Thread Content
Safety protection technical requirements for tooth shaving machines JB 10227—2001 Approved by the China National Machinery Industry Federation on March 29, 2001; implemented on July 1, 2001. Preface: Chapters 3 of this standard, as well as sections 4.2.4.2, 4.3.3.3, 4.7.1, 4.7.3, and 4.9.3.2 are of a recommended nature, while the remaining sections are mandatory. This standard is formulated in accordance with GB 15760—1995 \"General technical requirements for safety protection of metal cutting machines\", and in line with GB/T 16856—1997 \"Principles for risk assessment in mechanical safety\". It is developed on the basis of a hazard analysis of gear shaving machines, taking into account the structural characteristics of such machines, and serves as a supplement and refinement to GB 15760. The drafting rules of this standard comply with the requirements of GB/T 16755—1997 \"Mechanical safety — Rules for drafting and presentation of safety standards\". Standards complementary to this standard include: JB/T 3731—1992 Parameters for tooth trimming machines ； JB/T 3732—1994 Tooth Trimming Machine Accuracy ； JB/T 3732.2—1999 Tooth Trimming Machines — Technical Requirements ； JB/T 6094-1992 Tooth Shaving Machines – Series Catalogue ； JB/T 8485.1—1996 Technical Requirements for CNC Gear Trimming Machines ； JB/T 8485.2-1998 Numerical control gear shaving machines – Precision inspection. This standard was proposed by the National Technical Committee for Standardization of Metal Cutting Machine Tools. This standard is under the jurisdiction of the Cylindrical Gear Machine Subcommittee of the National Standardization Technical Committee for Metal Cutting Machines. Drafting units of this standard: Chongqing Cylindrical Gear Machine Tool Research Institute, Nanjing No. 2 Machine Tool Factory. Main drafters of this standard: Yu Hongli, Zhang Yujie, Yan Jianping, Liu Qiang, Xu Shaohua, Li Yi, Ma Xianju. 1 Scope This standard specifies the main technical requirements, measures, and evaluation for the safety protection of gear shaving machines. This standard applies to gear shaving machines with a maximum workpiece diameter of 125–500 mm. 2 Referenced Standards The provisions contained in the following standards become part of this standard by being referenced herein. At the time of publication of this standard, all versions listed are valid. All standards will be revised, and those using this standard should consider the possibility of using the latest versions of the following standards. GB 2893—1982 Safety Colors; GB 2894—1996 Safety Signs; GB/T 3167—1993 Pictographic Symbols for Operating Instructions of Metal Cutting Machines; GB/T 3168—1993 Pictographic Symbols for Operating Instructions of Numerically Controlled Machines; GB/T 5226.1—1996 Industrial Machinery and Electrical Equipment – Part 1: General Technical Requirements; GB/T 6527.2—1986 Guidelines for the Use of Safety Colors; GB/T 6576—1986 Lubrication Systems for Machine Tools; GB 8196—1987 Safety Requirements for Protective Covers on Mechanical Equipment; GB 8197—1987 Safety Requirements for Protective Screens; GB 12265.1—1997 Machinery Safety – Safe Distances to Prevent Upper Limbs from Reaching Hazardous Areas; GB 12265.2—2000 Machinery Safety – Safe Distances to Prevent Lower Limbs from Reaching Hazardous Areas; GB 12265.3—1997 Machinery Safety – Minimum Distances to Avoid Compression of Various Body Parts; GB/T 15706.1—1995 Machinery Safety – Basic Concepts and General Design Principles – Part 1: Basic Terms and Methodology; GB/T 15706.2—1995 Machinery Safety – Basic Concepts and General Design Principles – Part 2: Technical Principles and Specifications; GB 15760—1995 General Technical Requirements for Safety Protections on Metal Cutting Machines; GB/T 16769—1997 Methods for Measuring Noise Sound Pressure Levels of Metal Cutting Machines; GB/T 17161—1997 Operating Directions of Control Devices for Machine Tools; JB/T 8356.1—1996 Technical Requirements for Packaging of Machine Tools; JB/T 8356.2—1996 Packaging Boxes for Machine Tools; JB/T 9875—1999 Preparation of Technical Documents Accompanying Metal Cutting Machines; JB/T 10051—1999 General Technical Requirements for Hydraulic Systems of Metal Cutting Machines. 3 Hazards of Machine Tools 3.1 Hazards Related to Machinery 3.1.1 The sharp edges, corners, protrusions, and openings on the exposed parts of machine tools can pose risks of puncture and cutting injuries to people. 3.1.2 Dangers that may arise from chip and cutting fluid splashes. 3.1.3 The danger posed by the reciprocating movement of the longitudinal slide (or worktable), vertical slide, and tangential slide potentially exceeding the working area. 3.1.4 A failure of the control system can pose a risk of damaging the machine tool. 3.1.5 Dangers that may arise if the mechanical clamping device fails to clamp the tool and workpiece. 3.1.6 Dangers arising from the lack of interlock protection devices at the adjustment parts of machine tool gears and pulleys. 3.1.7 Dangers associated with machine tools equipped with ball screws due to the absence of braking devices. 3.1.8 The lack of protective devices on the exposed guide rail surfaces may pose a risk of damaging the machine tool. 3.1.9 Dangers that may arise from people or other objects entering the working area in the absence of protective measures or protective interlock devices. 3.1.10 In the event of an accidental power interruption, mechanical inertia may pose a risk of damaging the cutting tool and the workpiece. 3.2 Dangers of electrical systems 3.2.1 Dangers arising from non-compliance with power supply regulations 3.2.1.1 Dangers caused by electrical systems not meeting power supply requirements. 3.2.1.2 Dangers caused by the machine tool power supply wiring configuration not meeting the specifications. 3.2.1.3 Dangers caused by the machine tool power cut-off (isolation) switch not meeting the requirements. 3.2.2 Dangers of electric shock 3.2.2.1 Improper shielding of live parts can pose a risk of direct electric shock. 3.2.2.2 Poor grounding of live equipment may pose a risk of indirect electric shock. 3.2.2.3 Poor insulation of live parts may pose a risk of electric shock. 3.2.3 Dangers caused by improper protection of electrical equipment 3.2.3.1 Exceeding the rated current in electrical equipment can lead to damage to such equipment. 3.2.3.2 Overloading the motor can lead to its damage. 3.2.3.3 Dangers that may arise from electrical equipment malfunctioning due to power outages or voltage drops. 3.2.4 Dangers caused by emergency situations. 3.2.5 Dangers caused by control devices such as buttons and indicator lights not meeting specifications, as well as improper selection of wires. 3.2.6 Dangers caused by lighting fixtures that do not meet the requirements. 3.3 Hazards of hydraulic and lubrication systems 3.3.1 Hazards arising from non-compliance with hydraulic system requirements. 3.3.2 Dangers caused by overpressure resulting from hydraulic system failures or improper operation of hydraulic components. 3.3.3 The risk of machine damage caused by improper lubrication of the machine tool. 3.4 Dangers of noise: The risk of hearing loss and physical and mental illnesses in humans due to noise not meeting regulatory standards. 3.5 Hazards arising from materials and substances: Hazards caused by the improper selection of materials for machine tool components. 3.6 Dangers arising from ignoring human ergonomics principles in machine tool design 3.6.1 An inappropriate height of the machine tool control handles above the ground affects operation. 3.6.2 The excessive operating force required for the machine tool’s control knobs and handles can affect the operator’s health. 3.6.3 Improper installation of the reading mechanism of the measuring device can affect the operator’s health. 3.6.4 Flickering, distracting glare, and shadow areas caused by inadequate machine tool lighting may pose a risk of incorrect operations by the operator. 3.6.5 Dangers caused by chaotic control directions of machine tool control devices. 3.7 Dangers arising from inadequate safety protection measures – Dangers caused by improper design of safety protection devices. 3.8 Dangers that may result from the lack of necessary usage information. 3.9 Dangers caused by improper packaging, storage, and transportation of machine tools. 4 Safety Requirements and Measures 4.1 General Requirements 4.1.1 All potential hazards associated with the machine tool should be eliminated or reduced as much as possible through proper design; this can generally be achieved in accordance with the provisions of 5.1–5.3 in GB/T 15706.1—1995 and Chapter 3 of GB/T 15706.2—1995. 4.1.2 For hazards that cannot be eliminated, necessary safety protection measures should be taken as much as possible, or safety protection devices should be installed. 4.1.3 For certain hazards that are difficult to protect against, usage information should be provided in the instructions; where necessary, warning signs should also be placed near the hazardous areas. 4.2 Safety requirements and measures for machinery 4.2.1 The exposed parts of the machine tool that may be touched should be as smooth and flat as possible; there should be no sharp edges, corners, protrusions, or openings that could cause injury to people. 4.2.2 The machine tool should be capable of effectively recovering coolant, and protective baffles should be installed to prevent coolant and chips from splashing. The device for fixing the coolant nozzle should be able to secure it in the desired position in a convenient, safe, and reliable manner. 4.2.3 The longitudinal slide (or worktable), vertical slide, and tangential slide shall be equipped with maximum travel limit devices. 4.2.4 The control system shall not lead to the occurrence of hazardous situations. 4.2.4.1 The control system shall ensure the reliability of its functions; it must be able to withstand the expected loads and external influences, as well as logical errors, interruptions, and damage to the carriers of machine tool control information, without this leading to dangerous situations. 4.2.4.2 For machine tools in which not the entire working area can be seen from the operating position, acoustic or optical start-up warning signal devices should generally be installed. 4.2, 4.3 The position of the control devices should be such that it prevents errors and additional hazards during operation. 4.2.4.4 On CNC machines, a selection switch for the operating mode should be provided for each control function; each position of this switch allows only one specific control method and operating mode. Other methods (such as code control) can also be used to select the operating mode. 4.2.4.5 When the machine tool stops, the cessation of independent feed motion shall not be delayed beyond the cessation of the main motion. 4.2.4.6 In the event of an emergency stop or a failure in the power system, moving parts should come to a halt immediately; vertical moving parts should retract or stay in place, and should not fall by themselves. 4.2.4.7 When the machine tool is operating in cyclic mode, manual mode operations are ineffective (except for emergency stop operations). 4.2.4.8 A “stop” control device should be provided near each “start” control device. An emergency stop control device shall be provided at each working or operating position, and the operation of this emergency stop control device shall not affect the functionality of the devices designed to protect the operator or the machine tool. 4.2.5 The mechanical clamping device shall ensure that the tool and workpiece do not fall or get thrown out. The start and end of machine tool operation should generally be interlocked with the clamping and releasing of mechanical clamps. In the event of an emergency stop or a failure in the power system, the mechanical clamping device should maintain its clamping force on the tool and workpiece; otherwise, reliable safety protection devices must be installed. 4.2.6 Interlock protection devices shall be provided at the adjustment areas of machine tool gears and pulleys, as well as in their vicinity. 4.2.7 Braking measures shall be taken for vertically or inclined mounted ball screws. 4.2.8 The exposed guide rail surfaces shall be equipped with protective devices (such as dust protection, chip removal devices, and guards). 4.2.9 Moving parts and transmission mechanisms of machine tools that may pose a danger should generally be enclosed. If enclosure is not possible, safety protection devices should be installed, or safety colors indicating danger should be applied near the hazardous areas of the machine tool, or safety warning signs should be placed there, or safety colors can be applied directly to the surface of the hazardous parts. Warning signs shall comply with the provisions of GB 2894, and safety colors shall conform to the requirements of 2.5 in GB 2893—1982 and 2.6 in GB/T 6527.2—1986. 4.2.10 Sudden power outages should not pose a danger to personnel or equipment ； Once power is restored, the machine tool must not start on its own. 4.3 Safety requirements and measures for electrical systems 4.3.1 The power supply shall comply with the provisions of GB/T 5226.1. 4.3.1.1 The power supply requirements for the electrical system of machine tools shall comply with the provisions in 4.3 of GB/T 5226.1—1996. 4.3.1.2 The wiring type and requirements for the machine tool power supply shall comply with the provisions of 5.1 in GB/T 5226.1—1996. 4.3.1.3 The power cut-off (isolation) switch shall comply with the provisions of 5.3 in GB/T 5226.1—1996. 4.3.2 Protection against electric shock shall comply with the provisions of Chapter 6 in GB/T 5226.1—1996. 4.3.2.1 The shielding of live parts shall comply with the provisions of 6.2.1 in GB/T 5226.1—1996. 4.3.2.2 The protection against indirect contact electricity shall comply with the provisions of 6.3 or 6.4 in GB/T 5226.1—1996. The grounding of electrical equipment shall be safe and reliable, and shall also comply with the provisions of Chapter 8 in GB/T 5226.1—1996. 4.3.2.3 The insulation protection of live parts shall comply with the provisions of 6.2.2 in GB/T 5226.1—1996. 4.3.3 The protection of electrical equipment shall comply with the provisions of Chapter 7 in GB/T 5226.1—1996. 4.3.3.1 The overcurrent protection shall comply with the provisions of 7.2 in GB/T 5226.1—1996. 4.3.3.2 The overload protection of the motor shall comply with the provisions of 7.3 in GB/T 5226.1—1996. 4.3.3.3 The protection against power interruptions or voltage drops followed by recovery shall comply with the provisions of 7.5 in GB/T 5226.1—1996. 4.3.4 The emergency stop shall comply with the provisions of 9.2.5.4 and 10.7 in GB/T 5226.1—1996. 4.3.5 Control devices such as buttons and indicator lights shall comply with the provisions of Chapter 10 in GB/T 5226.1—1996. The selection of wires and cables should generally comply with the provisions of Chapter 14 in GB/T 5226.1—1996. 4.3.6 The local lighting fixtures for machine tools shall generally comply with the provisions of 17.2 in GB/T 5226.1—1996. 4.4 Safety requirements and measures for hydraulic and lubrication systems: The hydraulic and lubrication systems must ensure the proper operation of the machine tool as well as protect human safety. The safety requirements for hydraulic systems shall comply with the provisions in Chapter 5 of JB/T 10051—1999, while those for lubrication systems generally shall conform to the provisions in 5.9 and Chapter 7 of GB/T 6576—1986. 4.5 Safety requirements for noise: When the machine tool is in operation, there should be no abnormal screeching or banging sounds. During forward and reverse low, medium, and high-speed no-load operation, its noise sound pressure level shall not exceed 83 dB(A). Under the cutting conditions specified for the corresponding products, the load noise of machine tools shall comply with relevant regulations on environmental protection and hygiene. 4.6 Safety requirements and measures for materials and substances: The selection of materials for machine tool components shall comply with relevant regulations on environmental protection and hygiene. 4.7 Safety requirements and measures adopted in accordance with human factors engineering principles 4.7.1 The installation height of the machine tool control handles (from the ground or the operating platform surface to the middle of the handle) is generally 0.5–1.85 m. 4.7.2 The operating force of hand wheels and handles should be uniform throughout their range of motion, and it should generally not exceed the values specified in Table 1. Table 1 Weight of machine tools: t≤2, 2～5, 5～10, >10. Operating force for handwheels and handles: N 60, 100, 120, 160. 4.7.3 For measuring devices whose readings are monitored frequently, the installation height of their reading mechanism should generally be between 0.7 and 1.7 meters. For observation reading mechanisms that are not used frequently, the installation height can range from 0.3 to 2.5 m. 4.7.4 Machine tool lighting fixtures shall not exhibit flicker or distracting glare. 4.7.5 The operation direction of the machine tool control device shall comply with the provisions of GB/T 17161; when the machine tool does not conform to this due to its structure, corresponding markings shall be provided on the machine tool. 4.8 Safety requirements and measures for safety protection devices: For hazards that cannot be appropriately avoided or sufficiently restricted through design, safety protection devices should generally be selected appropriately in accordance with the provisions of Chapter 4 in GB/T 15706.2—1995 to provide protection. The performance of safety protection devices must be reliable; they should not pose additional hazards, nor should they limit the functions of the machine tool. They also should not impose excessive restrictions on the operation, adjustment, and maintenance of the machine tool, and must be firmly and securely fixed in place. When the machine tool is equipped with interlocked protective devices, it must be ensured that the machine tool cannot be started until the protective devices are closed; once the protective devices are opened, the machine tool should stop operating. The safety distance between protective devices and the hazardous parts of machine tools shall comply with the provisions of GB 12265.1–12265.3. The materials and dimensions of the safety protection devices shall comply with the provisions of GB 8196 and GB 8197. 4.9 Usage Information 4.9.1 General Requirements 4.9.1.1 Usage information consists of text, signals, symbols, or charts, which can be used alone or in combination to convey information to the user. 4.9.1.2 The information provided shall clearly specify the intended use of the machine tool, as well as include all the instructions necessary to ensure its safe and correct operation. 4.9.1.3 Information for use should not be used to compensate for design flaws. 4.9.1.4 The information for use must include transportation, delivery, trial operation (assembly, installation, and adjustment), use (setting, programming or process change, operation, cleaning, fault detection, and machine tool maintenance). 4.9.2 The information to be used should be configured based on the machine tool’s structure, risks, and the duration for which it is to be used by the operator. 4.9.3 The usage information can be provided by the machine tool itself, random technical documents (especially the instruction manual), and other means (such as various signals and textual warnings). The machine tool’s instruction manual should clarify its safety features, safety precautions, as well as the safety requirements for operation, adjustment, and maintenance. 4.9.3.1 Markings, symbols (pictograms) and textual warnings shall generally comply with the provisions of 5.4 in GB/T 15706.2—1995 and GB/T 3167, GB/T 3168. 4.9.3.2 Random technical documents shall generally comply with the provisions of 5.5 in GB/T 15706.2—1995 and JB/T 9875. 4.9.3.3 Signal and warning devices shall comply with the provisions of 5.3 in GB/T 15706.2—1995. 4.10 Safety requirements and measures for the packaging, storage, and transportation of machine tools: The safety requirements and measures for the packaging, storage, and transportation of machine tools should generally comply with the provisions of 13.1 and 13.2 in GB/T 15760—1995, as well as JB/T 8356.1–8356.2. 5 Assessment of safety requirements and measures 5.1 General assessment 5.1.1 Assess whether the machine tool is designed to avoid or minimize hazards as much as possible. It limits people’s exposure to danger by reducing the need for operators to enter hazardous areas. 5.1.2 Assess whether the machine tool has taken the necessary safety precautions or installed safety devices to address the residual hazards. 5.1.3 Assess the usage information of the machine tool to determine whether it informs and warns the user about risks that cannot be eliminated or sufficiently reduced through design, as well as residual risks for which the safety protection devices are ineffective or only partially effective. 5.2 Evaluation of mechanical safety requirements and measures 5.2.1 Check whether the machine tool complies with the provisions of 4.2.1. 5.2.2 Check whether the machine tool is equipped with reliable protective shields to prevent coolant from splashing and chips from flying. 5.2.3 Check whether the machine tool complies with the requirements of 4.2.3, 4.2.4(b), 4.2.5, 4.2.6, 4.2.7, and 4.2.8. 5.2.4 Check whether the machine tool complies with the requirements of 4.2.9, and whether the safety protection devices are firm and reliable. 5.2.5 Check whether the machine tool complies with the requirements of 4.2.10. 5.3 Evaluation of safety requirements and measures for electrical systems 5.3.1 Check whether the machine tool complies with the provisions of 4.3. 5.3.2 Electrical equipment shall undergo tests for the continuity of the protective grounding circuit, insulation resistance, voltage withstanding capacity, protection against residual voltage, and functional tests in accordance with the provisions of Chapter 20 in GB/T 5226.1—1996. 5.4 Evaluation of safety requirements and measures for hydraulic and lubrication systems: Check whether the machine tool’s hydraulic and lubrication systems meet the requirements of 4.4. 5.5 Evaluation of machine tool noise: Check in accordance with GB/T 16769 whether the sound pressure level of the machine tool noise meets the requirements specified in 4.5. 5.6 Evaluation of safety requirements and measures for materials and substances: Check whether the selection of materials for the main components of the machine tool complies with the provisions in 4.6. 5.7 Evaluation of safety protection measures adopted in accordance with human factors engineering principles 5.7.1 Check whether the installation height of the machine tool control handles complies with the requirements of 4.7.1. 5.7.2 Check whether the operating force of the machine tool handwheels and handles meets the requirements specified in 4.7.2. 5.7.3 Check whether the reading mechanism of the machine tool’s measuring device complies with the requirements of 4.7.3. 5.7.4 Check whether the machine tool lighting device complies with the requirements of 4.7.4. 5.7.5 Check whether the operating direction of the machine tool control device complies with the requirements of 4.7.5. 5.8 Evaluation of safety protection devices: Check whether the machine tool’s safety protection devices comply with the requirements of 4.8. 5.9 Evaluation of the information provided 5.9.1 Assess whether the machine tool’s user manual specifies the machine’s safety features, safety precautions, and the safety rules to be followed during operation, adjustment, and maintenance. 5.9.2 Assess whether the usage information complies with the requirements of 4.9. 5.10 Evaluation of safety requirements and measures for the installation, storage, and transportation of machine tools: Check whether the packaging and transportation of the machine tools meet the requirements of 4.10.1, and verify that the packaging boxes used for the machine tools comply with the provisions of 4.10.2. 6 Responsibilities 6.1 The manufacturer shall provide an instruction manual for each machine tool. The instruction manual shall clarify the safety responsibilities specified in 6.2 to 6.4. At the same time, the instruction manual shall meet the evaluation requirements for usage information specified in this standard. 6.2 The manufacturer shall be responsible for the safety protection of the machine tools provided and the auxiliary equipment supplied together with them. 6.3 The user is responsible for the safety protection of the fixtures, tooling, and auxiliary equipment they add, as well as for the safety protection of the machine tool’s working area after they alter or modify the original tooling, auxiliary equipment, or the machine tool itself. 6.4 The user is responsible for any dangers resulting from the installation, operation, and maintenance of the machine tool in violation of the instruction manual.