Die Safety Blocks and Accessories |
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Rockford Systems has the largest selection of styles and sizes of die safety blocks including:
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X-shaped |
U-shaped |
Octagonal-shaped |
Adjustable screw
safety blocks |
Introduction |
 According to OSHA 29 CFR 1910.217, “The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press.” They are not required during die setting unless die blocks are included in your die setting procedure. They also satisfy the lockout/tagout requirements for isolating mechanical energy.
Die safety blocks are placed between the die
punch and holder with the machine stroke up. They are rated to support a static load. The static load represents the combined weight of the press ram, ram components (ram-adjust assembly and connection rod[s] or pitman arm[s]), and the upper die.
In some applications, as many as four safety blocks may be required. This is determined by the size of the press bed and the weight the blocks must support. On larger presses, the total slide weight must then be distributed among the quantity of safety blocks required.
The ram is usually adjustable; therefore, wedges or the adjustable screw device is offered to provide a proper fit. If the die takes up most of the space on the die set, it may be difficult to find a place to insert the block. To avoid accidentally stroking the press or leaving the safety block in the die after use, an electrical power cut-off interlock system should be used.
Note: Electrical interlocking of die safety blocks to the machine’s motor and control circuits is required by ANSI B11.19.
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Aluminum Die Safety Block System
This high-strength die safety block is lightweight and comes in several sizes. The unique shape and mechanical properties of the 6061-T6 material have been calculated according to stringent structural aluminum design analysis standards to provide high strength.
To determine the number of die safety blocks required, the static load each die safety block will support, and the length of each block, please follow the instructions below and on the next page.
1. Determining the static load the die safety block(s) will support:
The actual static load that the die safety block(s) will support is determined by adding the actual weights of the press slide and slide components (ram-adjustment assembly, connection rod[s] or pitman arm[s], and the upper die).
If this weight cannot be determined, an approximate static load can be calculated using the information and formulas which follows below.
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Allow 2000 pounds of static load for each cubic foot displaced in the press bed area (front to back x right to left) multiplied by the shut height (die space) of the press. Note: When using this formula, the calculated approximated static load has a safety factor of two (2).
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2. Determining the Die Safety Block Length
With the machine at the top of its stroke; stroke up—adjustment up (S.U.A.U.–see previous page), measure the space between the upper and lower die set plates (not the distance between the bolster and slide). This gives the maximum safety block length. To determine the stroke up—adjustment down (S.U.A.D.–see previous page) measurement, subtract the ram adjustment from the S.U.A.U. figure. This provides the minimum length of the die safety block.
Total Length of Die Safety Block Required ___________"
EXCEPTIONS
A. If wedges will be used, subtract 1 1⁄2" maximum. This is an allowance for variation in the stopping point of the crankshaft or adjustment of the ram.
Total Length of Die Safety Block Required ____________"
B. When an adjustable screw is added to an octagonal safety block, the minimum length of the aluminum portion of the safety block is as follows:
For small and medium safety blocks
2 1⁄2" plus the size of the adjustable screw device
For large safety blocks
3" plus the size of the adjustable screw device
When an adjustable screw device is added to an octagonal safety block and the screw is all the way inside of the safety block, it will add 2" to the overall length of small and medium safety blocks and 2 1⁄2" to the overall length of large safety blocks. Therefore, subtract 2" for small or medium blocks and 2 1⁄2" for large blocks to determine the length of the aluminum portion of the die block.
Example: If the minimum overall length of the small or medium safety block required is 10 1⁄2" with any size adjustable screw device, the aluminum portion of the safety block would be 8 1⁄2" (10 1⁄2" - 2" = 8 1⁄2").
Example: If the minimum overall length of the large safety block required is 16" with any size adjustable screw device, the aluminum portion of the safety block would be 13 1⁄2" (16" - 2 1⁄2" = 13 1⁄2").
Total Length of the Aluminum Portion of the Die Safety Block ___________"
3. Determining the Size of the Die Safety Block
The size of the die safety block (small, medium, large) is determined by one or both of the following factors:
A. The size of the block itself and the area available in the die. (See static load charts.)
B. The static load capacity of the block (small, medium, large) versus the total static load being supported. (See static load charts.)
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| X-Shaped Safety Blocks |
To determine the number of safety blocks required, the static load each safety block will support, and the length of each block, please click here.
The X-shaped safety blocks can be furnished four different ways:
A) Cut to length with a hole and pin for an interlock chain or wedges
B) Cut to length only
C) In a nine-foot length
D) Cut to length with a hole and pin for an interlock chain
or wedges and a base plate installed (order base plate
separately)
Please consult factory for pricing on items A-B & D
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Ordering Information
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| U-Shaped Safety Blocks |
To determine the number of safety blocks required, the static load each safety block will support, and the length of each block, please click here.
The U-shaped safety blocks can be furnished three different ways:
A) Cut to length with a hole and pin for an interlock chain or wedges
B) Cut to length only
Please consult factory for pricing on items A-B
C) In a nine-foot length
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| Octagonal Safety Blocks |
To determine the number of safety blocks required, the static load each safety block will support, and the length of each block, please click here.
The octagonal safety blocks can be furnished four different ways:
A) Cut to length with a hole and pin for an interlock chain and with an adjustable
screw device installed (order adjustable screw device separately; see below)
B) Cut to length with a hole and pin for an interlock chain or wedges
C) Cut to length only
Please consult factory for pricing on items A-B-C
D) In a nine-foot length
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| Adjustable Screw Device—For use with Octagonal safety blocks only |
This heavy-duty steel screw device is added to the octagonal shaped safety blocks. These screws are needed to prevent any space between the block and die when various dies are used or when the slide is adjusted.
Note: If an adjustable screw device is mounted to an octagonal safety block, you must use the approximate static loads shown in the chart. This is because the adjustable screw devices will not hold as heavy a static load as the octagonal safety blocks by themselves. |
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DIE SAFETY BLOCK ACCESSORIES |
SAFETY BLOCK BASE
This safety block base can be added to U-shaped, octagonal shaped, and X-shaped safety blocks. The base adds stability to help prevent the die block from tipping over. Available in 1/2"-thick steel or aluminum. |
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Ordering Information—Steel Bases for U-Shaped and Octagonal-Shaped Safety Blocks
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Ordering Information—Steel Bases for X-Shaped Safety Blocks
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Ordering Information—Aluminum Bases for Octagonal-Shaped Safety Blocks
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Ordering Information—Aluminum Bases for X-Shaped Safety Blocks
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SAFETY WEDGES
These wedges prevent hazardous movement of the press slide if a space is created between the block and die when various dies are used or when the slide is adjusted. All cut-to-length wedges are furnished with a 24" chain. Available in aluminum or hardwood. |
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LIFTING HANDLE
This aluminum lifting handle is a convenient option for all safety blocks that are used frequently. |
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HOLDERS
These holders are designed to accept U-shaped, octagonal, X-shaped, and adjustable safety blocks. They are constructed of heavy-gauge steel and painted safety orange. The holders attach easily to the machine with two ¼" fasteners. A strap is furnished with each holder to keep the block in place. Safety wedges can also be stored in the holders. |
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ELECTRICAL INTERLOCK SYSTEMS
According to ANSI B11.19-2003, safety blocks “shall be interlocked with the machine to prevent actuation of hazardous motion of the machine.” The following interlock systems will satisfy this requirement. The interlock must be interfaced into the control system so that when the plug is pulled, the power to the main drive motor and control is disconnected. If the machine has a mechanical energy source, such as a flywheel, it must come to rest before the die block can be inserted. The interlock system is available in a yellow plug with one contact or an orange plug with two contacts. The interlock system includes the plug, a 12" or 24" long chain, a receptacle, and an electrical mounting box. |
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WARNING LABELS —
Part No. KST-323—English
Part No. KST-323S—Spanish
The warning label illustrated to the right is provided with all safety blocks and should be affixed directly to each safety block. If a safety block is not tall enough for the label to fit, affix it to a prominent location on the machine. All personnel operating or working around the machine must be required to read, understand, and adhere to all warnings on this label. If the label becomes destroyed or unreadable, it MUST be replaced. Contact the factory immediately for a replacement label and do not operate the equipment until the warning label is in place. |
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MAXIMUM LOAD LABEL—Part No. KST-330
The maximum load label shown to the right is provided with all safety blocks and is affixed directly to each safety block. If the label becomes destroyed or unreadable, contact the factory for a replacement label. The maximum load in tons should be written legibly on the label in permanent marker based on the maximum load chart. |
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ADJUSTABLE DIE SAFETY BLOCKS |
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These adjustable safety blocks feature a tough malleable-iron bell-bottom base, a convenient handle for lifting, and precision-cut acme threads for easy adjustment and extra rigidity. The adjusting screw can be easily adjusted up or down by hand. Turning holes are also provided in the screw neck to facilitate the use of a turning bar, if required. |
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