Operate the energy storage stud welding machine in strict accordance with the following safety regulations to ensure the safety of personnel and equipment:
Personal Protective Equipment (PPE)
Insulating GlovesWorkers must wear insulating gloves with a voltage withstand rating of ≥5000V to prevent electric shock.
Safety Glasses/MasksSelect welding masks with shade number ≥10 to protect against intense electric arc light.
Protective GarmentsWear flame-retardant workwear to prevent sparks from igniting clothing.
Earmuffs/EarbudsWelding noise may exceed 85dB, hearing protection is required.
2. Equipment Safety Inspections
Before Every Day's Boot-Up：
Check for proper grounding wire condition (ground resistance ≤ 4Ω).
The cable has been confirmed to have no cracks in the insulation and no breaches in the jacket.
The emergency stop button function has been tested and is operating normally.
Routine maintenance：
Monthly inspections for capacitor sets for leakage and electrode head wear.
Quarterly calibration of welding parameters to prevent energy output deviation.
3. Work Environment Requirements
Ventilation and Fire Protection：
Ensure proper ventilation in the welding area (recommended airspeed ≥ 0.5 m/s).
Flammable materials (such as oil drums, cardboard boxes) are prohibited from being stored within a radius of 5 meters.
Space Isolation：
Welding areas must be enclosed with barriers to prevent unauthorized access.
Install insulating matting on the ground to prevent short circuits caused by metal shavings.
4. Operational Safety Standards
Pre-welding Preparation：
Clean the contact surface between the stud and the base material (oil stains and oxide layers need to be sanded).
When adjusting electrode pressure, the power must be turned off and the stored energy released.
Welding process：
Do not touch the electrode head, cable joints, or other live components.
Observe the direction of splashes and adjust the protective screen position promptly.
Exception Handling：
In case of continuous splashes or sparks, immediately press the emergency stop button.
After equipment alarms, investigate and resolve issues (such as insufficient energy storage, parameter errors) before restarting.
Emergency Measures
Electric shock first aid：
If someone is electrocuted, immediately turn off the power or use a dry wooden stick to move the cable away.
Perform CPR on individuals experiencing respiratory arrest.
Fire Response：
Equipped with dry chemical fire extinguishers; water is prohibited for extinguishing electrical fires.
The welding area must be equipped with smoke detectors and an automatic sprinkler system.
6. Training and Certification
Staff Requirements：
Operators must hold a special operation permit (welding and hot cutting category).
New employees are required to complete a specialized training program provided by the equipment manufacturer (theoretical and practical training of at least 16 hours).
Safety Mantra：
Insulation in place, grounding reliable; parameters adjusted, sparks don't fly.
"Ventilation in place, fire out of sight; emergency stop, life is paramount!"
By strictly adhering to safety regulations, the risk of using battery storage stud welders can be significantly reduced, ensuring production safety.
