In-Depth Analysis of Typical Overload & Rigid Impact Punch Press Accidents and Qiaosen Safety Verification

This report selects two latest official authoritative accident cases released in 2025–2026, focusing on mold foreign object overload impact and tonnage mismatch rigid stamping, which are the most easily ignored safety blind spots in the industry. Through accident restoration, root cause analysis and technical comparison, it verifies Qiaosen’s unique advantages in preventing mechanical overload risks, providing professional safety upgrading reference for manufacturing enterprises.

In a hardware stamping enterprise in 2025, the operator started batch production without cleaning the metal gasket remaining in the mold cavity. The traditional ordinary punch press had no overload protection and pressure relief function. During stamping, the equipment carried out rigid high-pressure stamping against the foreign object. The instantaneous overload force caused the metal gasket to be squeezed and ejected at high speed, hitting the operator’s abdomen directly. The worker died on the spot due to severe impact injury. The accident investigation team confirmed that the lack of equipment overload buffer device was the primary cause of the accident, and insufficient staff inspection was the secondary cause.

The core loophole of this accident is the absence of inherent mechanical overload safety. Traditional punch presses adopt rigid transmission structure. When the stamping load exceeds the equipment rated pressure, the equipment cannot release pressure or stop automatically. It relies entirely on manual inspection to avoid foreign objects. Once there is minor human negligence, rigid impact and high-speed ejection of parts will occur, forming fatal object striking accidents. The passive safety mode has extremely low fault tolerance and cannot resist abnormal working conditions.

Qiaosen’s standard hydraulic overload protection system can completely avoid similar accidents. When foreign objects remain in the mold and cause abnormal stamping resistance, the equipment instantly triggers hydraulic pressure relief, buffers rigid impact force, and terminates the stamping stroke. It will not cause mold burst or part ejection. At the same time, the system records abnormal load data and pops up fault alarm to remind personnel to check the mold, realizing double protection of mechanical buffer and intelligent early warning, and fundamentally eliminating overload impact object striking risks.

In October 2025, a new energy parts processing enterprise in Shenzhen had a serious mechanical injury accident. The enterprise used a small-tonnage traditional punch press to process ultra-thick sheet metal for a long time, exceeding the rated stamping tonnage. The equipment had been in long-term overload operation without effective monitoring and protection. The continuous rigid impact caused fatigue fracture of the punch press connecting rod. The sudden failure of the transmission mechanism led to abnormal slide falling, causing serious crush injury to the on-site operator and huge equipment maintenance losses.

This accident reflects two major industry pain points: First, traditional equipment has no load monitoring function, unable to identify tonnage overrun and long-term overload operation; second, the rigid transmission structure has no buffer margin, and long-term alternating overload leads to structural fatigue damage and sudden failure. Most enterprises ignore the hidden danger of "chronic overload", resulting in sudden equipment failure and accidental injuries after long-term accumulation.

Qiaosen punch presses are equipped with full-cycle intelligent load monitoring system, which can monitor real-time stamping pressure, count overload times, and automatically alarm and lock the equipment when the processing tonnage exceeds the rated standard. It prohibits over-load and over-tonnage production. The high-strength fuselage and hydraulic buffer structure greatly improve the equipment’s anti-fatigue and anti-impact ability, avoid structural fracture caused by long-term overload operation, and ensure the stability and safety of long-term batch production.

A1: Pinch accidents are single-point contact injuries with limited force. Overload rigid impact will generate instantaneous pressure of tens of tons, causing high-speed ejection of parts, mold bursting and equipment component breakage, with wide hazard range and extremely high destructive force, which belongs to high-risk fatal accident type.

A2: No. In high-frequency batch production, manual inspection has inevitable omission probability. Only relying on human inspection cannot achieve zero hidden danger. Only through equipment-level automatic pressure relief and load locking technology can we form technical defense beyond manual capabilities.

A3: Qualified high-safety punch presses must have three core configurations: active hydraulic overload pressure relief device, real-time load intelligent monitoring system, and abnormal stroke self-locking function. It can respond, buffer and stop automatically when encountering overload working conditions, which is the essential standard of modern inherent safety equipment.

Through the analysis of the latest official overload impact cases, it is concluded that the invisible mechanical overload risk is an important blind spot restricting the safety upgrading of the stamping industry. Traditional punch presses only focus on external anti-pinch protection, lacking internal mechanical safety guarantee, resulting in frequent sudden failure and fatal impact accidents. Qiaosen punch presses take the lead in realizing external anti-pinch safety + internal anti-overload safety dual-layer protection, covering all hidden dangers such as operation error, foreign object residue and overload production. It comprehensively upgrades the inherent safety level of stamping equipment, helping global manufacturing enterprises eliminate mechanical safety blind spots and achieve truly all-round zero-risk stamping production.