Operator safety is critical in any type of lifting operations. Safety is always top of mind in manufacturing and assembly processes. When you are using an electric balancer or air balancer (pneumatic balancer), there are safety features built into balancers that can enhance your safety program. In this post we will talk about the safety features your electric or air balancer should have to create a safer work environment.
Electric balancers and air balancers are one tool to assist in assembly operations and other manufacturing operations when the operator needs to float a load. You will commonly see balancers used to hold a tool to perform an operation. A weld gun can be suspended at a specific height for the operator to attach components in an assembly line. Balancers are commonly used during the physical assembly process to suspend or float a component as it is attached to another component. When integrated with a mechanical or powered gripper, balancers can be tailored to lift a complex or odd shaped component so it is handled safely while floating or holding the component as it is attached to another component.
Air Versus Electric Power
The way electric and air balancers are powered can be perceived as a difference in safety. Both types of balancers are designed to be used safely but it is always critical to match your needs with the proper balancer. Air balancers are powered by clean air, the same compressed, clean air you already have running through your factory. If you have clean, compressed air already running through your manufacturing facility, this could be a deciding factor when making your balancer choice. Because they are not powered with electricity, they have a 100% duty factor.
Electric balancers are powered by electricity, similar to electric chain hoists. If you have existing chain hoists in your manufacturing facility, you know you will likely have the proper electrical parameters needed to add a balancer. Even though an electric balancer is powered by electricity, it has the safety factors and certifications needed for your geographic location to operate safely.
Ergonomics
A vital element of any lifting and material handling process are ergonomics. Ergonomics can be defined as fitting the job to the person to lessen the risks of MSD’s, or musculoskeletal disorders. OSHA reports that MSDs accounted for 33% of all worker injury and illness cases in 2013. MSDs can affect the muscles, nerves, blood vessels, and tendons of workers in different industries and occupations through lifting heavy items, bending, reaching overhead, pushing and pulling heavy loads, awkward body postures, and repetitive motions. Balancers can help meet your ergonomic goals by reducing or eliminating the need for manual lifting and holding. They can also be programmed to lift a component to a specified height so the component can move with the operator to the next assembly operation.
Snatched Loads
A snatched load describes when the load handling speed suddenly increases drastically. This can cause injury to the operator and to the load. A balancer should have a safety feature to mitigate snatched loads. Both the Demag D-BP II Air Balancer and DCBS Electric Balancer have this safety feature integrated as a standard option.
With the D-BP II air balancer, the Load Weight Compensation feature comes standard on all balancer models and lifts every load, regardless of weight, at the same speed. This creates predictable movements for the operator. In addition, the patented overspeed brake stops extremely fast upward motion of the hook or rope drum if a load were to fall off during handling or the rope cut. This brake is easy to reset so operators can get to work quickly.
The Demag DCBS electric balancer has similar functionality integrated into its operating system, similar to Demag DC chain hoists. Since the DCBS is built on the same platform, you get the same benefits.
Dropped or Sinking Loads
As a load is floating on some balancers, you might see the load sinking or dropping. A sinking load could be dangerous to operators or personnel in the area. Balancers should have features to prevent this from happening. The Demag D-BP II air balancer has a patented seal that maintains air pressure in the chamber. The V-shape of the seal prevents air pressure leaks due to the smaller surface area of the seal to keep more constant pressure. Other balancers use a standard seal that creates more opportunity for leaking.
The Demag DCBS electric balancer is powered by electricity and is programmable to your needs. The intelligent handle of the DCBS has a light barrier sensor where you can easily set the brake. This holds the load at the needed height. When you are ready to move the load again, you can simply break the light barrier on the handle by gripping the handle or breaking the barrier and using both hands to move the load.
Safety Parameters for Grippers and End Effectors
In many applications, air balancers and electric balancers are used with an integrated gripper or other type of end effector tooling. Both types of balancers have different methodologies for creating these parameters. With the DCBS electric balancer, there is software within the hoist that has programmable parameters. Connecting the balancer to a laptop with the cord, allows you access to the “SoftTerm32” software to set the parameters needed for the grippers or end effectors. For example, the parameters you can set for safety include allowing a gripper to pick up only a specified weight or setting a weight parameter to meet before the load is released.
In contrast, setting parameters on air balancers is not completed though a program but rather through regulating the air pressure within the chamber. On standard up/ down balancers, you may determine the air pressure to float a specific component by attaching the load and then adjusting the air pressure valve in the body. On a one, two, or three load balancer, you may go through a similar process but doing this with the multiple loads on the balancer. An optional safety feature for grippers and end effectors is a visual system which can be set to indicate when the release of a load is safe or unsafe. The Interlock Visualization Display can be integrated into the controls and shows a red or green indicator light when used with mechanical grippers. This feature is a visual cue to the operator showing when it is safe to release a load or not.
When you use air balancers or electric balancers in your operations, make sure you know what safety features are available. Understand your processes, whether you are looking for a balancer in a manufacturing or assembly process, and your company’s safety goals. Lifting devices like air balancers and electric balancers can reduce or eliminate manual lifting. Make sure the balancer you choose helps protect your operators from snatched loads or sinking loads. When end effector tooling and grippers are used with balancers, make sure you can program or determine the necessary weight limits to reduce the chance a load is dropped or released at an unsafe time. Whether you determine an air or electric balancer will optimize your operations, make sure you do the research to see the safety features available to protect your workforce.
Learn more about Demag Air and Electric Balancers for your facility!
If you need an electric balancer, read more about what the Demag DCBS Electric Balancer can bring to your operations. The DCBS is priced for companies large and small.