Mechanical damage during resistance welding

In the bustling environment of a factory's tool shop, it's imperative that safety protocols during complex tasks such as resistance welding are rigorously followed to prevent mechanical injuries. The incident of a worker leading his apprentice in the use of a butt welding machine is a stark reminder of the critical need for coordination and proper technique to avoid disastrous outcomes. This unfortunate event transpired when the master, while installing the weldment on the electrode clamp and aligning the position, instructed the apprentice to support the tail of the workpiece. Without ensuring clear communication and mutual understanding, the upper arm of the pneumatic clamp was pressed down, resulting in the apprentice’s right index finger being trapped between the tail of the workpiece and the shim. This led to a gruesome injury – the end of the index finger suffered a rupture and an open fracture.

The primary causes of this accident were lack of synchronization between the master and the apprentice, and improper holding technique of the shim by the apprentice. Effective prevention strategies must include not only closely coordinated teamwork with prearranged verbal signals and confirmations but also the use of specialized tools to hold the iron securely, thereby keeping fingers away from hazardous clamp jaws. Furthermore, enhancing the welding machine's fixture capability to allow multi-directional adjustments would significantly minimize the risk of such incidents. Lastly, it’s essential to embed a culture of safety through continuous learning and meticulous adherence to safety production skills, ensuring that both seasoned workers and apprentices are well-versed in safe operational procedures. This multifaceted approach, combining preemptive planning and ongoing education, can significantly mitigate the risks of mechanical injuries during resistance welding tasks and establish a safer working environment within the tool shop.