO 11202:1996
For example: for a sound power level Lw (A) = 97 dB (measured value); uncertainty K = 4 dB for measurement made in accordance with EN ISO 3746:1995
If the accuracy of the declared emission values is to be verified, measurement shall be made using the same method and the same operating conditions
The noise declaration shall be accompanied by the following statement:
Emission levels quoted do not guarantee safe working conditions, as they only indicate potential exposure risks While there is a correlation between emission and exposure levels, this relationship cannot reliably dictate the need for additional safety measures Actual exposure levels are influenced by various factors, including the workroom characteristics, the number of machines, adjacent processes, and the duration of operator exposure to noise Additionally, permissible exposure levels differ across countries Understanding this information allows machine users to better assess hazards and risks.
When creating sales literature for guillotine shears, it is essential to include information on noise emission reduction and any necessary operator protections, such as hearing, eye, and foot protection Additionally, clear instructions for safe use must be provided, including limitations on work-piece sizes and guidance on handling oversized materials while considering potential risks Comprehensive instructions for safe setting, trial strokes, maintenance, repair, cleaning, and programming should address all hazards, including ejection risks from work-pieces and blades Lastly, ensure that individuals preparing guillotine shears for use receive adequate training and instruction to operate the equipment safely.
⎯ changing the blade and adjusting the blade;
⎯ the maintenance of fluid quality and filter changes;
Accident causation and prevention are critical aspects of workplace safety It is essential to conduct pre-production inspections of guards and protective devices following maintenance and repair of tools Specifications for fluids used in hydraulic systems, as well as filters and lubrication for transmission systems, must be clearly defined Additionally, it is important to identify foreseeable failure modes and provide guidance on their detection, prevention, and correction through regular maintenance Instructions for testing or examining components that impact safety functions after replacement should be included, along with guidelines for the periodic maintenance, testing, and examination of guillotine shears, guards, and protective devices, specifying the necessary intervals for these activities.
It is advisable to create checklists for the operations outlined in items e), l), and p) Specifically, a dedicated checklist for safety examinations should be established, allowing the examiner to sign off on the completed assessments.
Calculation of minimum safety distances
A.1 The minimum distance at which
⎯ ESPE using AOPDs in the form of vertical light curtains,
⎯ interlocking guards without guard locking shall be placed from the danger zone is to be calculated according to the general formula laid down in S clause 5 of
The formula for calculating the minimum safety distance, denoted as \$S\$, is given by \$S = (K \times t) + C\$ In this equation, \$S\$ represents the minimum distance in millimeters from the nearest danger point, which is influenced by the moving blade or clamp, to a detection point that must be at least 100 mm away and capable of detecting objects as small as 14 mm The parameter \$K\$ indicates the approach speed of the body or its parts, measured in millimeters per second The variable \$t\$ refers to the overall system stopping performance, or response time, expressed in seconds Lastly, \$C\$ accounts for any additional distance in millimeters that reflects the intrusion into the danger zone before the protective device is activated.
In guillotine shears, the total time \( t \) is calculated as \( t = t_1 + t_2 + t_3 + \Delta t \) Here, \( t_1 \) represents the stopping time of the guillotine shear, which includes the response times of the hydraulic and electrical control systems, as detailed in annex B, along with the maximum time required to stop the blade or to close the clamps \( t_2 \) accounts for the response time of the safeguarding system, while \( t_3 \) encompasses all other measurable response times Finally, \( \Delta t \) denotes the uncertainty in the timing.
To determine the value of K, an approach speed of 1,600 mm/s is required for guards that do not have guard locking For vertically arranged Active Optoelectronic Protective Devices (AOPDs), an approach speed of 2,000 mm/s is applicable when the minimum distance is 500 mm or less If the minimum distance exceeds 500 mm, an approach speed of 1,600 mm/s can be utilized.
A.3 In order to determine C for light curtains, see A.6, A.7 and A.8 For early opening interlocking guards without guard locking, C can be zero
When assessing the overall stopping performance of a system under the most extreme normal conditions, several critical factors must be considered These include the beam speed during the closing stroke, which leads to the longest stopping time, the temperature affecting the relevant system components, the tool mass that contributes to the maximum stopping duration, the pressure conditions that result in extended stopping times, and the wear of the components involved in the stopping function.
When the position of protective devices linked to the guillotine shear can be adjusted, these devices must be interlocked or lockable to ensure the minimum distance is maintained This design ensures that any movement of the devices requires the use of tools or keys, enhancing safety and compliance.
A.6 With regard to the detection capability of vertical format light curtains, the additional distance C in Table A.1 shall at least be used when calculating the minimum distance S
Detection capability mm Additional distance C mm
A.7 For the overall response time and the related safety distance in respect of light curtains (see 5.3.3.4)
The response time of the redundant hydraulic/pneumatic systems
The overall stopping time of the blade and clamps for each model and size of guillotine shear must be measured separately for every operating channel, with at least 10 measurements taken during construction For comparison purposes, the highest measured value or the mean plus three times the standard deviation should be used.
If the overall stopping time differs more than 50 %, it has to be taken into consideration for calculation of the safety distance
B.2 If the difference is less than 50 %, the overall stopping time measurement can be carried out under normal operating conditions and used for the calculation of the safety distance
B.3 If the difference exceeds 50 %, the safety distance shall be calculated 1,3 times the overall stopping time of B.2 This measurement has to be carried out for each individual guillotine shear
Example of a hydraulic control circuit for a guillotine shear provided with fixed guards or light curtain
2 Hold-down jack C Piloted nonreturn valve
Figure C.1 — Example of a hydraulic control circuit for a guillotine shear provided shear with a fixed guard
Figure C.2 — Example of hydraulic control circuit for a guillotine shear provided with light curtain (5.3.3.4)
Conditions for noise measurement of guillotine shears
The installation and mounting conditions must reflect the typical usage of the guillotine shear, ensuring consistency for both sound power levels and emission sound pressure levels.
The position of the guillotine shear being tested must be clearly marked with a sketch that includes details of any reflective surfaces that may affect the measured noise emission values.
D.3 The recommended operating condition shall be 80 % of the maximum stroking rate
D.4 The noise measurement procedure used for obtaining the noise emission values shall be described by indicating the measurement procedure and the microphone positions chosen from the options listed in
EN ISO 11202 and, if necessary, in EN ISO 3746:1995
A comprehensive sketch must be provided, illustrating all measurement positions where sound pressure levels have been recorded, along with the normal position of the operator(s) This sketch can be integrated with the description of the guillotine shear location as outlined in section 5.8.5.3.
! Relationship between this European Standard and the Essential Requirements of EU Directive 98/37/EC, amended by Directive 98/79/EC