Welding ba tare da jig ko abin ɗamara ba yana kama da haɗa kayan ɗaki ba tare da littafin koyarwa ba—mai yiwuwa, amma mai haɗari, rashin daidaituwa, kuma da wuya a iya maimaitawa. A cikin babban haɗe-haɗe, ƙarami-zuwa-matsakaici samar da girma-musamman don maƙallan mota, abubuwan haɗin aikin gona, ko gidaje kayan aikin gini-jig da kayan walda ba na zaɓi ba. Yana da kashin bayan kwanciyar hankali, maimaita walda, da amincin mai aiki.
Mun ga abokan ciniki da yawa suna jigilar sassan labarin farko kawai don gano kuskuren 0.3 mm a cikin ramukan hawa bayan murdiya ta zafi. Wasu kuma suna sake yin aiki da kashi 18 cikin ɗari na welded majalisai saboda canjin sashe yayin wucewar MIG. Waɗannan ba “al’amuran tsari ba ne.” Suna tazarar tsayawa. A Botou Haijun Metal Products Co., Ltd., muna ƙira, ingantawa, da tura kayan aikin walda na al'ada ba a matsayin ƙara-kan ba-amma azaman haɗaɗɗun ƙwayoyin walda da kanta.
Me yasa Kayan Gyaran Kashe-Shelf Ya Fasa Ƙarƙashin Ƙarƙashin Ƙira na Gaskiya
Daidaitaccen daidaitawa na zamani yana aiki don samfura. Amma jigs na ainihi dole ne su tsira da hawan keke na 5,000+, tsayayya da haɓakawar spatter, ɗaukar rawar jiki daga tociyoyin robotic, da kiyaye ± 0.15 mm maimaitawa a duk canje-canje. Mun taɓa bincika wani mai siyar da Tier-2 wanda kayan aikin “duniya” ya yi amfani da ƙuƙumman bazara. Bayan hawan keke na 472, karfin matsawa ya ragu da kashi 33%. Shigar weld ya bambanta da 22%. Tushen dalili? Babu ramuwa na faɗaɗa thermal a cikin kayan farantin tushe.
Gaskiya jig da kayan walda mafita suna buƙatar wayar da kan ƙarfe-ba kawai shimfidar injina ba. Sansanin karfen da aka yi birgima a ƙarƙashin zafi na gida; aluminum subplates fadada sauri fiye da bakin workpieces; ko da juzu'in juzu'i yana shafar daidaiton yanki. Injiniyoyin mu suna ƙididdige ƙididdige ƙididdiga na thermal drift coefficients kafin yanke farantin farko. Shi ya sa duk abin da muka gina ya haɗa da:
Kayan tushe mai ƙarfi (ASTM A572 Gr.50 ko EN 10025 S355JR) Ƙaƙƙarfan fil ɗin ganowa tare da juriyar diamita ± 0.01 mm Ƙarfin ƙwanƙwasa wanda aka ƙididdige ta kowane jumhuriyar haɗin gwiwa-ba tsarin saiti na “high/matsakaici/ƙasas” ba Ƙaddamar da garkuwar spatter waɗanda ke hawa * ba tare da * tsoma baki tare da kusurwoyin shiga wuta ba Lokacin Gyaran Welding Ya Zama Sashe na Tsarin DFM Naku
Wasu na iya yin gardama: "Za mu fara walƙiya da farko, sa'an nan kuma mu injin datum ɗin." Wannan yana ƙara farashi, jinkiri, da haɗari. A Haijun, mun shigar da dabaru na ƙayyadaddun ƙayyadaddun ƙayyadaddun ƙirar ƙira don sake dubawar masana'anta. Idan sashin ku yana da ramuka masu hawa coplanar guda uku da aka raba nisan mm 120 - kuma yana buƙatar 90 ° fillet welds akan flanges biyu masu kusa - za mu yi alama cewa madaidaicin madaidaicin dole ne ya samo asali daga saman mafi girman lebur * na farko *, ba ƙaramin gefen ba. Me yasa? Domin tuntuɓar yanki na ƙasa yana rage jujjuyawa ƙarƙashin nauyi mai nauyi har zuwa 60% tare da masu gano baki-kawai.
Wannan ba ka'idar ba ce. Ɗaya daga cikin OEM aikin gona na Turai ya rage ƙimar izinin aikin injin bayan walda daga 82% zuwa 99.4% bayan ɗaukar dabarun gano wuri-wuri. Saitin su na asali sun yi amfani da fil ɗin dowel akan fasalulluka na biyu. Namu ya tsaya zuwa radius na farko na lanƙwasa-wanda ba ya taɓa shafan lokacin bazara. Sakamako? Karancin sake yin aiki, mafi tsananin yarda da GD&T, da daidaiton tsayin baka a duk fasinjojin walda 14.
Yadda Muka Tabbatar da Ayyukan Tsayawa - Kafin Ka Yanke Karfe
Ba mu dogara ga tsayayyen FEA kadai ba. Kowane tsari yana ɗaukar matakan tabbatarwa kai tsaye guda uku:
Gwajin zagayowar ba'a: Dry-gudu tare da sassa na wakilci a cikakken saurin samarwa - auna lalacewa ta wurin ganowa, gajiyawar matsawa, da ma'aikaci ya isa ambulaf Tabbatar da juriya na Spatter: Minti 15 na simulated MIG waldi ta amfani da ainihin ƙimar ciyarwar waya da haɗin gas ɗin garkuwa - sannan bincika mannewar spatter akan filaye masu mahimmanci. Gwajin jiƙa na thermal: Rike na'urar a 85 ° C na tsawon awanni 2 don yin kwatankwacin yanayin canjin shago-lokacin sake duba duk wuraren datum tare da CMM Wannan horon yana bayyana dalilin da yasa abokan cinikinmu ke ba da rahoton rashin daidaituwa da ke da alaƙa a cikin rahoton binciken ƙarshe a cikin watanni 27 da suka gabata. Hakanan yana nufin babu wani abin mamaki sake yin aiki yayin da ake ƙirƙira daga raka'a samfur 50 zuwa ayyukan samarwa 2,000/wata.
Daga Tsara Tsara zuwa Taro mai Cikakkun Waya-Haɗewar Aiki Guda ɗaya
Haɗin kai tsaye yana canza komai. A Haijun, ƙungiyar guda ɗaya wacce ta keɓance kayan aikin walda ɗinku kuma tana tsara birki ɗin latsa CNC wanda ke ƙirƙirar ɓangaren, zaɓi maki mara nauyi don juriyar lalata, kuma yana tabbatar da ƙarfin walda na ƙarshe ta ISO 15614-1. Babu handoffs. Babu asarar fassara tsakanin sassan. Lokacin da braket ɗin ku yana buƙatar walƙiyar fillet na 3-mm akan flange na aluminium 0.8-mm, injiniyoyinmu sun tuntuɓi kai tsaye tare da masu fasahar walƙiya-saboda suna raba bene ɗaya.
Wannan shine yadda muke isar da majalisi masu cikakken walda tare da kiran GD&T da aka riƙe zuwa ± 0.2 mm—har ma akan sassan da ke da haɗin gwiwar walda 12+ da gaurayawan kayan abu. Babu 'yan kwangila na waje. Babu jurewa tari-up mamaki. Kawai an tsara tsarin sarrafa tsari, daga danyen nada zuwa jigilar kaya.
Ga masana'antun da suka yi magani jig da kayan walda a matsayin kayan aikin injiniya-ba kayan aiki masu amfani ba-bambancin yana nunawa a cikin yawan amfanin ƙasa na farko, ƙimar gazawar filin, da kuma riƙe abokin ciniki. Ba a samun daidaito a tafkin walda. An kulle shi kafin baka ya buge. Fara da madaidaicin kafa. Gina daga can.
