English (UK) 
简体中文 Why are conveyor line injuries so common? The data showsAccident at 73% due to failure to install protective devicesbut (not)Non-compliance accounts for 70% of casualties. From drum roll clip to belt tear, from mechanical strangulation to fire spread, behind each type of risk is a lesson in blood and tears. This article will focus on 8 core measures, through the three-dimensional Q&A matrix to dismantle the key points of protection - from the basic principles to the scene of practice, from the implementation of the norms to the bottom of the emergency, for the front-line personnel to build up a life line of defence.
Measure 1: Physical isolation protection - why is this the first line of life and death?
fundamental question: The core of physical isolation is the blocking of human-machine contact paths. Conveyor drive roller, tail, coupling and other parts of the high-speed rotation of the formation of the"Bite point."The first time clothing or a limb becomes involved, it can be disabling in 0.5 seconds.
Hands-on scenarios::
- Shield Selection: Closed metal cover to cover rotating parts (e.g. drums, chains) with mesh holes ≤ 5 mm to prevent fingers from reaching in;
- Bridge ladder setup: An anti-slip platform must be erected at the crossing point, with a handrail height of ≥1.1 metres and a pedal load-bearing capacity of ≥150kg;
- safety distance: The distance between the equipment and the sidewalls of the roadway is ≥ 0.5 metres, and ≥ 0.8 metres on the pedestrian side.
Cost Warning: An unguarded drum once caused a miner's sleeve to become entangled and his entire arm amputated; and a compliant bridge ladder has reduced similar accidents by 92%.
Measure 2: Dual-insurance emergency stop system - how to make a stop faster than an injury can occur?
fundamental question: the prime disposal time for an incident is only 3-5 seconds, and manual pulling of the gate requires running delays.Dual-channel emergency stop(Pull Cord + Button) Covering Blind Spots.
Hands-on scenarios::
- Drawstring wiring: Emergency stop rope is set up every 20 metres along the conveyor line, with a sagging height of 1.2-1.5 metres, triggering the power failure of the whole line;
- button positioning: Installation of red mushroom head buttons at the nose, tail and bridge ladder entrances, with a delayed start of ≤0.5 seconds;
- lockout mechanism: Hanging during maintenance"Do not close" mechanical locksThe key is carried by the operator.
Cost Warning: A cement factory worker ended up with a comminuted leg fracture after failing to reach the single emergency stop button 15 metres away from him when he got stuck.
Measure 3: Flame-retardant explosion-proof upgrade - why ordinary tape equals arson hazard?
fundamental questionNon-flame-retardant tape friction heating to 400 ℃ that is spontaneous combustion, and the fire along the belt surface spread speed of 1.5m/s.
Hands-on scenarios::
- Tape Selection: must be usedMT668 Standard Flame Retardant Tape, burning length ≤1.5m/min;
- Fluid Coupler Media: Banning of easy-to-use fuels in favour ofFlame retardant emulsion or waterMedium;
- Roller MaterialMetal shell + ceramic bearings are selected to eliminate high temperature deformation of plastic rollers.
Cost WarningA mine in Guizhou used a non-flame-retardant belt and 16 people were suffocated by toxic smoke after a slip and fire, while the flame-retardant belt could fight for 15 minutes of escape time.
Measure 4: Intelligent Protection Devices - How can sensors replace human eyes on defence?
fundamental question: The manual inspection leakage rate is over 40%, and theMulti-sensor linkageCaptures risks not visible to the naked eye.
Hands-on scenarios::
- Slip monitoring: Installation of speed sensor, belt speed below drum 95% automatic power off;
- Tear Warning: Installation underneath the discharge openingAnti-tear sensorsThe foreign object is punctured for 0.3 seconds to stop the machine;
- Coal stacking linkage: Automatic shutdown of the upstream feeder when triggered by the coal pile sensor.
Cost WarningThe coal mine that did not install anti-tearing device caused 300 metres of belt to tear longitudinally due to gangue jamming, with a direct loss of more than 2 million yuan.
Measure 5: Behavioural exclusion zone control - why is "saving a step" the same as "crossing the threshold"?
fundamental question:.Seventy per cent of accidents stem from unauthorised operation, including lethal manoeuvres such as straddling, riding, and cleaning without stopping.
Hands-on scenarios::
- road ban sign: "No crossing" reflective signs are set up every 50 metres along the equipment, and red and yellow warning lines are painted in the danger zone;
- Tool control: Cleaning of the rollers must be done with1.5 metre long-handled scraperIt is strictly forbidden to scrape directly with a shovel;
- dress code: Tighten cuffs and trouser legs, tuck long hair into hats, and disable cotton gauze gloves.
Cost WarningShaoguan workers with a wooden stick to poke the block of iron, even people with a stick into the tail wheel, compliance operation should be "power outage → hanging → magnetic bar suction removal".
Measure 6: Rigid Maintenance Cycle - What is a "small bolt causing a big problem"?
fundamental question:.Roller bearing corrosion, loose bracket boltsTriggered a runout tear on the 80%.
Hands-on scenarios::
- DDT: Touch the temperature of the drum (>60℃ is alarmed), clear the coal accumulation of the rollers;
- item for each weekly reviewCheck for wire rope breakage (single strand >10% to be replaced), measure chain pitch (increase 5% to be scrapped);
- item for monthly inspection: Calibration roller level (error ≤ 2mm), tensioning force test (sag ≤ bandwidth 2%).
Cost Warning: Failure to replace rusted-out rollers at a steel mill caused the belt to run off and crack the frame, with debris piercing a worker's helmet.
Measure 7: Practical emergency training - why can't drills be "just going through the motions"?
fundamental question:.50% Casualties widened by blind rescuesIf pulling a rolled up person causes secondary injuries.
Hands-on scenarios::
- Haemostasis simulation: Training for limb involvement"Tape cutting → padded steel plate → hydraulic top support"The three-step method;
- fire fighting practice: Quarterly drills smoke alarm → automatic sprinkler activation → hydrant docking;
- escape routeFluorescent signage is provided every 100 metres in the tunnel, pointing to the nearest refuge.
Cost Warning: A logistics warehouse worker's arm was stuck, and his companion aggravated the laceration by forcibly reversing the belt; a compliant operation should have immobilised the injured limb before cutting.
Measure 8: Penetrating safety training - how can a signature test not be a formality?
fundamental question:.Accident rate of temporary workers is three times higher than that of regular workersThis is a loophole that stems from the "signing on behalf of" and "crash course" training loopholes.
Hands-on scenarios::
- VR accident reconstruction: Simulate the roller roll clamping process with virtual reality to reinforce muscle memory;
- Case Cross Reference Examination:: Written tests incorporate real accident options (e.g., "Can you clear a roadblock with a stick?"). If the error rate is >5%, retraining will be conducted;
- Family notification letter: Explain the list of violations to the family and sign the joint commitment.
Cost Warning：未经培训的临时工误触启动按钮，致使维修人员双腿截肢。
终极悖论：最贵的防护永远便宜过最便宜的人命——某矿投入10万元加装8类保护装置，使年事故赔偿从300万降至0；而阻燃胶带单价虽高30%，但火灾概率归零。安全从来不是成本，而是唯一稳赚不赔的生产力投资。
