The eccentric presses These are machines widely used in multiple industrial sectors for their ability to stamp, cut and form sheet metal. However, many of these machines were designed before current safety regulations, such as the Royal Decree 1215/97, which represents a high risk for operators if not properly maintained.
In this article, we analyse a practical case that we recently carried out of Industrial machinery suitability ancient, in which the die-cutting process has been automated by a bespoke pneumatic piston. This solution not only improves security, but also maintains operational efficiency and convenience, complying with the Machinery regulations in force.
The problem: an unsuitable press with risk elements
The intervention arose from a work inspection at an industrial refrigeration company located in Alaquàs (Valencia). During the visit, it was detected that several machines, including an eccentric press, did not meet the minimum safety requirements established by the regulations.
Critical press points:
- Mechanical pedal-activated die-cutting system.
- Continuous feeding of sheet metal from a coil, through a shear to the mould.
- Need for access for adjustments and mould changes, which increased exposure to dangerous moving parts.
- Absence of security fencing and modern emergency stop devices such as a Emergency slide.
- Limited space around the machine to incorporate guarding solutions.
This scenario not only contravened Royal Decree 1215/97, but also posed an unacceptable risk to operators, especially during maintenance or adjustment phases of the press.
The solution: automation and safeguarding with regulatory criteria
The project's objective was clear: to carry out the Suitability of eccentric presses in accordance with Royal Decree 1215/97, fulfilling the criteria of the Machinery regulations without compromising operational efficiency. To achieve this, a comprehensive solution was designed and installed, combining:
Pneumatic piston die-cutting automation.
Security fencing to measure with aluminium profile and polycarbonate.
Control panel with electrical safety features.
Fixed and movable guards according to UNE-EN ISO 14120:2016.
Control system in accordance with standard UNE-EN 60204-1:2019.
Die-cutting automation
One of the key elements of the project was the replacement of the mechanical pedal with a double acting pneumatic cylinder custom-made. This component allows automatizar el proceso die-cutting, eliminating the need for direct operator interaction and reducing the risk of entrapment.
The new system is controlled from a control panel that includes a mode selector (manual/automatic). In manual mode, the press operates stroke by stroke; in automatic mode, the piston drives the die continuously as long as the system remains enabled.
For control, an electrically operated valve and a safety module have been incorporated, which guarantees a performance level of PL=d, ensuring the reliability of the stop system in case of emergencies or component failures.
Safety fencing and guards
The Perimeter fence It is manufactured from structural aluminium profile and transparent polycarbonate, allowing good visibility of the process without compromising safety. Incorporated are:
Enclosed access doors with magnetic sensors.
Signage using standardised pictograms.
Fixed metal guards in hard-to-reach areas and 3D-printed guards in specific areas such as shafts or difficult-to-cover moving parts.
Additionally, an extra control panel has been installed upstream to allow for voltage isolation of the machine, a key measure for safe interventions during maintenance tasks.
Emergency brake and reset
It has been integrated a Emergency slide accessible from the operator's front area. Following an emergency stop or door opening, the system requires a Rearm manual to resume operation, thereby minimising the possibility of unexpected starts.
This functionality is essential for meeting the criteria of the RD1215 and with the aforementioned harmonised standards.
Advantages of the implemented solution
The project suitability of machinery RD1215/97 it has represented a substantial improvement in all aspects related to Machine safety. The main advantages obtained are:
Mechanical risk reduction associated with access to dangerous areas.
Process automation, which allows for efficient production to be maintained without direct intervention in the drive.
Regulatory compliance with Royal Decree 1215/97 and European legislation on machinery.
Modular and replicable system: the developed solution can be applied to other eccentric presses with similar characteristics, allowing for the standardisation of future adaptations.
A solution applicable to many old presses
This case is especially relevant because many industries continue to use Mechanical foot-pedal eccentric presses similar. These machines, though robust and functional, become a weak point from the perspective of Workplace safety if they are not updated in accordance with current legislation.
The automation using a pneumatic cylinder presents itself as a Versatile, cost-effective, and adaptable solution. Furthermore, when integrated with a modern control system and security fencing suitable, allows to comply with the Machinery regulations without needing to replace the entire machine.
Modernising without replacing: how to adapt old machinery to current regulations
The Industrial machinery suitability must not be understood solely as a legal obligation, but as an investment in worker safety and the company's operational continuity. In this project, it has been possible to modernise an eccentric press without compromising production, incorporating a system for Automation security, reliable and compliant with regulations.
From the security fencing until the integration of pneumatic piston, this type of intervention allows for an extension of the machines' lifespan and a significant reduction in the risk of workplace accidents. And most importantly: they are solutions that can be applied to many other industrial facilities with similar problems.
If you'd like to learn about more success stories regarding suitability, you can visit our blogs on:«Compliance with RD1215/97 for an industrial die-cutting machine«, «Success Story with Safety Assessment and CE Marking for Food Machinery»and much more.
