How to ensure safety during equipment maintenance?

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Before equipment maintenance: 1. Preparation of personal protective equipment. Before entering the workshop, it is necessary to wear work clothing, protective gloves, safety glasses, and other personal protective equipment. 2. Analyze the maintenance work to be carried out, identify potential risks, and take appropriate measures. 3. When working at heights, it is necessary to wear safety equipment for working at heights; a warning sign must be placed below the person working at height to alert others to the risk of falling objects. 4. Before repairing the equipment, check first whether the electrical, hydraulic, and pneumatic power sources have been disconnected; place warning signs such as “Under repair” or “Do not close” at the switches, or assign a dedicated supervisor to oversee the process. The supervisor must not perform any operations or engage in activities unrelated to supervision. 5. Before repairing the equipment, it is necessary to inspect, analyze, and understand the causes of the equipment failures as well as its current condition. 6. Before repairing, maintaining, or servicing the equipment, it is necessary to cut off the main power supply to the equipment, as well as the power supplies and air supplies for control components such as photoelectric switches, limit switches, proximity switches, and pneumatic components, as well as other auxiliary components. Repair, maintenance, or servicing can only be carried out after confirming that the equipment will not operate accidentally. 7. Power must be cut off for maintenance; work on equipment while it is still powered must be carried out under the supervision of a supervisor. Machine tool maintenance must be performed with the power turned off, and single-person maintenance is strictly prohibited when the equipment is still powered. When work must be carried out on live electrical equipment, in addition to maintaining good insulation between the workers and the live parts as well as the ground, there must also be a qualified electrician on site to monitor the workers and remind them or stop any unsafe behaviors at any time. Special attention should be paid to preventing short circuits during live maintenance. When servicing or measuring terminals that are close together, special care must be taken to prevent short circuits. Because the terminal connections that are close to each other have different potentials, a slight carelessness during measurement or maintenance can lead to a short-circuit accident. During maintenance, the eyes are usually very close to the area being repaired; in the event of a short circuit, the sparks generated can easily cause damage to the eyes. Furthermore, short circuits can also reduce the service life of certain components or even cause them to burn out. 8. Maintenance personnel must be familiar with the circuit principles of machine tool electrical systems. Machine tool electrical maintenance is a highly practical task; it is encouraged to take action based on practical experience, but blind handling of tasks is firmly opposed. Maintenance personnel must be familiar with the basic principles of machine tool electricity. During equipment maintenance: 1. It is strictly prohibited to come into direct contact with the equipment and its components while it is in operation. 2. When using manual means to move components during work, personnel must coordinate properly; when multiple people are involved in lifting, one person should take command to ensure synchronized movements, with careful lifting, setting down, and moving forward. 3. Be mindful of the safety of those around you as well as your own while working, to prevent injuries caused by swinging tools, tools falling, or flying debris from workpieces. When working in groups of two or more, it is important to coordinate with each other and place the workpieces neatly and steadily. 4. When using power tools, always check the tightness of fasteners and rotating parts; ensure they are secure before using the tool. 5. During work at heights, always check that the safety belt is fastened securely to ensure safe use. 6. Under normal circumstances, work is prohibited on rotating or moving equipment and their associated circuits. If it is necessary to carry out inspections, cleanings, and investigations on rotating or moving equipment, it is essential to fasten the cuffs and wear a work hat to prevent being caught or injured by the rotating parts. 7. It is prohibited to disassemble automated control equipment while it is powered on, such as PLC modules, on-line instruments, and the circuit boards of pneumatic valves, in order to avoid damaging the electronic components. 8. It is prohibited to perform maintenance on the equipment while it is still running. 9. Safe voltage should be used for maintenance lighting. Lighting fixtures used for maintenance must operate at a safe voltage of 36V or less; the lamp holders should be equipped with guards, and the use of voltages higher than 36V is strictly prohibited. The 36V voltage is the **standard safe voltage level designated for use in general applications. When maintaining machine tools, using a voltage not exceeding 36V makes it easier for maintenance personnel to get free in the event of an electric shock, thus ensuring their safety. At the same time, maintenance personnel should also pay special attention to the fact that using safe voltage does not guarantee absolute safety. **The standard stipulates that when electrical equipment uses a safety voltage exceeding 24V, protective measures must be taken to prevent direct contact with live parts. 10. Pay attention to safety when using lifting tools. Sometimes, lifting tools are required for machine tool maintenance; when using them, safety must be prioritized. Before use, check whether the equipment is in good condition. Do not lift loads beyond their capacity, and avoid lifting them at an angle. No one is allowed to stand under the load during the lifting process. 11. During maintenance, damaged components should be replaced only after the cause of the fault has been eliminated. When identifying the fault point and fixing it, it should be noted that locating the fault point should not be considered the end of the process; further analysis is required to determine the root cause of the fault. For example, when dealing with a fault where an electric motor has burned out, one must not mistakenly assume that the problem is resolved simply by repairing the burnt-out motor or replacing it with a new motor of the same model. Instead, it’s necessary to determine the cause of the motor’s overload—whether it’s due to excessive load or an inappropriate selection of the motor, i.e., one with insufficient power. Both scenarios can lead to motor overload. Therefore, when dealing with such faults, it is necessary to identify and eliminate the cause of the fault before replacing the appliance with a new one. After equipment maintenance: 1. Before starting the equipment, check that the protective devices and fastening screws are in good condition, and that the switches for electrical, hydraulic, and pneumatic power sources are functional. Conduct a test run to verify proper operation; only after it works correctly should the equipment be put into use. Always follow the equipment’s safety operating procedures when using it. 2. After completing the tasks, clean the area promptly to maintain cleanliness and order; oil and wastewater must not be left on the floor to prevent slips and injuries. 3. For machine tools that have been repaired, the performance of all protective devices must meet the safety requirements during use. 4. The electrical system of the repaired machine tool must meet quality standards. After the machine tool has been repaired and before it is tested, the repair technicians should conduct a thorough inspection; the electrical system of the repaired machine tool must satisfy the following requirements: the insulation resistance must be within acceptable limits ； The thread ends don’t pierce, and all joints are tightened ； Neat appearance, without any damage or carbonization ； All contacts are intact, smooth, and in good contact ； The pressure spring and reaction force spring have sufficient elasticity ； The manipulation and reset mechanisms are flexible and reliable ； The various armatures move smoothly without any jamming ； The arc chute is intact, clean, and securely installed ； The magnitude of the tuned values meets the circuit requirements ； The indicator device can emit signals normally. 5. Pay attention to accumulating maintenance experience. After each maintenance task, it is necessary to summarize the experience in a timely manner and keep proper maintenance records.