Kowane gazawar kafa na BIW yana farawa iri ɗaya - ba tare da faɗuwa ba, amma tare da kuskuren dabara a lokacin takt na farko. Mun gan shi a nahiyoyi uku: motsi na 0.15 mm datum a cikin ma'aunin fakitin gefe yana haifar da tarin juriya a cikin tashoshi shida; farantin tushe mai waldadi bayan awanni 48 na ci gaba da aiki; matsananciyar ciwon huhu yana rasa ƙarfi a yanayin yanayin 32°C—kawai sama da yanayin zafi na lokacin rani a Chennai ko Monterrey.
Me yasa Tsarin Kafaffen BIW shine Injin shiru na Ingantaccen Kera Motoci
Ƙaƙwalwar BIW ba kawai ƙarfe mai riƙe da takarda ba. Fassarar zahiri ce ta GD&T niyya zuwa gaskiyar kinematic mai maimaitawa. A Botou Haijun Metal Products Co., Ltd., mun gina kuma mun inganta sama da 1,270 BIW na'urori tun daga 2016-kowane ɗayan an gwada shi a ƙarƙashin nauyin samarwa na gaske, hawan zafi, da tazarar kulawa. Bayananmu sun nuna cewa kashi 68% na dakatarwar layin da ba a shirya ba a cikin Tier-1 na shagunan jiki suna komawa zuwa tushen tushen abubuwan da suka dace: mai ganowa ya wuce 0.08 mm, tsayayyen tushe ƙasa da 2.3 × 10⁵ N/mm, ko lalata ƙarfi ya wuce 12% sama da 10,000 hawan keke.
Babban kalubale? Dole ne ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙa'idodi sun cika sharuɗɗa huɗu waɗanda ba za a iya sasantawa ba lokaci guda: kwanciyar hankali kinematic (babu takurawa), thermal neutrality (ΔL ≤ 0.03 mm daga 20-40 ° C), dorewar sabis (≥ 500,000 hawan keke ba tare da recalibration ba), da ergonomics na mutum (ƙarfin kunnawa ≤ 22 N, lokacin sake zagayowar ≤ 4.2 seconds). Yi sulhu da kowa-kuma inganci ya rushe.
Hukunce-hukuncen Ƙirƙirar Ƙira guda uku na Gaskiya waɗanda ke Yi ko ɓata Ayyukan Daidaitawa na BIW
1. Zaɓin kayan abu ba game da ƙarfi ba ne - game da ƙwaƙwalwar ƙira ne. Mun dakatar da amfani da karfe A36 don faranti na tushe a cikin 2020. Adadin sa na haɓakar thermal (12.0 × 10⁻⁶/°C) ya haifar da ɗimbin ma'auni yayin tashin zafin tsakiyar-motsi. A yau, mun ƙididdige ASTM A572 Grade 50 tare da taimako na damuwa bayan machining-kuma kawai lokacin da aka haɗa su tare da yanayin tsufa na sa'o'i 72. Don masu gano madaidaicin madaidaicin, muna amfani da bakin karfe na 17-4 PH, zafin zafi zuwa H900 (485 HB), samun kwanciyar hankali a cikin ± 1.3 HRc sama da shekaru 3 na amfani da filin.
2. Dabarar ɗaurewa tana ƙayyade daidaiton sakin sashi-ba kawai riƙe iko ba. Matsakaicin huhu ya gaza lokacin da iska ta ƙunshi> 0.5 ppm man ko raɓa ya wuce 3°C. Maganin mu: clamping biyu-hanyoyi. Matsala na farko suna amfani da silinda ISO 15552 tare da na'urori masu auna matsayi; na biyu “taushi-taushi” clamps aika da spring-loaded urethane pads (Shre A 70) da matsa 1.2 mm kafin lamba-kasar da hakora a kan Class-A saman. Rayuwar zagayowar ta tashi daga 180,000 zuwa 620,000 actuations.
3. Tsarin datum dole ne yayi madubi jerin taron-ba samfurin CAD ba. OEM ɗaya na Turai ya nace akan 3-2-1 gano kowane tasha. Mun gina shi. Sa'an nan kallo part fit deteriorate bayan Tasha 4. Tushen? Ainihin jeri na weld ɗinsu ya ɗora sashin ba daidai ba, yana haifar da nakasar naƙasa wanda kayan aikin ba zai iya ramawa ba. Mun sake tsarawa tare da canja wurin datum na jeri: Tashar 1 ta kulle flanges na bene; Tashar 3 tana ƙara goyan bayan sill na gefe * kawai bayan * walƙiya panel; Tasha 6 tana gabatar da masu gano layin dogo-ba a da ba. Yawan amfanin farko-farko ya tashi daga 71% zuwa 99.4%.
Abin da Yawancin Injiniyan Ke Kulawa (da Yadda ake Gyara shi)
Wasu suna jayayya cewa ƙirar ƙirar injina ce kawai - kawai ƙididdige ƙarfi kuma zaɓi kayan. Amma bayanan filin mu ya saba wa hakan. A cikin kashi 41% na gyare-gyaren da aka ƙi, kuskuren bai kasance mai tsari ba. It was human: operators bypassing safety interlocks because clamp actuators required 32 N of force, or technicians skipping calibration because CMM probe access demanded full disassembly.
Mun gyara wannan tare da ƙwararren ƙira:
Tilasta taswira: Kowane hannu, lefa, da feda yana jurewa ingantacciyar ergonomic-mafi girman ƙarfin kunnawa wanda aka rufe a 18 N, ƙayyadaddun nisan tafiya a 42-48 mm Kulawa- na farko lissafi: Duk fasteners suna zaune a cikin 120 ° baka na isar mai aiki; Ana sarrafa maƙasudin daidaitawa kai tsaye a cikin jikunan da aka haɗa-ba a ƙara su azaman faranti-a kan faranti ba Thermal decoupling: Tushen faranti suna hawa akan masu keɓanta na elastomeric (durometer 55 Shore A) tare da juzu'i na 0.8 mm - toshe watsa girgizar ƙasan kanti a ƙasa 15 Hz Wannan ba ka'idar ba ce. Ƙofa mai zurfi mai zurfi na kwanan nan don shirin EV ta Arewacin Amirka ya gudanar da hawan keke na 14,200 ba tare da katsewa ba kafin kulawa ta farko - wanda ya zarce manufa ta OEM da 310%.
Daga Zane zuwa Aiwatar da Ayyuka: Ƙa'idar Tabbatar da Haihun
Ba mu jigilar kayan aiki ba - muna jigilar ingantaccen iya aiki. Kowane madaidaicin BIW yana ɗaukar matakan tabbatarwa guda huɗu:
Haɗin simintin DFMFEA mai cikakken jiki (ANSYS Mechanical) yana yin ƙirar drift thermal, murdiya, da gajiya mai zagaye miliyan 10 - ta amfani da bayanan gwajin kayan aiki daga ɗakin binciken mu na cikin gida. Gwajin samfur na zahiri: 72-hour haɓaka gwajin rayuwa a ƙarƙashin ainihin matsi na pneumatic, hawan zafin jiki (20-45 ° C), da kuma ɗaukar nauyin robot (± 15% bambancin ƙarfi) Shagon-bene bushe-gudu: An shigar da shi a wurin abokin ciniki don canje-canje 3 - auna ma'auni mai maimaitawa (Cpk ≥ 1.67), lokacin sake zagayowar matsawa (± 0.15 s), da ƙimar ra'ayoyin mai aiki Takardun da za a iya ganowaRahoton ƙarshe ya haɗa da overlays na CMM scan, karatun ma'auni, da samfuran log ɗin kulawa-duk an kawo su cikin sa'o'i 72 na kashewa Botou Haijun Metal Products Co., Ltd. yana aiki daga birnin Botou - zuciyar yanayin yanayin sanyi na kasar Sin - inda daidaito ba zaɓi bane. Yana da tushe. Lokacin da kuke buƙatar a biw kafa wanda ke riƙe gaskiya a cikin yanayi, canje-canje, da canje-canjen mai siyarwa, farawa da ƙwaƙwalwar ƙima-ba kawai adadin ƙarfe ba.
