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According to the accident statistics of the Ministry of Industry, the number of mechanical injury accidents and the number of serious injuries accounted for the first place in various accidents in the chemical system. Mechanical injury accidents often occur in production and processing, mechanical operations and so on. Therefore, strengthening management, earnestly doing safety education, improving employee safety awareness, paying attention to improving working conditions, and improving the level of mechanization and automation in the production process are important ways to eliminate or reduce casualties.
First, the relevant definition Mechanical injury: mainly refers to the form of mechanical equipment (stationary) parts, tools, processing parts directly contact with the human body caused by pinch, collision, shearing, entanglement, twisting, grinding, cutting, thorns and other forms of injury. Exposed transmission parts of various types of rotating machinery (such as gears, shafts, tracks, etc.) and reciprocating parts may cause mechanical damage to the human body. Second, the risk factors of general mechanical equipment Mechanical equipment hazards are mainly the moving parts of the equipment, such as transmissions and tools, moving parts and chips. If the equipment is defective, the guard fails, or the operation is improper, it may cause personal injury or death at any time. Mechanical transmission is divided into gear transmission, chain drive and belt drive. Dynamic equipment under the power drive, the occurrence of rotating mechanical damage, there are often the following situations. 1) Since the components do not meet the requirements, such as unreasonable mechanical design, the transmission parts and protruding rotating parts are exposed, without protection, etc., or their own safety protection awareness is poor, careless and illegal operation may cause the handles and clothes to be twisted into them to cause injury. For example, in 1994, on January 21, a maintenance worker at a chemical plant in Hunan Province cleaned the No. 3 coal bar machine. When the protective cover on the coupling was removed, the work clothes were not buckled, and the clothes angle was coupled. The bolts are hooked and the clothes are twisted together into the coupling between the coupling and the foundation, and the patient is killed by the rescue. 2) In the chain drive and belt drive, the pulley is easy to get involved in the tool or the limb of the person. 3) When the chain and the belt are broken, the joint is easy to catch the human body, and the belt flies and wounds. 4) The friction and high belt speed during the transmission process are also easy to cause the transmission belt to generate static electricity, generate static sparks, and easily cause fire and explosion. 5) Extrusion, many rotating machinery, such as rubber calenders, mixers, etc., when the operator fails to operate, the hand will be rolled into the rotating drum, causing crush injury accidents. For example, in April 1996, during the process of treating a tire in the finished product workshop on the third floor of a vulcanization workshop in a rubber factory in Guangzhou, the interface between the guide roller and the horizontal conveyor belt was stuck, the body leaned forward and lost the center of gravity, and the right hand held the running belt. Was caught in, and the neck was severely squeezed to death. 6) The object is used as a component of the rotary motion to generate centrifugal force during the movement. The faster the rotation speed, the greater the centrifugal force generated. If the part has defects such as cracks and cannot withstand large centrifugal force, it will rupture and fly out at high speed. Once the operator is hit by a high-speed flying debris, the damage is serious. Pressure machines have a certain pressure-applying part, and the pressure-applying part is the most dangerous. Because such equipment is mostly manual operation, the operator is prone to fatigue and boredom, and human error occurs. If the feed is not allowed to cause the raw material to fly, the mold is displaced, the hand enters the danger zone, etc., it is easy to cause personal injury accidents. There are three main reasons for mechanical injury: one is the artificial unsafe factor; the other is the defect of the mechanical equipment itself; the third is the poor operating environment. 1. Man-made insecurities The operator must operate the machine and must be familiar with the machine in order to control the machine before the machine can serve us. Human unsafe behavior refers to the occurrence of mechanical injury accidents caused by unfamiliar operating procedures of the machine or violation of operating procedures. Human unsafe behavior, management problems, and workers' own problems can be roughly summarized into the following aspects. 1) Operation errors, operational errors may be manifested in two aspects. First, unfamiliar with the operating procedures or unskillful operation of the machine, and second, lack of concentration or fatigue. 2) Violation of the operating procedures, mainly in the absence of safety procedures, or accidents caused by long-term operation, in order to save trouble, do not follow the requirements of safe operating procedures, resulting in casualties. 3) Violation of labor discipline, mainly manifested in: because the operator wants to shoot time, wants to complete the task early, get off work, knowing that the operation rules are violated, but relying on the luck of the illegal operation, because of the difference between the thoughts cast a big mistake. 4) Non-standard wear, mainly in: wear uniforms and caps according to the regulations, or the clothes are not complete, or the laces are not tied. As a result, accidents occur because the clothes angle, cuffs, hair or shoelaces are caught by the machine. 5) Violation of the command, leading the violation of the command is also one of the reasons for the mechanical injury accident. Mainly manifested in: I am not familiar with the safe operating procedures, but ordered others to violate the operating procedures; or agreed to let the workers without safety education and technical training to post, so it is prone to accidents. 6) The safety operation procedures are not perfect, and the operators have no rules to follow or the procedures are not perfect during operation, so that the safety work cannot be implemented. 7) Into the danger zone, the danger zone refers to the area where the mechanical equipment may cause harm to people. For example, the main shaft coupling part of the compressor, the belt conveyor corridor, etc. are all dangerous areas. 2, the defects of the device itself Dynamic equipment is a moving object. If the quality is not good and the management is not strict, unsafe factors may occur. 1) The mechanical design is unreasonable, or the strength calculation error, or the selection of mechanical equipment is improper, or there is no safety protection facilities, safety devices and signal devices, or there are problems in the installation, so that the mechanical equipment itself is defective or not working. 2) The maintenance, repair and maintenance of mechanical equipment are not timely or the quality of inspection is poor, and there are unsafe factors. For example, in the rolling workshop of a tire factory in Jiangsu Province, when the four-roll calender was technically modified, due to poor installation, the motor suddenly broke down, the roll reversed, and the squad leader was on the chest, and died after being rescued. 3. Poor operating environment If the operator works in an environment with poor lighting, poor ventilation, and poor dust and detoxification, misoperation may occur. To prevent the occurrence of mechanical injury accidents, it is necessary to start from the safety management work to prevent unsafe behavior and eliminate the unsafe state of the mechanical machine. At the same time, it is also necessary to solve the problems of safety protection and safety insurance of mechanical and mechanical equipment in engineering technology. 1. Strict safety management, improve the safety management system of mechanical equipment, and prevent unsafe behaviors. According to various types of mechanical equipment, according to its characteristics, the safety operation procedures are formulated. The contents are as follows: 1) Working principle, structure and various technical performance indicators of dynamic mechanical equipment. 2) Specifications, materials and conditions of use of the main components. 3) Safe operation methods and safety precautions when parking. 4) Treatment methods for various types of accidents. 5) The important protection parts and dangerous area of ​​the mechanical equipment. 6) Good maintenance and regular maintenance. Improve the safety operation procedures of various mechanical equipment, and also strictly enforce it, in order to ensure safe production, reduce and eliminate the occurrence of mechanical injury accidents. Prevent human unsafe behavior Educate employees to strictly abide by the safety procedures and basic code of conduct to prevent mechanical injury. 1) Proper use and maintenance of protective equipment. The place where the protective facilities should be installed must be installed, otherwise it is not allowed to operate; the protective facilities that need to be repaired must be repaired in time, and must be reinstalled after the repair is completed. 2) It is not allowed to dismantle the protective equipment of mechanical equipment. The management of protective facilities must be handled by a special person in the security department. 3) The rotating parts are not stopped. Do not perform any operation on the mechanical equipment. Because the machine has a large centrifugal force during operation, it is dangerous to carry out the operations in production or to clean and maintain. 4) Do not enter dangerous workplaces and dangerous areas without authorization. Safety fences and safety color standards must be established according to the standards. For example, in the vicinity of belt conveyors, machine tools and large compressors, safety guardrails and safety signs should be provided; all personnel are required to walk in safe areas, and do not walk around for convenience. 5) If the machine electrical safety interlocking device has a malfunction, it must be stopped and repaired in time. 6) Machine equipment must not be overloaded. 7) Do not place objects on the rotating parts, so as to avoid flying out of the objects when driving, and a hitting accident occurs. 8) Proper use and wear of individual labor protection products. Labor insurance products are essential for the safety and health of workers. Protective clothing such as clothing, hats, shoes, gas masks and gloves must be properly worn. Protective equipment should be selected according to actual working conditions. For example, workers in machine tool positions are not allowed to wear gloves, but protective glasses should be worn. Protective clothing should be worn in positions exposed to acid and alkali, and protective glasses should be worn at the same time. For women with long hair, they must wear a work cap to operate. As a worker who operates the equipment, you must operate as follows: 1) Dress as required. Open clothing must be fastened, cuffs tied tightly, and long hair plugs in the hat. Remember to wear gloves when working on machines with rotating parts. 2) When the machine is running, it is forbidden to adjust or measure the workpiece by hand. Stop the measurement and move the tool holder to a safe position. 3) The workpiece and the tool must be securely attached, and it is forbidden to touch the rotating parts of the machine by hand. 4) Ensure the necessary safety space for the operation, and strictly implement the prescribed signal when the machine starts to operate. 5) For the work of cleaning the roller shaft, cutting knife and other dangerous parts close to the dangerous parts, use clamps (such as hooks, iron brushes, etc.). 6) It is forbidden to put tools, measuring tools, fixtures and workpieces on the machine or gearbox to prevent falling and hurting people. 7) When the machine is shut down for cleaning, refueling, inspection and maintenance, the starting device of the machine must be locked and the warning sign should be hung; Safety technical requirements for the mobile device itself 1) The safety equipment should be equipped with safety interlocks as much as possible. For example, in the post where mechanical injury operations may occur, add protective measures or multi-directional automatic or manual emergency brakes. The brake rope is connected with a crank arm pressure plate by a stud, and an adjustment spring is added on the pressure plate. The brake rope inlet is flared, and the crank arm pressure plate, the spring, the screw thread, the limit switch and the like are fixed in the box. When braking, just pull the brake rope in any direction, pull the arm arm pressure plate on both sides, and drive the electric limit switch to brake quickly. 2) The stressed parts of the moving equipment must be strictly tested and qualified before use. At the same time, it should be replaced within the specified service life. 3) The mechanical equipment for overage service must be scientifically certified before use or downgraded. Safety protection of mobile equipment All mechanical transmission parts are dangerous, especially in exposed parts and protruding parts of the machine, such as without guards, which can easily cause injury to workers. Especially in the process of cleaning machinery, assembling machines, overhauling machines and oiling, or when the machine suddenly starts and stops suddenly, it is often the case that the worker is injured by the absence of the guard or is caught by the transmission part of the machine. Therefore, there must be reliable guards for the machine drive section. The structure of commonly used mechanical and mechanical equipment is very different, and the specific safety protection measures are also different. But in general, you can follow some of the following protective measures. 1) Protective parts or guards must be installed on movable parts that may be touched or involved by the operator, such as gear transmission, rack and pinion drive, belt drive, and chain sprocket drive. The location of the fence and shield, the spacing of the fence, the width of the metal mesh, and the size of the opening must be determined according to the operator's hand and body range of motion. 2) To prevent the movement of the mechanical machine from exceeding the limit position, a reliable limit safety device should be installed. 3) For high-speed rotating centrifuges, grinding wheels and large fans, protective measures must be taken to ensure that the operator or nearby equipment is not damaged. Requirements for safety guards, fences and guards 1) The operator is not able to reach the parts in operation. 2) When the operator approaches the moving parts, the mechanical equipment should be able to stop automatically. 3) Safety guards should be easy to inspect, adjust and repair. 4) The installation is firm and the repair is completed in time. Safety requirements for mobile equipment 1) The operating position of the moving equipment should be provided with a non-slip, fall-proof safety platform and railings. 2) When the operation position of the moving equipment is more than 2m, a safe and reliable operating platform, ladder and railing should be arranged. 3) The operating position of the moving equipment must have good lighting and ventilation. 4) For mechanical equipment with high noise, soundproofing facilities should be provided, or protective equipment such as earplugs should be provided to employees. 1. The danger of the transmission
2, the danger of pressure machinery
Third, the cause of mechanical damage
Safety measures to prevent accidents
8) When you feel dangerous, immediately operate the emergency stop button.
(Source: EHS Club)
[Editor: Chen Guofang]
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