Kowane gazawar na'urar BIW yana farawa iri ɗaya - ba tare da haɗari ba, amma tare da ɓata lokaci mara kyau yayin tseren matukin jirgi na farko. Mun gan shi sau biyu a wannan shekara: wani mai siyar da Tier-1 a Jamus ya soke 473 welded subsemblies saboda ƙarfin ƙarfi ya bambanta ± 12% a cikin tashoshi iri ɗaya guda uku. Tushen dalili? Ba gajiyawar kayan abu ko kuskuren ƙira-amma rashin daidaituwar bayanan datum yayin tabbatarwar ginawa. Abin da ya sa "BIW fixture" ba kawai sashi ba ne; shi ne shuru arbiter na girman girman girman maki 3,000+ a kowane jiki.
Me yasa Tsarin Ƙaddamarwa na BIW ke Ƙarfafa Saurin Samar da Motoci
Tsarin BIW yana yin aiki ɗaya tare da gefen sifili don yin shawarwari: riƙe sassa na ƙarfe a cikin ± 0.15 mm yayin da bindigogin MIG na mutum-mutumi suna ajiye kilogiram 8-12 na ƙarfe na walda a cikin minti ɗaya. Rashin yin hakan, kuma kuna haifar da ƙwanƙwasa-sake yin aiki yana jinkirin ɗaukar lokaci, sake yin aiki yana haifar da ɓarnawar zafi, karkatar da ƙarfi ta hannu, kuma shimming yana lalata ingancin GD&T. A Botou Haijun Metal Products Co., Ltd., mun gina fiye da 210 na al'ada na BIW tun daga 2019 don abokan ciniki a Arewacin Amurka da Turai. A kowane hali, mafi girman kayan aiki sun raba halaye guda uku waɗanda ba za a iya sasantawa ba: tsarin gine-ginen datum, daɗaɗɗen maɓalli mai ƙarfi tare da ≤0.005 mm runout, da kuma haɗaɗɗen wuraren tunani masu isa ga CMM a farkon datums A-B-C.
Yawancin ƙungiyoyi ba su la'akari da yadda taurin ƙaya ke shafar ingancin walda. Bayananmu yana nuna alaƙa kai tsaye: kayan aiki tare da faranti mai tushe ƙarƙashin kauri 60 mm suna haifar da 23% ƙarin murdiya bayan walda a cikin majalissar dogo na rufi fiye da waɗanda ke da sansanonin simintin ƙarfe na 80 mm. Me yasa? Ƙananan faranti suna jujjuyawa ƙarƙashin nauyin 4.2 kN masu matsawa - isa don matsawa matsayi a tsakiyar walda. Yanzu mun ƙididdige mafi ƙarancin kauri na tushe ta aikace-aikacen: 65 mm don bangarori na ciki na ƙofa, 75 mm don kwanon rufi, 85 mm don cikakkun masu ɗaukar ƙasa.
Matsalolin Haƙiƙan Duniya Uku Babu Manhaja Yayi Gargaɗi Game da
Wasu na iya jayayya cewa simintin CAD yana kawar da haɗarin jiki. Koyaya, gwajin bene na kantinmu ya tabbatar da akasin haka. Fadada thermal kadai yana lalata 17% na ginin rubutun farko-ko da lokacin da FEA ke hasashen cikakken kwanciyar hankali. Ga abin da a zahiri ya karye:
Datum yana motsawa daga maimaita hawan keke mai zafi: Firam ɗin daidaitawa na Aluminum suna faɗaɗa 2.4 × sauri fiye da sassan ƙarfe. Bayan 420 weld cycles, mun auna 0.11 mm drift a cikin Z-axis locators akan na baya kwata kwata-isa mu ƙin 100% na sassa a kan karshe dubawa ma'auni. Tsangwama tare da hanyar mutum-mutumi: Tsarin matsi mai maki 3 na “ingantattun” abokin ciniki ya toshe 38° na jujjuya wuyan hannu. Sakamako? Weld tsallakewa, porosity, da rashin shiri mara shiri. Yanzu muna buƙatar ingantacciyar hanyar mutum-mutumi ta layi kafin fara aikin mashin ɗin. Rashin daidaiton ƙarewar saman saman tsakanin kayan aiki da sashi: Ra 0.8 μm saman fayafai akan sassa na ƙarfe mai sanyi (Ra 1.6 μm) ya haifar da ƙananan scratches waɗanda ke yaduwa zuwa lahani na fenti. Magani: Matsakaicin yanayin saman tsakanin ± 0.2 μm - kuma tabbatar da bayanan martaba, ba dubawa na gani ba. Yadda Zaɓin Abu Yake Canza Komai-Baya Ƙimar Kuɗi
Masu gano bakin karfe suna tsayayya da lalacewa, amma suna gudanar da zafi 15 × sauri fiye da taurin kayan aiki. Wannan yana da amfani-har sai kun gane zafi yana ƙaura zuwa ɓangaren datums yayin walda, yana haifar da faɗaɗa a cikin gida. Mun canza zuwa AISI H13 karfe kayan aiki (52-54 HRC) don duk masu gano wuri mai mahimmanci bayan gwaji ya nuna cewa yana riƙe daidaitattun matsayi 3.7 × ya fi tsayi fiye da bakin karfe a ƙarƙashin jadawalin weld iri ɗaya.
Tushen abu yana da mahimmanci kamar haka. Simintin ƙarfe yana ba da damping amma yana ƙara nauyi da sauye-sauyen simintin. Matsayinmu na yanzu shine EN-GJS-600-3 ductile iron-ƙarfin ƙarfi mafi ƙarancin 600 MPa, garantin spheroidization na graphite> 90%, da ƙarancin injin ≤0.02 mm/m². Don yin kwatancen gaggawa, muna amfani da AL-6082-T6 mai warware damuwa, amma tare da abubuwan da aka saka na ƙarfe na Laser kawai a wuraren mu'amala. Kar a taɓa aluminum-kawai don kayan aikin samarwa.
Muna inganta kowane kayan aiki na BIW tare da bincike na jeri guda uku: 1) ma'aunin CMM na duk masu ganowa a kan CAD mara kyau, 2) gwajin maimaitawa (zagaye 10, max ≤0.01 mm), da 3) gwajin aiki tare da ainihin sassa masu hatimi a ƙarƙashin cikakken nauyin ɗaukar nauyi. Idan kowane mataki ya gaza, muna sake dubawa-ba sake yin aiki ba.
Zayyana don Ƙarfafawa-Ba Taro kawai ba
Dole ne madaidaicin BIW ya tsira ta zagayowar 500,000 ba tare da sake gyarawa ba. Wannan yana buƙatar ƙira-don-sabis, ba kawai ƙira-don-taro ba. Mun shigar da fasalulluka na sabis kai tsaye zuwa cikin lissafi: fitilun masu ganowa tare da filayen hex na 12 mm don cirewar da ake sarrafa ƙarfi, tashoshi masu sanyaya waɗanda aka ratsa ta cikin faranti na tushe (ba hoses na waje ba), da daidaitattun ramukan hawa M8 da aka baje a tazara na mm 100 - don haka abokan ciniki za su iya sake dawo da matsi na pneumatic ba tare da sake fasalin ba.
Botou Haijun's ISO-compliant kayan aiki yana gudanar da kayan aikin ginawa akan cibiyoyin injinan CNC tare da ramuwar zafi na ainihin lokaci. Kowane gyare-gyaren da aka gama yana jigilar kaya tare da rahoton tantancewa, gami da bayanan sikanin CMM, karatun rashin ƙarfi, da tabbatar da ƙarfi a kowace tasha. Babu zato. Babu "kamar yadda aka gina" kimanin.
Lokacin da aikin gyaran BIW ɗin ku na gaba ya fara, yi tambayoyi biyu da farko: Menene mafi munin yanayin zafi da zai gani? Kuma wanne ma'auni ne ke ɗaukar mafi girman tarin juriya? Amsa waɗanda kafin buɗe CAD-kuma za ku guje wa 80% na gazawar filin. Ba a samun daidaito a binciken ƙarshe. An kulle shi a farkon wuri mai gano wuri.
Don ƙungiyoyin injiniya suna gina abubuwan haɗin gwiwa na BIW waɗanda ke ba da daidaitattun yawan amfanin ƙasa na farko, kwanciyar hankali, da rayuwar sabis fiye da shekaru 5-biw kafa aikin yana farawa da horo na ƙarfe, ba kawai shimfidar injina ba. Wannan shine ma'aunin da muke yin injiniya a Botou Haijun Metal Products Co., Ltd.
