Dec 2001 – Paper 2 Question 7

a) Explain the principles of an interlocked machine guard. (4)

 A machine cannot start up or become dangerous with the guard open

 When the machine is in a dangerous condition, either the guard cannot be opened or
opening the guard causes the machine to become safe

b) Identify ways in which the following types of electrical, cam-activated position switches
(limit switches) may fail to operate as intended:

i) Negatively operated (or ‘normally open’). (3)

 Guard closed – switch depressed – light off – machine circuit working

 Defeated by taping up the plunger
 Fail through spring failure
 Welding together of the contacts due to electrical arcing
 Damage or debris inside the switch

ii) Positively operated (or ‘normally closed’). (3)

 Guard closed – switch released – light off – machine circuit working

 Fail due to misalignment between the cam and cam follower
 By being removed from its fixing point
 By wear or damage to the plunger
 By over-travel of the guard
 c) By means of a labelled sketch, show the method of operation of an interlocked guarding
system incorporating two position switches (limit switches) operating in opposite modes
together with a simple self-monitoring arrangement utilising the ‘spare’ contacts within
each switch. (10)

Positively
operated –
normally
closed

Guard Light off –

machine
guarded

Negatively
operated –
normally open

Hazard

Machine
circuit

Positively
operated –
normally
closed

Guard Light on –
machine not
guarded

Negatively
operated –
normally open

Hazard