机械压力机产品安全质量检验方法浅析.doc

机械压力机产品安全质量检验方法浅析
1 概述
机械压力机是通用型压力机形式进行工作，加上压力机的工作行程次数比较高，紧张工作易使操作工人疲劳，因而操作时存在许多危险因素，时有操作者断手伤臂事故发生，有的甚至危及生命安全。因此，对于机械压力机来说，除了要求有高的精度和，主要型式有可倾式压力机、开式固定台压力机、闭式压力机。主要用于金属板材的冲孔、落料、弯曲、折边、浅拉伸、压印及其他冷冲压工序，是机械、仪器仪表、五金、汽车、轻工、电子等行业的必备设备。由于机械压力机主要是通过冲压、剪切、挤压、冲击的可靠性外，更重要的是它必须有相当高的操作安全性。合格的机械压力机必须要有完备的运行可靠的安全保护装置，以保证机器在使用过程中，在出现任何危及人身安全的情况下，都能及时排除故障。除此之外，对机器的主要结构及其关键件也要能实现超载下的保护。近些年来，随着以生产玩具、五金、家电、汽车、摩托车、仪器仪表配件为主的乡镇、个体民营企业的蓬勃发展，各种机械压力机的使用量激增。由于受经济利益驱使，许多压力机都不带任何安全保护装置，人身事故不断发生。作为产品技术监督检测部门的工作，有义务、有责任、有能力严格把好机械压力机产品的质量关，防止人身伤害事故发生。
本文主要依据两个强制性标准——GB17120-1997《锻压机械 安全技术条件》、JB3350-1993《机械压力机 安全技术要求》探讨机械压力机产品在安全质量方面的检验方法。
2 对标准要求的技术分析
2.1 标准的强制性
这两项标准都是国家和机械行业颁布的强制性标准，是国家对机械压力机产品进行监督抽查的主要检验依据，是每个压力机生产企业必须遵照的标准。如果用户使用设备出现人身伤害事故时，可以依据有关强制性标准规定追究设备供方的法律责任，由设备供方对受伤者进行赔偿。产品技术监督检测部门的工作人员在对机械压力机产品进行监督检查的同时，也要督促企业按强制性标准组织生产，确保产品的安全性能符合要求。同时还应该向广大用户大力宣传这两个强制性标准，让他们知道在选用机械压力机时，要对照标准选用配有合格的安全保护装置的产品，以保证操作工人的人身安全。
2.2 标准规范的内容范围
GB17120-1997规定了锻压机械在设计、制造和使用等方面的安全技术要求; JB3350-1993规定了机械压力机类产品及安全附件的安全技术要求。众所周知，锻压机械范围非常广（包括自由锻空气锤、螺旋压力机等等），而机械压力机仅是锻压机械中的一类，它不仅用于金属型加工，还用于其他方面（如非金属下料、成形）。但标准 JB3350-1993中明确规定不适用于螺旋压力机，这是值得注意的一个问题。
在内容上，两个标准相辅相成，有共同点，也有差异，可以相互补充，相互完善。GB17120-1997主要从产品的设计，制造和使用方面来规定安全要求；而标准JB3350-1993除了对机械压力机各个系统及其附件作了安全规定外，还规定了压力机主机制造厂和安全保护装置、安全附件制造厂的责任，这为解决机械压力机事故产生的纠纷提供了依据和方法。
3 依据标准制订相应的检测方法
综合两个标准的内容、特点，制订相应的检测方案时，将检测项目分为考核和考查项目。列入考核的项目必须全部达标才能判定产品合格，否则不合格。考查项目仅进行检验，不作为判定的依据。
按标准要求，考查项目共有8个，分别是从梯子、栏杆和平台的安全要求、安全标志与显示、电气系统的一般性能、操作控制检验、安全保护装置、防松要求、飞轮盘杆要求、使用说明书的要求等几个方面来考查。
（1）梯子、栏杆和平台
压力机维修、保养需在离地面3m以上的机身顶面进行时，应设有梯子、围栏、栏杆及平台。平台上铺板应防滑，边沿至少翘起80mm，栏杆高度不应低于1050mm。引上机身顶面的固定梯子，离地面1m以上至少应有一节脚踏杆与控制系统相联锁。当踏上该节脚踏杆时，主电机失电断开。
（2）安全标志与显示
压力机控制各种操作指示、安全警告指示都应在压力机的相应部位上有明显的标志。警告性标志应符合GB/2894 和GB/T5226.1.1-1996中18.2的要求。压力机离地面3m以上的顶面围栏的对角端和高出于栏杆的部件的最高点应设置红色安全指示灯。易对操作者产生碰撞、夹紧、挤压的部位应按规定涂以黑色与黄色相间隔的条纹标志，根据需要亦可只涂成黄色。其他各种指示信号的颜色含义应符合GB/T5226.1.1-1996中10.3.2的规定。在大型压力机操作面板上要有反映压力机安全运行、工作状态、发生故障状态或有关数据的显示。
（3）电气系统的一般性能
所有电气元件安装均需便于接近和拆卸。电器元件与壁板间应留有适当间隙。电控装置必须符合最低防护等级，电气系统的各种按钮及指示灯的颜色，导线的绝缘层颜色和截面符合要求。所有导线连接特别是保护电路的连接必须牢靠不得松动。导线的接头必须用冷压端子，接触良好。导线从一个端子至另一个端子必须是连续的，中间不许有接头。电控装置与门上导线的连接必须两端均固定，不应依靠端子板或元件端子作固定。
（4）操作控制检验
内容有操作规范、带锁转换开关、预控动作、紧急停止。 操作规范与调节机构、辅机间的控制应有联锁。带刚性离合器的压力机必须具有单次行程规范。压力机单次行程操作规范时，不得出现连续冲压行程， 每次行程，工作部件应停止在设计规定的停止点。 带锁转换开关就是操作规范的选择应采用带钥匙锁定的转换开关，也可对各操作规范分别采用带钥匙锁定的转换开关。 预控动作是对选用连续行程操作规范时，应在操作过程中设有预控动作环节。机器在连续行程工作规范时，每次启动必须先按压预控按钮，然后再按压启动按钮，操纵系统才能启动工作部件。 压力机上必须有紧急停止按钮，并应能自锁。紧急停止按钮应设置在操作者易于接近，操作无危险的地方。多人协同操作的压力机，每个操作点都应设 置紧急停止按钮。紧急停止按钮必须在任何操作规范中都能迅速停止压力机工作，但不得断开其工作可能引起事故的夹紧装置、制动装置或其他装置。紧急停止按钮被重调以前，任何启动机器的操作应是无效的。
（5）安全保护装置
每台压力机一般都应配置一种或一种以上安全保护装置。在用户认可情况下，随机配有安全操作附件或是因工艺操作需要，压力机性能、结构特征不同，配有专用的送料装置或专用的安全保护装置的情况下可以例外。 安全保护装置选配要求：应首选双手操作安全装置，根据需要再选用光线式安全保护装置。当压力机运行左右两端存在不安全因素时，也应采用安全防护措施。压力机配置的安全保护装置，应满足以下的要求：滑块向下运行时，操作者身体的任何部位都不可能进入或停留于工作危险区内；若操作者身体的任何部位进入工作危险区界限以内时，滑块应立即被制动；在操作者的手放开操作按钮并伸向工作危险区界限的时间间隔内，应在手到达工作危险界限之前，滑块被立即制动。
（6）防松要求
压力机上所有螺钉、螺栓、螺母、销钉等紧固件和弹簧，因其破损、松脱会导致意外或零部件移位、跌落时，必须采取防松措施。
（7）飞轮盘杆要求
压力机盘动飞轮的专用盘杆应与操作窑联锁，其结构应做到在完成盘动工作后可顺利地从盘孔内退出。
（8）使用说明书的要求
a) 应给出机器的尺寸、重量、重心位置及搬运说明。
b) 应给出机器的固定要求、装配和安装条件、机器与动力源的连接说明。
c) 应给出机器及其附件、防护装置和安全装置的详细说明；机器的应用范围及禁用范围、电气装置的有关数据。
d) 应给出对设定与调整的说明、停机的模式与方法。
e) 应给出检查的性质和频次、对维修人员的要求等。
f) 编制安全警告和必须小心注意的问题时，应使用各种颜色、符号和粗黑字体加以强调。
4 说明
本文关注的只是机械压力机在安全要求方面的检验方法，在实际检测中，还应参照具体类型的机械压力机及其有关的标准，制定性能和精度的检测方法。随着现代科技的高速发展，很多机械的自动化程度越来越高。机械压力机的发展也不例外，有些机械压力机用于自动生产线上，有些机械压力机采用机械手来进行上下料的操作，取代了手工操作，还有些高智能化的安全保护设备，比起标准中所要求安全保护装置先进的多，因而也就不存在本文提出的相关安全隐患问题。

The Simplied Analyse to the Method of Inspection of Products Safe Quality of the Mechanical Press
1 Summary
The mechanical press is a common press, there are the main patterns inclining type presses, turning on type fix a press, closing type press. Used mainly in washing the hole, blanking, bending, hem, drawing, impressing and other cold and pressing the process shallowly of metal panel, it is the indispensable apparatus in trades such as machinery, the instrument and apparatus, five metals, car, light industry, electron,etc.. Because the mechanical press mainly carries on the work through the form of pressing, shearing, pushing, assaulting, in addition, working journey of press number of times high, tense working apt to make, operate worker to be tired, therefore there are a lot of dangerous factors while operating, operator's broken hands injure the arm accident and happen occasionally, some even threaten the security of life. So, to mechanical press, except that there are high precision and dependability to demand the more important thing is it must have quite high operation security. The mechanical press qualified must have complete reliable security protector of operation, so as to ensure the machine in the course of using, in a situation that any appears to threaten the security of rights of the person, can fix a breakdown in time. In addition, main structure and their key piece in machine can realize, overload protection under too. In the last few years, with the flourishing development of the villages and towns taking producing toy, the five metals, electrical home appliances, car, motorcycle, instrument and apparatus fittings as main fact, individual enterprise run by the local people, the consumption of different mechanical presses is increased sharply. Because of drive economic benefits, a lot of press bring safe protector any, the personal injury is happening constantly. Measure the work of the department as the technical supervision of the products, is obligated, have responsibility, have the ability to guarantee quality of the mechanical press products strictly, prevent the occurrence of bodily injury accident.
Two mandatory standards of main basis of this text——GB17120-1997 " metal forming machinery safe practice condition ", JB3350-1993 " safe technical requirement of mechanical press ", probe into the mechanical press products method of inspection in safe quality.
2 The analysis of technological to the standard requires
2.1 standard ones are mandatory
These two standards are both mandatory standards that countries and mechanical trades issue, it is the country that carries on the main test basis that spots check of supervision to the mechanical press products, it is the standard that each press manufacturing enterprise must follow. If when users use the apparatus to present the bodily injury accident, can stipulate that investigate the apparatus supplier's legal liability according to relevant mandatory standards, the apparatus supplier compensates the wounded. The technical supervision of the products measures the staff members of the department while supervising and inspecting the mechanical press products, performance fulfils requirements to supervise enterprises to organize and produce according to the mandatory standard too and ensure the safety of products. Should also propagate these two mandatory standards to the masses of users in a more cost-effective manner at the same time, let them know that should contrast the standard and is selected for use and furnished with the products of the security protector qualified while selecting the mechanical press for use, so as to ensure that operates workers' personal security.
2.2 content ranges with normal standard
GB17120-1997 has stipulated the metal forming machinery security technical requirement in designing, making and using etc.; JB3350-1993 has stipulated the mechanical press products and security technical requirement for the security attachment. As everyone knows, metal forming machinery range is very wide (including freedom forges the air hammer, spiral press,etc).And the mechanical press is only one kind in metal forming machinery, it is not merely used in the metal type to process, still used in other respects ' Such as nonmetal unloading, take shape). But define in standard JB3350-1993 the regulation does not apply to the spiral press, this is a noteworthy question.
In content, two standards complement each other, there are common points, there is a difference too, can supplement each other, complete each other. GB17120-1997 makes and uses toes stipulate and requires safely from the design of product mainly; And except standard JB3350-1993 has made security regulations to mechanical press each system and attachment, have also stipulated press host computer factory and security protector, responsibility of the security attachment factory, and the method that this has offered basis for solving dispute emerging in mechanical press accident.
3 The corresponding detection method according to the standard
Synthesize two standard contents, characteristics, while making the corresponding detection scheme, will measure the project to divide into examining and checking item. Could judge the products are qualified to must list all up to standard in the project examined, otherwise not up to standard. The checking item is only examined, the basis that the non-performance judges.
According to the standard requirement, there are 8 checking items, including from the ladder, the security requirements of railing and platform, safety sign and reveal, electric general performance, locking requirement of system, operational control test,safety protection device,flywheel records of pole requirement, requirement of operation instructions,etc. several respect come, examine.
(1) Ladder, railing and platform
Maintain, maintain needing when the overhead fuselage top surface above 3 m go on with press, there should be ladder, rail, railing and platform. The bed board is in conformity with the slip resistance on the platform, tilt 80 mm at least in the border, the height of the railing should not be lower than 1050 mm. Guide, go fuselage carry Taxi fixed ladder, overhead 1m should have a section of pedal pole and control system interlock at least while being above. When setting foot on the pedal pole of this festival, the main electrical machinery loses electric disconnection.
(2) Safety sign and revealing
The press controls various operation and points out, warns safely that point out that should there are obvious signs at the corresponding position of the press. The warning sign should accord with the demands for 18.2 in GB/2894 and GB/T5226.1.1-1996. Press overhead 3m above top surface opposite angle end and high to should set up the red safe indicator lamp out of peak of part of railing of rail. Apt to should paint with getting black and yellow charms alternate stripe sign to operator position collided, clamped, pinched to produce according to regulation, can also be only painted yellow according to the need. Various other regulations of the 10.3.2 while instructing the color meaning of the signal to accord with GB/T5226.1.1-1996. Reflect safe operation of presses, working state, the state or display about data of breaking down on operating the panel in the large-scale press.
(3) General performance of the electric system
All electric component installation need to be easy to be close and dismantle. Should leave the appropriate interval among component and panel of the electric apparatus. The automatically controlled device must accord with and protect the grade, the colors of different pressing the button and indicator lamps of the electric system minimumly, insulating barrier color and section of the wire fulfil requirements. All wire is connected especially the connection of protecting the circuit must be firm can't become flexible. Piecing of wire must with cold to pigeonhole end son, keep in touch well. The wire must be continuous to another end son from an end son, mustn't be connected in the middle. The necessary both ends of connection of the wire are fixed on automatically controlled device and door, should not rely on the sub board of end or component end son to do fixedly.
(4) Operational control test
Content and operating specifications, locking switch, the pre-control action, emergency stop. Specification and regulation, the auxiliary control due interlock. Rigid clutch with the press must have a single trip norms. Press a single trip and operating specifications, not lasting for stamping itinerary and the length, working parts should stop at the stop design point. Locking switch is the choice of operating specifications should be used with a key lock switch. it can regulate the operation were used with a key lock switch. Pre-control movements in the choice of continuous journey operating specifications, it should operate with the process of pre-control movements links. Machinery consecutive trip to standardize the work, every time a start must first push pre-control button, and then push start button, control system can start working parts. Press must have an emergency stop button, and be able to self-locking. Emergency stop button should be installed in close to the operator to easily operate without dangerous place. Operating synergies over the press, every operational point should set up emergency stop button. Emergency stop button in any operational norms can quickly stop Press, but not disconnect their work may lead to accidents clamping devices, brake or other devices. Emergency stop button is to re-deploy before launching any operation of the machine should be invalid.
(5) Safety protection device
Each configuration press in general, be one or more security devices. In recognition of the user, equipped with random safe operation of the annex or due to operational requirements, performance Press, structural characteristics of different equipped with a dedicated feeding devices or dedicated security devices to protect the circumstances, it can be exceptions. Safety protection device matching requirements : first choice hands operational safety devices, according need to use light-security protection devices. When the press running around at both ends of insecurity factors, we should also adopt security measures. Press configuration protection of the safety devices, should meet the following requirements : slider down operation, the operator of any part of the body can enter or remain in dangerous work area; If the operator of any part of the body into the risks of working within the boundaries, the slider should immediately braking; in the hands of the operator to operate the button and open toward the dangerous work of the boundaries of the time intervals, should work in hand reached dangerous limits, the slider was immediately brake.
(6) Require lockingly
Fasteners such as screws, bolt, nut, pin,etc. and spring on the press, because damage, loose to take off, can cause unexpected its or spare part shift, fall, must take the locking measure.
(7) Flywheel a pole requirement
Press records of special-purpose records of pole to move flywheel should with operate kiln interlock, structure its should make sure, finish record move, can withdraw in records of hole smoothly work.
(8) Requirement for the operation instructions
a) Should provide size, weight, weight position of machine and carry, pro