advanced ergonomic … ergonomic palm... · work methods analysis and ergonomic checklist analysis...

www.pinnaclesystems.com

www.pinnaclesystems.com www.pinnaclesystems.com

Safety Sensors and Controls for Industrial Machine Guarding Systems


Advanced Ergonomic Engineering

The safest and only “control reliable” ergonomic zero force palm button that can be used as a two hand control device for operator safety.

PressControlUL508

LISTED42EL

ULSubject491


Cumulative Trauma Disorders (CTDs) is the mostcommontermusedtorefertothediseasesrelatedtotheupperlimbs.Similartermsusedtodescribetheseproblemareasare: • repetitivestraininjuries • occupationalcervicobrachialdisorders • occupationaloverusesyndromesCumulativeTraumaDisordersarecausedbyrepetitivestressesonaparticularbodypartafterperiodsofjobrelatedmicro-trauma.Basicallytherearethreetypesofinjuriestothemachineoperator.Theseinjuriesincludenerve disorders, tendon disorders or neuro-vasculardisorders.NerveDisorders-CarpalTunnelSyndrome(CTS)Common Tendon Disorders-Tendinitis, Tenosynovitis,DeQuervain's disease, Stenosing Tendsynovitas,StenosingTenosynovitasCrepitans.NeurovascularDisorders-Thoracicoutletsyndrome.

The Industrial Problem of Cumulative Trauma Disorders (CTDs) and Carpal Tunnel Syndrome (CTS)

Benefits Human Factor Engineering (Ergonomics)UltraTouch® has been designed to interact with theoperator, machine operation, and the work place in asafeandefficientway.Thiseffectivedesignofequipmentwill be most helpful in the controlling of Carpal TunnelSyndrome and other Cumulative Trauma Disorders.

Productivity IncreasesIncreases in productivity are achieved by a reductionin operator fatigue and operator injury alongwith basic production line cycle time decreases.

Employee MoraleEasier job related actions and movements with bothworkmethodsanalysisandergonomicchecklistanalysisprovideahealthierandmorepositiveworkenvironment.

Fatigue ControlEase of safe machine activation enables the machineoperators to utilize their energy for more productiveefforts.The reductionof fatigue isanessential elementwhentryingtocontrolCumulativeTraumaDisorderssuchasCarpalTunnelSyndrome.

What UltraTouch® Does For YouThe patented soundergonomic design criteriaof UltraTouch® advancesmachine cycle initiationintothe21stcentury.TheUltraTouch system hasbeen designed so themachine operator caninitiate the machine cyclewith their hand and wristareaintheneutralpositionand with no exertion offorceorpressure.This minimizes hand,wrist, and arm stressesrelated to the potentiallyharmful extension andflexion positions of thehand required to activateconventionalspring-loadedpalm buttons. No flexingof the wrist is necessarywithUltraTouch®.

Wrist and hand positionsare most important ascontributing elements ofCarpal Tunnel Syndrome.Wristposition is importantbecauseitaffectsthelengthandtensionrelationshipofcontracting muscles. Astheangleofthejoint(wrist)increases or decreasesbeyond its midpoint(neutral position), there isa proportional decreasein the machine operatorseffective strength. Thismeans thatmore exertionor tendon tension isrequired todoa taskwithabentwristthanthesametask with the wrist in theneutralposition.Handandwrist posture along withforce required are basecontributing elements toCarpalTunnelSyndrome.

MedianNerve

PalmarSide DorsalSide


Economic JustificationThere are substantial costs related to Carpal TunnelSyndromeversusthecostsandbenefitstopreventthem.Variousfactorsthatcanbeincorporatedintotheanalysisarereducedoverheadcosts,employeemorale,reductionsin non-productive time, and improved productivity.Factors involvedwithoverheadexpensemay include:medical costs, compensation costs, lost productivitydue to injuries, absenteeism, and labor turnover.

Workman's Compensation Cost ControlUltraTouch® can reduce the costs related toCumulativeTraumaDisordersinrelationtoWorkman'sCompensation Insurance claims. Both medical anddisabilitycostscanbereducedwiththecontrolofCarpalTunnelSyndrome.The actual costs of Cumulative Trauma DisordersandCarpalTunnelSyndromeareactuallyhigher thanthosecoveredbyWorkman'sCompensationInsurance.Insurancedoesnotcovermedicaltreatmentsrendereddirectly by the employer, and many employeessupplement the disability coverage provided bythe insurance carrier. Additional costs are incurredwhen expenses are paid for by the injuredworker orby comprehensive health insurance, which may beprovidedbytheemployerasafringebenefit.

Reduced MaintenanceThe solid state design of UltraTouch® assures longlife when compared to conventional spring-loadedmechanicalpalmbuttons.Theonlycomponentwithamovingpartistheindustrialgradecaptivecontactsafetyrelay,andit isratedforanexcessof10millioncyclesandiseasilyreplaceable.The UltraTouch® module is designed to be a directreplacement into existing operator run bar stationswhichisatruemaintenanceandinstallationtimesaver.

ApplicationsTheUltraTouch®systemisdesignedtoactivateelectric,pneumatic, air clutch, and hydraulic equipment suchas punch presses, press brakes, molding machines,assembly equipment, tube benders, compactingpresses, riveters, etc. Virtually any machine that iscurrentlyusingconventionalmechanicalspring-loadedpalm buttons can now utilize the sound ergonomicdesignofUltraTouch®.

The UltraTouch® systemnegates these problemsbypermitting themachineoperator to activate themachine with no forceor pressure and with theoperators hand and wristin the premier ergonomicposition of neutral, 0ºdeviation and 100% handpowerposition.UltraTouch®eliminatesthenormal pressure requiredformachineactivationwithconventionalpalmbuttonsof the median, ulnar andradial nerve at the wristandhandarea.UltraTouch® also permitsthe machine operatorto activate the machinecyclewithorwithouthandprotection devices suchassplintsandevenheavymetal fabrication workgloves.

The machine operator’sreference hand and wristpositions illustrate thedegree of wrist deviation(bending) expressed asa percentage of handpower grip as measuredin the neutral (natural)position.TheUltraTouch®systemutilizesthepremierergonomic position ofneutral, 0º deviation and100% hand power for themachineoperator.The photo shows anoperator’s hand actuatingthe UltraTouch® modulewiththecorrectergonomichandposition.

The hand is at rest withno angle or bending atthe wrist joint and thehandisatthe“thumbsup”position.Thisisthesamenatural hand and wristpositionthat ismaintainedwhen ones arms are atrest hanging at their side.There is no need to cupand curl the fingers or torollthewristtoactuatetheUltraTouch®system.This further illustrates thetotal advanced ergonomicengineering displayed bytheUltraTouch®design.

Neutral

0º,100%25º,80%

45º,75%

Radial Ulnar

45º,75%

Extension

Flexion

45º,60%

65º,45%

100%

Reference - Hand and Wrist Positions


ThepatentedUltraTouch®systemhasbeendesignedas a direct replacement for standard spring-loadedmechanicalpalmbuttonsandisdesignedtofitintoexistingoperator palm button stations without modification.

TheUltraTouch®enclosureisamoldedhighstrengthNEMA4polycarbonatemoduledesignedtomeetthehigh impact and vibration requirements of industry.Thesolidstateelectronicsof theUltraTouch®switchincorporates an advanced redundant diverse sensordesign.Thismeansthateachmodulehastwodifferentsensorswith isolatedcircuitsalongwithamonitoringredundant circuit. The circuitry of UltraTouch is alsodesigned to provide second-order failure protection.This gives theUltraTouch® an unparalleled level ofsafety and assurance against inadvertent actuation,or failing in the "on" or conductingmode,which is acommon problem found throughout industry withcompetitive ergonomic switch replacements. TheUltraTouch® design is so safe against inadvertentactuationthattwoUltraTouch®moduleswhenspacedandlocatedproperlyinaccordancetoOSHAandANSIhand control distance formulas (the same formula isused formechanicalpalmbuttons),permit itsuseas

an operator safety two-hand control device. TheUltraTouch®dualdissimilarsensorformatisdesignedforthemachineoperatortoactuatetheswitch,andthatnoinadvertentforeignobjectssuchassleeves,insects,broomsticks,playingcards,rags,mistsordropletscanactivateortriggertheswitch.ThisgivesUltaTouchanunparalleled level of safetywhile giving the operatorthe benefit of using the correct ergonomic handpositionofneutral,0ºdeviationand100%handpower.

UltraTouch® ConfigurationThe UltraTouch® dual dissimilar sensor ergonomicpalmswitchisconfiguredinthefollowingmanner:AU-shapedsensorsactuationchannel(shownbelow)providesa triggeringpoint for themachineoperatorshand. This is where the invisible infrared light beamis locatedand is crossing thechannel.There isalsoa unique U-shaped location sensor mounted on theinside of the UltraTouch® enclosure that hugs thesensorchannelandisinsulatedbytheenclosureitself.When the machine operator inserts their hand intothesensoractuation tunnel, both the infraredsensorand the locationsensormustbesatisfied inorder toenergize an electromechanical relay to send a cycle

UltraTouch® Design

NEMA4SealedHousing

GreenStatusIndicator

Location,SensorField

RedStatusIndicator

MountingHoles(4)

SensorsActuationTunnel

InfraredBeamSensor

PatentNumber5,410,148-U.S.PatentandTrademarkOfficePressControl

UL508LISTED42EL

ULSubject491


start signal to the machine. Both individual sensorswithin eachmodule are time interlocked, and if bothsensorsarenottriggeredconcurrentlybytheoperator’shand, the UltraTouch® output will be inhibited tothe machine control. The module also contains twovisibleLEDindicatorswhichinformsthestatusoftheUltraTouch® module to the operator. A green LEDindicates that the relay contacts are closed, bothsensorshavebeenactivated,andnofailureshavebeendetected.TheredLEDindicatesthattherelaycontactsareopenandnosatisfactoryconditionsweredetectedonbothsensors.ThisadvancedpatentedUltraTouch®design is not available on any competitive unit andgives theUltraTouch® user an unparalleled level ofsafety when using ergonomic zero force actuationdevices.Additionally,theoperatorwillbeactivatingthemachineproperlybyusingthecorrectergonomichandpositionofneutral,0ºdeviation,and100%handpower.

Easy to InstallUltraTouch® installs with ease and comes withcompleteinstallationinstructions.Simple module design permits direct exchange forexisting spring-loaded mechanical palm buttons andevenutilizes theexistingscrewholeson therunbar.All systemshavenormally open (N.O.) andnormallyclosed(N.C.)contacts,andarealsoavailableinafourpole wiring configuration depending on the machinecontrolrequirements.Theultimateinversatility!New installations and retrofit projects are completelyinstalled in minutes by a qualified electrician. Alsosupplied is a toll free 800 number if any questionsshouldarisebyyourinstallationpersonnel.

UltraSafe DesignEach UltraTouch® switch module incorporates thefollowingsafetydesignfeatures:• Twodissimilarsensors a)Infraredsensor b)Positivelocationsensor• Redundantcircuitry• Chatterfreedesigncircuit• Anti-noisecircuit• Nofalsetriponpowerupcircuit• Captivecontactsafetyrelays• Operatorstatusindicators• Interlockcircuitbetweenthediversesensors• ImmunetoEMIandRFInoise• Immunetoweldfieldinterference• Controlreliabledesign

OSHA, ANSI & CSA StandardsThe mounting locations of UltraTouch® mustconform to all State, Province, and Federal codesand all regulations pertaining to the subjectmachine onwhich theUltraTouch® is to be applied.

Point of Operation GuardingTheUltraTouch®systemisamachinecycle initiationcomponent that isdesignedtobea two-handcontroldeviceforthemachineoperator.Ifapointofoperationguardingdeviceisdesiredorrequired,pleasecontactyourlocaldistributororthefactoryfordevicestocomplywithANSIB11.1orthevariousOSHAregulations.

UltraTouch® Design Cont.

References for Proper InstallationPleaserefertothefollowingANSI(AmericanNationalStandardsInstitute)Standardsfortheproperinstallationlocationfor“twohandcontroldevices”foryourspecificmachineandapplication.

ANSIStandardB11.19-2003AnnexDSafetyDistance(Informative)

ANSIStandardB11.1-2009AnnexCSafetyDistance(Informative)


Ergonomic Palm Button Replacement Grid Checklist“Compare the Difference” UltraTouch

* RequirestwoUltraTouch modulesspacedandmountedinaccordancewithcurrentOSHAandANSIstandards.OSHAandANSIstandardsalsorequiremachinestohave“controlreliable”controlcircuitry.

YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________ YES ________ ________

YES ________ ________

YES ________ ________

YES ________ ________ YES ________ ________

YES ________ ________

YES ________ ________

YES ________ ________

YES ________ ________

YES ________ ________ YES ________ ________ YES ________ ________

YES ________ ________

YES ________ ________ YES ________ ________ YES ________ ________

• Diversedualsensordesign • Control reliabledesignofsensorcircuits • Redundantcircuitry • Incorporatessecond-ordercircuitfailureprotection • Internalself-checkingofinfraredsensorandsystemcircuits • Built-intimedinterlockwithineachmoduleforthetwodiverse

sensors • Utilizescaptivecontactsafetyrelays • Diagnosticsofsensorcircuitsanddiversesensorsinterlockcircuit • Notaffectedbyexternalinfraredlightsources • Built-inhysteresis • Nofalsetriponpowerup • Anti-noisecircuitrybuilt-in • Chatterfreedesignbuiltin • Weldfieldimmune • EMIandRFIimmune • Completelyself-containedunit,requiresnoadditionalrelaysor

interfaceboards • Operatorstatusindicatorlights– A.Red–Readytocycle B.Green–Cycleinitiated • Fastreacting–Lessthan20ms • NEMA4enclosure • Designsavailableforallmachines: 110VAC – 2poleor4poleconfiguration 24VDC – 2poleor4poleconfiguration • Directlyinterchangeablewithexistingmechanicalpalmbuttons: A.Electrically B.Mechanically • Requirescorrectergonomichandpositionforzeroforcemachine

actuationofneutral,0ºdeviation,and100%handpower • Cannotbeactuatedbyscrewdrivers,playingcards,rags,sleeves,

broomsticks,mistsordroplets • Tactilefeedbackfeelrequirestheoperatortohavetheproperhand

locationforbothsafetyandergonomics • Cannotbeactuatedbytheoperator’selbows • Canbeusedasanoperatortwo-handsafetycontroldevice* • ComplieswithallapplicablesectionsofOSHA,ANSIandCSA

standardsforoperatortwo-handcontroldevices • Repairableunit–notadisposabledesign • Captivescrewsandgasketssuppliedtoeaseinstallation • Two-yearwarranty • MadeinUSA

DesignCriteria

PressControlUL508

LISTED42EL

ULSubject491


UltraTouch® Models Model # Description

UL-101-2P

UL-102-2P

UL-301-2P

UL-401-2P

UL-501-2P

UL-601Specify

AC or DC

8500

TwoUltraTouchmodulesmountedonaNEMA12operatorstationrunbar.TheUltraTouchmodulesaremountedinaccordancetoOSHA,ANSI,andCSAstandardsinregardstorunbuttonspacing.

TwoUltraTouchmodulesmountedonaNEMA12operatorstationrunbarwitharedmushroomemergencystopbuttonlocatedinthecenter.Excellentforinstallationsrequiringanemergencystopbuttonfortheoperator.AllthemodulesaremountedinaccordancetoOSHA,ANSI,andCSAstandardsinregardstorunbuttonspacing.

TwoUltraTouchmodulesmountedonaNEMA12operatorstationrunbarwitharedmushroomemergencystopbuttonlocatedinthecenterandayellowmushroomtopbuttonlocatedoffcenter.Idealforthemetalstamping/metalfabricationindustry.AllthemodulesaremountedinaccordancetoOSHA,ANSI,andCSAstandardsinregardstorunbuttonspacing.

Anti-tiedown/concurrentoperationmodule.Thisassemblysuppliesthecontrolthat,whenaddedtotwoUltraTouchdevices,assuresthattheoperatoroccupiesbothhandsandmustinitiatebothUltraTouchdeviceswithinapresetperiodoftime.Theanti-tiedown/concurrentmodulecomesinaNEMA12enclosureandcanbeaddedtoanyofthestyles.NEMA12enclosure6”(152mm)x8”(203mm)x6”(152mm).Thisisrequiredonallmachinesthatdonothavethiscapabilityinthemachinecontrol.(Availablewithoutcontrolbox.Part#UL-601-NBmodule.Requires4”(102mm)x5”(127mm)space.)

OneUltraTouchmodulewithacompleteself-containedNEMA12enclosure.DimensionalconfigurationofNEMA12enclosureof3.50”(89mm)x6.375”(162mm)x2.95”(75mm).ExcellentforinstallationswhentheUltraTouch systemmustbemountedindividuallyduetospacelimitations.

TheModel8500adjustablepedestalmountcanbeutilizedformountingtheoperatorstationsortheUltraTouchmodulesoffthemachine.TheseadjustableheightpedestalsarepaintedOSHAyellowandareofheavyangleconstructionwithafloormountingplatethatcanbelaggedtothefloor.Theadjustableheightfeatureassuresthecorrectergonomicpositionforvarioussizeoperators.Thiswillhelpcontrolstretchingandpullingstrainsoftheoperator.

OneUltraTouchmodule--Directreplacementintomostexistingoperatorstationsintoexistingmechanicalpalmbuttonsspaceandscrewconfigurations.Excellentforretrofitprojects.

SpecificationsNEMA4SealedHousingSolidStateCircuitryDualSensorSources--Infrared/CapacitiveResponseTime<20msCSAApproved,ULListedModulerequiresa2”(51mm)mountingdepthinrunbar

Current Requirements110VAC 2pole--50mA 4pole--60mA24VDC 2pole--150mA 4pole--250mAOperator Status Indicator --LED’s A.Red--Readytocycle B.Green--CycleinitiatedRelay Type --CaptiveContactSafetyRelayRelay Rating--8amp@220VAC;8amp@120VAC

Relay Cycle LifeMechanical--50millioncyclesElectrical--100,000cyclesat220VAC,4amp

Voltage Range --+/-10%Warranty --2years

PressControlUL508

LISTED42EL

ULSubject491


Ordering Procedure

Wiring Configuration Ordering Procedure

2 PoleDouble Throw Relay120 VACModel #UL-101-2P

4 PoleDouble Throw Relay120 VACModel #

UL-101-4P

24VDCVoltage System2 PoleDouble Throw RelayModel #

UL-101-2P-DC

24VDCVoltage System4 PoleDouble Throw RelayModel #

UL-101-4P-DC

UltraTouch machineactuationdevicesarenottobeusedonfullrevolutionpowerpressesoronmachineryutilizingrestraintsorpull-outdevicesasthepointofoperationguardingsystems.

RelayContactRating

16amps

RelayContactRating

8amps

RelayContactRating

8amps

RelayContactRating

8amps

Whenordering,pleasespecifyquantitydesiredandModelNumbershownonprecedingpage.Addthesuffix4PtotheModelNumbertodesignatetheUltraTouchModeltobesuppliedwitha4poledoublethrowrelayconfiguration.Examples:UL-101-4P,UL-102-4P,UL-301-4P,UL-401-4P,UL-501-4P

Whenordering,pleasespecifyquantitydesiredandModelNumbershownonprecedingpage.Addthesuffix2P-DCtotheModelNumbertodesignatetheModeltobesuppliedwitha24VDC2polesystem.Examples:UL-101-2P-DC,UL-102-2P-DC,UL-301-2P-DC,UL-401-2P-DC,UL-501-2P-DC

Ifcustomizedassembliesarerequired,pleaseconsultthefactory.Whenordering,pleasespecifyquantityrequired.

Whenordering,pleasespecifyquantitydesiredandModelNumbershownonprecedingpage.Addthesuffix4P-DCtotheModelNumbertodesignatetheModeltobesuppliedwitha24VDC4polesystem.Examples:UL-101-4P-DC,UL-102-4P-DC,UL-301-4P-DC,UL-401-4P-DC,UL-501-4P-DC

Relayoperateswhenhandisinsertedintosensorsactuationtunnel.




OUTPUT OUTPUTPOWER

NEUTRAL LINE

OUTPUT OUTPUTPOWER

NEUTRAL LINE

OUTPUT OUTPUT

OUTPUT OUTPUTPOWER

NEUTRAL LINE

OUTPUT OUTPUTPOWER

NEUTRAL LINE

OUTPUT OUTPUT


UL-101UltraTouch®

ModuleEnclosureSpecifications•Material0.125inplastic

UL-102Module BaseAll StylesEnclosureSpecifications•NEMA13•14Gauge•SteelEnclosure

Specials 1.Stainlesssteelmodulebases. 2.Castmalleableironmodulebases.

UL-301UL-401UL-501All StylesEnclosureSpecifications•NEMA13•14Gauge•SteelEnclosure

UL-601EnclosureSpecifications•NEMA12&13•UL50Type12&13•JICStd.EGP-1967•CSAEnclosure5•IEC529,IP65•14Gauge•SteelEnclosure

Mounting DimensionsDimensionsinInches


TonnageMonitoring DieProtectionSystems

RotaryCamBasedClutch/BrakeControls

ResolverBasedClutch/BrakeControls

ServoFeedInterface ProgrammableLimitSwitches

PunchPressAutomationControlsTimeBasedBrakeMonitor

• PunchPressClutch/BrakeControls• ResolverBasedClutch/BrakeControls• RotaryCamBasedClutch/BrakeControls• PunchPressAutomationControls• TimeBasedBrakeMonitor• DieProtectionSystems• OSHAandANSICompliantControls• ProgrammableLimitSwitches

• TonnageMonitoring• ServoFeedInterface• CustomizedPunchPressControls• PressBrakeGuardingforMechanical, AirClutchandHydraulicPressBrakes• StainlessSteelEnclosuresAvailable• LazerSafe-Safeguardingsystemfor HydraulicPressBrakes

™

Press Controls and Guarding for the Metal Stamping / Forming Industry

www.pressroomelectronics.com (412) 262-1115


NOTES

ResolverBasedClutch/BrakeControls


[email protected] [email protected]

www.pinnaclesystems.com AdditionalproductstoachieveyourTotal Safety Solution!!!-SafetyLightCurtains(AllTypesandStyles)-UniversalSafetyControllerHUB/SafetyPLC-SafetyMatSystemsandControls -AreaGuardingSystems -NSDSafetyMatSystems -STTSSafetyMatSystems -DirectionofTravelMats -High-TempWeldingMats-ErgonomicPalmButtons -UltraTouchPalmButtons-SafetyInterlockSwitches(includingexplosionproof)-Customized“controlreliable”controlsfordualsolenoidactivatedpneumaticandhydraulicvalveapplications-FencingwithInterlocks-E-StopButtons-StackLights

-EnergyIsolationandSinglePointLockoutSystems-PlantSurveys,RiskAssessment&InstallationServices-CustomizedControlPanels;StainlessSteelenclosuresavailableforallproductsPunch Press / Metal Stamping Industry -ResolverorRotaryCamBasedClutch/Brake Controls-OSHA/ANSICompliant -PunchPressAutomationControllers -Time-BasedBrakeMonitors -ProgrammableLimitSwitches -DieProtection&TonnageMonitoringSystems -ServoFeedInterfacesPress Brake Guarding and Controls -PressBrakeGuardingforMechanical,AirClutch andHydraulicPressBrakes -PressBrakeControlSystems

Sales and Marketing OfficeP.O.Box100088Pittsburgh,PA15233

TollFree: (800)569-7697Phone: (412)262-3950Fax: (412)[email protected]

Manufacturing and Service Center3715SwensonAvenueSaintCharles,IL60174Phone: (630)443-9320Fax: (630)[email protected]

Wehavedesignedourequipmenttotheveryhighestperformanceandsafetystandardsknowntothecurrenttechnologicalstateoftheart,asevidencedbyourU.S.A.andforeignpatentsissuedandpending.However,theinstallation,usage,andsuitability,andfitnessofourequipmentforanypurpose,knownorunknown,isinterdependentupontheperformanceofotherequipmentnotmanufactured,installed,securedormaintainedbyPinnacleSystems,Inc.

Wecannotanddonotacceptresponsibilityforanyoverallsystemperformancewhenfactorssuchasthese,arebeyondourcontrol.


advanced ergonomic … ergonomic palm... · work methods analysis and ergonomic checklist analysis...

Documents