C



C.O.R.E.

Community of Robotic Engineers

Team 2062

Waukesha, WI

Safety Manual

Safety Captain- Aaron May

Table of Contents

ITEM……………...…….Page #

What is safety?...........................1

Safety Rules.…………………..1

Pit Area...………...…….......1

Work Shop………...……….2

PPE………………………....3

Event……………...………..3

Battery safety…...……………..4

Electrical safety…...…………...4

Pneumatic safety…...………….4

5S Principals…………………..4

Robot Inspection Form..………5

Pit Inspection Form..……..……6

Correction Forms …...………...7

Page 6

Page 7

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401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

What is Safety?

Safety -The state of being safe; freedom from the occurrence or risk of injury, danger, or loss. ><

Safety Rules - Safety FIRST! --- Don’t learn Safety by accident

It is very important that the following rules are followed to prevent injury.

Pit Rules

Safety Attitude - Think Safe, Act Safe, Be Safe

• No Running.

• If in doubt, ask.

• No Horseplay.

• Use common sense.

• Use the right tool for the job.

PPE (Personal Protective Equipment)

• Safety glasses must be worn at all times in the pits.

• Use proper hand protection when needed.

• Do not wear loose or baggy clothing.

• No open toed or open heeled shoes.

• No jewelry or necklaces.

LOTO (Lock Out Tag Out) - Disconnect power before any work is done

• Disconnect batteries.

• Release any pressure in pneumatic system.

• Unplug battery chargers when not in use.

Good House Keeping

• Everything has its place.

• Use 5S principles.

• No food or drink in pit.

Proper Lifting Techniques

• Lift with legs, not the back.

• Get help if what you are lifting is heavy.

• Use the lifter handles for the robot.

In case of Emergency

• Know where the nearest severe weather shelter is.

• Know where the nearest fire exit is.

• Know where your team’s evacuation meeting point is.

Report ALL accidents or injuries to (mentor and pit administration)

Page 1

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

Work Shop Safety

1. Eye Protection must be worn in the shop when activities are happening.

2. Eye Protection must be clean and able to see through

3. Do Not wear loose clothing, neck ties, necklaces, jewelry or gloves while operating machinery. Long hair should be tied back or under a hat.

4. Do not carry sharp, pointed tools in your pockets.

5. While using a drill, hold the work piece firmly. While drilling or cutting a small work piece, hold the part with a vice, clamp, or pliers.

6. Keep the floor around your work area clear of scraps, tools, materials oil or water so people don’t trip over items or slip.

7. Only the machinery operator should be in the operating zone of the machinery. If you are not operating the machine stay away and don’t distract the operator. If you are helping the operator with the process, follow the operator’s instructions.

8. Keep your mind and attention on the operation. Do not be talking or looking around. Watch what you are doing.

9. If a machine/equipment has sign on it “do not use” or “out of order”, it is never acceptable to ignore the sign and use the equipment.

10. Never splash any liquid (solvents, developers, cleaners, chemicals) on anyone.

11. If chemicals get in your eyes they should be flushed with fresh water from the sink.

12. Any equipment/electrical tool that gives you an electrical shock should be reported to the instructor and labeled “do not use”.

13. Never push, shove, or horseplay in the shop. Someone could get hurt.

14. Never make adjustments to a machine while the machine is running. Always stop the machine and wait until the blade has stopped before making the adjustment.

15. Do not use any machine unless you have been instructed in the safe operation of that machine. If unsure ask a mentor.

16. It is not acceptable to leave a machine running after you leave it.

17. Keep your hands about 4 inches away from the cutting path of the blade at all times.

18. When using portable electrical tools, keep the cord away from the cutting blade’s path.

19. Many shop accidents happen with chisels. People push the chisel into their other hand. When using cutting hand tools, like a chisel, be careful not to push the tool’s cutting edge towards your body parts.

20. Never remove a machine’s safety guard, while operating the device. If this is required because of the work piece’s size - see a mentor.

21. ALL ACCIDENTS need to be reported to a mentor. Small cuts need cleaning and a band aid. You or your parents should be aware of your last tetanus shot. Serious accidents will require parent permission to take you to an emergency room for medical treatment.

Don’t Learn Safety by Accident

Page 2

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

Personal Protective Equipment (PPE)

1. Gloves:

• Gloves are required when handling the robot and crate.

• Gloves are also required when handling chemicals and electrical equipment.

• Never wear gloves when working with power tools.

• Use gloves when crating and uncrating the robot.

• Use gloves when transporting or lifting the robot

2. Safety Glasses:

• Eye protection is required in the work shop, pit area, on the practice fields and during competition at all times.

• They will protect your eyes from:

o Flying objects

o Sharp objects

o Chemicals

o Other hazardous materials

3. Shoes:

Closed toe and closed heal shoes are required in the Pit area, work shop, practice fields, competition areas.

4. Clothes:

Long, non-baggy pants are required in the pit and work shop.

Baggy and loose clothes are not permitted in the pit and work shop.

Do not wear jewelry, necklaces, ties, etc.

(Any clothing that could get caught in any type of machinery is not allowed in the pit and work shop)

5. Hearing protection:

Use ear plugs when there is a possibility of damage to hearing

o Ex. cutting metal

Event

• No running at all times.

• When transporting the robot have one person clear the way in front of the cart.

• Use the buddy system at all times.

• Let a mentor know where you are at all times.

• No standing on tables

Page 3

Battery safety:

• Never carry the battery by the wires.

• Check the battery after every match for damage

• If the battery is dropped it should be disposed of properly because of possible leak/damage.

• If battery leaks; dispose of it properly. Tell the Pit Administrator to obtain sodium bicarbonate (baking soda) to put on the acid that leaked out.

• For proper battery disposal procedure, see MSDS.

• If contact is made with battery acid, see MSDS for first aid.

• Use latex gloves when handling a leaky battery.

Electrical safety:

• Have the power shut off and the battery disconnected when working on the robot or electrical system.

• Shut the power off and disconnect the battery from the robot after every match.

Pneumatic safety:

• Pneumatics must not be energized, (no compressed air in system) when the robot or pneumatics system is being worked on or the robot is sitting around.

• Bleed the Pneumatics after every match.

• Stand back when testing pneumatic devices.

Lock Out Tag Out

Lock Out Tag Out (LOTO) is a standard that is used in industry to prevent a machine from being powered up while someone is working on it. The way we use LOTO is when the drivers take the robot off the field and put LOTO box on the robot and take it to the pit for post-match inspection. While the robot is locked out, the only person allowed to take off a tag is the person who owns that tag or a mentor with a tag. If someone who does not have a tag sees a problem with the robot they should tell someone who owns a tag to lockout the robot so he or she could fix the problem.

5’S Principals

|1 | Sort |Sort through items and put in groups, needed and not used. Get rid of unused items. |

|2 | Shine |Do major cleaning of work area. (clean regularly). |

|3 | Set in order |Organize the work area – A place for everything and everything in its place. |

|4 | Standardize |Use pit inspection list twice a day for the pit area. |

|5 | Sustain |Make 5S a way of life. Assure that all team members know the importance of 5S for the success of the |

| | |team. |

Page 4

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

401 E Roberta Ave, Waukesha, WI 53186 (262) 970-3148

Robot Inspection Form

This Checklist Must be Completed After Each Match (2009 Season)

Date ________Time ___:_____AM / PM

Controls File checklist

Notes Initials

_________ _____ 1 – Change Battery with a fully charged battery.

_________ _____ 2 – Battery connections on the removed battery checked for tightness.

_________ _____ 3 – Removed Battery is put on charge.

_________ _____ 4 – Connections on main breaker checked to be tight.

_________ _____ 5 – All data connections are checked to be tight.

-Check on attached sheet (Circle ones that are not tight)

_________ _____ 6 – All power connections are checked to be tight.

_________ _____ 7 – All power connections are checked to be tight.

GPIO 1 GPIO 2-3 GPIO 7

_________ _____ 8 – All connections on the PWM controllers checked to be tight.

PWM 1 PWM 2 PWM 3 PWM 4

PWM 5 PWM 6 PWM 7

_________ _____ 9 – Check gear tooth sensor on shooter

Mechanical Secure Working

Notes Initials

_________ _____ 10 – Vertical conveyer belt:

Belt Tension Pulleys aligned Belt not Damaged

_________ _____ 11 – Horizontal conveyer belt:

Belt Tension Pulleys aligned Belt not Damaged

_________ _____ 12 – Check for loose bolts:

Frame Shooter Conveyer

_________ _____ 13 – Wheel Sprockets check for being tight and in-line:

Drive Train Shooter

_________ _____ 14 – Chain tension:

Drive wheels Shooter Conveyer

_________ _____ 15 – Wheel alignments:

Drive wheels Shooter

_________ _____ 16 – Wheel Shaft Hitch Clips:

Drive Train Conveyer

_________ _____ 17 - Motors and Gearboxes tight and secure.

_________ _____ 20 – Check Bumpers for Damage

Power up Test

Notes Initials

_________ _____ 18 – Vertical Conveyer:

Forward Reverse

_________ _____ 18 – Horizontal Conveyer:

Forward Reverse

_________ _____ 18 – Shooter:

Rotates Wheel Spins

_________ _____ 19 – Drive system works:

Forward Reverse Left turn Right turn

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