Project Book Bosch Rexroth Guarding

Project Book
Bosch Rexroth Guarding
Revision Date: 22nd April 2013
Revision Number: Version 4
Table Of Components
1
Table of revisions
2
Service and support
3
3.1
3.2
3.3
Introduction
Scope of Document
Company Overview
Product Overview
4
Machinery Directive
5
Standard Installation Criteria
6
Component List
2
1 Table of Revisions
Vers.
No.
Revision Revision
Date
Paragraph
Affected
Revised By
1.0
2.0
2.0
3.0
27-7-2010
1-8-2012
1-8-2012
11-4-2013
All
All
All
5,6
Stuart Cheyne
D Halford
D Halford
D Halford
4.0
22-4-2013
6
D Halford
Original
Part numbers updated
Inclusion of additional parts
Removal of 90x90 post sets and
accessories
Amendment to door kit
3
2. Service and Support
Contact at Bosch Rexroth :
Bosch Rexroth LTD
Mr Garry Haines
Group Leader
Technical Support
Broadway Lane South, Cerney, Cirencester, Gloucestershire GL7 5UH - Great Britain
Tel. +44 (0) 1285 863000
Fax +44 (0) 1285 863003
Email: garry.haines@boschrexroth.co.uk
Bosch Rexroth LTD
Mr Ross Townshend
National Product Specialist
Broadway Lane South, Cerney, Cirencester, Gloucestershire GL7 5UH - Great Britain
Tel. +44 (0) 1285 863000
Mobile. +44 (0) 7836 560444
Fax +44 (0) 1285 863003
Email: ross.townshend@boschrexroth.co.uk
Bosch Rexroth LTD
Mr. David Halford
Key Account Manager - JLR
Broadway Lane South, Cerney, Cirencester, Gloucestershire GL7 5UH - Great Britain
Tel. +44 (0) 1285 863033
Mobile. +44 (0) 7790 488050
Fax +44 (0) 1285 863003
Email: dave.halford@boschrexroth.co.uk
4
Contact at Jaguar Land Rover Halewood :
Jaguar Land Rover Ltd
Mr Doug Ikin
Senior Electrical Controls Engineer
Controls & Standards Department
JLR Manufacturing Engineering
Halewood, Merseyside, L24 9BJ – Great Britain
Tel. + (44) 151 448 4349
Mobile. + (44) 7854 164723
Fax. + (44) 0151 4483956
Email: dikin1@jaguarLand Rover.com
Jaguar Land Rover Ltd
Mr Ian Cowhig
Standards and Controls Engineer,
Standards & Controls Engineering,
Halewood, Merseyside, L24 9BJ – Great Britain
Tel: 0151-448-3826
Mob: 07854 165220
Fax: 0151-448-3956
Email: icowhig@jaguarLand Rover.com
Contact at Jaguar Land Rover Castle Bromwich & Solihull:
Jaguar Land Rover Ltd
Mr James Cmoch
Standards and Controls Engineer,
Standards & Controls Engineering,
Castle Bromwich, Birmingham, B35 7RA – Great Britain
Tel: 02476 205022
Mob: 07854 313625
Email: jcmoch@jaguarLand Rover.com
Jaguar Land Rover Ltd
Mr Jason Ell
Senior Engineer Electrical,
Standards & Controls Engineering,
Castle Bromwich, Birmingham, B35 7RA – Great Britain
Tel: 02476 205022
Mob: 07854 164330
Email: jell@jaguarLand Rover.com
5
3. Introduction
3.1 Scope of Document
This Program Book provides a guide to current legislation, Installation criteria and a list of Bosch
Rexroth Products to be used for any guarding programs for the Jaguar Land Rover group of
companies.
3.2 Company Overview
Bosch Rexroth AG, formed in 2001 through the merger of Bosch Automation Technology and
Rexroth, is a wholly owned subsidiary of Robert Bosch GmBH with 25,500 employees worldwide.
Bosch Rexroth has subsidiaries in 36 countries and a dealer network that spans 80 countries.
The Modular Profile System is an essential part of the “Drive and Control” offerings from Bosch
Rexroth AG. The Modular Profile System is 100% compatible with linear motion and transfer
technology components, as well as pneumatic components. Logistics and worldwide availability of
products is a decisive strength of the company and the high-capacity central warehouse in Stuttgart,
Germany supports numerous subsidiaries and sales partners with their on-site storage, by supplying
our customers around the world on schedule.
3.3 Product Overview
The Bosch Rexroth components which are recommended for guarding at Jaguar Land Rover
are listed on the following pages. For additional information on these components and systems,
please use the link to the web site listed below.
http://www.boschrexroth.com
6
4. Machinery Directive
Machinery Directive 2006/42/EC
The Machinery Directive, which went into effect on December 12, 2009, states that the fastenings for
fixed safety devices can only be loosened or removed by the use of tools. Fastening materials must
remain connected to the devices or the machine after safety devices have been removed.
It states as follows
Fixed guards are:

From the installation design/project planner designated as a maintenance area
The rule is : ( attachment l 1.4.2.1) :



Fixed guards must be fixed by systems that can be opened or removed only with tools
Their fixing systems must remain attached to the guards or to the machinery when the guards
are removed
Where possible, guards must be incapable of remaining in place without their fixings
So this means all guards which are likely to be removed i.e. designated maintenance areas must
retain the fixings in place if the guarding is removed. Guarding which will remain in place for the life of
its use does not require retaining devices.
No maintenance area = Usage MGE standard range

designated maintenance
areas
- currently losable
 Securing captivity with new
MGE add on products
= need for action!
Door element
(MGE captive)
Usage MGE
standard range

Installation without a protecting devices


Sliding door element
(MGE captive)
Usage MGE standard range
Due to the potential of any panel having to be removed for maintenance purposes Jaguar Land
Rover have made the decision that all guard panels must have retention devices.
7
5. Standard Installation Criteria
In order to maintain a common approach to all guarding on site JLR specify the following for guarding
which is 2 metres and below in height:
1.
2.
3.
4.
5.
6.
All corner posts to be 45x45
All end of run posts to be 45 x 90
Posts adjacent to a corner post are to be 45 x 90
Every second support post in a straight run of fencing is to be 45x90
Door frames 45x90
Where an area is deemed a maintenance access area for fork lift trucks, ensure that fence
post feet fixings are bolt type and not stud type fixings so that it will be possible to remove the
complete post-set and fixings.
7. Safety strips to be used on ALL panel supports ( JLR specification )
8. Standard maximum height of fence line is to be 2 metres. Written deviation required from JLR
if heights greater than this are required. All posts which are greater than 2 metres in height
are to 45 x 90 profile
9. Door stop rails are to be mounted to the door edge and NOT the door post.
Posts adjacent to a
corner are to be 45 x 90
45 x 45 Post
Fixture
45 x 90 Post
Operator
Load Area
Gate
8
10. Post foot mounts to placed in such a way as to avoid any trip hazards external of the cell
( See picture below)
11. All cut outs must have trimmed edges ( See picture)
Incorrect
Correct
12. Door handles to be fitted in the position shown
9
6. Component List
Protective Frame
Panels
No dividing bar
Protective Frame
Panels
Order no.
Size & Conn.
Element Area
3 842 522
466
Panel
B=500
HR=1800
Order no.
Size & Conn.
Element Area
3 842 522
467
Panel
B=750
HR=1800
Order no.
Size & Conn.
Element Area
3 842 522
468
Panel
B=1000
HR=1800
Order no.
Size & Conn.
Element Area
3 842 522
469
Panel
B=1500
HR=1800
Order no.
Size & Conn.
Element Area
3 842 525
158
Panel
B=2000
HR=1800
Order no.
Size & Conn.
Element Area
3 842 523
167
Panel
B=1000
HR=1800
Order no.
Size & Conn.
Element Area
Weight
Comments
Single pack
Galvanised steel
mesh
Weight
Comments
Single pack
Galvanised steel
mesh
Weight
Comments
Single pack
Galvanised steel
mesh
Weight
Comments
Single pack
Galvanised steel
mesh
Weight
Comments
Single pack
Galvanised steel
mesh
Vertical dividing bar
Door Panel
Weight
Comments
Single pack
Galvanised steel
mesh
Horizontal dividing bar
Fortess Lock
Mounting Kit
Weight
Back plate & Bracket
R987329162 Standard Door
Order no.
Size & Conn.
R987340348
Sliding Door
Comments
Element Area
Weight
Comments
Back plate & Bracket
10
JLR specified
complete door kit.
Order no.
Size & Conn.
Contains all components
for a standard 1m wide
door assy – see assy dwg.
on page 12
R987400365
JLR complete
door kit
Order no.
Size & Conn.
Element Area
Contents
Comments
3 842 523
166
Bosch Rexroth
Door kit
HR = 1800
B=1000
2 x hinges, 45 x
45L rail, stop rail
and handle
Complete kit to make
1000 panel into a
hinged door
Order no.
Size & Conn.
Element Area
Contents
Comments
3 842 525
782
Double Door
kit
HR = 2000
4 x hinges , stop
rail and handles
Complete kit to make
2 x1000 panels into a
hinged double door
Order no.
Size & Conn.
Element Area
Contents
Comments
3 842 524
163
Sliding Door
kit
HR = 1800
B=1000
Top rail, bottom
rail , handle and
stops
Complete kit to make
a 1000 panel into a
sliding door
Order no.
Size & Conn.
Element Area
Contents
Comments
3 842 524
166
Sliding Door
kit
HR = 1800
B=2000
Top rail, bottom
rail , handle,
stops and
supporting wheel
Complete kit to make
a 2000 panel into a
sliding door
Order no.
Size & Conn.
Element Area
Foot Plate
Comments
R987277089
45x45 support
H=2000
120 x 120
Single pack
Order no.
Size & Conn.
Element Area
Foot Plate
Comments
R987277090
45x90 support
H=2000
150 x 150
Single pack
Hinged door kit
Requires door panel and
support post to complete
Double door kit
Requires door panels and
support post to complete
Sliding door kit
with superstructure
Requires door panel and
support posts to complete
Sliding door Kits
Without super
structure
Requires door panel and
support posts to complete
Post Set Assembled
Inc: Post, Foot plate & Cap
Element Area
Contents
Comments
See assy dwg on
page 12
11
TERMINAL BOX NOT SUPPLIED
WITH KIT OF PARTS
Standard 1 Metre Door Kit – all component parts
12
Sliding Door Kit – all component parts
13
Suspension Brackets
Order no.
Size & Conn.
Element Area
Weight
3 842 522
481
Safety Strips
Comments
Complete pack to
hang 1 panel
Order no.
Size & Conn.
3 842 542
146
Safety Strip
Element Area
Weight
Comments
10 per pack
Each panel requires 2
strips
14
Foot Plate
45 x 45L extrusion
45x90L extrusion
Edge profile
Edge profile
Order no.
Size & Conn.
Element Area
3 842 524
469
Foot plate
To suit 45 x 45
and 45x90
Order no.
Size & Conn.
Element Area
3 842 992
425/5600
Extrusion
45 x 45L x
5600mm long
3 842 511
702
Extrusion
LE20 x L =5600
Order no.
Size & Conn.
Element Area
3 842 992
432/5600
Extrusion
45 x 90L x
5600mm long
3 842 511
782
Extrusion
LE12 x L =5600
Order no.
Size & Conn.
Element Area
3 842 992
972/5600
Extrusion
30 x 30 WG40
5600mm long
3 842 522
464
Extrusion
LE20 x L =5600
Order no.
Size & Conn.
Element Area
3 842 992
973/5600
Extrusion
30 x 45 WG40
5600mm long
3 842 522
465
Extrusion
LE20 x L =5600
Weight
Comments
Weight
Comments
Box of 20 lengths of
extrusion, 5600mm
long
Weight
Comments
Box of 12 lengths of
extrusion, 5600mm
long
Weight
Comments
Box of 20 lengths of
extrusion, 5600mm
long
Weight
Comments
Box of 20 lengths of
extrusion, 5600mm
long
15
Sundries
Floor bolt
Shim
Order no.
Size & Conn.
Element Area
3 842 517
058
End cap
45x45L
Order no.
Size & Conn.
Element Area
3 842 511
783
End cap
45x90L
Order no.
Size & Conn.
Element Area
3 842 522
345
End cap with
hole
30 x 30L
Order no.
Size & Conn.
Element Area
3 842 528
721
M8 x 30 T-bolt
Post to foot
fitting kit
Order no.
Size & Conn.
Element Area
3 842 345
081
M8 nut
Post to foot
fitting kit
Order no.
Size & Conn.
Element Area
3 842 530
236
S12 x 30 – T50
Self-tapping
bolt
Post to foot
fitting kit
Order no.
Size & Conn.
Element Area
3 842 527
174
Self tapping
bolt
S8x25-T40
Order no.
Size & Conn.
Element Area
3 842 526
561
Floor bolt
10mm diam.
Order no.
Size & Conn.
Element Area
3 842 528
189
1mm thick
Shim
Weight
Comments
Pack of 20 off
Weight
Comments
Pack of 20 off
Weight
Comments
Pack of 100 off
Weight
Comments
Pack of 100 off
Weight
Comments
Pack of 100 off
Weight
Comments
Pack of 100 off
Weight
Comments
Pack of 100 off
Weight
Comments
Pack of 100
Weight
Comments
Pack of 100
16