TRANSFER CAR GUIDANCE

AND SAFE WORKING

PRACTICES
 Guidance Content

Contents Slide Number

Transfer car definition 3
Transfer car hazards and hazard areas 4
Hazardous scenarios 5
Elimination 6
Prevent access to the transfer car 7 - 11
Prevent contact with the transfer car - proximity lasers 12 -19
Prevent contact with the transfer car - proximity alert systems 20 - 23
Control access to the transfer car lane 24
Sound and visual warning 25 - 27
Crossing points 28 - 33
Identification of the transfer car routes 34
Floor markings / Signage 35 - 36
Conveyor layout 37 - 40
Elimination of conveyor entrapment points 41 - 43
Minimising conveyor shear points 44
Safe distances and minimum gaps 45 - 48
Other general control measures 49 - 51
Appendices 52 - 53
 Transfer Car Definition

DEFINITION
Transfer cars are moveable cars with installed manual or power -
driven conveyors for the transportation of material units. These
material units are transferred from continuous conveyors, are
moved laterally and discharged to another continuous conveyor of
another machine or conveyor.

Transfer cars can reach speeds up to 180 m/min with large stopping
distances and can be fully automatic or manually driven by
operators.
 Transfer Car Hazards and Hazard Areas

Injuries from contact with moving transfer cars

Struck by moving transfer car
Struck by moving transfer car due to malfunction of control system (unexpected
start up, unexpected overrun)
Trapped between transfer car and conveyor lines.
Crushed between transfer car and a fixed structure / object
Trapped / crushed between transfer car and a falling load.
Impact from transfer car and other vehicles e.g. FLT
Potential hazard areas
Transfer car lanes / cells
Cross over passageways
Transfer car WIP areas
Transfer car maintenance areas
 Hazardous Scenarios

1. Person in the path / route within

the stopping distance of the
transfer car.

2. Person in the path / route just

outside the stopping distance of
the transfer car.

3. Person in the path / route

currently undetected.

4. Person close to the path / route.

5. Person “hidden” behind a stack of

corrugated board.
 Elimination – TC1

Eliminate transfer car use and replace with mechanical / conveyor systems
Prevent access to the transfer car – TC 2
Physical enclosure

Physical enclosure of the transfer car route

• Install a combination of fixed guarding /

safety system to protect the restricted area
with controlled gated entry – control
philosophy in place to ensure that the
transfer car cannot operate whilst there is
activity / presence in the car cell.

• Height of the fence to a minimum of

1400mm from the floor. The gap between the
floor to the bottom of the fence should be no
more than 180mm.

• Reach distances to the hazard should be

considered using the BS EN 13857 standard
(upper and lower limb reach distances).
 Prevent access to the transfer car – TC 3

Controlled gated entry / Key Exchange

Principle of key exchange is one key per person and that person exchanges the key with a
second key from the gate. The person holds on to the key during entry. This is for lane entry, not
for maintenance tasks on the transfer car.

Example - There are 3 different lettered keys:-

A = Master key – Will only fit into side of control panel and releases keys B.
B = Gate release key – To be removed from control panel and inserted into safety gates to
release key
C = Person retain key – To be kept on person at all times whilst inside the guarded area.
 Prevent access to the transfer car – TC 4

Key-in-pocket (initial situation)

Dangerous area (transfer car)

protected by e.g. a metal fence.

If an operator needs to enter the

area, the machine must shutdown.

When the machine has been shut

down, the person can go inside and
do their work.

As long as persons are in the

dangerous zone, the machine must
not be switched on again by
anyone.
 Prevent access to the transfer car – TC 5

Key-in-pocket (solution approach)

An operator must authenticate himself (sign in) with his personal transponder
key at the (cell) door.

If the operator is authenticated, he can shut down the machine and open the
door, remove the key and enter the facility. Other operators can also sign in
with their personal key and enter the facility.

Only when all signed in operators left the facility and signed out with their
personal key, the machine can subsequently be started.
 Prevent access to the transfer car – TC 6

Key-in-pocket (Safety Function)

 Identification of persons and

 protection against accidental (machine)
start-up
 as long as at least one user is signed in.

PL d Cat. 3 according to EN ISO 13849-1

SIL CL 2 according to EN 62061
SIL 2 according to IEC 61508
 Prevent contact with the transfer car – TC 7
Proximity Lasers

Front Safety Proximity Laser Rear Safety Proximity Laser Over / Under scanning

Where scanning underneath of the conveyor is not possible because the

conveyors are completely covered, this area has to be safeguarded by a
second laser scanner
 Prevent contact with the transfer car - TC 8
Proximity Lasers

On the front and rear of the transfer car where safety proximity lasers have been
installed. These lasers are designed to slow down and stop the transfer car if
there are people or objects in front of it. Even though the laser scans for objects,
you still need to be aware of its limitations.
Prevent contact with the transfer car - TC 9
Proximity Lasers

Protection by optoelectronic detection;

stops the transfer at a predetermined set
distance

• Second laser scanner

• Scanning above the conveyor if a

safeguarding of the movement of the
transfer car is secured by a laser
scanner.

• This scanner has to scan the area

above the conveyor by at least 100 mm.
Prevent contact with the hazard - TC 10
Proximity Lasers

Instructions – Setting on Lasers

The installation of the scanners and the
evaluation of the electronics must fulfil
the requirements of PL d of ISO 13849-
1:2015.
 Prevent contact with the transfer car - TC 11
Proximity Lasers

When setting up the scanners they need to be adjusted (mapped) in a way that there
are no blind spots and a person standing or lying in the transfer car lane or on the edge
of the conveyor is detected and the transfer car comes to a complete stop before
contact is made.

Therefore, it is necessary to optimally adapt the geometry of the protective field to

the existing conveyor dimensions.
4. Prevent contact with the transfer car - TC 12
Testing Proximity Lasers (Example)
Prevent contact with the transfer car - TC 13
Testing Proximity Lasers (Example)
 Prevent contact with the transfer car - TC 14
Testing Proximity Lasers (Example)

The results of the tests should be recorded on a control sheet such as the one below.

Example control sheet.

Date test Laser unit Tests OK Comments Signature

carried out Y/N
Lower
forward
Lower
reverse
Upper
forward
Upper
Reverse
 Prevent contact with the transfer car – TC 15
Proximity Alert System

Accident and collision prevention system

Utilising the latest ultra wideband (UWB) technology.

Setting proximity zones around the transfer car allowing for the detection of people
with the ability to give warning to pedestrians, slow the car down or stop the car.

Tag and Sensors

 4. Prevent contact with the transfer car – TC 16
Proximity Alert System Example

• 2 UWB Antenna – located at the front and rear of the transfer car enabling a
complete detection zone within figure of 8 zone pattern.
• 1 display unit on the transfer car.
• 2 Detection zones - Zone 1 alert zone (warning) Zone 2 danger zone.

Tag and Control Box

Prevent contact with the transfer car – TC 17

Proximity Alert System

Sensor Location - Examples

Prevent contact with the transfer car – TC 18
Proximity Alert System

Tag Holder Options

 Reduce the risk – TC 19
Control access to the transfer car lane

Where practical, access to the transfer car lane should be prohibited at all times.
For any routine tasks ( moving materials to machines etc) or non routine tasks
(engineering/ maintenance work including work on conveyors). LOTOTO must be
applied and the transfer car MUST be locked-off to prevent any movement. A
PtW must also be issued. Reliance purely on a proximity alert system is NOT
acceptable in these situations.
 Reduce the risk - TC 20
Sound and Visual Warning

Each transfer car shall have visual and acoustic machine condition indicators.
Prior to a transfer car setting off, a 6 second pulsed audible alarm should be
automatically activated.
 Reduce the risk - TC 21
Sound and Visual Warning

Visual warning solution for automatic transfer car systems which operates in
the direction of travel when the transfer car is moving.
 Reduce the risk - TC 22
Sound and Visual Warning

The visual indicators shall use the following colours to indicate the transfer car
condition
Visual Indicator - Colour Meaning Action by operator
Red flashing Hazardous condition (E stop) Immediate action to deal with the
hazardous condition

Yellow flashing Transfer car in transit

Blue flashing Safety function activated Mandatory safety related control system.
Reset required

Green Transfer car stationary in automatic mode

White Transfer car in manual mode

The acoustic signals shall use the following tones to indicate the transfer car condition
Acoustic signal Meaning Action by operator
Continuous tone Hazardous condition (E stop) Immediate action to deal with the
hazardous condition

Six second duration pulsed tone Transfer car about to move

Pulsed tone Transfer car in transit
No tone Safety function activated Mandatory safety related control system.
Reset required
 Reduce the risk - TC 23
Crossing Points

• Where it is necessary for pedestrians to cross a transfer car lane / route, it is

recommended to have defined crossing points along the route.

• Crossing point methods should consider the hierarchy of controls based on

the risk.

The following are four examples that could be adopted.

 Reduce the risk - TC 24
Crossing points – Hierarchy Example 1

Access Request Gates - Request to entry system

Guard locking switches can be used which will lock the access gate closed
until the transfer car is stationery and in a safe location.

The transfer car will not move until the access gate is closed and locked.
 Reduce the risk - TC 25

Crossing points – Hierarchy Example 2

Barriers with passing request - They open

depending on the position of the transfer car
and have ability to ‘park’ the car to allow safe
crossing.

Depending on the position of the transfer

car, the system indicates a status colour. In
order to cross, you must request the
passage and await a safe signal to
progress.
 Reduce the risk - TC 26

Crossing points – Hierarchy Example - 3

Crossing point status indicators - Light

system (traffic light) linked to the transfer
car position. Indicates if safe to cross or
not.
 Reduce the risk - TC 27

Crossing points – Hierarchy Example 4

Barrier crossing – A push button is Chicane barriers which warns the

required to open the barrier. If the person they are about to cross a
transfer car is in the crossing zone, transfer car lane.
the barrier is inhibited until it is safe to
cross.
 Reduce the risk - TC 28
Crossing points – Hierarchy Example - 5

• Reduce as much as possible the number of

crossing points of pedestrian ways through transfer
car route / path.

• The transfer routes can only be crossed at the

authorised crossing points by pedestrians.

• They must be clearly marked and with the

necessary protective measures in place

• If there are crush points that can’t be sufficiently

protected, safe crossing system mandatory to
neutralize the hazard.
 Reduce the risk - TC 29
Identification of the transfer car route

The transfer routes should be

painted in such a way that both
the transfer route and the possible
crossing points that exist will be
easily identifiable.

Keep Clear - Red Safe Zone

Reduce the risk - TC 30

Floor markings / signage

Reduce the risk - TC 31
Warning Signage
 Prevent contact with hazard - TC 32
Conveyor Layout

• Conveyor systems are used extensively in the industry to feed material units
on and off transfer cars, and there is a danger that people can be crushed
and shearing risks for persons standing between the conveyor and the
transfer car.

• In order to avoid a foot or body entanglement hazard between transfer car

structure and other conveyor structures or the corrugated stacks on the
storage area/conveyors, entrapment points must be eliminated, and
minimum distances must be kept
Prevent contact with hazard - TC 33
Raise the floor area

• Raise all floor areas to the same level as the

conveyor and transfer car by installing
working platforms.

• If there are protective structures along the

route, prevent access to the route.

• The distance should be >500 mm (distance to

escape).

• If there is an opening, the platform should be

>1000 mm wide.
Prevent contact with hazard - TC 34

Conveyor Layout

Conveyors spread - There are free

spaces between conveyors, therefore there
may be many potential crushing and
shearing risks.

It is strongly recommended to reduce the

number of open spaces between
conveyors as much as possible.
Reduce the risk - TC 35
Conveyor Layout

Front ended not fully covered

Allowing a distance of at least 150 mm
from the conveyor edge to enable a
trouble-free scanning of the area
underneath the conveyor.
 Prevent contact with hazard - TC 36
Elimination of conveyor entrapment points

Continuous side plate at the same height

where possible as the conveyor is the most
simple solution to eliminate crush points
with transfer cars.
 Prevent contact with hazard - TC 37
Elimination of conveyor entrapment points

Only the starting and finishing point are

open ended, the rest of the conveyors are
joined together.
With this configuration, the crushing and
shearing risks are minimised.
 Prevent contact with hazard - TC 38
Elimination of conveyor entrapment points

Front ended covering of the roller

conveyor
Where there is a combination of conveyors
in the same transfer car route, it may not
be possible to allow a distance beneath
them of 150 mm.
Conveyors are completely covered to avoid
trapping points. The gap between the fixed
plate and the conveyor should not be
greater than 5mm.
 Reduce the risk - TC 39
Minimising conveyor shearing points

Ensure foam pads or metal plates are fitted on both sides of every conveyor leading to
the transfer car route. These are designed to push any objects away from the car and
to minimise entrapment risk.
 Reduce the risk - TC 34
Safe distances and minimum gaps

In order to avoid an entanglement hazard

between foot and transfer car, the transfer
car has to be covered laterally in a manner
that the distance to the floor does not
exceed 25 mm. If this is not possible a
distance of at least 120 mm has to be kept.

Please refer to BS EN 349 ISO

13854:2017 (Minimum gaps to avoid
crushing to parts of the human bodies).
 Reduce the risk - TC 40
Safe distances and minimum gaps

The maximum distance between transfer

25MM car and lateral front covers of the
<-> conveyors has to be no greater than 25
mm. A space as small as possible should
be aimed for in order to avoid a crushing of
body parts in this area. Please refer to ISO
13854:2017 (Minimum gaps to avoid
crushing to parts of the human bodies).

.
 Reduce the risk - TC 41
Safe distances and minimum gaps

A distance of at least 500 mm for body

height between transfer car and fixed
elements such as building stanchions. If
this is not possible, a risk assessment has
to be done to define safety counter
measures.

180 mm between structures if the structure

at leg height.

Please refer to ISO 13854:2017 (Minimum

gaps to avoid crushing to parts of the
human bodies).
 Reduce the risk - TC 42
Safe distances and minimum gaps

In all the scenarios, it is strongly recommended

lining the spaces between the conveyors by filling
the spaces with horizontal plates.

These should be installed at the same height

level of the conveyor and should be set out at a
length of at least 1m like a platform in order to
avoid additional tripping points.
 Other general control measures - TC 43

Automatic / Manual Operating Modes

Operation modes - There is likely to be only two

operating modes available on the TC:
1) Automatic operation mode
2) Manual operation mode

If the transfer car has been designed and constructed to

allow it to operate in both modes, each mode will require
protective safety control measures and a clear SSoW
All control devices must be clearly identifiable and must
correspond to a single operating or control mode.
Operators and maintenance personnel will need to be
competent in the use and different operating functions for
both modes.
Ensure there are local safe systems of work in place which include safe access and
egress and switching the car from automatic to manual mode and vice versa.
 Other general control measures - TC 44
Access and egress safely

Ascend & descend in a Safe manner Hold barrier & gain good balance when
operating the transfer car manually.

Only access and egress the transfer car when it is stationery / parked up.

Ensure there are local safe systems of work in place which include safe access and
egress.
 Other general control measures - TC 45

Energy Isolation – Lock out, Tag out, Try out.

It is critical that energy isolation (lock out tag out try out) has been applied prior to any
non routine intervention which includes engineering / maintenance / cleaning tasks on
the transfer car and associated conveyor systems.

This includes all energy sources (electric, pneumatic) on the transfer car and conveyor
systems.

Local safe system of work and energy isolation procedure must be in place.

A system needs to be in place for monitoring compliance with all LOTOTO procedures.
 Other general control measures - TC 46
Preventing Slips, trips and falls
Information Tools to use
HSE website
 Appendices
Transfer Car Incident

What Happened
• Operator went to assist two
colleagues sort out an out of line
stack.
• It is likely he had his right foot on
the roller and left foot on the floor
• TC was behind him and he did not
hear or see the car movement
• The scanner did not pick him up
• The car struck him and kept moving

Direction
Contact Point of Car
 Appendices
Transfer Car Incident

What Happened
• Curve would have pulled his leg in – rather
than push it away
• He was dragged 4m before the car was
stopped.
• He colleagues freed him
• He was badly injured
• His colleagues attached a tourniquet to halt
the bleeding.
• Emergency services arrived and took him
to hospital.
• His lost his left leg below the knee