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PROJECT SHOWCASE

Safety controls and guarding for specialty alloys manufacturer

Challenge

A specialty alloys manufacturer needed to install a sheet metal cut-to-length (CTL) line in their facility. Then they needed a solution for safety controls and machine safety components. The CTL line includes three machines that are located on an open warehouse floor, so part of the challenge was how to run electricity to the equipment.

Solution

We worked with the manufacturer during installation to bring electricity to CTL equipment. It was decided that electric cables should not run underneath the floor or above the equipment. So, we designed a solution to run cables along the floor and enclose them in floor mats, so that the electrical cables did not pose a trip hazard.

For the machine safety solution, we started with a risk assessment. We identified safety hazards, recommended solutions, and quoted the work.

Then our team started building out the solution.

We fabricated components and guarding to be used on and around the CTL line, including:

  • Posts around the perimeter
  • The gate that covers the cutter
  • Brackets that hold light curtains
  • Flat pieces around pinch points

Our control panel shop designed, assembled, and tested the control panel. E-stops on the three machines in the CTL line are integrated into one safety circuit.

The posts mark out the perimeter around the CTL line. Safety scanners monitor the zone inside the perimeter so that if any people cross the perimeter while the line is in automatic mode, an e-stop will trigger.

Each post has a stack light that indicates the status of the CTL line. Colors signify the following statuses:

  • Green: Safe to run line in automatic mode.
  • Blue: Maintenance mode. People may enter the perimeter to set up the line. Light curtains around the blade stay active.
  • Yellow: Request to Enter. When an operator uses the switch on the post near the back of the line to Request to Enter, the safety scanner on the post mutes so that the operator can enter to take away the cart of material. Safety scanners around the rest of the equipment and light curtains near the blade stay active.
  • Red (solid): E-stopped. The operator needs to reset the system by pressing the reset button on the control panel.
  • Red (blinking): Something is causing an issue that prevents the line from running. For example, a person may be in the zone and needs to exit the perimeter before the line can run.

After everything was installed at the customer’s facility, we commissioned the CTL line. We also wrote a standard operating procedure document for the safety system.

Results

With safety guarding and controls in place, the manufacturer can run the CTL line in automatic mode, while monitoring the zone around the machine. The CTL line will stop running if a person enters the zone. People can enter the zone around the equipment by using Maintenance mode and Request to Enter controls.

DenTech’s fabrication, automation, electrical control panel, and installation teams were able to complete this work in-house, from start to finish. We’ve designed fabrication solutions for this manufacturer in the past and were excited to develop safety solutions for their facility.

Learn more about our machine safety capabilities.

Capabilities in this Project:

  • Site survey
  • Risk assessment
  • Fabrication
  • Machine safety guarding
  • Electrical installation
  • Design, assembly, and testing of electrical control panel
  • PLC programming
  • SOP documentation

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