Russian FederationTI
TI-112-2002 Standard instruction on labor protection for the cutter of elastomers and rubber
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TI-112-2002
TYPICAL INSTRUCTION ON LABOR SAFETY
FOR ELASTOMER AND RUBBER CUTTER
1. General safety requirements
1.1. This instruction provides for the basic requirements for organizing and carrying out the safe operation of an elastomer and rubber cutter in the production of auto-molding and paronite gasket products.
1.2. Individuals at least 18 years of age who have passed:
- vocational training and having an appropriate certificate in the profession;
- preliminary medical examination and received a conclusion on suitability for this profession;
- introductory briefing on labor safety, fire safety and provision of first aid to the victim;
- initial briefing at the workplace and trained in safe methods and techniques for performing work.
1.3. A cutter of elastomers and rubber, employed at a job where the organization of labor provides for the combination of production professions, must be trained in all types of work, pass exams and obtain a permit.
1.4. The cutter of elastomers and rubber must pass:
- periodic medical examinations - annually;
- repeated briefing on labor safety - at least once a quarter;
- training in safe methods and techniques of work and testing their knowledge in the scope of the program approved by the administration of the enterprise - once a year;
- unscheduled and targeted briefing on labor safety - as needed.
1.5. A cutter of elastomers and rubber with signs of obvious malaise, in a state of alcoholic or drug intoxication is not allowed to work.
1.6. The cutter of elastomers and rubber is obliged: to comply with the rules of internal labor regulations and labor discipline; timely and accurately execute the orders of the administration; comply with technological discipline, requirements for labor protection, safety, fire safety and industrial sanitation; observe the order of movement on the territory of the enterprise; know the meaning of the safety signs, sound and light signals used at the enterprise, be attentive to the signals given and comply with their requirements.
1.7. In the event that any issues related to its safe performance arise in the course of work, it is necessary to immediately notify the employee responsible for the safe performance of work (foreman or shift supervisor).
1.8. During the entire work shift, the established regime of work and rest must be observed. Resting and smoking is allowed only in specially designated areas.
1.9. For drinking, use water only from drinking fountains or drinking tanks.
1.10. Eating should be done only in specially equipped rooms (buffet, dining room).
1.11. Harmful and dangerous production factors at the workplace of the cutter of elastomers and rubber are: increased noise level, asboric and asbestos-bakelite dust, moving parts of production equipment.
1.12. The administration of the enterprise must provide the cutter of elastomers and rubber with special clothing, footwear and personal protective equipment:
- cotton suit - 1 set per year;
- combined mittens - 12 pairs per year;
- leather boots - 1 pair per year;
- goggles - to wear;
- respirator - to wear.
1.13. The cutter of elastomers and rubber is not allowed to work without work clothes, special footwear and personal protective equipment that are required by the production conditions.
1.14. The cutter of elastomers and rubber is obliged to: comply with fire safety requirements at work, as well as observe and maintain the fire-fighting regime; observe safety precautions when working with substances and materials that are dangerous in terms of fire hazard; know the actions in case of emergency, evacuation routes and emergency exits from the workshop; know how to use primary fire extinguishing equipment.
1.15. About cases of injury and all malfunctions in the operation of mechanisms and equipment, violations of technological regimes, deterioration of working conditions, the occurrence of emergency situations, the cutter of elastomers and rubber must inform the foreman (chief) of the shift.
1.16. In case of illness, poisoning or an accident, the elastomer and rubber cutter must stop working, inform the foreman (chief) of the shift and seek medical help.
1.17. In case of an accident with another employee, it is necessary: to provide the injured person with first aid, to report the incident to the foreman (chief) of the shift, to take measures to preserve the situation of the case.
1.18. In the process of work, the cutter of elastomers and rubber must observe the rules of personal hygiene: wash hands with soap and water before eating, keep the workplace, overalls and personal protective equipment clean.
1.19. As it gets dirty or worn, the overalls of the cutter of elastomers and rubber should be dry-cleaned, laundered or repaired at the expense of the enterprise. Home washing is not allowed.
1.20. For failure to comply with the safety requirements set forth in this manual, depending on the nature of the violations committed and their consequences, the cutter of elastomers and rubber bears disciplinary, financial or criminal liability in accordance with the current legislation of the Russian Federation.
2. Safety requirements before starting work
2.1. Inspect, tidy up and put on overalls.
2.2. Prepare the necessary personal protective equipment for work.
2.3. Accept the shift from the elastomer and rubber cutter who is handing over the shift, find out about the malfunctions and malfunctions that occurred in the operation of equipment and mechanisms during the shift.
2.4. Check the cleanliness of the workplace, remove the clutter of aisles and driveways.
2.5. Check the availability and serviceability of the necessary tools, fixtures and containers.
2.6. Check the serviceability of fences, equipment grounding, ventilation.
2.7. Make sure that the cutting wheels are in good condition and do not touch the drum and tension chains. Check the operation of the machine for cutting cushioning materials at idle.
2.8. Check the condition of the guillotine shears and the turntable of the conveyor, as well as the illumination of the workplace.
2.9. Check that the instrumentation and the emergency stop switch are working.
2.10. Report all noticed shortcomings to the foreman (chief) of the shift and start work only after they are eliminated.
3. Safety requirements during operation
3.1. Do not perform work in poor lighting of the workplace.
3.2. Do not clutter up aisles and driveways with containers and other items.
3.3. Do not leave running equipment unattended and do not allow unauthorized personnel to work on the equipment.
3.4. Place workpieces in stable stacks.
3.5. When feeding briquettes, do not bring your fingers close to the pressure rollers of guillotines, chains and cutting disks.
3.6. Lay the briquettes into the feed drum carefully, without distortion at the moment when the end stops are at the bottom.
3.7. Check the correctness and quality of cutting briquettes.
3.8. Do not cut briquettes on a liner cutter if the drum does not match the size of the workpiece.
3.9. Work with the cutting wheel guard lowered and secured.
3.10. Do not cut foreign objects on the interlining cutting machine.
3.11. Be careful when rotating the turntable. Do not touch yourself and nearby workers with the frame of the table.
§ 71. Cutter of elastomers and rubber of the 1st category
Job Description. Cutting rubber products to a given size with a special knife on lathes or special machines with an accuracy of more than 0.3 mm or performing operations only for unpacking rubber. Selection of washers, selection and sharpening of cutters and knives. Putting the workpiece on the mandrel and fixing it in the machine chuck. Starting the machine and cutting workpieces in accordance with the technical requirements. At the end of cutting, the machine stops, the products are removed from the mandrel and the cut products are stored in containers.
Must know: methods of cutting rubber products; product design; requirements for product quality; arrangement of machines for cutting and fixtures; types and types of rubbers, their purpose in production.
Work examples
1. Rings from scraps of bicycle tubes - cutting.
2. Rings and covers for heating pads, bubbles for ice and other sanitary products - cutting.
3. Esmarch mugs, ebonite bushings for oxygen bags - cutting.
4. Bicycle chamber tubes - cutting.
§ 72. Cutter of elastomers and rubber of the 2nd category
Job Description. Cutting by hand or on lathes or special cutting machines of various rubber products with an accuracy of 0.2 - 0.3 mm or preparation for the production of rubbers. Fixing products on the washer or shaft of the machine, installing stops, knives and cutters, cutting into parts in accordance with technical requirements. Removal of the cut fabric roller from the machine, removal of the cut roller tape and its transfer to the subsequent operation. Sharpening and changing cutters. Performing operations for greasing and tying cut belts when cutting belt plates on a Zhurmanov machine.
In the preparation of rubbers: unloading rubber, cleaning it from external contaminants and marking by types and grades. Laminating natural rubber by hand into separate sheets for the manufacture of particularly responsible rubber compounds; control of each sheet by transillumination with reflector lamps and removal of foreign inclusions from the processed sheets. Manual cutting of rubber, regenerator, gutta-percha and other elastomers into pieces of fixed sizes and various configurations.
Must know: methods of cutting rubber products; methods of pre-treatment of each type of rubber; product design; technical requirements for products; device and rules for setting up equipment.
Work examples
1. Wickels for rings (fruit and vegetable production) - cutting.
2. Insulating tape - cutting.
3. Eraser rubber - cutting.
§ 73. Cutter of elastomers and rubber of the 3rd category
Job Description. Cutting rubber products with an accuracy of 0.2 mm on lathes or other special machines. Cutting various vulcanized plates into rubber threads or end belts and caterpillar tracks on specialized machines. Cutting rubber products on a circular knife. Cutting rubber, regenerate, gutta-percha and other elastomers by hand or with the help of special devices into pieces of specified sizes and various configurations. Cutting the sponge chamber after straining with special knives. Bringing the blank of the sponge chamber to a given weight by cutting off excess rubber. Bead and tread trimming on pneumatic or disc bead cutters. Self-tuning and maintenance of machines for cutting plates. Setting knives. Monitoring the operation of the machine and the cutting process. Change of knives.
Must know: technological process of cutting rubber technical products, rubber products and plates, elastomers; design and purpose of products; requirements for product quality; rubber brands; device and rules for setting up equipment.
Work examples
1. Spongy chambers - cutting with special knives.
2. Rubber thread - cutting on Weyer or Shaw machines.
3. Plates for belt and caterpillar belts - cutting on a Zhurmanov machine with self-tuning of the machine.
4. Plates "mipor" of separators - cutting.
5. Scrap rubber - cutting on machine tools.
Cutter for cutting CGSH (oversized tires), series "BB" designed for cutting tires into pieces. The cutter easily cuts into pieces, fragments of tractor and Belazovsky tires. Tires are cut into two bead rings, two sidewalls, a treadmill cut along the radius into two parts, a total of 4-8 ring fragments. The resulting fragments in the form of rings are ready for deeper processing. Transportation, loading, storage of such split tires is several times cheaper compared to solid tires. In addition, we get a semi-finished product suitable for deeper processing into crumb rubber using standard equipment. For further grinding, hydraulic alligator shears of the NS series are used. It can be used as independent or additional equipment in rubber processing lines. The machine is mobile, can be transported to the place of accumulation of tires.
Working principle of BB tire cutters:
- Before recycling, the tire must be checked for the presence of foreign objects (stuck nails, rebar, stones, etc.)
- Tires are transported to the recycling site. The movement can take place: by a manual loader of the rokhla type, by a mechanized forklift, by means of an electric hoist, by a worker manually or in the back of a car with a crane installation on board.
- The worn tire is lifted with the help of a tire lifting and landing system (an additional option of the BB machine) or a manual or mechanical winch, an electric hoist to the level of the landing clamping cartridge and is inserted into it.
- The cartridge clamps the tire, this is done by the worker: mechanically spreads the clamping paws of the cartridge. One of the clamping legs of the seat cartridge must be exactly in the center, on top, otherwise the tire will be clamped unevenly. The tire should sit in the cartridge until it stops.
- After that, the chuck drive is turned on and the tire starts to rotate.
- Initially, the lower knife cuts the tire in the center of the treadmill. The knife enters the rotating tire gradually, the worker brings it in through the extension system (according to the principle of the lathe cutter). When cutting thick rubber, the tire in the tread area is cut in approximately 4-5 revolutions of the tire. After completely cutting the tire along the center of symmetry, the lower knife moves back.
- Next, the system for extending the upper side knife is activated, the sidewall (bead) of the tire is cut out. The side knife, like the bottom one, is brought in by the worker through a mechanical drive, gradually. At this point of the cut, the tire has a thinner layer of rubber and is cut in an average of 2-3 turns.
- Next, the knife extension system is shifted to the seat ring and, as in step 7, the seat ring is gradually cut out.
- After that, the seating cartridge drive is turned off, the seating cartridge is slightly unclenched and then the workers remove all the cut parts (if the weight of the fragments is large, then they are removed using the tire lifting and landing system or other mechanized method).
- The second symmetrical part of the tire with the bead and seat ring not yet cut is hung into the clamping chuck by means of a lifting mechanism.
- Next, the machine turns on, cut out (as in paragraph 7.8) the board and the landing ring.
- All parts of the tire are put aside or go to the second stage of processing.
- The cutting torch is equipped with a landing chuck, which is included in the standard equipment of the machine. The manufacturer recommends recycling tires in groups that differ in bore diameter, which saves time on machine settings. When moving from one group to another, it is necessary to rearrange the clamping paws of the chuck through the holes.
At the output, we have a tire cut into 6 rings. Including cut out and 2 landing rings with a thick bundle of thick bead wire in a rubber sheath. As a rule, cut rings from cars, trucks and CGs do not go for further processing and are removed at the very first stage of disposal.
Separately, a number of features of large-sized tires should be noted:
- KGSh are tires over 1200 mm in diameter. Up to 1200 mm these are passenger, truck tires.
- due to their design features, it is problematic to pull out a thick bead wire from the CGW using a hydraulic cord breaker of the DS-500 type. The hydraulic steel cord puller can remove the steel bundle from tires with outer diameter up to 1200mm. Based on the foregoing, it is possible to remove a thick bead wire in the seat ring bundle from the KGSH only by cutting it out together with the seat ring on BB series machines.
- machines of the BB series allow you to cut a large tire into fragments that can be easily processed on standard equipment. In its entirety, the processing of CGG and SKGGG requires expensive equipment, which is more than 15 times higher than the cost of BB series machines. With such processing of HF, the energy consumption is disproportionately higher. The equipment is heavy and not mobile. Machines of the BB series make the processing of CGS low-cost.
- In the production of CGSH and SKGSH, the highest quality rubber compounds are used. The rubber crumb obtained from the tire fragments is of high quality and is in greater demand than ordinary tire crumb.
- The cost of recycling CNG is significantly higher than the recycling of conventional tires for organizations that donate tires. Therefore, for a tire recycler, with the possibility of recycling CGR, this is a higher profitability of production.
Advantages:
- The cutter has high productivity, at low En. consumption.
- Light weight dimensions, which makes it mobile and easily transportable.
- High strength of all nodes, multiple margin of safety.
- Knives are almost not blunt and, if necessary, are simply sharpened.
- The cutter is easy to operate, maintain and operate.
- In the entire history of the creation of this series of BB machines, there has not been a single breakdown!
Machine BB-400 for cutting tires with a diameter up to 1600 mm.
Cuts tires with outer diameter from 600 to 1600 mm into four to six parts: two seat rings, two sidewalls, cuts the tread tread into two parts.
Optionally, a mechanism for lifting and landing tires is attached, with a capacity of up to 500 kg.
Machine BB-500 for processing Belaz-type tires and other tires with outer diameter up to 2000 mm.
Cuts tires with a diameter of 900 to 2000 mm. into four to six parts: two seat rings, two sidewalls, cuts the tread tread into two parts.
Optionally, a mechanism for lifting and landing tires is attached, g. p up to 800 kg.
BB-600 machine for processing tires of the Belaz type and other tires with an outer diameter of up to 3000 mm.
Cuts tires with a diameter of 1500 to 3000 mm. into four to six parts: two seat rings, two sidewalls, cuts the tread tread into two parts.
As an option, a mechanism for lifting and landing tires is attached, up to 2000 kg.
BB-700 machine for processing tires of the Belaz type and other tires with an outer diameter of up to 3500 mm.
Cuts tires with a diameter of 1800 to 3500 mm into four or six parts: two seating rings, two sidewalls, cuts the tread tread into two parts.
As an option, a mechanism for lifting and landing tires is attached, up to 4000 kg.
Comparison table of "BB" series tire cutters:
| Model | ||||
|---|---|---|---|---|
| Dimensions, mm | ||||
| Length | 1800 | 2200 | 3000 | 3500 |
| Width | 1800 | 2200 | 2800 | 3000 |
| Height | 1300/2500* | 1600/2800* | 2000/3800* | 2500/4500* |
| Weight, kg | 800 | 1200 | 1600 | 2000 |
| Power, kW/h | 2,2 | 3 | 5,5 | 7,5 |
| Average en. consumption, no more than kW/h | 1,2 | 1,5 | 3 | 5 |
| Cutter type | mechanical | mechanical | mechanical | mechanical |
| Tire diameter up to, mm | 500-2000 | 600-2000 | 1500-3000 | 1800-3500 |
| Productivity, kg/h | 600-1600 | 1000-3000 | 1500-4000 | |
| Place of use: | ||||
| tire accumulation areas | * | * | * | * |
| tire collection points | * | * | ||
| tire recycling lines | * | * | * | * |
| Number of attendants, per shift | 1-2 | 2 |
* machine height with tire lifting system.
Waterjet cutting is an excellent technology that is used to cut a wide variety of materials, including rubber. The density and thickness of the rubber layer can be almost any. For example, the thickness of the material can be from 0.1mm to 300mm and even more. Usually, waterjet cutting rubber ordered in the manufacture of gaskets and seals for various mechanisms, in the manufacture of non-serial samples or parts, where it is simply too expensive to order large quantities. In the manufacture of elements of complex configuration. And there were also situations when owners of rare cars needed to replace a damaged gasket and ordering one from the manufacturer was longer and more expensive than cutting it on a waterjet cutting machine. In addition, it can be used to make car parts from other materials such as metal or plastic.
We can cut to order a gasket of any complexity, if you have a drawing or a sample. When the machine program file is compiled, it can be saved to a USB flash drive or disk and used again in the future, or slightly edited and used again.
At water jet cutting rubber There are a number of advantages over other technologies. For example, low cost. In addition, during waterjet cutting, there are no mechanical and high-temperature effects, as when cutting with a laser, cutter or plasma, the characteristics of the material being processed do not change, the cut is very high-quality and accurate, the edges of the material being processed are not melted, and the characteristics of the web material as a whole do not change.
Prices for waterjet cutting rubber
Waterjet cutting of rubber - examples of work
Rubber cutting - video
An identification number: etks31-23
Ranks:
1-digit
ID number: etks31-23-1
Job Description:
Cutting rubber products to a given size with a special knife on lathes or special machines with an accuracy of more than 0.3 mm or performing an operation only for unpacking rubber. selection of washers, selection and sharpening of cutters and knives. putting the workpiece on the mandrel and fixing it in the machine chuck. start-up of the machine and cutting of blanks in accordance with technical requirements. at the end of cutting - stop the machine, remove the products from the mandrel and store the cut products in containers.
Must know:
Methods for cutting rubber products, product design, product quality requirements, arrangement of cutting machines and fixtures, types and types of rubbers, their purpose in production
Work examples:
1) rings from scraps of bicycle tubes - cutting; 2) rings and covers for heating pads, bubbles for ice and other sanitary products - cutting; 3) Esmarch mugs, ebonite bushings for oxygen bags - cutting; 4) bicycle chamber tubes - cutting.
Note:
2-digit
ID number: etks31-23-2
Job Description:
Cutting by hand or on lathes or special cutting machines of various rubber products with an accuracy of 0.2-0.3 mm or preparation for the production of rubbers. fixing products on the washer or shaft of the machine, installing stops, knives and cutters, cutting into parts in accordance with technical requirements. we will remove the cut roller of fabric from the machine, we will eat the cut tape of the roller and transfer it to the subsequent operation. sharpening and changing blades. performance of operations on lubrication and a bunch of cut belts when cutting belt plates on a Zhurmanov machine. in the preparation of rubbers, unloading of rubber, cleaning it from external contaminants and marking by types and grades. manual lamination of natural rubber into separate sheets for the manufacture of especially responsible rubber compounds, control of each sheet by transillumination with reflector lamps and removal of foreign inclusions from the processed sheets. cutting rubber, reclaimed rubber, gutta-percha and other elastomers by hand into pieces of specified sizes and various configurations.
Must know:
Techniques for cutting rubber products; methods of pre-treatment of each type of rubber; product design; technical requirements for products; device and rules for setting up equipment
Work examples:
1) wickels for rings (fruit and vegetable production) - cutting; 2) electrical tape - cutting; 3) rubber eraser - cutting.
Note:
3-digit
ID number: etks31-23-3
Job Description:
Cutting rubber products with an accuracy of 0.2 mm on lathes or other special machines. cutting various vulcanized plates into rubber threads or trailer belts and caterpillar tracks on specialized machines. cutting rubber products on a circular knife. cutting rubber, regenerate, gutta-percha and other elastomers manually or with the help of special devices into pieces of specified sizes and various configurations. cutting of the sponge chamber after straining with special knives. bringing the blank of the sponge chamber to a predetermined weight by cutting off excess rubber. bead and tread trimming on pneumatic or disc bead cutters. self-tuning and maintenance of machines for cutting plates. knife setting. monitoring the operation of the machine and the cutting process. knife change.
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