Konke ukusilela komdlalo we-BIW kuqala ngendlela efanayo-hayi ngokuntlitheka, kodwa ngolungelelwaniso olufihlakeleyo ngexesha lokuqhuba kovavanyo lokuqala. Siyibone kabini kulo nyaka: umthengisi we-Tier-1 eJamani ulahle ii-subassemblies ezidityanisiweyo ezingama-473 kuba amandla okuqinisa ahluke ± 12% kwizikhululo ezithathu ezifanayo. Oyena nobangela? Ayikokudinwa okubonakalayo okanye impazamo yoyilo-kodwa ireferensi yedatha engahambelaniyo ngexesha lokuqinisekiswa kolwakhiwo. Yiyo loo nto "i-BIW fixture" ingeyonto nje; ngumlamli othe cwaka wemfezeko yomgangatho kuwo wonke ama-3,000+ amanqaku e-weld ngomzimba ngamnye.
Kutheni i-BIW Fixture Design iyalela i-Automotive Production Velocity
Isixhobo se-BIW senza umsebenzi omnye ngo-zero margin wothethathethwano: ukubamba amacandelo entsimbi ngaphakathi kwe-±0.15 mm ngelixa imipu yerobhothi ye-MIG ifaka i-8-12 kg yentsimbi ye-weld ngomzuzu. Ayiphumelelanga loo nto, kwaye udala i-cascade-ukusebenza kwakhona kucotha ixesha le-takt, ukuphinda kusetyenzwe kuphembelela ukugqwetheka kwe-thermal, ukugqwesa kunyanzelise ukubambezeleka ngesandla, kwaye ukubengezela kungasebenzi ukuqinisekiswa kwe-GD&T. E-Botou Haijun Metal Products Co., Ltd., sakhe ngaphezulu kwe-210 ye-BIW fixtures ukususela ngo-2019 kubathengi baseMntla Melika naseYurophu. Kuzo zonke iimeko, olona lungiso luphezulu lwabelane ngeempawu ezintathu ezingaxoxiswana: uyilo lwemodyuli yedatum, izikhonkwane zelocator eziqinileyo ezine-≤0.005 mm runout, kunye ne-CMM-accessible reference spheres ezidityanisiweyo kwii-datum eziphambili A-B-C.
Uninzi lwamaqela alujongeli phantsi ukuba kungakanani ukuqina komdlalo okuchaphazela umgangatho we-weld. Idatha yethu ibonisa ulungelelwaniso oluthe ngqo: izixhobo ezisekelwe kwiiplati eziphantsi kwe-60 mm ubukhulu zivelisa i-23% ngaphezulu kokuphazamiseka kwe-post-weld kwiindibano ze-roof rail kunezo zineziseko ze-80 mm zentsimbi. Ngoba? Iipleyiti ezibhityileyo zigoba phantsi kwe-4.2 kN imithwalo ebambezelayo-eyoneleyo ukuba itshintshe indawo kwindawo phakathi kwe-weld. Ngoku sichaza ubuncinci besiseko sobunzima ngokufaka isicelo: 65 mm kwiipaneli zangaphakathi zeengcango, 75 mm kwiipani zomgangatho, 85 mm ezithwala ezigcweleyo zangaphantsi.
Imigibe emithathu yokwenyani yeHlabathi akukho Manuwali ilumkisa ngayo
Abanye banokuphikisa ukuba ukulinganisa kweCAD kuphelisa umngcipheko womzimba. Nangona kunjalo, iimvavanyo zethu zomgangatho wevenkile zibonisa ngenye indlela. Ukwandiswa kwe-Thermal yedwa kuphazamisa i-17% yenqaku lokuqala lokwakha-nangona iimodeli ze-FEA ziqikelela uzinzo olugqibeleleyo. Nantsi eyona nto iqhekezayo:
I-Datum irhubuluza ukusuka kwibhayisekile ephindaphindiweyo yobushushu: Iifreyimu ze-Aluminiyam zandisa i-2.4 × ngokukhawuleza kuneendawo zentsimbi. Emva kwemijikelo ye-weld engama-420, silinganise i-0.11 mm drift kwi-Z-axis locators kwi-fixture panel yekota yangasemva-yanele ukwala i-100% yamalungu xa kuthelekiswa ne-check gauges yokugqibela. Uphazamiseko olubambekayo kwindlela yerobhothi: Isakhiwo somxumi "esilungisiweyo" samanqaku ama-3 sivale i-38 ° yokujikeleza kwesihlahla serobhothi. Isiphumo? I-Weld skips, i-porosity, kunye nexesha lokuphumla elingacwangciswanga. Ngoku sifuna ukuqinisekiswa kwendlela yerobhothi engaxhunyiwe kwi-intanethi ngaphambi kokuba kuqale ukwenziwa komatshini. Ukungahambelani komphezulu phakathi komdlalo kunye nenxalenye: I-Ra 0.8 μm yokulungisa iindawo kwiindawo zentsimbi eziqengqelekayo ezibandayo (Ra 1.6 μm) zibangele imikrwelo emincinci esasazeke kwiziphene zepeyinti. Isisombululo: fanisa uburhabaxa bomphezulu ngaphakathi ± 0.2 μm-kwaye uqinisekise ngeprofilometer, hayi uhlolo olubonakalayo. Indlela Ukhetho Lwezinto Ezibonakalayo Oluyitshintsha Ngayo Yonke Into—Ngaphaya Kweendleko Nje
Abafaki bensimbi abangenasici baxhathisa ukunxiba, kodwa baqhuba ubushushu be-15 × ngokukhawuleza kunentsimbi yesixhobo esiqinileyo. Oko kuvakala kuluncedo-ude uqonde ukuba ubushushu bufuduka bube yinxalenye yee-datums ngexesha le-welding, ibangela ukwandiswa kwendawo. Satshintshela kwi-AISI H13 isixhobo sensimbi (52-54 HRC) kuzo zonke iindawo ezibalulekileyo emva kovavanyo lubonise ukuba lubambe ukuchaneka kwendawo 3.7 × ixesha elide kune-stainless phantsi kweeshedyuli ze-weld ezifanayo.
Izinto eziphathekayo ezisisiseko zibaluleke kakhulu. Intsimbi yokuphosa ibonelela ngokudambisa kodwa yongeza ubunzima kunye nokuguquguquka kokuphosa. Umgangatho wethu wangoku yi-EN-GJS-600-3 i-iron ye-ductile-ubuncinci bokuqina be-tensile 600 MPa, i-graphite spheroidization eqinisekisiweyo> 90%, kunye ne-flatness yomatshini ≤0.02 mm/m². Ukwenza iprototyping engxamisekileyo, sisebenzisa i-AL-6082-T6 yoxinzelelo, kodwa kuphela ngofakelo lwentsimbi ye-laser-sintered kwi-interfaces yendawo. Ungaze i-aluminiyam-kuphela kwizixhobo zemveliso.
Siqinisekisa lonke uhlobo lwe-BIW ngeetshekhi ezilandelelanayo ezintathu: 1) Umlinganiselo weCMM wazo zonke iindawo ezichasene ne-CAD yegama, 2) uvavanyo lokuphindaphinda (imijikelo eli-10, ukutenxa okukhulu ≤0.01 mm), kunye no-3) uvavanyo olusebenzayo olunamalungu okwenene agximfiziwe phantsi komthwalo ogcweleyo wokubamba. Ukuba naliphi na inyathelo liyasilela, sihlaziya-hayi ukuphinda sisebenze.
UYilo Lokwenziwa Kwezinto—Ayikho nje iNdibano
Umzobo we-BIW kufuneka uphile kwimijikelo engama-500,000 ngaphandle kohlengahlengiso. Oko kufuna uyilo lwenkonzo, hayi uyilo lwe-assembly kuphela. Sifakela iimpawu zenkonzo ngokuthe ngqo kwijometri: izikhonkwane ze-locator ezine-12 mm iiflethi ze-hex zokususwa kwe-torque-controlled, iziteshi zokupholisa ezihamba ngeeplate zesiseko (kungekhona i-hoses yangaphandle), kunye nemingxuma esemgangathweni ye-M8 efakwe kwizithuba ze-100 mm-ukuze abathengi bakwazi ukubuyisela i-clamps pneumatic ngaphandle kokulungiswa kwakhona.
Indawo ehambelana ne-ISO ye-Botou Haijun iqhuba i-fixture yakha kumaziko omatshini e-CNC anembuyekezo yexesha langempela lobushushu. Zonke iinqanawa ezigqityiweyo ezigqityiweyo ezinengxelo yolungelelwaniso olulandelekayo, kubandakanywa idatha ye-CMM yokuskena, ukufundwa koburhabaxa bomphezulu, kunye nokuqinisekiswa kwamandla okubamba kwisikhululo ngasinye. Akukho ngqikelelo. Akukho qikelelo "njengolwakhiwe".
Xa iprojekthi yakho yokulungisa i-BIW elandelayo iqala, buza imibuzo emibini kuqala: Yeyiphi eyona meko imbi kakhulu ye-thermal gradient eya kuyibona? Kwaye yeyiphi inqaku ledatha ethwele elona nqanaba liphezulu lokunyamezelana? Phendula abo ngaphambi kokuvula i-CAD-kwaye uya kuphepha i-80% yokungaphumeleli kwintsimi. Ukuchaneka akufezekiswanga kuhlolo lokugqibela. Itshixiwe kwindawo yokuqala yokubeka ipini.
Kumaqela obunjineli abakha izilungiso ze-BIW ezinikezela ngesivuno sokuqala esingaguqukiyo, uzinzo olulinganayo, kunye nobomi benkonzo obungaphaya kweminyaka emi-5—ukulungiswa kwe-biw ukusebenza kuqala ngoqeqesho lwesinyithi, hayi nje uyilo lomatshini. Lo ngumgangatho esiwusebenzisayo kwiinjineli eBotou Haijun Metal Products Co., Ltd.
