Assessing required safety measures for belt conveyors : Designing a safety assessment tool regarding standard 620+A1:2010

Abstract: This is a Master of Science Thesis in Industrial Design Engineering conducted at Luleå University of Technology with the orientation towards product design and development. This report comprises 30 credits, started autumn 2019 and ended in the beginning of 2020. This thesis was done together with SITE, in cooperation with LKAB to together find a solution that could verify standard 620+A1:2010, to conclude if requirement of engaging more protection at belt conveyors would be necessary. The purpose of this master thesis is to find a solution in the form of a safety assessment tool which could aid investigations regarding standard 620+A1:2010 and whether the requirements are fulfilled or not regarding nip points on carrying and return idlers. This thesis also includes additional requirements given by LKAB that must be followed. The result should consist of a concept that can, with the help of a 50x50mm plate, determine if a conveyor belt can be lifted 50 mm with a force of 150 N. To be able to find a solution to this problem a design process named Snowflake has been used which consists of four phases: Context, Ideation, Concept and Product. The work is built on a theoretical framework with topics such as industrial design engineering, belt conveyors, ergonomics, user experience, interaction design and usability. This, combined with several creative methods to enhance creativity and inspiration followed by an extensive evaluation process, enabled the project team to develop a solution to the acknowledged problem. The project resulted in a conceptual tool that, with the help of a torque wrench, can determine the amount of force required during a safety assessment. Its shape allows measurements to be performed on belt conveyors with a vast variety of roller dimensions. The tool is designed to allow the user to use minimal effort to operate in all its usage stages, from carrying the tool to using it. By having a distance gauge that moves when the tool lifts the belt and stays at the threshold value, the results can be read away from the nip point which increases user safety and usability. The result fulfils the stated criteria and is therefore considered to be a successful result, but it may also serve as a foundation for further development considering the extensive theoretical research which supports the design and functions, despite it being a conceptual product. In the end, the project has resulted in a tool that clearly answers whether safety protectors are required for belt conveyors at nip points, according to parameters stated in safety standard 620+A1:2010, regarding carrying and return idlers.