GB2620257A

GB2620257A - A metalworking safety device

Info

Publication number: GB2620257A
Application number: GB2307007.1A
Authority: GB
Inventors: Roger Britton Matthew
Original assignee: BAE Systems PLC
Current assignee: BAE Systems PLC
Priority date: 2022-05-11
Filing date: 2023-05-11
Publication date: 2024-01-03
Anticipated expiration: 2043-05-11
Also published as: GB202307007D0; GB2618575A; GB2620257B

Abstract

A safety device 100 for use during metalworking includes an electromagnet 120 located on one side of a screen 110, adapted to produce a magnetic field 125 across the screen. A collection tray 130 is located along a lower edge of the screen, on the opposite side to the electromagnet. A power management unit (PMU, 160, Figure 2) is connected to the electromagnet. A communication means 170 is adapted to pair the PMU to a metalworking tool 150. The PMU is adapted to: monitor the working status of a paired metalworking tool; power the electromagnet ON when the paired metalworking tool is being operated; and power the electromagnet OFF when the paired metalworking tool is idle or off. Weighing means may be used to measure the amount of collected particulate matter 135 such as ferrous dust, swarf, debris, or metal particles. The PMU may be adapted to power the electromagnet ON immediately upon operation of the paired tool and power the electromagnet OFF after a pre-determined delay after the tool is idle or switched off. The PMU may be adapted to power the electromagnet either ON or OFF simultaneously according to the working status of the paired tool.

Description

A METALWORKING SAFETY DEVICE

FIELD

The present invention relates to safety equipment for metalworking, and more specifically, to the efficient and safe capture of metal dust and debris created during metalworking.

BACKGROUND

During metalworking procedures such as cutting, grinding and welding etc., a significant amount of waste metal (also known as swarf, chips, turnings, things, or shavings) may be generated and propelled outwards from the working piece. If left un-obstructed, the waste metal may spread out onto a working area floor or into objects in the near vicinity. These metal particles may be hot and therefore increase the risk of unwanted heating and possible fires.

Additionally, the velocity of some of these particulates may cause a significant projectile hazard for nearby machinery, and even work-place suitable Personal Protection Equipment (PPE) may not fully protect an individual. The velocity also leads to a significant spread of waste material around the working area, which is a safety hazard for slips trips and falls. Additionally a build-up of metal dust over time can require costly clean up and work-place risk assessments. Metal dust contamination can be an issue for electronic devices, and so such electronic devices in the vicinity require higher ingress protection ratings. Additionally higher concentrations of airborne particulates can be hazardous to workers if not correctly captured.

To prevent injury, PPE is often worn as a safety precaution, and floor markings may be used to cordon off metalworking areas. However, these markings may be easily missed or ignored, and PPE may be incorrectly worn hence propelled metal particulates present a significant risk to bystanders or machinery operators' safety. Local Exhaust Ventilators (LEVs) are also common-place in metalworking environments, but require significant work-piece encapsulation to enable pressurised air flow. Metal intake can drastically reduce the longevity of LEV devices, increasing the maintenance and filter replacement requirements. -2 -

The present invention aims to address these problems by providing an improved safety system adapted to capture, direct and collect projectile metal particulates generated throughout the metalworking process.

SUMMARY

According to first aspect of the present invention, there is provided a safety device for use during metalworking. The safety device comprises a (substantially upright) screen, an electromagnet located on one side of the screen, a collection tray along the lower edge of the screen (on the opposite side of the screen to the electromagnet), a power management unit (PMU) connect to the electromagnet and a communication means for pairing the PMU and a metalworking tool. The screen prevents any lose metal particles or dust from escaping the metalworking area. The electromagnet is adapted to produce a magnetic field across the screen, and the PMU is adapted monitor the working status of the paired metalworking tool and to switch ON the electromagnet when the paired metalworking tool is being operated, and switch OFF the electromagnet when the paired metalworking tool is idle or off. The electromagnet therefore captures the metallic dust and particulate matter thrown into the air by the metalworking tool. The dust and particulate matter is also less likely to ricochet from the screen because of the magnetic field. When the tool, and therefore the paired PMU and connected electromagnet, is switched off, any captured metal dust or particulate matter falls into the collection tray at the bottom of the screen for easy collection and disposal.

In one example, whilst the PMU is adapted to turn the electromagnet on upon operation of the metalworking tool, so as to immediately capture any dust or particulate matter thrown into the air towards the safety device, the PMU is adapted to turn the electromagnet off after a short pre-determined delay once the metalworking tool is idle or switched off. This ensures that any dust or particulate matter still in-flight towards the screen when the metalworking tool is switched off are still captured by the delayed shut-down of the electromagnetic field.

Alternatively, in another example the PMU powers the electromagnet simultaneously with the paired metalworking tool, so that when the -3 -metalworking tool is in-use the electromagnet is powered and when the metalworking tool is powered-down, the electromagnet is automatically powered-down as well.

In a further example, the safety device also comprises weighing means, adapted to weigh the increase in the weight of the safety system, and thus the amount of collected dust or particulate matter collected by the electromagnetic field and suspended on the screen. When the weighing means measures an increase in weight above a pre-determined value, the PMU briefly switches the electromagnet off, and then back on again. This helps keep the safety screen clear of excessive debris, and able to collect more dust and particulate matter thrown from the metalworking tool, whilst periodically depositing any collected dust or particulate matter in the collection tray once a predetermined amount has been collected.

In another example, the safety device also comprises at least one angled slat across the screen, on the opposite side to the electromagnet, i.e. facing the metalworking area. The slats reduce the amount of any ricocheting dust or particulate matter by deflecting any incoming dust or particulate matter (preferably downwards towards the collection tray).

In another example, there is provided a system for capturing metal dust and debris during metalworking. The system comprises at least one of the previously mentioned safety devices and a metalworking tool paired with the safety device via the communication means of the safety device. The system helps prevent ricochet by capturing metallic dust and particulate matter thrown into the air by the metalworking tool. When the metalworking tool is idle or powered off, the safety device's electromagnet is powered off, and any captured metal dust and particulate matter falls off of the screen into the collection tray.

BRIEF DESCRIPTION OF THE FIGURES

Embodiments of the invention will now be described by way of example only with reference to the figures, in which: Figure 1 shows an example safety device comprising a screen and an electromagnet; Figure 2 shows a schematic view of the example safety device; and -4 -Figure 3 shows another example safety device comprising a screen with directional slats and an electromagnet.

DETAILED DESCRIPTION

Figure 1 shows a safety device 100 for use during metalworking. During metalworking, a significant amount of waste metal 155 is often generated in the form of metal dust and particles, and propelled outwards from the metalworking tools 150 as they are used. The safety device 100 comprises a screen 110 which is intended to contain any waste material 155 within the metalworking 10 area. In the example shown, the screen 110 is substantially flat and substantially upright. However, it will be appreciated by the skilled person that other examples, such as curved, tilted, or multiple articulated screens may be employed in a similar manner to achieve the inventive effect described herein. The safety device 100 also comprises an electromagnet 120 located adjacent to the screen 110, and preferably on the opposite side to which the metalworking is taking place. In one example, the electromagnet is located between two outer screen edges, sandwiched there between. When activated, the electromagnet 120 generates a magnetic field 125 across the screen 110 which helps capture ferromagnetic/ferrous metal dust and particles 155 and prevent any of the particles 155 from ricocheting off the screen 100. The ferrous metal dust and particles 155 are instead captured by the magnetic field 125, and held against the screen 110. The safety device 100 may comprise multiple electromagnets 120 in order to generate a suitable magnetic field 125 across the screen 110 (or multiple screens).

Figure 2 shows a schematic system diagram of the setup shown in Figure 1. The safety device 100 comprises a power management unit (PMU) 160. The PMU 160 is connected to the electromagnet 120 and can power the electromagnet 120 on and off. The PMU 160 is paired with a metalworking tool 150 and monitors the working status of a tool by a communication means 170.

The communication means 170 can be a wired/wireless connection, such as a wired serial data connection or a Bluetooth connection, or an indirect connection through the use of devices such as electrical power sensors, to measure the power drawn by a metalworking tool from the metalworking tool's power supply. In one example, the PMU 160 is externally powered and -5 -information about the working status of the metalworking tool is sent from the metalworking tool 150 to the PMU 160 via the communication means 170. Subsequently, and based on a predetermined set of criteria relating to the working status of the metalworking tool, the electromagnet 120 is powered either ON or OFF.

In another example the PMU 160 could be paired with a metalworking tool via a plug adapter that is located between the metalworking tool and the power source for the metalworking tool. When the metalworking tool draws power (above a predetermined threshold) the PMU is adapted to power the electromagnet on simultaneously with the activation of the metalworking tool 150.

It will be appreciated by the skilled person that the PMU 160 could be implemented in variety of different ways to monitor and recognise the working status of a metalworking tool (whether this information is outputted from the tool or the tool's power-use is sensed) and power the electromagnet on or off accordingly.

Therefore, when the metalworking tool 150 is being used, the electromagnet 120 is powered on, and any metal particles or dust 155 thrown from the tool 150 may be captured by magnetic field 125 surrounding the safety device 100. When the metalworking tool 150 is idling, or switched off, then the electromagnet 120 is also powered off. Any collected dust or particulate matter will fall off the screen 110. In one example, the PMU 150 switches off power to the electromagnet 120 after a pre-determined delay (e.g. 0-3 seconds) after the metalworking tool 150 is not being used (e.g. idle or switched-off). This allows the safety device 100 to capture any ferrous metal particles or dust 155 that are still in flight as the metalworking tool 150 is switched-off.

The safety device 100 also comprises a tray 130 which runs along the lower edge of the screen 110 on the opposite side to the electromagnet 120. The tray may be either permanently attached to the screen 110, or removeably attached for ease of emptying. To prevent unwanted magnetism, the tray may be made out of non-magnetic materials.

When the electromagnet 120 is deactivated by the PMU, e.g. when the metalworking tool 150 is switched off or idling, any collected ferrous metal dust or particles will fall from the screen 110, and are collected in the tray 130. The -6 -collected ferrous metal dust and particles 135 can be easily removed and disposed of after the metalworking has been completed.

In the interests of usability, the safety device 100 may be relocated through mobility means such as wheels, or alternatively, the screens 110 may be hung from a railing system.

The screen 110 may be solid, or fabric/textile-based and supported by a rigid frame. In one example, the screen 110 is also made of a ferrous material, so that the electromagnet 120 induces a magnetic field in the screen 110 itself, thus becoming magnetic and aiding the attraction and collection of ferrous dust and particles 155.

In another example, the screen 110 is coated in a low-friction coating to assist any collected ferrous material falling from the screen 110 into the collection tray 130 when the electromagnet 120 is switched off.

Figure 3 shows a further example of the safety device 100 as described above, comprising a series of slats 140. In the example shown, the slats are arranged horizontally and angled so that any incoming ferrous particles 155 are deflected downwards, towards the collection tray 130. In one example the slats are made from a ferrous material, and a magnetic field is induced in the slats by the magnetic field 125. The slats 140 may also comprise a low-friction coating to assist the incoming dust and particles 155 being deflected from the slats 140, and not-sticking to them when the electromagnet 120 is turned off. The slats 140 may be curved or flat, and preferably are horizontally aligned and angled so that any incoming metal dust or particulate matter 155 is deflected downwards upon impact with the slats 140. However, in another example, the slats could be arranged at any angle, e.g. vertically. The slats 140 not-only help deflect incoming metal dust and particulate matter 155, but also help prevent any fast-moving metal dust or particles 155 from bouncing back off of the screen 110 onto the work floor. The slats 140 also help capture any non-ferrous dust or particles 155 generated by the metalworking, since they are still deflected (preferably downwards), despite not being affected by the magnetic field 125.

The slats 140 should be arranged such that the angle, overlap and depth of the slats prevent any dust or particulate matter 155 ricocheting back off the screen 110 and onto the working floor. It will be appreciated by the skilled person that the slats 140 are arranged and overlapped in a suitable manner, -7 -e.g. the first edge of a first slat should overlap with the second edge of a second, adjacent, slat, then the particles and dust 155 are more likely to be caught by the slats 140 and screen 110 and fall to the collection tray 130. In a preferred embodiment, the slats are located leaving a small gap between the edge closest to the screen and the surface of the screen, to allow for any dust or particulate matter 155 to fall down, to the tray.

The invention may also be realised wherein the screen 110 itself is curved, or angled downwards with respect to the metalworking area, so that any fast-moving metal dust or particles 155 do no ricochet back to the metalworking area.

In a further example, the safety device 100 is equipped with weighing means incorporating weight sensors. The weight sensors can be implemented in a number of ways, for example in ground supports or wheels supporting the safety device 100, or if the screen 110 is hung from a railing system, the weight sensors could be incorporated into the hanging means.

The weighing means may further incorporate a processor to record at least one initial weight value, and store a predetermined weight difference value. Alternatively, or perhaps as well, the PMU may incorporate the processing means necessary to record an initial weight value, and a predetermined weight difference value. When the electromagnet is powered on, the processor records the weight value of the safety device (the initial weight value), and as dust or particulate matter 155 is accumulated (on the screen, or in the tray) the weight sensors will measure an increase in weight in comparison to the initial value. The weighing means is coupled to the PMU, so that the electromagnet 120 can (momentarily) be turned off by the PMU 160 if the processor determines that the weight of the safety system 100 has increased by a pre-determined amount (owing to the accumulated metal dust and particles 155). When this occurs, the electromagnet 120 is temporarily switched off by the PMU (for a predetermined amount of time, e.g. a second) so that the collected dust and particulate matter falls into the collecting tray 130, and the electromagnet 120 can be quickly re-activated again. As the electromagnet is powered back on, the processor updates the initial weight value of the safety device to the current weight value of the safety device measured by the weight sensors, and the process may be repeated. This way, the safety system may be -8 -programmed to reset the electromagnet every time a predetermined amount of dust or particulate matter 155 is collected by the screen (and tray), e.g. 100g. Alternatively, or in combination with any of the power control methods discussed above, the electromagnet 120 may be automatically powered off and back on again periodically by the PMU, i.e. after a pre-determined time for example every 10 minutes, for 3 seconds, so that any collected ferrous metal particles or dust fall from the screen 110 into the collection tray 130.

It will be understood by the skilled person that whilst the example shows a user and a hand-held metalworking tool, the invention can similarly be realised with a range of metalworking tools, whether they are handheld platform or surface based, manually operated or un-manned. -g -

Claims

CLAIMS1. A safety device for use during metals.,sprking, the safety device comprising: a screen: an electromagnet located on one side of the screen, and adapted to produce a magnetic field across the screen: a collection tray located along the lower edge of the screen on the opposite side to the electromagnet; a power management unit (PMU) connected to the electromagnet: and a communication means adapted to pair the PMU to a metalworking tool, wherein the PMU is adapted to: monitor the working status of a paired metalworking tool; power the electromagnet ON when the paired metalworking tool is being operated; and power the electromagnet OFF when the paired -netalworking tool is le or off.
2. .he safety device according to claim I wherein the AMU is adapted to: power the electromagnet ON immediately upon operation of the paired metalworking tool; and power the electromagnet OFF after a pre-determined delay after the metalworking tool is idle or switched off.
The safety device according to claim 1 wherein the PMU is adapted to power the electromagnet either ON or OFF simultaneously according to the working status of the paired metalworking tool.
4. The safety device according to any proceeding claim, comprising weighing means adapted to measure the amount of collected particulate matter :looted by the safety device, and wherein the PVIL1 is adapted to: switch off the electromagnet when the weighing means senses that the weight of the safety system has increased by a pre-determined value; and automatically switch the electromagnet back on again after a predetermined delay.
5. The safety device according to any proceeding claim, comprising at least one angled slat on the opposite side of the screen to the electromagnet.A system for the capture of metal dust and debris created during metalworking, the system comprising: the safety device according, to any proceeding claim and a metalworking tool paired via the communication means of the safety device.