Preface
The safe use of the placement machine includes two aspects: personal and equipment safety. Personal safety is the first priority. It involves laws and regulations, corporate culture, corporate social responsibility, employee training, rules and regulations, etc. It is a must in the application of the placement machine. Stay focused on the first priority.
1. Three basic elements of safety
1. Safety concept is fundamental
(1) Safety is a basic human need
Safety is one of the basic human needs, the most basic survival need for everyone, the foundation and lifeline for the existence and development of enterprises, and the fundamental guarantee for national economic development. Every member of the enterprise, from senior executives to ordinary employees, should firmly establish the safety concept of "safety first, prevention first". No matter what management model or profit model, safety is the fundamental model; no matter which product line, which In the production line, safety is the lifeline; only with safety can there be peace; with peace can development be achieved.
(2) Safety is an eternal theme in production
Safety is an eternal theme in production and will never change. Whether we are facing high-risk mining and transportation, or relatively less dangerous electronics manufacturing industries, safety risks are everywhere and occur all the time. A high sense of responsibility, unremitting efforts, and a never-relaxed safety mindset are the fundamental guarantees for safe production; carelessness and a sense of luck are always the enemies of safety.
(3) Safety management focuses on prevention beforehand
The characteristic of modern enterprise safety management is that safety management has gradually begun to transform from traditional accident handling to prevention beforehand, from passive safety of "I want safety" to active safety of "I want safety, I can be safe". Today, when we are people-oriented, promote scientific development, and create a harmonious society, we must take the concept of safety into the hearts of the people and implement it in every link.
2. Regulations and systems are guarantees
(1) Regulations and standards are the basic guarantee
Relevant safety regulations and standards, from international conventions, national decrees, national standards, industry standards, regional standards, to corporate standards, provide basic guarantees for safety at various levels. For example, the country’s Labor Protection Law, Law on the Protection of Workers’ Rights and Interests, and Law on the Protection of Women and Children’s Rights and Interests fundamentally stipulate the responsibilities and rights of employers and workers regarding labor safety and health; various standards for relevant equipment, tools, and materials, etc. , all put safety first, and these fundamentally provide safety guarantees.
(2) Safety rules and regulations are hard-won
In factories and enterprises, all production processes, from the operation of the production line to the implementation of each process and the safe operation of each piece of equipment, almost without exception have various safety systems in place. Most of these systems are formulated on the basis of scientific analysis, and many provisions are based on practical experience. It can be said that many system provisions are the result of painful lessons and even the blood and lives of predecessors. Illegal operation not only disrespects knowledge and predecessors, but also disrespects life and oneself.
(3) The root causes of the accident all involve violations of regulations
No matter what nature of the accident occurs, as long as you analyze it carefully, you will find that it was caused by non-implementation of safety regulations and violation of regulations. For example, misoperation accidents are caused by failure to follow operating procedures, failure to follow dispatch orders, or failure to follow industry regulations. Habitual violations are the root cause of accidents.
(4) Develop safety habits
The so-called habit is a behavior that is consolidated and becomes necessary due to repeated operations. Habits have a great influence on people's behavior. Scientific research shows that only about 5% of a person's daily behavior is non-habitual, and the remaining 95% is habitual. Therefore, developing habits that are conducive to safety is an important way to reduce the chance and probability of accidents.
The prerequisite for cultivating safe habits is the implementation of various rules and regulations, and the core lies in the development of behavior. The development of a habit requires a process and requires experience. Developing safety habits is not only the highest state and ultimate goal of enterprise safety education, but also the embodiment of workers' basic qualities and the guarantee of happiness.
3. Technical measures are barriers
Due to the importance of safety to human survival and development and the seriousness of safety accidents in the development of modern science and technology, the field of modern science and technology has gradually formed an independent safety science and technology, specializing in understanding the occurrence and development laws of accidents, and researching and developing accident prevention methods. Prevention strategies and control techniques. This book only covers a part of the field of safety technology, that is, the role of safety technical measures in industrial production safety.
(1) Safety awareness and rules and regulations cannot ensure safety
The difference between human beings and robots is that humans have seven emotions and six desires. No matter how high safety awareness and perfect rules and regulations are, safety cannot be guaranteed 100%. Making mistakes or being careless can be said to be human characteristics or human nature. Moreover, robots may be interfered with or malfunction, so safety technology must be used as much as possible to provide the final barrier and line of defense.
(2) Safety technical measures must prevent and accommodate human errors
Safety technical measures mainly use various science and technologies mastered by human beings to provide the most complete safety guarantee for production processes and equipment. It not only requires guarantees when people do not make mistakes, but also further requires new safety technical measures to prevent people from making mistakes, even when Buffer and tolerate human mistakes within a certain range. For example, the safety technology of detection, alarm and mechanical teaming has been applied in many processing machinery. When the detection mechanism senses that a part of the human body has entered a dangerous part, it immediately sends out a sound and light alarm and controls the relevant parts of the machine to stop the movement that may cause an accident. , thus ensuring safety even if the operator violates regulations. With the development of modern sensor technology, automation technology, electronic information technology and close control technology, various safety technical measures for processes and equipment are becoming increasingly perfect, which will provide an increasingly reliable guarantee for human safety.
(3) Tasks of safety technology
① Analyze the causes of various accidents;
② Research ways to prevent various accidents;
③ Improve the intrinsic safety of equipment;
④ Strengthen equipment safety through technical measures.
Various safety technical measures are based on the principle of changing dangerous operations into safe operations, changing tedious operations into simple operations, and changing manual operations into automatic operations. The ultimate goal of safe production is achieved by improving safety equipment, working environment or operating methods.
(4) Technical safety still ranks first among human factors
Any kind of advanced technology requires people to master it, and any equipment with complete safety technical measures requires people to manage and maintain it. Therefore, in the final analysis, it is still inseparable from the human factor and the improvement of management and workers. Quality, safety awareness and technical level are the most fundamental safety guarantees.
2. Safety regulations for placement machines
Compared with high-risk process equipment in the manufacturing field (for example, high-energy process equipment such as welding, casting and pressure processing, pressure vessels, high-voltage equipment, etc.), the safety risks of placement machines are relatively small. However, if it is believed that safety can be ignored in the application of placement machines, then the placement machine may become a high-risk equipment. The motion system of the placement machine has considerable energy, which increases the risk of personal injury when moving at high speed. What's more, many illegal operations and abnormal operations are very likely to cause damage to the machine. Therefore, safe use is still the top priority in the application of placement machines.
1. Preparation and safety before use
① Conduct strict training for operators. The training content includes:
• Carefully study technical information such as product instructions or operating manuals;
• Understand the working principle of the placement machine;
• Understand the composition and structure of the placement machine;
• Master the correct operation method;
• Understand safety measures and precautions;
• Understand maintenance knowledge and general troubleshooting methods.
② Develop practical safety operating procedures.
③ Operators must pass the assessment before they can work with a certificate.
2. Safety Guidelines for Using SMT Machines
① The placement machine is operated by designated personnel, and non-designated personnel are prohibited from using the machine.
② Only one operator is allowed to operate a machine. It is strictly prohibited for two or more people to operate the machine at the same time. In special cases, the supervisor must agree and confirm the operation sequence and signals.
③ Confirm before starting:
• Whether the working air pressure is within the allowable range and whether the feeder is properly installed;
• Confirm that the machine is not under maintenance;
• Confirm that there are no missing tools or other debris in the Z axis of the X-Y platform;
• Confirm that there is no person or any body part within the range that the machine can operate normally;
• There cannot be any idle feeder on the Z-axis station.
④ When replacing materials, be sure to confirm that the "material, tray, table, and Z position" are consistent, and make a record of the material replacement.
⑤ During operation, do not put your head, hands, or other foreign objects into the safety door.
⑥ After replacing materials, you must check whether the feeder is properly installed.
⑦ Check the machine safety device:
• Confirm that the safety device is correctly installed in the specified position before operating;
• When disassembling the safety device, be sure to install it in its original position and confirm the normal operation of the machine;
• Paste warning signs on the machine correctly so that they are clearly visible. If peeling or staining occurs, replace them with new signs in a timely manner;
• When the safety device fails, never operate the machine after removing the safety device;
• If the safety device is removed and then operated, it may cause casualties.
⑧ Changes in machine parameter settings must be made through the responsible engineer.
⑨ Do not open the door of the electrical box while the machine is working.
⑩ If there is a collision or abnormal noise or other abnormalities during the operation of the machine, the operator should stop the machine in time, notify relevant personnel to handle it, and report to the equipment supervisor.
⑪ Keep the environment tidy and equipment clean:
• Use a clean cloth to clean machine surfaces such as the display screen, operating keyboard, and safety cover;
• Use a vacuum cleaner and a clean cloth to clean the clamping platform and rails inside the machine, and use tweezers to remove scattered components from the narrow parts that cannot be sucked by the vacuum cleaner;
• Use a vacuum cleaner to clean the nozzle platform, and be careful not to bend or damage the nozzle when cleaning;
• Clean the feeder platform with a vacuum cleaner and a clean cloth;
• Regularly clean the material tape and waste box in the feeder;
• Empty waste bins.
3. Inspect and maintain the safety of the placement machine
① Inspection and maintenance of the placement machine must be carried out by professionals with equipment maintenance qualifications.
② Equipment maintenance personnel must carefully read the machine repair manual and master the skills proficiently.
③ Any maintenance and replacement of parts on the machine must be performed with the power supply disconnected.
④ When replacing parts, qualified products originating or approved by the equipment supplier must be used.
⑤ For safety reasons, when teaching or adjusting the machine, keep your hand on the operation panel or the EMG button (emergency stop button) of the teaching or teaching box so that the machine can be stopped at any time.
⑥ When unplugging the power plug, hold the plug instead of the power cord.
⑦ In order to prevent accidents caused by sudden start, before repairing parts with pneumatic devices, release the compressed air in the air path first, and then perform maintenance operations.
⑧ In order to prevent personal injury, after repairing, adjusting, or replacing parts, be sure to confirm whether the screws and nuts are tightened as required.
Special reminder: Cutting off the power means turning off the main power switch and then unplugging the power plug from the socket or disconnecting the power cable from the power supply side.
4. Safe usage environment of chip placement machine
① To prevent accidents caused by incorrect operation, the working environment should avoid strong electromagnetic interference (for example, high-frequency welding machines and electromagnetic heating devices, etc.);
② The power supply voltage cannot exceed the rated voltage of the machine;
③ The air supply pressure cannot exceed the rated pressure of the machine;
④ For safe use, please use it in the following environment:
• Ambient temperature during operation +10℃～+35℃;
• The relative temperature during operation is below 50% (35℃) and below 90% (20℃).
3. SMT safety signs
In order to ensure the safe operation of equipment, one of the common measures in the industry is to set various safety signs on machines and production sites to warn or remind operators and other workers. These safety signs are both industry-unified and industry-specific. Understanding and correctly applying them is of great significance to ensuring safety.
1. Safety color
In order to be eye-catching, various safety signs set on machines and production sites usually use various colors to represent different meanings. The four colors of red, blue, yellow and green are internationally unified "safety color" standards, as shown in the table below.
2. Common safety tips for placement machines
In addition to the color, there are also text prompts. Since most domestic mainstream placement machines are currently imported, you need to understand the relevant meanings in Chinese and English. Commonly used Chinese and English text prompts are shown in the table below.
3. Commonly used and combined icons
Because graphics are easy to identify, eye-catching and easy to remember, they are widely used in safety warnings. Every industry has its own special safety graphics. The following table is a common general graphics in the security field.
Safety-related text reminders are often combined with common icons and specific text terms to make them more clear and eye-catching. The figure below is an example of some combination warnings commonly used in placement machines.
4. Safety signs of Universal SMT machines
SMT machines produced by different countries and regions and different suppliers, on the premise of complying with international unified regulations and practices, and based on the characteristics and experience of their own products, set safety warning icons for the company's products, as shown in the figure below is the global sticker Safety warning icons commonly used in chip machines.
Descriptions of the various signs in the picture above are as follows.
① This interface is only for ESD anti-static bracelets. Do not use this interface as the ground wire of the device.
② Danger area, only trained personnel can approach this area.
③ This sensitive area is used for ESD-sensitive components, and preventive measures should be taken during operation.
④ When the Lockout/Tagout icon prompt appears on the machine, you must cut off the power of the machine, shut down the machine, and execute the machine's Lockout/Tagout program to ensure the personal safety of the operator.
⑤ Be careful, there is a risk of electric shock.
⑥ Entanglement label: Do not touch this area of the machine when the machine is running. Yellow/black indicates that injury may occur. The image represents possible occurrence/danger. This image represents the danger of entanglement.
⑦ Refer to the service manual icon. When you see this icon, you should refer to the service manual.
⑧ Collision label: When there is this label on the machine, the user reaches into the part of the machine cover.
⑨ Squeeze label: When there is this label on the machine, the user's fingers may be squeezed.
⑩ Note: Indicates potentially dangerous situations and warns of unsafe operations that may cause damage to the machine.
⑪ Warning: Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury.
⑫ Danger: Indicates an imminently dangerous situation which, if not avoided, may result in death or serious injury.
⑬ Push danger label: When there is this label on the machine, the user should not push that part of the machine.
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