The Importance of Machine Guarding

Machine guarding is essential in environments where heavy machinery, high-speed equipment, and hazardous tools are used. According to the Occupational Safety and Health Administration (OSHA), machine-related injuries account for a substantial percentage of workplace accidents. Common incidents include entanglement, crushing, cutting, and even fatal injuries caused by moving parts.

Effective machine guarding mitigates these risks by providing a physical barrier between workers and hazardous components such as blades, gears, and belts. It also prevents debris and materials from being ejected during operation, protecting nearby personnel. Beyond physical safety, well-maintained guarding reduces liability and demonstrates a company’s commitment to employee welfare.

Types of Machine Guards

There are several types of machine guards, each tailored to specific applications and equipment:

• Fixed Guards: Permanent barriers that provide robust protection against moving parts. Commonly used on conveyors, gears, and cutting tools, these guards are simple, reliable, and cost-effective.
• Interlocked Guards: Equipped with sensors that shut down machinery when the guard is removed or tampered with. This ensures that workers cannot access hazardous areas during operation.
• Adjustable Guards: Flexible solutions designed for machines that require frequent adjustments. These guards can be repositioned to accommodate various tasks without compromising safety.
• Self-Adjusting Guards: Often found on woodworking equipment, these guards adjust automatically based on the size of the material being processed, maintaining a consistent barrier.

Machine Guarding Standards and Compliance

Compliance with safety standards is not optional; it’s a legal requirement. OSHA outlines specific regulations for machine guarding under standard 1910.212, which mandates that moving parts must be shielded to prevent injury. Additional guidelines from organizations such as the American National Standards Institute (ANSI) and the International Organization for Standardization (ISO) provide detailed specifications for guard design and implementation.

Failing to meet these standards can result in significant penalties and, more critically, endanger the lives of workers. Regular audits, inspections, and employee training are essential to ensure compliance and maintain a safe working environment.

Innovations in Machine Guarding

The evolution of technology has introduced innovative solutions in machine guarding, enhancing both functionality and usability. Modern guards now integrate advanced materials, ergonomic designs, and automation for improved efficiency and worker convenience.

• Smart Guarding Systems: Equipped with sensors and IoT capabilities, these systems monitor machinery in real time, providing alerts for potential hazards and maintenance needs.
• Transparent Guards: Made from durable, shatter-resistant materials like polycarbonate, these guards allow operators to visually monitor machine operations without compromising safety.
• Ergonomic Designs: Guards are increasingly designed with user comfort in mind, reducing physical strain during operation and maintenance.

Benefits Beyond Safety

While the primary purpose of machine guarding is to protect workers, its benefits extend far beyond safety. By minimizing accidents and downtime, guarding systems contribute to increased productivity and cost savings. Efficiently guarded machines experience less wear and tear, reducing maintenance needs and extending equipment lifespan.

Moreover, a strong safety record enhances a company’s reputation, attracting skilled workers and fostering trust among clients and stakeholders. Investing in high-quality guarding systems is not just a regulatory necessity; it’s a strategic business decision.

Implementing Effective Machine Guarding

Implementing an effective machine guarding program requires a comprehensive approach:

• Hazard Assessment: Identify potential hazards associated with machinery and prioritize areas requiring immediate attention.
• Guard Selection: Choose appropriate guarding solutions based on machine type, operational requirements, and worker interaction.
• Training and Awareness: Educate employees on the importance of machine guarding, proper usage, and reporting procedures for damaged or missing guards.
• Regular Maintenance: Inspect and maintain guards regularly to ensure they remain functional and compliant with safety standards.
• Continuous Improvement: Stay updated on technological advancements and regulatory changes to enhance your guarding systems over time.

Conclusion

Machine guarding is an indispensable element of workplace safety, protecting workers from harm while boosting operational efficiency. As industries continue to adopt advanced technologies, the integration of innovative guarding solutions ensures that safety standards evolve alongside progress. By prioritizing safety through effective machine guarding, businesses can create secure, productive environments where employees thrive.

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Regular preventive maintenance (PM) on forging equipment offers additional benefits. Ensuring the machinery operates without unforeseen failures or malfunctions reduces maintenance needs and lowers repair costs. Furthermore, it decreases the likelihood of producing defective or substandard products. Safety is also improved by minimizing potential hazards and reducing the risk of injuries.

Although many forgers follow routine maintenance guidelines, most continue production until the equipment breaks down. Given the longevity of certain forging machines in operation since the 1950s and 60s, technicians may lack the knowledge required to troubleshoot problems or recognize worn or failing components, which increases the risk of a major breakdown. Studies have shown that the cost of unplanned maintenance can be three times higher than planned maintenance.

“The purpose of a systematic preventative maintenance program is to identify and address potential issues before they escalate. PM is designed to optimize machine reliability and performance while saving costs over time by avoiding serious breakdowns,” says Bill Goodwin, Vice President of Sales and Engineering Ajax/CECO/Erie Press (ACE), the largest forging equipment supplier in North America.

Traditionally, PM is performed by facility personnel who conduct routine inspections, maintenance, and repairs on assets to ensure that they are functioning properly. However, a growing number of forgers are discovering the value of partnering with equipment OEMs for customizable PM programs that incorporate the industry’s best proactive maintenance practices.

“In essence, the OEM becomes an extension of the forger’s maintenance team through best practice PM, proactive training, and even spare parts programs. The goal is to customize the program to fit within the budget and provide as much, or as little, support as needed,” says Goodwin. ACE, with 145 years of experience in equipment manufacturing and more than 300 years of combined forging knowledge, is the longest-running, most experienced forging company in the world. The OEM provides a comprehensive array of forging equipment including upsetters, presses, programmable hammers, forging rolls, and automation solutions for various forging materials such as carbon steels, aluminum, titanium, and super alloys.

The Importance of Forging Equipment PM

Today, ACE is offering the most comprehensive preventative maintenance program in the forming and forging industry. The customized program not only includes training activities and scheduled replacement of consumables, but also develops repeatable maintenance tasks and follows PM best practices for forging and forming equipment.

In this program, the OEM first conducts a preliminary review of any existing PM program documentation of what is currently performed. This includes the life cycle of frequently replaced parts.

Next, the OEM conducts a “health check” to determine the equipment’s current condition, running clearance, electrical system, and pump performance. Based on the results of the health check, the OEM recommends corrective actions to restore the equipment to its original specifications.

ACE is in a unique position to utilize the full documentation of equipment in its broad portfolio of brands, along with extensive maintenance and repair experience accumulated over many decades. With its core brands founded in the 1800s, the company offers a full line of products, including standard mechanical forging presses, upset forging machines, forging rolls, hydraulic forging, forming, compression molding, cold extrusion, compaction, and roll ring preform presses along with stretch forming and straightening machines, solid die forgers, trim presses, programmable die forgers, and custom-engineered hydraulic presses.

In the next step, a customized preventive maintenance program is created. This can vary, but typically involves following best practices for lubrication; daily visual inspections for signs of wear, leaks, or damage; listening for abnormal vibrations/noises when equipment is running that can indicate underlying issues; monitoring the presence of dirt or other foreign particles that can deteriorate the machinery’s efficiency; regular calibration to avoid misalignment or imbalanced equipment; and documenting all checks, observations, and maintenance tasks performed.

Goodwin stresses that the extent of the PM program is based on factors such as the type of equipment, production, onsite support, and desired PM intervals. “It can be scaled up or down to take into account the maintenance team’s experience, availability, and turnover,” he says.

Although PM is typically performed on-site, some actions can be completed remotely. ACE utilizes advanced collaboration tools and real-time video communications to connect with technicians so each can see, discuss, annotate, and resolve many situations at hand.

Spare Parts Programs to Minimize Downtime

Ensuring smooth operations goes beyond just the maintenance of forging equipment. It also entails having essential spare parts available at a moment’s notice to minimize production downtime.

Consequently, the PM program can also include a separate spare parts stocking program that anticipates expected maintenance requirements. By utilizing measurable production rates, ACE can proactively schedule service and replacement of critical parts through an online portal. Potential critical failures can be identified and addressed before occurring.

To ensure the highest production uptime of forging equipment and prevent lengthy unexpected downtime, the stocking program typically not only includes consumables but also essential parts that can traditionally have very long lead times.

“Common consumables include friction plates and driving plates for presses and upsetters, or piston heads, rods, rings, and packings for hammers. However, it is even more important to stock main gears, eccentric shafts, and rams to avoid long lead times for replacement,” says Goodwin.

According to Goodwin, with the parts stocking program the forger only pays a percentage of the cost up front and the balance when they take possession of the part – up to 2 years later. With minimal up-front investment, the custom stocking program can eliminate many months of downtime waiting on long lead time parts. Express shipping costs are also eliminated since parts are readily available.

Even though the high impact nature of forging will eventually take its toll, with proper PM the equipment can be kept productive for many decades, and potentially for the better part of a century.

“Ensuring proper PM is not merely a task, but an investment in the longevity of your forging equipment, the quality of your products, and the productivity and safety of your workforce. By implementing a proactive PM program, manufacturers can position themselves to reap the maximum benefits from their equipment for decades to come,” concludes Goodwin.

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Why OSHA Inspections Matter

OSHA is dedicated to maintaining safe workplaces, and inspections play a vital role in enforcing this mission. Companies in high-risk industries, those with recent complaints, or workplaces where severe injuries have occurred are among those most likely to face an OSHA inspection. Beyond the immediate implications of an inspection, keeping workplaces in compliance with OSHA standards significantly reduces the likelihood of injuries, improves morale, and even enhances productivity.

Preparation Is Key: Laying the Groundwork for a Successful Inspection

Review and Organize Documentation A well-maintained record of safety documentation is the foundation of a strong inspection process. OSHA mandates that employers keep accurate records of workplace injuries and illnesses, including OSHA 300, 301, and 300A forms. Ensuring these documents are current, accurate, and easily accessible demonstrates a commitment to compliance and can make a positive impression on inspectors.

Ensure Training Compliance Safety training, especially on OSHA-regulated topics like hazard communication and personal protective equipment (PPE), is essential. Keep a log of training records that includes dates, employee names, and the content covered. OSHA inspectors will assess these records to verify that training is thorough and frequent enough to mitigate known risks effectively.

Conduct Routine Safety Audits Regular safety audits offer insights into potential hazards and ensure that corrective measures are taken before they escalate. Forming a safety committee or assigning a safety officer to oversee these audits can foster a culture of proactive safety management. Documenting these audits and their findings is equally important, as OSHA inspectors may review these records as part of their evaluation.

Prepare for the Inspection with Mock Walkthroughs Conducting a mock OSHA inspection can identify areas for improvement and highlight any gaps in safety practices. This exercise not only ensures compliance but also familiarizes team members with the inspection process, minimizing stress when an actual inspection occurs.

Understanding the Inspection Process

When an OSHA Compliance Safety and Health Officer (CSHO) arrives for an inspection, they will typically begin with an Opening Conference. In this phase, the CSHO explains the purpose of the visit, which may be scheduled or unannounced, depending on the circumstances. For instance, inspections related to severe incidents or imminent dangers are often unscheduled to capture real-time practices.

Request Identification and Verify the Scope of the Inspection Politely ask the CSHO for identification and ensure their credentials are in order. Once identification is confirmed, clarify the inspection scope, as some inspections may focus on specific hazards, while others may be comprehensive. Designating a company representative to handle communications with the inspector helps maintain organization and control over the inspection process.

Define Internal Roles and Responsibilities Assigning specific roles—such as a point person to accompany the inspector and a record-keeper to document the inspection process—helps ensure that key aspects of the inspection are handled promptly and accurately.

The Walkaround: Ensuring Compliance in Real Time

During the Walkaround Inspection, the CSHO will tour the facility, inspecting specific areas, equipment, and work practices. This stage is critical, as it provides the most direct insight into OSHA’s evaluation of your workplace.

Document the Inspector’s Movements and Observations During the walkaround, your designated company representative should take detailed notes on every area inspected, equipment observed, and any specific safety practices noted by the inspector. Photos can also be valuable for your records, particularly if the inspector highlights areas of concern.

Display Normal Working Conditions Ensure that work operations during the inspection reflect typical conditions rather than adjusting or halting activities. This approach demonstrates transparency and adherence to safety standards as they are practiced day-to-day, which can work to your advantage.

Limit Access to Confidential Areas OSHA allows employers to mark certain areas as confidential if they contain sensitive information or trade secrets. Discuss these designations in advance and inform the inspector of any restrictions, while still accommodating the needs of the inspection.

Handle Employee and Management Interviews with Care Inspectors often interview employees during the inspection process. To facilitate these interviews:

• Educate Employees on Their Rights: Inform employees that they have the right to request a representative, refuse recording, and answer questions without speculation. These interviews offer employees a chance to share their experiences openly, and educating them about the process beforehand can promote a constructive atmosphere.
• Debrief After Interviews: After the interviews, consider holding a brief meeting with employees to review topics discussed, which helps maintain alignment across safety practices.

Addressing Findings in the Closing Conference

Following the walkaround, the inspection concludes with a Closing Conference. During this phase, the CSHO will discuss any preliminary findings, answer questions, and clarify possible violations.

Seek Clarification on Any Observations or Citations It’s essential to ask questions and fully understand any citations, associated standards, and the nature of identified issues. Taking detailed notes during the conference will be valuable if further action is required.

Request Additional Time for Follow-Up If the inspector requires additional documentation or corrective actions, confirm a timeline for follow-up. This request provides a clear path for remedying concerns and completing outstanding requirements.

Post-Inspection: Follow-Up and Record-Keeping

Once an inspection concludes and any citations have been issued, OSHA requires employers to post citations in a visible area within the workplace for at least three days or until the cited issue is corrected. This posting period offers transparency and helps reinforce accountability.

Establish a Corrective Action Plan For citations that require action, creating a corrective plan with clear timelines, assigned responsibilities, and specific steps can ensure timely completion. Document every step taken to remedy each issue, as this information may be reviewed in future inspections.

Document All Follow-Up Actions Each action taken should be documented and stored for future reference. A comprehensive record not only aids in verifying compliance for future inspections but also supports continuous improvement in safety practices.

Maintain an Ongoing Compliance Program Implementing an ongoing compliance program ensures long-term adherence to OSHA standards. Regularly reviewing safety protocols, updating training programs, and conducting frequent audits are key to maintaining a safe work environment. For companies facing recurrent inspections or those in high-risk industries, such measures can significantly reduce the likelihood of future citations.

Leveraging Technology for Compliance Management

Digital tools can streamline OSHA compliance by centralizing safety documentation, tracking audits, and simplifying incident reporting. Companies like VelocityEHS offer solutions that help automate many compliance-related tasks, enabling efficient management of safety protocols and providing real-time data insights. Solutions like VelocityEHS not only support compliance but also empower employers to proactively address safety issues before they result in incidents or penalties.

In Summary

Successfully navigating an OSHA inspection comes down to thorough preparation, clear communication, and responsive follow-up. By maintaining up-to-date documentation, conducting regular audits, and fostering a culture of safety, organizations can minimize disruptions from inspections and focus on long-term improvement. Every step taken toward compliance is also a step toward a safer, more efficient, and productive workplace.

The post Navigating OSHA Inspections: Your Guide to Safety and Compliance Success appeared first on IndMacDig | Industrial Machinery Digest.

Specifically, combining lasers and advanced robotics within enclosed workcells enables operators to efficiently and repeatedly clean components of different sizes, shapes, and materials on a level previously unattainable through manual methods.

“Automated laser cleaning systems are designed to cost-effectively clean high volumes of even the largest format parts and equipment and can be tailored to suit the size and complexity of the parts, while eliminating concerns over operator safety,” says Wayne Tupuola, CEO, Orlando, Florida-based Laser Photonics (NASDAQ: LASE), a leading global industrial developer of laser systems for cleaning and other material processing applications.

Industrial manufacturers frequently need to remove corrosion, grease, residue, and old coatings, or roughen the surface of metals prior to coating components and equipment. At times, contaminants or toxic substances need to be eliminated before further processing.

The challenge is that conventional methods like sandblasting, dry ice blasting, and chemical stripping are messy, time and labor intensive including preparation and cleanup, and require costly consumables. These methods can also pose risks to applicators and the environment so are scrutinized by regulators like OSHA and EPA.

As a much more efficient alternative, a laser cleaning robotic workcell usually consists of at least one laser-wielding robot, controllers, and safety equipment in a custom, see-through enclosure. These collaborative robots, or cobots, excel at tasks like the laser cleaning of parts which involve repetition, freeing up employees to work on other activities.

The CleanTech Robotic Cell from Laser Photonics, for example, utilizes a robotic arm that holds a “laser gun” with cleaning, roughening, and finishing capabilities. The robotic arm is programmable via a tablet/controller where the operator would input the coordinates for material processing. The cleaning laser can be replaced with a welding or cutting laser. If required, the workcell can be split into two sections – the robot cleans on one side, while an operator installs a part to be cleaned on the other side.

“The operator can lay out several components for cleaning over the flatbed, set the cleaning coordinates, and leave the robot processing,” explains Tupuola.

He points to advancements in laser technology that complement and expedite the efficient cleaning of such shapes.

“Dual axis laser technology enables the cleaning of target areas more effectively and quickly if they are complex and uneven,” adds Tupuola. “Plus, our proprietary technologies allow the laser to move in various directions and clean hard-to-reach areas.”

Manufacturers of larger format components can find useful laser systems like Laser Photonics’ CleanTech Titan FX, which offers up to a 6’ x 12’ work envelope for automated laser cleaning, rust removal, and surface conditioning. This industrial, turnkey laser cleaning giant can operate as a standalone unit or be easily integrated into a production line environment.

“Large format automated laser cleaning systems can expedite the processing of [applications like] automotive tire rims, molds, oil and gas flanges, or even sheets for the hull of a ship or other vessel,” says Tupuola. He notes that the size and configuration of the enclosures can be customized to accommodate the size and nature of the parts that require cleaning, with the lasers operating at a range of power levels.

Another significant benefit to such automation is improved operator and environment safety.

“For extra safety, our custom-tailored automated laser systems are enclosed in a Class I safety workcell. We can also integrate dust and residue collection, as well as a fume extractor that captures vapors during the cleaning of toxic substances,” says Tupuola.

This type of advanced laser cleaning equipment is designed to accommodate rigorous safety regulations. As an example, Laser Photonics’ CleanTech systems can help businesses achieve compliance with OSHA regulations and make environmentally responsible decisions in accordance with EPA’s waste management guidelines.

Abrasive sandblasting involves forcefully projecting a stream of abrasive particles onto a surface, usually with compressed air or steam. The silica sand used in abrasive blasting typically fractures into fine particles and becomes airborne, which can cause serious or fatal respiratory disease. Particles from the coatings, plating, anodizing, corrosion, and even lead paint being removed can also be inhaled. To avoid breathing in particulates, operators must wear full HEPA suits when sandblasting.

With chemical stripping, harsh chemicals are used to strip metal-based objects of paint, rust, and other contaminants to bare metal – potentially exposing operators to corrosive acids and noxious chemical fumes. In addition, disposing of toxic chemicals is costly and closely regulated. Laser cleaning seeks to solve or minimize these issues.

Unlike conventional methods, the laser cleaning systems require no consumables other than electric power, minimal labor, and minimal maintenance. The longevity and low-maintenance design of these industrial-grade robotic laser cleaning systems further adds to their value, increasing ROI, and making replacement unnecessary for decades.

Programming the laser ablation procedure with a cobot workcell can be accomplished with a touchscreen. Generally, programming includes setting coordinates for the sample, ablation pattern, power output, and cleaning speed, according to Tupuola.

“Installation and programming are needed, but once it’s set up, robotic cell cleaning is fast, precise, thorough, and controlled. So, it’s a very convenient, optimized process if the parts being cleaned are the same,” says Tupuola.

Tupuola adds that Laser Photonics is now working on integrating 3D scanners into the robotic workcell. This would automate the focusing of the laser and eliminate some of the programming now done by an operator.

While precision laser-based systems have been effectively used to remove rust, residues, contaminants, and paint, this approach commonly involves manual labor. Automated robotic laser cleaning systems provide manufacturers safer, easier, more eco-friendly options.

To meet demand more efficiently, a growing number of manufacturers across a wide range of industries will increasingly turn to these laser systems to cost-effectively clean higher volumes of components with the control and speed required for decades to come.

About the Author

Del Williams is a technical writer based in Torrance, California.

The post Advanced Laser Cleaning Robotic Workcells Turbocharge Industrial Processes appeared first on IndMacDig | Industrial Machinery Digest.

The Hidden Dangers of Metalworking Fluids

Metalworking fluids are vital in reducing heat and friction during machining processes. However, they are also prone to contamination by microorganisms such as bacteria and fungi, which can lead to biofilm formation. These contaminants not only degrade the quality of the fluid but also pose severe health risks to workers. Exposure to contaminated MWFs can cause a range of health issues, including dermatitis, respiratory problems, and even more severe conditions like sepsis or chronic lung diseases.

Additionally, the presence of biological contaminants can lead to unpleasant odors, making the work environment uncomfortable and potentially hazardous. Traditional methods of managing these fluids often involve the use of harsh chemicals or frequent fluid replacement, both of which have their drawbacks, including increased costs, environmental impact, and potential safety risks associated with handling chemicals.

A New Era in Safety: The SUVOS BioCleanse Solution

Enter Bolb’s SUVOS BioCleanse UVC module, a cutting-edge solution designed to tackle the issues associated with MWF contamination head-on. The SUVOS BioCleanse leverages UV-C LED technology to deactivate or eliminate biological contaminants present in MWFs, thus extending the life of these fluids while simultaneously enhancing worker safety.

The technology works by emitting UVC light, which breaks down the DNA and RNA of harmful microorganisms, effectively stopping their growth and reducing the risk of contamination. This process not only keeps the fluids cleaner for longer periods but also helps in maintaining the pH balance, which is crucial for preventing corrosion and maintaining the effectiveness of the MWFs.

Safety and Cost-Effectiveness: A Dual Benefit

The implementation of SUVOS BioCleanse offers a dual advantage: improving safety while reducing costs. According to early adopters like T&K Machine, the technology has revolutionized their CNC machine maintenance processes. By eliminating the need for constant maintenance and fluid replacement, companies have reported significant savings—up to $2,000 per machine per year. This reduction in downtime, labor, and disposal costs adds up quickly, making it a financially sound investment.

But the benefits extend far beyond cost savings. By maintaining cleaner fluids, the risk of worker exposure to harmful contaminants is drastically reduced, leading to a safer and more comfortable working environment. This is particularly important in industries where compliance with safety standards is not just a matter of regulatory obligation but a core component of operational excellence.

Case Study: Implementing SUVOS BioCleanse in Real-World Settings

T&K Machine’s experience with SUVOS BioCleanse underscores its effectiveness. By incorporating this technology into their MWF management system, they have not only improved the quality of their cutting and cooling processes but also enhanced overall workplace safety. The technology’s ability to extend the life of MWFs from weeks to months without the need for chemical additives or frequent replacements highlights its potential to transform the industry.

Moreover, the use of SUVOS in centralized treatment systems capable of handling large volumes of MWFs has shown that even in high-capacity environments, the technology remains efficient and effective. The reduction in odors, the elimination of harmful biological hazards, and the overall improvement in the working environment make SUVOS BioCleanse a valuable addition to any metalworking operation.

Looking Ahead: The Future of MWF Management and Workplace Safety

As industries continue to prioritize both efficiency and safety, innovations like SUVOS BioCleanse are likely to become standard practice. The integration of such technologies into the broader framework of workplace safety not only protects workers but also enhances operational efficiency and reduces environmental impact.

For companies looking to improve their safety standards and operational efficiency, investing in advanced MWF management solutions like SUVOS BioCleanse offers a clear path forward. As the technology becomes more widely adopted, we can expect to see a significant reduction in the health risks associated with metalworking, alongside increased productivity and cost savings.

The adoption of Bolb’s SUVOS BioCleanse technology marks a significant step forward in the quest for safer, more efficient metalworking environments. By addressing the challenges posed by MWF contamination with innovative UVC technology, industries can protect their most valuable assets—their workers—while also enhancing their bottom line.

As the technology becomes more widely adopted, we can expect to see a significant reduction in the health risks associated with metalworking, alongside increased productivity and cost savings.

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Given the massive industrial outlay, proactively controlling corrosion is imperative and can have an equally impressive ROI.

“By using available corrosion control practices, it is estimated that savings of between 15 and 35% of the cost of corrosion could be realized, i.e., between US$375 and $875 billion annually on a global basis…The fact that corrosion control provides a cost benefit is a lesson learned over and over again by industry, often too late and following catastrophic events,” continues the NACE International IMPACT study.

However, traditional methods of removing corrosion can be messy, laborious, time consuming, and can even pose serious health hazards.

Today, one of the easiest to use and most effective alternatives in the war against corrosion is the increasingly important category of industrial-grade, clean technology lasers.

With this approach, precision laser-based systems are used to remove corrosion, contaminants, paint, and residues with a high-energy laser beam that leaves the substrate unaffected. Preparation and cleanup time are minimal, and the low-maintenance equipment can last decades. The technology minimizes operator exposure to potential environmental health hazards. In addition, no consumables are necessary.

Corrosion and the Limits of Conventional Control

Any industry with metal infrastructure, processing equipment, or products exposed to water, fluids, moisture, or atmospheric humidity continually fights corrosion, which causes the deterioration and loss of a material and its critical properties due to chemical, electrochemical reactions of the exposed surface with the surrounding environment. Corrosion affects the microstructure, mechanical properties, and physical appearance of the materials.

The direct cost of corrosion includes a loss of materials, equipment, and production, plus the cost of repair, maintenance, and replacement. Additional losses can result from accidents, injuries, and even loss of life as well as payments to repair environmental damage.

Within the continual struggle against industrial corrosion, one important niche area of corrosion control involves the pretreating of metal surfaces to remove corrosion and contaminants before coating or welding.

Although metal surface pretreatment is a small portion of industrial corrosion control, it is crucial to ensure the safety, performance, and longevity of products and structures.

Insufficient coating pretreatment can lead to inadequate protection from the environment, leading to potential coating failure, moisture entry, and accelerated corrosion as well as increased maintenance, early replacement, and warranty issues. Similarly, insufficient weld pretreatment to remove corrosion and contaminants can lead to weakened or failed welds and necessary rework as well as substantial safety, liability, and litigation risk.

A More Effective Weapon to Eliminate Corrosion

In many industries, it is necessary to remove corrosion, residue, oil, grease, or paint before coating a product or infrastructure to improve coating adhesion.

Toward this end, laser-based systems have significant advantages over traditional methods, starting with ease of use.

“With laser-based systems, an operator simply points and clicks a high-energy laser beam at the surface. The substrate is not affected by the laser, and the systems do not create any mess or byproducts. The approach is eco-friendly, energy-efficient, and completes the job in approximately half the time of traditional methods when preparation and cleanup are considered. Also, no consumables are required,” says Wayne Tupuola, CEO, Orlando, Florida-based Laser Photonics, a leading provider of patented industrial grade CleanTech® lasers for cleaning and surface conditioning. The company’s systems function either as mobile standalone units or can be integrated into production lines.

In the case of Laser Photonics, the laser systems are available in portable and stationary models ranging from 50 to 3,000-watts (a 4,000-watt version is in development) with chamber sizes from 3’ x 3’ in size to 6’ x 12’. The systems can also be installed in manufacturing lines in cabinets or operated by a robotic arm.

In industry, the laser pre-treatment of metal surfaces can be used to streamline various manufacturing processes. For instance, it has been used to remove rust from hundreds of automotive transmissions per day. It has also been utilized to eliminate corrosion from conveying system components.

The CleanTech lasers are also used to refurbish industrial infrastructure, such as when removing a previous coating along with any corrosion to facilitate the new coating’s adhesion to the surface.

Another common laser application involves pre-weld treatment to remove corrosion, mill scale, residue, and any impurities on the surface of the base material that would compromise the weld’s effectiveness. It is essential to avoid any such contamination on a weld’s surface, which could otherwise lead to a weakening of the weld’s mechanical properties, requiring rework.

Laser treatment is also used for post-weld cleaning to increase the life expectancy and corrosion resistance of a welded joint. Post-weld cleaning is important for stainless steel as well. Welding can cause a “heat tint,” a discolored, thickened top layer on the stainless steel around the weld bead within the heat affected zone that compromises corrosion resistance. Removing the heat tinted top layer is necessary to restore stainless steel’s full corrosion resistance and aesthetic value.

A further benefit of the laser systems is that some of the most advanced units are designed to last for decades. For example, CleanTech laser systems can last for 50,000 to 100,000 hours. In addition, virtually no maintenance is needed after purchase and no consumables are required.

Given the devastating cost of corrosion to industry and the inherent limitations of typical control methods, lasers are becoming a best practice technique to combat it in facilities and in the field. Laser treatment effectively removes corrosion for many industrial applications, minimizes cleanup time and operator exposure to potential environmental health hazards, lasts for decades, and requires no consumables.

For more information on laser cleaning solutions for surface preparation, contact Laser Photonics at (407) 804-1000 or visit www.laserphotonics.com.

About the Author

Del Williams is a technical writer based in Torrance, California.

The post In War Against Industrial Corrosion, Clean Lasers Prove Very Effective appeared first on IndMacDig | Industrial Machinery Digest.

The design of these canopy hoods prioritizes both safety and functionality. Optional side panels prevent cross drafts and further improve airflow while providing a way to contain chemical spills. This feature is crucial in preventing the spread of hazardous substances, thereby protecting workers and maintaining a safe working environment. The lightweight construction of the hoods makes them easy to install and adjust, allowing for flexible use in various laboratory and industrial settings.

One of the key benefits of these canopy hoods is their ability to enhance workplace safety by effectively managing hazardous fumes and vapors. The chemical-resistant materials used in their construction ensure that the hoods can withstand exposure to aggressive substances without degrading or compromising their protective properties. This durability is critical in environments where chemical spills and vapor release are common, as it helps maintain a safe and healthy work environment.

The Island Canopy Hoods can be customized with additional features such as integrated lighting and monitoring systems. These enhancements provide users with a comprehensive solution for managing air quality and safety. By improving ventilation and reducing the risk of exposure to harmful substances, these hoods play a vital role in maintaining a safe and productive work environment.

HEMCO Rust Proof Chemical Resistant Island Canopy Hoods are an invaluable addition to any industrial or laboratory setting where hazardous substances are present. Their robust construction, superior chemical resistance, and customizable features ensure that they provide reliable protection and enhance overall safety and productivity.

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LK Metrology’s software is designed to be compatible with a wide range of measuring instruments, from handheld devices to complex coordinate measuring machines (CMMs). This compatibility ensures that manufacturers can easily integrate the software into their existing systems, maximizing its benefits without the need for significant investments in new equipment. The software also includes advanced data analysis tools that help identify trends and potential issues, allowing for proactive maintenance and continuous improvement of safety practices.

One of the standout features of this software is its automated reporting capability. This feature simplifies the documentation process, ensuring that all measurements and safety checks are recorded accurately and efficiently. This not only enhances compliance with industry regulations but also provides valuable insights into the effectiveness of safety measures. By streamlining these processes, LK Metrology’s software enables manufacturers to focus more on their core operations, improving overall productivity.

In addition to enhancing safety, the software’s precision and efficiency contribute to increased productivity on the manufacturing floor. Accurate measurements reduce the need for rework and minimize downtime, allowing manufacturers to maintain high production rates. The real-time data processing capability ensures that any deviations from the norm are detected and addressed promptly, preventing small issues from escalating into major problems.

Overall, LK Metrology’s improved measuring software represents a significant advancement in manufacturing technology. By promoting safety and productivity, it helps manufacturers achieve higher standards of operation and ensures that they remain competitive in a rapidly evolving industry.

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In the low to medium flow rate range, these compact class systems guarantee an extremely economical 100% separation of clean and dirty oil in a full-flow process. Steffen Strobel, Sales Manager at Vomat: “In an automatic cycle – depending on the amount of dirt – this technology not only guarantees 100% separation of the dirty and clean oil via a frequency-controlled system pump, but also ensures that oil with a filter fineness of 3-5 µm is always available for the production process over a long period of time during cleaning using special high-performance precoat filters.”

Vomat relies on the use of highly efficient pumps to make the operation of the ultra-fine filtration systems energy-efficient. In conjunction with optimized process control, unnecessary energy losses are avoided. Vomat systems automatically control the filter flow and backwash cycles according to demand. This extends the service life of the filter elements and leads to significant energy and cost savings.

In contrast to conventional systems, which often work continuously at maximum filter performance, Vomat systems adapt to the current production process. For example, if grinding machines are running at a lower speed, only the required amount of cooling lubricant is filtered. In Vomat central systems that filter several grinding machines, some of which are not in operation, the filter capacity is automatically adapted to the cutting volume. This simultaneously reduces the heat supply to the medium, which means that less cooling capacity is required and energy consumption is further reduced.

During the full-flow backwashing process, on-demand backwashing brings further benefits: With Vomat filters, the backwash cycles are controlled depending on the degree of contamination of the filter elements. As soon as relevant contamination levels are reached, the time-delayed backwash starts for each individual filter. The other filters continue to ensure a continuous supply of clean oil. This fully automatic control and adjustment of the filter capacity enables efficient control of energy and operating costs.

The grinding sludge is disposed of using a special sedimentator with fully automatic treatment of recyclable materials with a residual moisture content of between 5 and 10 percent. Overall, the treatment process is extremely user-friendly. The sludge is fed directly into the recycling companies’ transport containers.

Steffen Strobel: “If cooling lubricants remain clean for longer in the machining process, they can also be used for longer periods of time. Vomat Technologie achieves this, for example, thanks to the needs-based backwashing of the Vomat ultrafine filtration systems in conjunction with special cooling concepts. This leads to significantly reduced machine downtimes for users and increases production efficiency while minimizing losses due to contamination and heat input into the medium. As a result, this also leads to considerable savings in energy costs.”

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Sami Atiya, President of ABB’s Robotics and Discrete Automation Business Area, emphasized the significance of this milestone, stating, “The opening of our refitted state-of-the-art US robotics headquarters in Auburn Hills, Michigan is a significant part of our global growth story, reaffirming our commitment to industry leadership in the US.” Atiya underscored the pivotal role of robotics and AI in addressing critical labor shortages, localized supply chains, and the imperative to operate sustainably. The enhanced facility, with its advanced AI-driven software and hardware, is poised to make ABB’s robots more accessible to a broader spectrum of businesses, empowering them to bolster resilience and competitiveness.

Governor Whitmer commended ABB’s $20 million investment in Auburn Hills, emphasizing its contribution to job creation and Michigan’s advanced manufacturing landscape. The investment, expected to generate over 70 high-skill jobs, underscores ABB’s dedication to local workforce development and education.

The upgraded Auburn Hills facility, boasting a 30% increase in space, positions ABB as a premier strategic robotics partner for its expanding clientele. Equipped with a state-of-the-art Customer Experience Center, the facility showcases ABB’s leading-edge hardware and software solutions, facilitating collaborative exploration of the latest digital and AI-powered automation technologies. Furthermore, the facility includes a training center aimed at educating over 3,000 workers and students annually, nurturing a skilled workforce primed for the AI-powered automation era.

John Bubnikovich, President of ABB United States Robotics Division, expressed enthusiasm for the facility’s expanded capabilities, stressing ABB’s commitment to pushing technological boundaries and fostering a more productive, sustainable future.

ABB’s investment in Michigan underscores its unwavering focus on the U.S. market and commitment to continued growth in the region. Supported by a $450,000 Michigan Business Development Program grant, the expansion is anticipated to create 72 highly skilled jobs and capitalize on the region’s technical talent pool. Additionally, ABB remains dedicated to providing upskilling and career opportunities, enabling individuals without prior experience or degrees to thrive in the robotics and automation industry.

This initiative represents part of ABB’s broader commitment to invest in its electrification and automation businesses across the United States, with a focus on driving industrial transformation and advancing sustainability.

About ABB

ABB is at the forefront of technology-driven electrification and automation solutions, aimed at fostering a more sustainable and resource-efficient future. With over 140 years of excellence, ABB’s innovative solutions empower industries worldwide, connecting engineering expertise with cutting-edge software to optimize manufacturing, mobility, energy, and operations.

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