Head protection on equipment with sharp corners 1

[DReimer]

On our equipment we've got a 1.5" square steel bar that is cantilevered out some distance to allow adjustment of an assembly along its length. Unfortunately the end of this bar is hanging in the air and is often in a position where one can strike his head on it.

I'm trying to find some off-the-shelf bumper cap to fit on the end, but have had no luck on google. Anyone ever used something like this? I need something that will be economical in quantities of 100-150 per year.

I've looked at dipped vinyl caps which would make the corners less dangerous, but they want me to buy a 7 year supply. I figure molded rubber or polyurethane would work well, but haven't had any luck finding them already designed for such an application.

Thanks,
Dean

 

[JStephen]

First choice would be to modify the layout to avoid the problem in the first place.

If you haven't done so, check a McMaster-Carr catalog- they have a bunch of different bumpers, caps, plugs, etc., and you're liable to find something workable there.

 

[drawoh]

DReimer,

Will a soft cap do the job? I can see a rubber cap preventing cuts, but someone is still banging their head on a solid object.

I would go for JStephen's first suggestion.

JHG

 

[IRstuff]

Why not buy a can of the vinyl dip and do it yourself? You can buy the stuff at the local Home Depot.

And if you doing 100-150 per yr, I don't see why you think you have too large a quantity of vinyl dip.

Particularly since you probably need two coats

TTFN

 

[DReimer]

To clarify, the bar is not in a normal access area. When the machine is operating normally it is actually behind an interlocked guard and is not a hazard. The perimeter of the machine keeps personnel away from the hazard as well. It is really only a problem when servicing/adjusting the machine and when we are building it here at our plant.

I agree with JStephen - the ideal is to alter the design to eliminate the problem. Like many things, however, it is easier said than done. Until we can make that happen, I need something that will keep someone from ripping a big gash in their scalp.

I checked McMaster-Carr and couldn't find exactly what I need, although they have some things I might try, and they gave me a couple ideas, too.

 

[MintJulep]

Pool noodles!

Bright colors, good padding, cheap.

 

[unclesyd]

Make a little wood mold and a sheet of shrink wrap and use a tube or two of the conforming packaging foam. You can get a little creative if you like.

Use something like this material.

http://www.sealedair.com/instapak_home.htm

 

[amorrison]

How about some suitably sized circular rubber hose that could be slipped (forced "square") over the steel end.

Some thick walled stuff like "wrapped water hose" (McMaster-Carr") maybe cut to 3 inches long with some silicone adhesive to secure in place. Make sure the rubber sticks out - say 1/2 inch to cover the steel corners.

 

[BillPSU]

Place a baggy around the end of the tube with a rubber band and then inject insulating foam into the baggy. Not pretty but should work.

 

[MikeHalloran]

If you can find a retail source, the AllSafe Bar-Gard A20 should work pretty well:

http://americanallsafe.com/catalog/singledisplay.asp?username=&category=Misc&version=consumer&id=722

20 years ago, the smaller A10 size, perfect for 1/2" lab rack, cost just pennies.



Mike Halloran
NOT speaking for
DeAngelo Marine Exhaust Inc.
Ft. Lauderdale, FL, USA

 

[arto]

http://www.caplugs.com/catalog/NavMenu.asp?classid=100

 

[unclesyd]

Look at busbar insulation shrink tubing and also look at the “Insulation Enhancement Products” in the pull down menu to the left.
I would probably give them a call.

http://energy.tycoelectronics.com/index.asp?act=page&pag_id=2&prl_id=5&pls_id=29

I was thinking about a fishing trip and remembered that we use throwaway insulating ropes for chaffing gear on our anchor and dock lines.

 

[Philrock]

If all else fails - how about punching a hole in a tennis ball and slipping it over the end of the bar?

 

[DReimer]

MikeHalloran - those rebar caps are exactly what I need, only I need them to fit over a square end.

arto - it's a similar type of cap that they want me to buy 700 of. I can't justify having 7 years worth of inventory of anything, even if they are cheap.

MintJulep - Pool noodles! That's a great idea! Our customers would either appreciate our sense of humour or think we were spiking our coffee.

Others - thanks for all the suggestions. I think I'll sketch something simple up and see if our urethane molders can do something cheap with some 40 durometer urethane.

I'm also thinking a 1/2" rubber sheet cut in a 3" diameter circle fastened to the end of the bar. If you struck it with your head it would tend to conform around the bar and protect you from the edge.

 

[cadcoke5]

In theater we wrap with sheet sponge rubber, and then wrap it with fabric tape (gaff tape).

McMaster also sells a variety of pipe insulation products. Some are in sheet form to wrap around a pipe. They also have pre-formed polyethylene elbows.

Another option is to use the tough rubber padding normally used for floor matts, and cut it up to wrap the square tube.

Joe dunfee

 

[griffengm]

tennis ball in bright yellow!

Griffy

 

[MikeHalloran]

I don't know about the big ones, but the medium rebar caps are not real fussy about the shape or size of what they protect you from. They have internal fins that deflect to accommodate a wide range of sizes and shapes of bar. If you wanted to learn about intelligent design with plastics, they'd be a good case study.






Mike Halloran
NOT speaking for
DeAngelo Marine Exhaust Inc.
Ft. Lauderdale, FL, USA

 

[Hydroformer]

I like the tennis ball but nothing beats the old stand-by, pillow & duct tape.

regards,

Hydroformer

 

[griffengm]

The tennis ball I can do without. Nap time in my cubicle with my pillow I cannot!

Griffy

 

[btrueblood]

The pool noodle is a great idea - nice bright color to provide a warning. The same stuff is available at local hardware stores and/or McMaster, in slit version, for insulating pipes - but it only comes in grey or black, which doesn't make a very good visual warning.

I would suggest having a piece of bright colored cloth or tape attached to the end, so that when the arm is in the "danger" position, the tape hangs down and provides a "warning" to the unwary operator. Maybe even labelled with "watch your head!".