1.

Introduction

1.1 BASIC:

Slips and fall

Environmental conditions and spills contribute to occurrences of falls and slips that can cause
workplace injuries. Many of these accidents damage the muscular or skeletal systems and result
in lost work. Such injuries often can be prevented by the placement of spill precaution signs, the
use of non-slip footwear and awareness education.

Falling Objects
Poorly positioned items and items that fall while being carried or manipulated by industrial
equipment can cause workplace injuries. These injuries can be particularly serious because they
typically affect the head and neck. Prevention measures include the use of safety headgear,
proper restraint of carried or manipulated objects, proper training on equipment use and the
placement of warning signs.
Chemical Burns
Chemicals in an industrial workplace can present the danger of burns, which often occur with
bodily contact during accidental spills or sprays. This type of threat demands specific responses,
particularly containment of the chemical to prevent additional contact injuries and prevention of
consequences such as contamination of the local water supply. Injury prevention begins with
identification of the chemical and a list of dangers related to its use. Personal protective
equipment such as eyewear must be made available to employees.

Improper Lifting
Employees who work in an industrial environment may suffer injuries due to the improper
manipulation of goods and equipment. A poor lifting technique can result in injuries to the back,
spine, limbs and extremities. In some cases, lifting injuries manifest over time rather than
immediately. This type of injury can be avoided with hands-on and classroom training and
proper supervision of workplace activity.
Accident avoiding system in pneumatic press as name implies that pneumatic means which is
operated on compressed air or steam operated, multipurpose that name implies that pneumatic
power is used to produce different product & varies in productivity. Machine provides a means
of provide a loads that otherwise could not operated by conventional mechanical. A common
pneumatic machine which has piston cylinder arrangement & which have any other arrangement
to transfer or convert the loads or motion.
The two mechanical advantage combines in a menu that results in a multiplying effect, than an
adding effect which yields a much larger overall mechanical advantages. The effacingly of this
machine can be determined from the basic definition of efficiency which is output / input. The
excurse in appropriate for mechanical energy/ technology or mechanical engg. Students for a
course in a applied fluid mechanics & Air power or machine design. The needed equipment is
readily available of the shaft of the very low cost. Especially in the field of fluid mechanics. If
engine is had worked for a satisfying theory before concerning & manufacturing product. The
present technology would not be achieved as developed as it is now. Never the less by
associating science with technology a valuable & essential support is ensured for a better control
of fluid system. The success of this project is due to the same amount of discernment which is
necessary for the application of theory. The complexity of pneumatic system is such that
experience gained in the field, along with the number of problem solved are the best guides. The
work consisted of the survey of the proposed technical solution. The control loop analysis & the
study at the consequences of breakdowns. For this anurnarical model was developed. It includes
the mechanical part & control automatic systems. This work allowed for a validation of a
technological choices & control state goes. Moreover we analyzed & qualified the weakness
considering the various possible breakdown cases.
In our project, we made a pneumatic model as some as piston cylinder arrangement. This
arrangement is totally mounted on material frame. Our experience in terms of the quality of the
phenomenon to be found in the fluid power control devices enables us today to define the
elements for the function. Our progress is due to the convergence of many applications & it is
easy to imagine to the failure that theory may cause when based on insufficient experience.

1.2 INDUSTRIAL FIRE & SAFETY:

Identification
To ensure a hazard-free work zone, employers must identify what safety risks exist in the work
environment. Some safety risks include heavy machinery, electrical equipment, harmful
substances and slip-and-fall accidents due to slippery, wet or unkempt walking surfaces.

Prevention and Solution

Preventing accidents and injuries can be accomplished by eliminating hazards from industrial
work areas. Safeguarding machinery makes equipment safer to use by protecting critical points
of operation. Personal protective equipment protects workers from exposure to harmful
substances, which keeps them healthy and safe. Educating workers about safety practices and
posting caution signs reduces risk factors.

Ongoing Safety Efforts

The assurance of safety is an ongoing effort. Employers must evaluate industrial work zones on a
regular basis to look for any unidentified risk factors, such as defective equipment. It is also
important for safety incidents to be reported so that employers are made aware of new safety risk
factors. Industrial accidents are those that occur at a person's workplace. An industrial accident,
or occupational accident, is an accident that occurs when an employee is at work. It includes any
type of accident or injury caused from a person's workplace. Industrial accidents can have a
number of causes. Sometimes it is simply a random accident caused by a slip or fall. Other times
these accidents are caused by improper work practices or negligence of the company. They can
happen from employers cutting corners when it comes to employee safety or proper job training.
Employer Responsibility
Employers are responsible for properly training employees and for making work environments
safe. Anytime an accident occurs at a workplace, the employer is responsible for the injury.
When accidents happen, the employee is protected by workers compensation insurance. This is
an insurance employers pay for these purposes.

Hazardous Substances
Industrial accidents also include injuries or illnesses incurred by employees due to exposure to
hazardous substances and materials. Long-term exposure to certain substances can result in
permanent or fatal injuries.

1. Turn off power to the machine before cleaning. This will avoid accidentally starting the
machine and injuring yourself.
2. Remove cutting tools. Take out drill bits, mills and remove lathe tools to reduce the chances of
getting cut. On the table saw lower the blade completely.
3. Put away all hand tools and other items around the tool so that you don’t make them dirtier.
4. Clean chips from the tool, the chip pans. Recycle clean chips where possible.
5. Put a light coat of way oil on the machine ways. Ask staff to show you where this oil is kept.
6. Sweep the floor in the area where you have been working.
7. Do not over use compressed air. Do not blow air into the bearing surfaces, and do not scatter
chips all over the shop. Sometimes a shop vacuum works better than the air gun.
8. Report missing, broken or damaged tools to shop staff.
9. Spend five minutes on general cleaning around the shop. We’re all in this together.

1.3 GENERAL SAFETY GUIDELINES:

1. Do not attempt to remove foreign objects from the eye or body. Report to the student health
service for medical treatment. If chemicals get in the eye(s), wash eye(s) for 15 minutes in an
open flow of water before proceeding for medical treatment. Notify campus rescue at 9-911.
2. Avoid excessive use of compressed air to blow dirt or chips from machinery to avoid
scattering chips. Never use compressed air guns to clean clothing, hair, or aim the gun at another
person.
3. Machines must be shut off when cleaning, repairing, or oiling.
4. Do not wear ties, loose clothing, jewelry, gloves, etc. around moving or rotating machinery.
Long hair must be tied back or covered to keep it away from moving machinery. Hand protection
in the form of suitable gloves should be used for handling hot objects, glass or sharp-edged
items.
5. Wear appropriate clothing for the job (i.e. do not wear short sleeve shirts or short pants when
welding).
6. Do not work in the shop if you are tired or in a hurry – this almost always ruins the work, and
often results in injury.
7. Never indulge in horseplay in the shop areas.
8. All machines must be operated with all required guards and shields in place.
9. A brush, hook, or special tool is preferred for removal of chips, shavings, etc. from the work
area. Never use your hands to clean cuttings – they are sharp!
10. Keep your fingers clear of the point of operation of machines by using special tools or
devices, such as, push sticks, hooks, pliers, etc. Never use a rag near moving machinery.
11. A hard hammer should not be used to strike a hardened tool or any machine part. Use a soft
faced hammer.
12. Keep the floor around machines clean, dry and free from trip hazards. Do not allow chips to
Accumulate.
13. Think through the entire job before starting. Ask for help if you have questions.
14. Before starting a machine, always check it for correct setup and always check to see if
machine is clear by operating it manually, if possible.
15. Do not drink alcoholic beverages before or during work in the machine shop area. Do not
bring food or snacks into the shop.
16. If you have not worked with a particular material before, check the hazardous materials data
sheets book for any specific precautions to be taken while working with the material. Also, ask
the shop personnel before cutting any unusual material.
17. Heavy sanding and grinding should only be done in well-ventilated areas, preferably on the
patio. Painting on the patio only – make sure that the doors to the shop are closed.
18. Follow all appropriate precautions when working with solvents, paints, adhesives or other
chemicals. Use appropriate protective equipment.
19. Safe procedures for most shop operations are described in the Health and Safety Procedures
Notebook located by the safety cabinet.
20. Check the power cords and plugs on portable tools for before using them.
21. Always store oily rags in an approved metal container.

1.4 THE BASIC RULES:

1. Never work alone. At least two adults must be in the shop when power tools are being used.
2. Never work when you are impaired. This includes when you are too tired, stressed or hurried
to work carefully.
3. If you cannot do a job safely in this shop, don’t do it. There are limits to what we can build
here.
4. Always wear closed-toe shoes in the shop. Tools, chips and fixtures are sharp, and often hot.
Shoes will help protect your feet from injury. Leather shoes are preferred when welding.
5. Eye protection is essential. Always wear safety glasses when working or cleaning tools.
Prescription glasses sold in the US with plastic lenses meet ANSI Standard Z87.1 for safety.
6. Remove or secure anything that might get caught in moving machinery.
Rings, necklaces, long hair and loose clothes that get caught in tools can drag you along.
7. Keep your hands away from sharp tools. Make sure that nothing that you do will cause you to
be cut.
8. Dust, chemicals and smoke can be dangerous – work in well-ventilated areas, Minimize
contamination and use appropriate protective equipment. The safety equipment cabinet is on the
patio.
9. If you’re unsure about the safe operation of a tool or any aspect of a job – ask for help! Have
shop staff check you out on a tool the first time you use one with which you are unfamiliar.
10. Clean up after yourself. Before you leave the shop each day all tools must be returned to the
toolbox, the machine cleaned and wiped down and the floor swept. Leave 10-15 minutes for
cleanup.
 1.5 SHOP SAFETY HANDOUT:

Information about the Shop, the Student Machine Shop is available to all College of Engineering
students, staff and faculty working on University projects. Everyone must read this safety
handout and pass a safety test before using the tools in the shop. The goal of this handout is to
summarize the risks that are inherent in metalworking and to provide some guidelines for
working safely. It is not intended to be a machining training manual. There are several good
books in the library and references on the web. The first step in preventing personal injury or
machine damage is to make sure that you know how to operate the equipment you will be using
correctly. If you are unsure – ask!
Because it is a communal area, used by so many people, it is important to keep the shop clean
and orderly. This means that every user must clean the machines and work areas they use, and
put away all tools and material before leaving the shop. In attention, hurried work, horseplay, bad
judgment, fatigue, improper clothing, defective tools, and poorly secured workpieces cause most
accidents. Avoid accidents by following all of the rules in this handout and asking for help if you
are unsure about the safest approach. Disregarding shop rules, working unsafely or leaving a
mess will result in suspension of shop privileges. These rules apply to the entire shop area
including the patio and student project work room.

1.6 SAFE DISTANCE SAFEGUARDING:

Make sure employees position themselves no closer than necessary and never closer than 4
inches from the power press brake point of operation. Develop, document, and use an effective
safe distance safeguarding program. Include methods for maintaining the minimum safe distance
requirements in, Follow this requirement when using safe distance safeguarding.

Follow these requirements for safe distance training for press brakes

1) Train your employees in the safe distance safeguarding program and include all of the
following:

➢ The need for safety awareness between the power press brake operator and, when required, the
helper.

➢ The purpose and function of operating controls, operating mode controls, die space height
adjustment positions, and other brake controls.

➢ The hazards of placing any parts of the body into the point of operation.
➢ The hazards related to each specific work piece bending operation.
➢ The purpose and function of hand-feeding tools.
➢ The dangers of unsafe work practices, inattention, horseplay, and misuse of equipment.
➢ The importance of reporting unsafe conditions immediately to the supervisor.

2) Make sure employees are proficient in safe distance safeguarding after training, and
follow both:

➢ Safe-operating instructions and recommendations of power press brake manufacturers.

➢ Industry-recognized safe working practices for power press brakes.

Provide auxiliary safety aids on press brakes

This rule applies if the safeguarding method prevents the operator from holding the workpiece
during the closing of the stroke.
Provide one of the following auxiliary safety aids that will allow operators to remove their hands
from the work during the closing of the stroke:
➢ Work supporting devices
➢ Magnetic material-position gages

Safeguard at the point of operation on press brakes

➢ Safeguard the point of operation on press brakes by at least one of the following:
– Physical guards
– Devices
– ¼ inch maximum die opening
– Safe Distance safeguarding, if all of the following apply:
➢ Physical barriers and devices such as two-hand controls, holdouts, restraints, and presence
sensors, are demonstrated to not be feasible.
➢ This safeguarding method is only for one-time fabrication, custom-made parts, or small quantity
runs of no more than 4 hours per month.
➢ A safety program is provided that includes safe work procedures, training, and supervision to
make sure work is performed using safe distance measures.
➢ There is no workplace record of injuries from failing to maintain a safe distance.

Conduct periodic safe distance inspections on press brakes

1) Conduct periodic inspections of safe distance procedures at least annually to make sure that
established procedures are being followed.
2) Make sure inspections are performed by a trained person who is not the person using the safe
distance procedure.
3) You must identify all of the following during safe distance procedure inspections:

➢ The date of the inspection.

➢ The person performing the inspection.
➢ The power press brake for which you are using the procedures.
➢ Any deviations or inadequacies with procedures and requirements.
➢ Joint reviews with each trained employee about their responsibilities under the safe distance
program.

Supervise the safe distance program for press brakes

• Provide adequate supervision to make sure that:
– Only trained employees operate power press brakes
– Employees use work practices learned in your training program
– Periodic safe distance inspections are conducted as outlined in, Conduct periodic safe distance
inspections on press brakes,
– Any deviations from, or inadequacies in, program procedures or work practices are promptly
corrected
– Designated safeguarding means are used, installed, and functioning properly
– Recommended hand-feeding tools are used, when needed
– To require retraining and other appropriate corrective action when necessary.

2. CONSTRUCTION

Pneumatic systems have much in common. They transmit energy from on energy generating
source to on energy used area. All pneumatic or hydraulic systems depends on Pascal’s law
named afta braised Pascal. This low state that pressurized fluid within a closed container such as
cylinder or pipe. Exerts equal force on all of the surfaces of the container. In pneumatic system,
there is on air is used in industrial pneumatic systems. This air includes many other properties of
fluid. The primary purpose of pneumatic system is to transmit energy from one location to
another.
In our project there is metal frame body on which pneumatic system is mounted, pneumatic
system is operated by 5 by 2 hand operated value. The pistons are work as same as punch & die
m/c multipurpose means we can provide certain arrangement as tat it performs different
operation. When we work with different parts of a fluid power system you will meet the various
units of measurement are those applying to pressure flow rate, area, temp, viscosity etc. since
these systems are used worldwide. Air, which is often used as pneumatic / working media, will
be compressed 1-2 percent of its entire volume when pressure of 300 psi is applied on air. In high
pressure system design compressibility of air may be particularly important where
compressibility of the fluid will affect the system operation & on efficiency of machine.
In our project, work table is most important port on which much more load is applied. So first
preference is goes to worktable its strength & toughness is more important. Pneumatic system
controls & circuiting shall be manufactured by the pneumatic parts manufacture & shall be
installed to provide the piston cylinder is specified. There is on manual control stations &
necessary control transformer shall be installed as specified under the applicable section. Manual
control stations shall provide hand operated control for reciprocating operation & a toggle switch
to override normal operating control & immediately shut off for emergency. As a corollary to the
foregoing object, it is an important aim of this invention to provide such a system that is
pneumatically operated & which opens or closes a series of pathways associated with
longitudinally spaced orifices along length of pipe from which operating actually perform.
The whole assembly is constructed step by step. Firstly the base or bed is tightly pitted by nuts &
bolts. The base part is necessary tight & fit to floor because our machine generates more & more
vibration at the time of operation. Construction is as same as drop forging machine but in our
machine we use punch & die operation. So it is also called press machine. Piston cylinder
arrangement is double acting pistons. The next major advance in high pressure compressed air
was used of double acting piston. In simple acting high pressure engine above, the cylinder is
vertical & the piston returns to the start or bottom of the stroke by gravity or forces applied. In
the double acting piston compressed air is admitted alternatively to each side of the piston while
the other is exhausting. This requires in let & exhaust parts at either end of the cylinder with flow
being control values.

This system increases the speed & smoothness of the reciprocation & allows the cylinder to be
mounted vertically. Power is transmitted from the piston by sliding rod scaled to the cylinder to
prevent the escape of air which in turn drives a connecting rod via a sliding crosshead. Then we
assemble our accident avoiding system is front side of machine with using another pneumatic
piston.

3. WORKING
The aim of the making this project is a control algorithm & system for static transmission for on
optimum tradeoff between stability & performance. The complexity of this particular static
transmission has required in depth analysis firstly in term of linear study completed by a non
linear study of the transmission components. The result of our modeling & simulation is a deeper
understanding of the systems behaviors. As name implies our machine can’t work step by step
but produce a product step by step.
The piston cylinder arrangement is as shown in fig. is operates as male system & raw material is
worked as female part.

The device is entirely pneumatic. The piston displacement opens up orifices piloting a value
which controls the piston. Before working, we see the control value. As per considering the
experience, in terms of the quality & quantity of the phenomenon to be found in the fluid power
control devices. 5/2 control value is mostly used for piston operation it has in two types. .i.e.
hydraulic operated and pneumatic operated. This value is allowed to provide air way as
considering piston operation is required.

The operation is trouble free due to better construction material of the components of the
components & their metallurgical material. There is in pneumatic operation there is as some as
press working. The lower part of a press from that acts as a table to which bluster plate is in thick
plate attached to the press bed & it is used for locating & supporting dia assembly. The female
part of a complete tool for producing work in press is called bed. The bolster plate is in thick
plate attached to the press bed & it is used for locating & supporting the assembly. A unit
assembly which incorporates a low & upper short, two or more guide parts & guidepost
bushings. The female part of a complete tool for producing work in press is called ‘ Die’ & a
plate which contains a die cavity is called die block. The male component of the die assembly
which is directly or indirectly moved & attached to the press ram is called punch. The lower shoe
or die holder is mounted on bluster plate. The die block is mounted on the low shoe & also the
guide posts are mounted on it. The upper part of the die set which contains guidepost busing is
called upper shoe. Clearance is necessary so that the punch can enter the die.
In our project we can use various types of dies are used. Compound dies, combination dies