I. Acquisition (lease)
1, into the site of the machinery must be a regular manufacturer, must have a "production license", "factory certificate".
2, strictly prohibit the acquisition and lease of the state expressly eliminated products, regulations are not allowed in the use of machinery and equipment.
3, it is strictly prohibited to purchase and lease, the test fails to meet the safety and technical standards of mechanical equipment.
4, it is strictly prohibited to lease the existence of serious accidents, there is no transformation or repair value of machinery and equipment.
Two, installation (demolition)
1, mechanical equipment has been approved by the relevant national or provincial departments of the inspection and testing institutions qualified, and through the national or provincial competent authorities of the organization's product technology appraisal.
2, shall not be installed belonging to the state, the province ordered the elimination or restriction of the use of mechanical equipment.
3, building construction enterprises purchased second-hand machinery and equipment, there must be national or provincial departments approved by the mechanical inspection and testing units issued by the quality and safety of technical inspection reports, and by the use of the unit to organize professional and technical personnel on the technical performance and quality of machinery and equipment acceptance, in line with the conditions of safe use, the use of the unit signed by the person in charge of the technical consent.
4, a variety of mechanical equipment should be prepared for the following technical documents: (1) mechanical equipment installation, dismantling and testing of graphic procedures and detailed instructions; (2) the safety insurance devices and limit devices debugging and instructions; (3) maintenance and transport instructions; (4) installation and operation procedures; (5) production license (the state has implemented the production of licensed lifting machinery and equipment), product identification certificate (6) accessories and supporting tools catalog; (7) other matters
5, engaged in the installation of machinery and equipment, demolition of units, according to law, should be issued by the competent administrative department of the corresponding level of qualification certificates and safety certificates issued by the qualification certificates can only be in the qualification certificate level permitted to engage in the installation of machinery and equipment, demolition of the scope of the activities.
6, mechanical equipment installation, removal unit, should be in accordance with the safety specifications for mechanical equipment and the requirements of the provisions of the installation, removal activities, mechanical equipment installation unit of mechanical equipment installation quality is responsible for its installation.
7, engaged in the installation of machinery and equipment, demolition of operators and managers, should be qualified by the competent administrative department of construction assessment, to obtain the national uniform format of construction machinery and equipment operators certificate before engaging in the corresponding operations or management.
Three, acceptance test
1, mechanical equipment installation unit must establish the following mechanical equipment installation project data files, and in the acceptance of the relevant technical information within 30 days after the transfer to the use of units, the use of units should be deposited in the safety and technical files of machinery and equipment:
(1), the contract or mission statement
(2), the installation of mechanical equipment and Acceptance information
(3) special construction programs and technical measures for mechanical equipment.
2, mechanical equipment installation can be used normally, in line with the relevant provisions, and use and other technical requirements.
Four, use
1, mechanical equipment operators, must be licensed.
2, the operation must be strictly enforced mechanical technical operating procedures and technical delivery.
3, non-mechanical labor operation to trace the responsible person, and according to the company's regulations.
V. Maintenance
1, the purpose of regular maintenance: the correct and reasonable use of machinery and equipment and careful and timely maintenance, the purpose is to ensure the normal operation of the equipment, extend the service life of machinery and equipment, to prevent undue damage, and undue mechanical accidents.
2, maintenance operations: cleaning, lubrication, adjustment, solid, corrosion, etc..
6, maintenance and renovation
1, small repairs: small repairs: small repairs of the work, mainly for the regular daily inspection of the problems found, part of the dismantled parts for inspection, repair, replacement or simple repair of less worn parts, while through the inspection, adjustment, fastening of mechanical parts and other technical means, to restore the performance of the equipment.
2, item repair: item repair is based on the actual technical state of the equipment, the state of deterioration has failed to meet the production process requirements of the project, according to the actual need for targeted repairs, item repair is generally necessary to partially dismantle, inspection, replacement or repair of failed parts, if necessary, partial repair and correction of the benchmark parts, so as to restore the performance and accuracy of the repaired part to ensure that the machinery in the whole Overhaul interval has a good technical condition and normal working performance.
3, overhaul: equipment overhaul is the machinery in the life cycle of a thorough inspection, and restoration of repair, overhaul, disassembly of all or most of the components of the equipment, repair of the reference parts, replacement or repair of all the parts do not fit, repair of the electrical system of the equipment, repair of the equipment, accessories, and refurbishment of the appearance of the equipment to achieve the comprehensive elimination of defects that existed before the repair to restore equipment, technical regulations, performance and accuracy. performance and accuracy.
VII, scrapping regulations and requirements
When the equipment can not be overhauled, there is no repair value.
Basic requirements for machinery safety
Machinery and equipment in the provisions of the entire period of use, shall not occur due to defects in the machinery and equipment itself caused by the current has been recognized by the various types of accidents endangering personal safety and occupational diseases causing damage to health, to avoid unnecessary physical exertion to the operator, mental stress and fatigue. Both the design of the intended function of the machine and the design of the safety protection should follow the following two basic ways: the choice of appropriate design structure, as far as possible to avoid danger or reduce the risk; by reducing the need for the operator to get into the danger zone, to limit the exposure of people to danger.
1. Sufficient resistance to damage, good reliability and adaptability to the environment
(1) reasonable mechanical structure type. The structure of mechanical equipment must be suitable for its intended function, can not be caused by unreasonable structural design of the normal operation of the machinery, obstacles, jamming or loose; can not be caused by the components or software flaws in the loss of microcomputer data or crash; can not be expected to occur in any of the design of the machinery and equipment can not be expected to be unreasonable in relation to the event.
(2) sufficient damage resistance. Mechanical components of the composition of the stress components and their connections, should meet the completion of the intended maximum load of sufficient strength, stiffness and component stability, during normal operation should not occur due to stress or the number of work cycles resulting in fracture or fatigue damage, excessive deformation or collapse; must also consider the premise of the mechanical equipment under the overall resistance to overturning or the stability of the wind and skid resistance, especially those due to the expected load or Uneven distribution of their own mass of machinery and those who can travel on the track or roadway machinery, should ensure that the transportation, operation, vibration or external forces will not occur under the overturning, to prevent the operation of the loss of control and produce undue displacement.
(3) the use of the environment has sufficient adaptability. Mechanical equipment must be used in the environment (such as temperature, humidity, air pressure, wind load, rain, snow, vibration, load, static electricity, magnetic and electric fields, radiation, dust, microorganisms, animals, corrosive media, etc.) with sufficient adaptability, especially corrosion or cavitation, aging wear resistance, anti-interference ability, not due to electrical components to produce insulation damage to make the control system parts and components of the temporary or permanent failure, or as a result of Physical, chemical, biological effects and cause accidents.
(4) improve the reliability of machinery. Reliability refers to the machine or its components in the specified conditions of use and the specified period, the ability to perform the specified functions without failure. Traditional mechanical design only according to the performance indicators of the product design, and reliability design in addition to ensure that the performance indicators, but also to ensure that the reliability of the product indicators, that is, the product's trouble-free, durability, maintenance, availability and economy, etc., the reliability of the product is the embodiment of the durability and reliability of the degree of a performance, and safety has a direct relationship.
2. shall not produce more than the standard provisions of harmful substances
(1) toxic and hazardous substances. Should be used for people harmless materials and substances (including machinery itself a variety of materials, processing raw materials, intermediate or final products, additives, lubricants, cleaning agents, as well as reacting with the working medium or environmental media and waste products). For unavoidable poisonous substances (e.g. dust, toxic substances, radiation, radioactivity, corrosion, etc.), measures such as confinement, emission (or absorption), isolation, purification, etc. should be considered in the design. In places where personnel are reasonably exposed, its composition and concentration should be lower than the provisions of the product safety and health standards, and shall not constitute a harmful effect on human health, nor shall it cause pollution to the environment.
(2) prevention of physical hazards. Mechanical noise, vibration, overheating and low temperature and other indicators must be controlled below the permissible indicators specified in the product safety standards to prevent psychological and physiological hazards to people.
(3) fire and explosion-proof. There are combustible gases, liquids, vapors, dust or other flammable and explosive or pyrophoric substances in the mechanical production equipment, should be considered in the design to prevent the running, bubbling, dripping, leaking, according to the specific configuration of the monitoring and alarm, explosion-proof pressure relief devices and fire safety facilities, to avoid or eliminate the friction and impact, sparks and static build-up, etc., and to prevent the resulting fire or explosion hazards.
3. Reliable and effective safety protection of any machinery have such and such a danger, when the machinery and equipment put into use, the production object (a variety of materials), environmental conditions and the operator is in a dynamic combination of the dangers of the situation is even greater. As long as the danger exists, even if the operator is well trained in technology and safety education, and there are perfect protocols, can not completely avoid the risk of mechanical injury accidents. Therefore, it is necessary to establish a reliable physical barrier, i.e., to equip the machinery with one or more guards, safety devices or other safety measures specifically designed to protect human safety. When there are problems with certain parts of the equipment or operation, it relies on the machinery itself to avoid accidents by taking a variety of safety and technical measures to ensure the safety of personnel and equipment. Dangerous or high accident rate of production equipment, must be equipped with safety guards at the factory.
4. Fulfillment of the requirements of safety ergonomics
Human-machine interface refers to the machine on the human and machine for information exchange and interaction interface. Display devices, control (manipulation) devices, human workspace and location and the operating environment, is the focus of human-machine requirements, should meet the anthropometric parameters, the human body's structural and functional characteristics, physiological and psychological conditions, in line with health requirements. Its purpose is to ensure that people can work safely, accurately, efficiently and comfortably, reduce errors and avoid danger.
5. Maintenance of safety
(1) mechanical repairability. Machine failure, in the prescribed conditions, according to the prescribed procedures or means of implementation of maintenance, can maintain or restore its implementation of the intended functional state, which is the machine's repairability. Failure of equipment can cause the loss of the intended function of the machine, bringing losses to the work, and dangerous failures can also cause accidents. In this sense, the solution of dangerous failures, restore the safe function, is the same as the elimination of safety hazards.
(2) the safety of maintenance operations. In the implementation of maintenance in accordance with the prescribed procedures, should be able to ensure the safety of personnel. Because the maintenance operation is different from the normal operation of special operations, often use some unconventional practices, such as removing the protective device, or make the safety device does not work. In order to avoid or reduce maintenance injuries, should be set in the control system maintenance operation mode; from the inspection and maintenance point of view, in the structural design of the internal parts of the accessibility of the consideration; if necessary, should be provided with the equipment for special inspection, maintenance tools or devices; in the more bulky and heavy parts, should also be considered to facilitate the lifting of the design.
Mechanical equipment operation safety management system
1, Purpose: the establishment of machinery and equipment safety management procedures
2, Scope: applicable to the company's machinery and equipment operation management
3, Responsible parties: the Safety Department, the Ministry of Engineering, the use of machinery and equipment units
4, Procedures:
4.1. Production operation of the equipment, all should be Develop sound safety regulations, safety and technical regulations, fire prevention system and maintenance system, and should always educate workers to implement.
4.2. The design, manufacture, installation and repair of all kinds of mechanical equipment must meet the safety requirements.
4.3 Where new construction, alteration, expansion and technological innovation, technological transformation projects, must be based on safety technology, industrial hygiene, labor protection point of view to determine the technical program, within the possible scope of mechanization and automation.
4.4. In the production process of toxic gases or dust, all of its equipment construction should try to make it airtight.
4.5. All kinds of pressure machinery pressure part, as well as other machinery to the human body have occurred in the part of the injury, should be equipped with safety devices.
4.5.1 Dangerous parts such as drive belts, open gears, grinding wheels, electric saws, couplings close to the ground, shafts, pulleys and flywheels, etc., are to be provided with safety devices.
4.5.2 It shall be practically impossible to cause accidents due to defective or ineffective safety devices.
4.6. Opening and closing devices, gates and ancillary equipment more than 2 meters above the ground should have a walkway of more than 0.6 meters, which should be surrounded by a strong and reliable railing of more than 1 meter in height.
4.7. In the motor and power transmission device, the part that personnel may contact, should be surrounded by a strong metal fence or cover.
4.8. Equipment dismantling, top walkways of storage tanks, passageways, stairways and other places where personnel are exposed to fall hazards shall be surrounded by strong fences, handrails or covers.
4.9. When the equipment being operated is found to have serious faults and there is a danger of accidents, the operation shall be stopped immediately and reported to the next level, and appropriate safety measures shall be taken.
4.10. Mechanical equipment in the parking machinery sweeping, refueling, inspection, repair, in order to prevent others to start, accidents should be appropriate safety devices and obvious signs.
4.11. Machinery is prohibited from doing the following while it is rotating:
4.11.1 Sweeping the rotating portion of the shaft or head with a hand held swab.
4.11.2 Removing or disabling safety devices and facilities.
4.11.3 Perform installation, disassembly, and repair work.
4.11.4 Pour lubricant to the rotating wheel joint.
4.12. The flap used and all other measuring instruments shall be set up in a suitable place with sufficient lighting for operation, observation and maintenance.
4.13. The use of the flap and other adjusting devices, to facilitate the operation of the management, anti-button flap or often closed flap and gate should be hung with a clear sign.
4.14. Pipes connected to the production system that are cut off should be blinded and clearly labeled.
4.15. In order to prevent combustible gases from generating explosions should pay attention to check:
4.15.1 The degree of tightness of combustible gas piping, equipment, to meet the basic requirements to prevent leakage.
4.15.2 in the combustible gas pipeline plant, should ensure adequate ventilation, prohibit arbitrary fire.
4.15.3 Do not allow combustible gas piping, equipment to generate negative pressure.
4.15.4 Pipes and equipment containing combustible gases must be replaced and analyzed before stopping for repair.
4.16. When starting and stopping must make a good check and contact work, after confirming that there is no problem, according to the provisions of the opening and stopping. 4.17. After the inspection and repair of the equipment driving, according to the "safety production overhaul system" in the relevant provisions of the implementation.
4.18. Infrastructure department equipment before the test drive should be organized to check the relevant departments, equipment and installation should be in line with the design specifications, to know the test drive regulations, safety and technical measures, by qualified operators in the test drive conductor on-site command, before the test drive.
Newly installed infrastructure equipment must be idle before going into production, qualified before the test run with load.
Stamping machinery safety operation and management
Stamping processing is the use of metal molds to separate or deform the steel or billet process method. It has the advantages of simple operation, high productivity, high precision of size and shape, capable of punching complex parts, and easy to realize mechanization and automation. Widely used in automobiles, tractors, motors, electrical instruments, light industry and other manufacturing industries.
One, stamping machine safety guards
Safety guards for stamping machine tools refers to the safety devices that try to separate the danger zone from the operator's hand when the slider goes down, or the operator's hand will be dialed out of the danger zone in a mandatory way. Commonly used guards are protective fences, dial hand guards, etc. (see the Ministry of Machinery Industry in May 1985 issued by the "stamping safety management regulations").
1. Fence-type guards
It is a protective fence added to the press to separate the operator from the danger zone or protected area. The fence moves with the slide of the press, and when the slide goes down, the fence goes down with it, separating the operator from the die, thus protecting the operator's safety.
2. Toggle guard
Toggle guard is a safety device that forces the operator's hand out of the danger zone when stamping. It pushes or pivots the hand out of the danger zone by means of a lever with a rubber that pushes the hand out of the danger zone on the downstroke of the slide.
This type of guard is simple in structure, but its force is large, and in most cases the reliable protection of the push-out effect is lagging behind. Newer toggle hand device interlocked with the control system, toggle hand device does not work, the press can not work.
3. Infrared protection device
Invisible infrared light emitted by the light source, not through the optical lens polymerization, and directly radiated. The receiver also does not go through the optical lens spotlight, but directly accept infrared light. It can effectively prevent the body from approaching the danger zone.
There are many types of press safety guards, in addition to the above, there are hand-held safety guards, tactile interlocking safety guards, two-handed operation safety guards.
Second, the press machine tool feeding device
Set the press machine tool feeding device, realize the feed mechanization, automation, is to improve productivity, to ensure safe production of important measures. Simple feeding device, can also play a role in ensuring.
1. Manual safety tools
In the medium-sized stamping presses, such as can not be mechanized feeding, can be used to send manual tools, materials, so that the stamping workers hands completely out of contact with the danger zone. Hand tools are mechanical tweezers, pliers, hooks, vacuum suction cups, pneumatic clamps and so on.
2. Simple manual feeding device
As long as the hand to promote the blank, so that the blank along the guide plate slides into the concave mold, that is, to achieve the purpose of feeding.
3. Mechanical feeding device
Mechanical feeding device structure is simple, accurate, easy to operate, safety, but also to improve production, should be promoted.
Three, management measures
To realize the safety of stamping, in addition to a variety of technical measures, it is also necessary to take a variety of management measures, mainly:
1. Establishment of process management system. Production should be carried out under the guidance of process documents, documents to have safety content, in the process of operation card must be clearly noted on the die safety status, number, equipped with the name of the safety tools, number and so on. With these specific and clear process documents as the basis for production, in order to prevent a variety of injuries caused by the lack of rules to follow or process discipline is not clear.
2. Establishment of stamping equipment and safety guards management system. Stamping equipment malfunction, safety guard failure, may be the material conditions that cause workers casualties. Therefore, to establish stamping equipment and safety guards maintenance and maintenance system, strict compliance with technical operating procedures. Before operation, we must carefully check the equipment manipulation system, safety guards, electrical appliances and the main fasteners, etc., to observe the operation of any special sound or other abnormalities, and found that the faults and hidden dangers should be immediately shut down for repairs, and forbid the "with disease" operation.
3. Develop safe operating procedures and management system, and educate workers to implement seriously. To resolutely stop the phenomenon of violation of the rules, for violation of the rules and cause personal or equipment accidents should be based on the responsibility system to give education and serious treatment.
4. Safe operation of the press.
Before work, first carefully check whether the manipulation mechanism is flexible, reliable, fasteners have no loose. Especially pay attention to the manipulation system of the spring has no failure or broken phenomenon. No-load test machine operation is normal, whether the slider single movement hysteresis or even punch phenomenon, whether the safety device is intact.
When feeding individual blanks by hand, a suitable special tool must be used. Safety devices should be used throughout the work.
If the machine is found to be operating with abnormal sound, producing continuous punching, malfunctioning operation or electrical faults, it should be stopped and serviced immediately.
When the press machine uses a foot switch, it must be equipped with a protective stopper. When the slider starts, the foot must immediately leave the pedal. In the process of machine operation, it is strictly prohibited to go to the rotating parts of the inspection and repair. Adjustment, repair and cleaning of molds must be carried out after stopping the machine.
After the work is finished, turn off the motor, tidy up the workplace, clean the press table, oil the press, wipe the machine and the die, and apply oil on the guide plate of the die and the slide. Work is complete, move the pedal to neutral or lock the pedal.