Our company‘s management measures to avoid the occurrence of punch injury accidents

It is also an effective measure to realize the safety of stamping operation under current conditions to set up safety protection devices on stamping equipment and dies or to use hand tools with low labor intensity and convenient and flexible use. For example, manual tools, mold shields, mechanical access devices, double button switches, mechanical handles, push and pull devices, photoelectric automatic protective devices, etc. are used. There are many forms of protective devices for stamping equipment, which can be divided into mechanical type, button type, photoelectric type, inductive type, etc. according to the structure.

The mechanical protective device is simple in structure and easy to manufacture, but it has a large interference to the operation. The operators do not like to use it, and the application is relatively small.

The photoelectric device is composed of a set of photoelectric switches and mechanical devices. When the operator‘s hand enters the mold area, the light beam is blocked and an electrical signal is sent, so that the sliding block stops moving and cannot go down, ensuring the safety of the operator. There are two types of photoelectric protection devices: infrared photoelectric protection device and incandescent photoelectric protection device. The photoelectric protective device is widely used because it is convenient to use and has no interference to the operation.

The contact type protective device uses the contact rod as a sensing element to control the movement of the sliding block. There are two types: normally open type and normally closed type. The protective device has the advantages of simple structure, low production cost and convenient operation, and workers can use several sets of devices in series when working. It is applicable to the press equipped with friction clutch and the press with modified rigid clutch.

To realize the mechanization and automation of stamping operation is the fundamental way to ensure the personal safety of workers and the safety of equipment. The best technical measure to achieve safe production is to realize the fully automatic production of stamping, feeding and reclaiming.

Practice has proved that the use of compound die and multi station continuous die to replace the dangerous die of single process, or the setting of mechanical feeding and unloading mechanism on the die to realize mechanization and automation can achieve the purpose of improving product quality and production efficiency, reducing labor intensity, facilitating operation and ensuring safety.

Technical description of safety protection device

At present, the safety protection device is the most effective safety protection device to protect the personal safety of stamping machine operators. It is better than the protective fence, mechanical handle, mechanical handle and other protective devices to avoid the occurrence of safety accidents due to improper operation or machine failure in the production process. It is applicable to ordinary punches (our company is equipped with a complete set of refitting devices, which can make ordinary punches operate more safely.), high-performance punches, mechanical presses, hydraulic presses, film presses, plate shears, industrial manipulators, packaging equipment and other automatic equipment, and can also be used for the protection or anti-theft of multi-faceted areas.

The safety protection devices are generally divided into two types, namely, anti radiation type and reflective type.

The radiation type safety protection device refers to the photoelectric protection device in which the light emitting unit and the light receiving unit are respectively in the light emitting unit and the light receiving unit, and the light emitted by the light emitting unit directly shines on the light receiving unit, thus forming a protective light curtain. The radiation type safety protection device is composed of controller, illuminator, light receiver, light transmission line and light transmission line, as shown in Figure 1.

Reflective safety protection device refers to the photoelectric protection device that the light emitting unit and the light receiving unit are all in the same sensor, and the light emitted by the light emitting unit is reflected back to the light receiving unit through the reflector, thus forming a protective light curtain. A safety protection screen is formed between the illuminator and the reflector. Whenever the safety protection screen is interfered or the equipment is not working normally, the illuminator will send signals to the press control system to prevent possible dangerous movement and stop the downward danger of the hammer. Reflective safety protection device consists of controller, sensor, reflector and transmission line.

At present, many enterprises still follow the simple manual operation method when using the stamping method to process production, that is, to directly load parts from the mold cavity by hand. Moreover, a large number of stamping equipment are responsible for the manufacturing task of a variety of products or processes. In this case, if there is no safety protection device for the stamping equipment and die, it is very easy to cause hand injuries. Therefore, it is an important task to strengthen safety protection, safety management and improve mechanization in stamping production to prevent accidents.

1. Analysis of injury in stamping operation

The causes of injury accidents caused by stamping operations include personnel, equipment, molds, processes and environment.

(1) People are the central link to achieve safe production

Stamping production is a continuous repetitive operation, and most small and medium-sized enterprises basically adopt manual operation. Due to the requirement of high speed and high production efficiency, one shift must send and take products by hand thousands of times, which consumes a lot of physical energy. Long working hours are easy to paralyze the operators (especially young workers), leading to mistakes and accidents. At the same time, leaders at all levels have improper production organization, lax safety production rules and regulations, poor safety management, command against rules, and pay no attention to safety production. In addition, operators operate against rules, take chances, be capricious, impatient, arrogant, and thoughtless, as well as large stamping machines operated by many people collectively, if they do not coordinate well, accidents are likely to occur.

(2) Impact of stamping equipment on safety production

Stamping equipment has a great impact on safety production. For example, the punch itself has defects, lacks safety protection devices, the clutch and brake are not flexible and reliable enough, the electrical control structure suddenly loses control and causes continuous impact, and the accessories and tools have defects, which are important reasons for the accident.

(3) Influence of Unsafe Factors in Stamping Die on Safety Production

The unsafe state of the die is directly related to the personal safety of the operator and the normal operation of the stamping production. In the process of structural design of stamping die, if the use of convenient safety tools is not considered, and the safety factors such as ensuring the convenience of feeding, sizing, discharging and waste cleaning are not considered, the operator‘s hand will stay in the closed area of the die for too long, which will inevitably lead to accidents. Therefore, scientific and safe mold design is extremely important.

(4) Impact of process documents on safety production

Process documents are not only the basis for production, but also an important basis for implementing process discipline. The typical document recording the stamping process is the process specification, which should include the whole process from the preparation of raw materials to the punching of finished products.

However, there is a serious loophole in the process documents, that is, most process documents do not clearly indicate the safety requirements and safety technical measures. In addition, the existing stamping safety regulations are not perfect. For example, the Regulations formulated by the factory generally include all stamping parts. Although it can reflect the commonness of stamping, it cannot reflect its characteristics. The Regulations often only generally write "generally use safety tools" and "do not put your hands into the mold for operation", but there are no specific technical measures for the different characteristics of each part, so that in the actual production process, there is a long-term situation of putting your hands into the mold for operation, which makes the safety management a mere formality, and the operators ignore the use of safety devices and tools and take risks to operate, causing accidents.

(5) Impact of environment on operators

The impact of the stamping environment on the operator is also very important. If the operation site is narrow, the products are not stacked completely, the operation site is not well lit, the ventilation is poor, and the noise and ambient temperature are too high or too low, accidents will be caused.

2. Preventive measures for stamping accidents

According to the above reason analysis, there are many preventive measures to prevent stamping accidents. First, we must strengthen safety management measures, and then take safety technical measures, both of which are indispensable.

(1) Safety management measures for stamping operation

The safety management of stamping operation is a comprehensive work, which requires not only technical measures, but also strict and sound management methods. The safety management of stamping operation involves the management of process, mold, equipment (including safety devices), production plan and safety technology education. If the process discipline is not strict, the mold management is not good, there are many potential equipment accidents, the organization of production is unqualified, the level of safe operation is low, and the discipline is lax, injury accidents will continue to occur.

Actively promote safety evaluation activities. Carry out safety evaluation activities, establish and improve safety production rules and regulations, especially the implementation of the "safety production responsibility system", so that each employee can clearly define their own safety responsibilities, strictly implement the stamping safety operation procedures, strengthen safety management, and eliminate the occurrence of liability accidents.

It is a very effective way to reduce stamping accidents to do a good job of safety education for employees. The enterprise often educates the staff on safety thought and safety technology knowledge, so that the stamping workers, technicians and production management personnel can firmly establish the idea of safety first, and master the safe operation technology of stamping equipment, molds and protective devices, which can avoid and reduce accidents.

It is necessary to strengthen the safety management of stamping process and incorporate safety technical measures and requirements into process documents. It can not only ensure the implementation of various safety technical measures and achieve effective safety production, but also clarify the safety production responsibility system of process technicians. If the safety production status, number, equipped safety tools and safety devices, name, number, etc. of the die are indicated on the process card, and specific and clear process documents are used as the production basis, accidents caused by reasons such as no rules to follow or unclear process discipline can be effectively prevented.

In addition, process technicians must always understand and master the problems existing in the production process, and constantly improve the process technology.

In the management process of stamping dies, first of all, regular inspection and maintenance must be carried out, and then the dies shall be distinguished by color code according to their threat to personal safety. For example, red represents dangerous mold, yellow represents safe mold, green represents automatic mold, etc.

In the safety management of stamping equipment, the equipment maintenance system shall be formulated first to maintain the equipment and safety devices regularly. Before operation, the operating system, safety devices, electrical appliances and main fasteners of the equipment must be carefully checked to see if they operate normally. It is strictly forbidden to operate the equipment "with faults".

In the process of production management of stamping operation, it is necessary to strengthen production planning and scheduling, reasonably formulate production schedule and deadline according to product structure and production scale, ensure balanced and orderly production, and avoid accidents caused by overtime.

(2) Safety technical measures for stamping operation.

The safety technical measures for stamping operation cover a wide range, including improving the stamping operation mode, reforming the die structure and realizing mechanical automation. The use of compound die, continuous die and multi position die can reduce the working procedure, simplify the working procedure, simplify the operation and reduce the operator‘s risk.

Hand safety tools. The use of hand safety tools can avoid accidents caused by unreasonable mold design and sudden equipment failure.

Common safety tools include elastic pliers, special pliers, magnetic sucker, tweezers, pliers, hooks, etc.

Protective measures for moulds. Including protection around the mold and mold structure improvement. For example, improve the dangerous area of the mold and expand the safe space; Set the mechanical discharge device. On the premise of not affecting die strength and product quality, the original single process dies for manual feeding are improved to improve safety.

It is also an effective measure to realize safety protection of large area of stamping operation under current conditions by setting safety protection devices on stamping equipment and dies or using manual tools with low labor intensity and convenient and flexible use.

Protective devices for stamping equipment. There are many forms of protective devices for stamping equipment, which can be divided into mechanical type, button type, photoelectric type, inductive type, etc. according to the structure.

The photoelectric device is composed of a set of photoelectric protectors and mechanical devices. When the operator‘s hand enters the mold area, the light beam is blocked and an electrical signal is sent, so that the sliding block stops moving and cannot go down, ensuring the safety of the operator. As the photoelectric protective device is convenient to use, it basically has no interference to the operation and is widely used.

Name of photoelectric safety protection device in the product industry:

Safety protector, photoelectric protector, safety grating, punch safety protector, safety light curtain, photoelectric eye, photoelectric safety protector, punch safety protector, infrared electric eye, machine tool safety protector, mechanical equipment safety protector, assembly line detection device, protective alarm device, finger protector, finger safety protector, finger anti cutting device, finger anti cutting device, and hand protector.

(3) Improve the working environment and strengthen self-protection measures

According to the standards of safety evaluation and the regulations of site management, reasonable equipment layout, safe stacking of products, reasonable lighting, appropriate temperature and good site safety environment can reduce accidents.