Lock 'N' Safe
The concept is simple: Lock 'N' Safe quickly, effectively and safely locks out lumber sorter bins to ensure the bin floor will not move when a worker is present in or below the bin area. Lock 'N' Safe is similar to a cable brake that stays open with compressed air, and requires no electricity to operate. Lock 'N' Safe units are easily installed in any type of bin sorter.
Entry into or below the bin area is typically done by labourers performing clean-up duties, production workers remedying skewed lumber on floor chains or maintenance personnel repairing or replacing equipment. Lock 'N' Safe is used instead of lowering the bins (lifts) onto positive mechanical stops (as required by WorkSafeBC regulations and guidelines G10.3) as this has proven to be extremely time consuming and is often done incorrectly.
Conventional mechanical safety stops are not designed to withstand the impact of a falling lift (i.e. from hydraulic or mechanical failure in suspension system), but lowering bins onto these stops is typically skipped as the sorter bin lift hydraulic system does not possess the power required to raise a partially full bin. The Lock 'N' Safe Lumber Sorter Bin Restraint System is used as a replacement for these conventional mechanical safety stops to ensure proper lockout is effortlessly completed each time.
Over 12,000 Lock 'N' Safe restraint units have been installed throughout North America, Australia, and New Zealand during the last 30 years. Our client base includes 40 of the top wood product companies in North America.
Lock 'N' Safe Rated Load Capacity
The factor of safety on each brake unit is five to one based on actual load tests made on prototypes. Each brake unit is shop-tested to 1.5x its rated load capacity on our test bench.
Load Capacity
| System | Standard (STD) |
Heavy Duty (HD)
|
| Working Load Per Brake Unit | 10,000 lbs. | 20,000 lbs. |
| Total Bin Weight (as a pair) | 20,000 lbs. | 40,000 lbs. |
Benefits
LOCKOUT
Fail safe lock (locks when air supply is removed)
– Locks out the lumber sorter bin in minutes
– Virtually maintenance free
– Uses existing mill air supply to operate
– Entire sorter can be locked out in one easy step with a single master air valve
PRODUCTION
– Bins can be locked out individually for clearing jammed or skewed lumber during production
– In the event of a cylinder or cable failure, the bin can be locked in its failed position and bypassed
BIN MAINTENANCE
– Bins can be locked out individually or in groups during maintenance shutdowns
– Eliminates bin-creep during shutdowns or weekends
– Easily applied to any new or existing lumber sorter
– Employees can feel confident when working under a bin
Properties
RESTRAINT UNITS
One restraint unit is mounted to each end of the bin floor using an adapter bracket. The restraint units are actuated by a highly durable Actuator (spring loaded, air released) typically used in commercial vehicle air brake systems. The restraint’s internal components are custom fabricated and have been tested to five times the rated load. The restraint unit’s moving components are lubricated during assembly for maintenance-free operation throughout its life. Each unit is tested to 1.5x of its rated load capacity after assembly.
SUSPENSION CABLES
The suspension cables are independently mounted to the frame of the sorter using custom-made anchor brackets. This steel core wire rope features a compact construction and therefore has a high resistance to crushing and excellent fatigue resistance. The Standard System comes with ¾” cables rated to 58,800 lbs., while the Heavy-Duty System comes with 1” cables rated to 103,400 lbs.
AIR HEADER
Each air header is specially designed and fabricated to suit the number of bins and bin spacing in order to supply compressed air to all of the restraint units. The air header is typically mounted near the top of the sorter on the lumber line side to allow easy access to the individual lockout valves.
AIR COMPONENTS
Each system is equipped with a regulator, a pressure switch, and a main lockout valve. The regulator ensures that the maximum air pressure for the system does not exceed 80 psi. The pressure switch will prevent the startup of the sorter drive if the air valve is locked or left in the off position or in the case that the pressure drops below the operating threshold. The main lockout valve, when placed in the “OFF” position, will bleed off all the air in the system and engage all restraint units.
Installation
The restraint units are welded to the floor of each lumber sorter bin, beyond the lumber line and clear line sides, using an adapter bracket designed specifically for each make and model of the sorter.
To complete the Lock ‘N’ Safe system, cables are mounted to the frame of the sorter using custom-made top and bottom anchor brackets. The cables, made to the specific length requirements of each sorter, are equipped with a swaged-on-ferrule that fits into the top anchor bracket. The cables are pre-tensioned through the restraint units and anchored to the bottom brackets.
A separate air header is installed on the lumber line side to supply compressed air to all of the restraint actuators. The air header is field-piped to the existing mill air supply. A coiled airline feeds compressed air from the air header to each of the lumber line side restraint units. An air hose is installed through the bin floor to supply air to the clear-line side actuators.