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Blocos Segurana Prensas - Rexroth
Blocos Segurana Prensas - Rexroth
Contedo
Introduo
Referncias normativas
Bloco tipo N
Bloco tipo P
Consideraes finais
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduo
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduo
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduo
Nvel 4
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduo
Conforme a norma ISO 13849, em prensas devem ser projetados e
utilizados sistemas que atinjam o maior grau de segurana
PL = reduo de risco e
Sistema de
controle de
prensa
PL = reduo de risco d
Segurana
Mquina
PL = reduo de risco c
Aplica
Aplicao
comum
na hidr
hidrulica
Circuitos
De grampo
tolerado
Baixo risco
exposio de. 10-8/h
para situaes perigosas
risco inaceitvel
Risco mdio
Risco
Risco alto
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduo
Os blocos de segurana para prensas
hidrulicas tipo N e P foram
desenvolvidos para adequao de
sistemas hidrulicos para prensas j
existentes e que no esto de acordo com
as normas de segurana.
O objetivo implementar a segurana
hidrulica em prensas, adicionando um
sistema hidrulico j existente, a funo de
segurana.
Devido a alta inrcia do movimento de
descida do martelo, em caso de
necessidade de parada de emergncia, a
hidrulica um meio eficiente para
interromper o movimento do cilindro.
7
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exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Introduo
Os blocos de segurana tipo N e
tipo P so compostos por circuito
hidrulico com duas vlvulas com
monitoramento e uma vlvula de segurana
contra multiplicao de presso.
Por meio das duas vlvulas monitoradas
possvel alcanar a categoria 4 de
segurana hidrulica conforme NBR 14153.
O objetivo do bloco de segurana
parar o movimento perigoso de descida
do martelo/cilindro por meio da hidrulica
conforme comando do controlador
de segurana !!!
A parada feita por meio do desligamento
do comando das vlvulas monitoradas
Falhas mecnicas
estruturais, o risco
no evitado por meio
do bloco de segurana.
Exemplos de falha mecnica:
- Rompimento de tubo
- Quebra do cilindro do martelo
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Contedo
Introduo
Referncias normativas
Bloco tipo N
Bloco tipo P
Consideraes finais
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Referncias normativas
Para a obteno de um correto projeto, fabricao e implementao
de mquinas e equipamentos, bem como sua conservao, manuteno
e descarte obrigatrio seguir as orientaes e especificaes contidas em
normas.
No Brasil, a principal diretiva de segurana para mquinas e equipamentos,
com fora de lei a Norma Regulamentadora do Ministrio do Trabalho
nmero 12 (NR12).
10
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Referncias normativas
NR 12 Segurana em Mquinas e Equipamentos
NBR 14153 Partes de sistemas de comando relacionados segurana
princpios gerais para projeto
NBR 14009 Segurana de mquinas princpios para apreciao de
riscos
NBR NM 213-2 Segurana em mquinas conceitos fundamentais e
princpios gerais de projeto
EN 954-1 Safety of machinery, safety related parts of control systems
EN 693 Hydraulic Presses - Safety
IEC EN 60204-1 Electrical equipament of machines part 1 General
requirements
11
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Referncias normativas
ISO 13849-1 Safety of machinery Safety related parts of control
systems ISO 12100 Safety of machinery General principles for design Risk
assessment and risk reduction
ISO 4413 Hydraulic fluid power General rules relating to systems
12
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Contedo
Introduo
Referncias normativas
Bloco tipo N
Bloco tipo P
Consideraes finais
13
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Bloco tipo N
O bloco tipo N um controle hidrulico
de segurana para prensas hidrulicas.
Ele composto de um circuito hidrulico
redundante por meio de vlvulas
direcionais com monitoramento.
Indicado para adequao de sistemas
hidrulicos existentes, onde existe a
necessidade de instalar um circuito
hidrulico categoria 4 (NBR 14153)
O movimento do cilindro do martelo
somente possvel mediante ao
acionamento do bloco.
14
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exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
PERIGO!
Hidrulica
existente
Bloco N
15
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exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
16
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
17
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exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Posio
neutra
Posio
atuada
Curso do embolo %
Esquema do sensor
18
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Cdigo
Descrio
Vazo mxima
(L/min)
Presso mxima
em P (bar)
R979012898
IH04M06NB-100-202-3X/G24K4
25
315
R979014086
IH04M10NB-100-202-3X/G24K4
50
315
R979023347
IH04M12NB-100-201-3X/G24K4 1)
100
315
R979020362
IH04M16NB-100-201-3X/G24K4 1)
180
315
19
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Contedo
Introduo
Referncias normativas
Bloco tipo N
Bloco tipo P
Consideraes finais
20
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Bloco tipo P
O bloco tipo P um controle hidrulico
de segurana para prensas hidrulicas.
Ele composto de um circuito hidrulico
redundante por meio de elementos lgicos
direcionais com monitoramento.
Indicado para adequao de sistemas
hidrulicos existentes, onde existe a
necessidade de instalar um circuito
hidrulico categoria 4 (NBR 14153).
O movimento do cilindro do martelo
somente possvel mediante ao
acionamento do bloco.
21
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Nota !!!
Conexes X3,X4
X6 e X7 podem ser
ligadas dependendo
do projeto
PERIGO!
Bloco P
Hidrulica
existente
22
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
23
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
24
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Posio
neutra
Posio
atuada
Curso do embolo %
Esquema do sensor
25
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
26
Cdigo
Descrio
Vazo mxima
(L/min)
Presso mxima
em P (bar)
R979022851
IH04ME16P7A1001-3X/G24K4
180
315
R979021239
IH04ME25P7A1001-3X/G24K4
300
315
R979016778
IH04ME32P7A1001-3X/G24K4
450
315
R979015889
IH04ME40P7A1001-3X/G24K4
700
315
R979020149
IH04ME50P7A1001-3X/G24K4
1100
315
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Contedo
Introduo
Referncias normativas
Bloco tipo N
Bloco tipo P
Consideraes finais
27
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Projeto de adequao
Para o dimensionamento e seleo do bloco de
adequao mais apropriado necessrio anlise
tcnica do circuito hidrulico existente na mquina.
Informaes como velocidades de trabalho, esforos,
presses, fora de sustentao, contrabalano do
martelo e o esquema atual da mquina so informaes
obrigatrias para a correta seleo do bloco.
Aps a seleo do bloco, o esquema existente da mquina
deve ser revisado e a documentao atualizada.
O projeto de adequao deve buscar manter o desempenho
da mquina o mais prximo possvel da condio original.
28
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exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Instalao
O bloco de adequao deve ser montado o mais
prximo possvel do cilindro.
O tubo que liga o bloco ao cilindro deve ser
dimensionado para resistir ao mximo esforo mecnico
e hidrulico existente na mquina aplicando um
coeficiente de segurana.
A tubulao deve fazer uso de conexes positivas e
flanges.
Os terminais preferencialmente devem ter a ponta
conformada a frio (sistema Vossform) ou deve ser
utilizado solda.
Tubo de segurana.
Exigncia de elevada
qualidade.
29
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Instalao
Devem ser observados boas prticas e alta qualidade
na montagem do tubo de segurana.
No so permitidas a utilizao de emendas ou junes
por conexes na tubulao entre o bloco e o cilindro.
O tubo deve ser preso com braadeiras e ter resistncia
e estabilidade aos efeitos de vibraes.
No permitido a utilizao de tubo com costura.
No permito a utilizao de conexes com anel de
cravamento conforme recomendao da EN 693.
Tubo de segurana.
Exigncia de elevada
qualidade.
30
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Instalao
Caso a mquina possua vibrao intensa caracterstica
a sua natureza de trabalho, condies de contorno e
outras medidas devem ser tomadas caso exista
impedimento ao uso de tubulao de segurana rgida.
Quanto a tubulao, demais exigncias vide as
referncias normativas.
Tubo de segurana.
Exigncia de elevada
qualidade.
31
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Comissionamento
O comissionamento e start-up devem ser realizados
por profissionais especializados em mecnica, hidrulica
e eltrica.
Medidas de segurana devem ser providenciadas
durante o comissionamento, tendo acesso a mquina
somente os envolvidos no trabalho.
Aps a finalizao da instalao, testes de ciclagem de
mquina devem ser realizados. Todo o procedimento de
teste, descrio, nmeros de ciclos, ferramenta usada,
produto conformado, etc, devem ser registrados em
relatrio.
No sendo evidenciado nenhum problema de ordem
eltrica, hidrulica e mecnica, e sendo constatado o
correto funcionamento e estabilidade da mquina, a
mesma poder ser homologada com o fechamento do
relatrio e documentao atualizada.
32
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Comissionamento
Somente aps a homolagao do teste (ver NBR 14153)
e finalizao da documentao, a mquina poder ser
liberada para a produo.
Catlogos de referncia para comissionamento
hidrulico
RP 07080 Montagem, colocao em operao e
manuteno de bombas e motores hidrulicos
RP 07100 Montagem, colocao em operao e
manuteno de cilindros hidrulicos
RP 07300 Montagem, colocao em operao e
manuteno de vlvulas industriais
RP 07900 Montagem, colocao em operao e
manuteno de instalaes hidrulicas
33
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Consideraes finais
Reforma e adequao
Toda a reforma e adequao deve ser emitido a
Anotao de Responsabilidade Tcnica (ART) por
Engenheiro responsvel junto a CREA.
34
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exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
18.010
17.010
Image: Sick AG
8.010
10.010
5.010
Valvula 1
Valvula 2
Valvula 3
35
Rodrigo Rodrigues | 05/18//2011 | DCBR/SSY | STRICT CONFIDENTIAL | Bosch Rexroth AG 2010. All rights reserved, also regarding any disposal,
exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
Machine Safety
Obrigado
Bosch Rexroth
Securing Your Future!
36
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