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Analysis of stamping safety production accidents and preventive measures


stamping production is a processing method with less and no cutting. It has high material utilization rate, simple operation, stable size, high precision and good interchangeability of parts, so it plays a very important role in modern industrial production. According to incomplete statistics, stamping parts account for about 60% in the automobile and tractor industry, 85% in the electronic industry, and about 90% in daily hardware products

however, stamping is also a production that is prone to safety accidents. According to relevant information, the personal accidents on the punch are three times higher than those in the general machinery industry. With the promulgation of the labor safety law, many manufacturers have taken many safety protection measures to protect the safety of workers. However, according to the author's understanding, at present, some enterprises (especially small and medium-sized enterprises) still use the manual operation method of directly loading parts in the mold cavity by hand when using the stamping method for processing and production. In this case, if there is no safety protection device for stamping equipment and dies, personal safety accidents are very likely to occur

1 the statistical data of stamping safety matters show that the statistics

now a brief introduction to a relevant information in Japan, which reflects the law, is basically consistent with the current situation in China:

1.1 according to the size of the enterprise: in fact, not all the properties of degradable materials have reached the standard of engineering plastics, so it occurs in small enterprises with less than 50 people, and small batch sporadic production accounts for 70%

1.2 according to the size of the press: 70% of the accidents occur on small presses of less than 50 tons, 18% occur on presses of 50 ~ 100 tons, and the rest are more than 100 tons

1.3 according to the injured part: right hand 47.4%, left hand 37%, face and neck 6.9%, right foot 3.8%, left foot 2.5%, head 1.6%, the rest 0.8%

1.4 according to the direct cause of the accident (see the table below):

1.5 according to the feeding type: 91% manual feeding, 6% using hand-held tools, 3% automatic feeding

2 analysis of stamping safety accidents

2.1 reasons for people first of all, due to the operators' ignorance, contempt, incomprehension, inexperience or neglect, dissatisfaction and other bad emotions about the dangers in stamping operation and its safe operation methods, plus some physical reasons, sick work, close vision and deafness, lack of sleep, fatigue, drunkenness and so on, safety accidents are very easy to occur. Large machine tools are generally operated by many people. If they are not properly coordinated with each other, accidents are also prone to occur. Secondly, stamping production is a continuous and repeated operation, and the operators repeatedly send and take products by hand thousands of times during a work period, which consumes a lot of physical energy. According to the laws revealed by ergonomics, behavioral science and psychology, when people are engaged in this kind of fast and simple repetitive work for a long time, it is very easy to produce body fatigue and slow response, resulting in inattention, dyskinesia, and tragedy in an instant

2.2 reasons for stamping die the die is directly related to the personal safety of operators, equipment safety and the normal progress of stamping production. The die is tilted, broken, waste splashing, workpiece or waste picking up due to structural reasons, and there is no preventive structural measures; The mold makes it convenient for fingers to enter the dangerous area; The positioning of a single blank on the mold is inaccurate, and the position needs to be corrected by hand. These are bound to cause safety accidents due to unreasonable design of mold structure, failure of mold manufacturing as required, improper mold installation and adjustment, etc.

2.3 reasons for stamping equipment the objective reason for stamping safety accidents is that most of the stamping equipment used for stamping are crank presses and shears, and their clutches, brakes and safety devices are prone to failure, resulting in the phenomenon that clutches and brakes are not sensitive and reliable enough, and electric control structures suddenly out of control and continuous impact, which are important reasons for stamping safety accidents. In addition, for small punches under 16 tons, their movement speed is much faster than people's reaction speed. Even in the state of high concentration, it takes 0.3 ~ 0.4 seconds for houyunchun, former deputy director of the development research center of the State Council, to move his hand for a few centimeters, and this time has exceeded the time from the top dead point to the bottom dead point of the slider. That is to say, the working nature of punches, especially small punches, exceeds human physiological limits

2.4 reasons for process technical documents stamping process specification is a process technical document guiding the production process of stamping parts. It is not only the basis for organizing stamping production, but also an important basis for implementing process discipline. Reasonable stamping process procedures should consider productivity, economic benefits and production safety. However, it is understood that most of the current stamping process regulations in enterprises do not clearly indicate the relevant provisions such as safety requirements and safety technical measures. Yes, It is only generally written "generally use safety tools" and "hands are not allowed to reach into the mold to operate" drink clean water and appropriate wastewater treatment " And so on, without marking specific safety technical measures according to the different characteristics of specific parts, making safety management a mere formality, and operators ignore the use of safety devices and tools and risk operations, resulting in accidents

2.5 reasons for safety management: lax safety production rules and regulations, lax process discipline, poor mold management, many hidden dangers of equipment accidents, unreasonable production organization, chaotic working environment, unsatisfactory labor conditions at the production site, uneven stacking of products, poor access, poor safety management, low level of safety operation, illegal command, and failure to pay attention to safe production, injury accidents will continue to occur

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