Safety analysis of CNC machine tool operation to ensure stable production!
1. The principle of "three must-checks" before operation
(1) Equipment status check
Confirm that the emergency stop button, protective door, air pressure/hydraulic system are normal, and there is no residual debris on the guide rail.
Check the wear of the tool and replace the tool that exceeds the tolerance of 0.1mm.
Verify the coolant concentration (5%-10% is recommended) to avoid overheating during processing.
(2) Double verification of the program
The first processing program needs to be run through simulation to observe whether the tool path interferes with the workpiece.
The G code needs to be reviewed by both the programmer and the operator, with a focus on checking the Z-axis tool point parameters.
(3) Personal protection is in place
Wear anti-smash shoes and goggles, long hair needs to be rolled up into a work hat, and it is strictly forbidden to wear gloves to operate the panel.
2. The "five prohibitions" red lines in processing
(1) It is strictly forbidden to skip the safety interlock
It is forbidden to short-circuit the protective door sensor manually, and keep the door closed when the equipment is running.
(2) It is strictly forbidden to adjust parameters blindly
The spindle speed and feed rate adjustment must be carried out according to the process card, and the fluctuation range shall not exceed 15% of the set value.
(3) It is strictly forbidden to clean the chips with bare hands.
After stopping the machine, use a special hook knife or air gun to clean it to avoid scratches caused by metal chips.
(4) It is strictly forbidden to operate while fatigued.
After working continuously for 2 hours, you need to change shifts and rest to prevent accidents caused by accidental key presses.
(5) It is strictly forbidden to operate with problems.
If you find abnormal noise, odor or program error, stop the machine immediately and hang the "waiting for maintenance" sign.
3.Emergency Response Guidelines
|
Fault type |
Procedure |
Taboo |
|
Tool breakage |
1. Press the emergency stop button |
Reach out and remove the debris without stopping the machine |
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2. Perform origin return after changing the tool |
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Program failure |
1. Switch to manual mode |
Forced power off causes coordinate loss |
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2. Back up the current coordinate data |
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Workpiece displacement |
1. Re-clamp and check the reference surface |
Continue processing when the clamping is not firm |
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2. Reduce the feed rate by 50% and try cutting |
4. Long-term safety management mechanism
(1) Three daily records
Equipment inspection form (including hydraulic value, lubrication status)
Tool replacement ledger (record service life)
Abnormal event report (report to the workshop director within 15 minutes)
(2) Weekly special training
Emergency drills simulating scenarios such as tool collision and overtravel
Analysis of typical accident cases in the industry
(3) Quarterly safety audit
Detection of ground resistance ≤4Ω, troubleshooting of line aging
Verification of grating scale accuracy error ≤0.02mm
CNC machine tool safety = standardized process × personnel awareness × management system. By establishing a full chain protection of "prevention-monitoring-response", the accident rate can be reduced by more than 80% (refer to ISO 16090 standard). Only by integrating safety regulations into every operating detail can we truly achieve zero-accident efficient production.