Pinch-point risk is a common operator risk around resistance welding in the absence of necessary safety practices or provisions. Several pinch-point risks exist, including weld cylinders, clamps, moveable tooling and production parts. The most common risk, in most machines, comes from the welding electrodes. Weld electrodes come together with a very high force--clamped against a body part, especially with pointed electrodes, that force can crush bone. I have seen a few welding machines with 1 -in.-dia. electrodes close at 5000 1b. of force. To minimize the risk, set the electrodes 1/2 in. or closer to the part in the separated state, for part load or unload. This helps prohibit fingers or hands from becoming pinched between the electrodes.
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