Konke ukwehluleka kwemidlalo ye-BIW kuqala ngendlela efanayo—hhayi ngokuphahlazeka, kodwa ngokungahambi kahle okucashile ngesikhathi sokushayela komshayeli wokuqala. Sikubone kabili kulo nyaka: umphakeli we-Tier-1 eJalimane ulahle ama-subassemblies ashiselwe angu-473 ngoba amandla okubamba ahluka ngo-±12% eziteshini ezintathu ezifanayo. Imbangela? Akukona ukukhathala okubalulekile noma iphutha lomklamo—kodwa ireferensi yedatha engahambisani phakathi nokuqinisekiswa kokwakhiwa kwesakhiwo. Yingakho "i-BIW fixture" ingeyona nje ingxenye; ingumxazululi othule wobuqotho bobukhulu kuwo wonke amaphoyinti wokushisela angu-3,000+ ngomzimba ngamunye.
Kungani i-BIW Fixture Design Ilawula Isivinini Sokukhiqiza Izimoto
Isakhiwo se-BIW senza umsebenzi owodwa onomkhawulo onguziro wezingxoxo: bamba izingxenye zeshidi lensimbi ngaphakathi kuka-±0.15 mm kuyilapho izibhamu ze-MIG zerobhothi zifaka u-8–12 kg wensimbi yokushisela ngomzuzu. Yehlulekile lokho, bese uvula i-cascade—ukusebenza kabusha kunciphisa isikhathi se-takt, ukusebenza kabusha kudala ukuhlanekezela okushisayo, ukuhlanekezela kuphoqa ukucwayiza okwenziwa ngesandla, futhi ukucwayiza kungasebenzi ukuqinisekiswa kwe-GD&T. E-Botou Haijun Metal Products Co., Ltd., sakhe izinto ezenziwe ngokwezifiso ze-BIW ezingaphezu kuka-210 kusukela ngo-2019 kumakhasimende aseNyakatho Melika naseYurophu. Kuzo zonke izimo, ukulungiswa okusebenza kahle kakhulu kwabelane ngezici ezintathu okungaxoxiswana ngazo: i-modular datum architecture, amaphinikhodi wendawo aqinile ano-≤0.005 mm runout, kanye nama-reference sphere ahlanganisiwe e-CMM kuma-datum ayisisekelo A-B-C.
Amaqembu amaningi awabukeli phansi ukuthi ukuqina kwemidlalo kuthinta ikhwalithi yokushisela. Idatha yethu ibonisa ukuhlobana okuqondile: izinto ezilungiswayo ezinamapuleti ayisisekelo angaphansi kuka-60 mm ubukhulu zikhiqiza u-23% ngaphezulu ukuhlanekezela kwangemuva kokushisela kuma-roof rail asembles kunalawo anezisekelo zensimbi ezisansimbi ezingu-80 mm. Kungani? Amapuleti azacile ayagobeka ngaphansi kwemithwalo yokubopha engu-4.2 kN—anele ukushintsha indawo emaphakathi ne-weld. Manje sicacisa ubukhulu besisekelo obuncane ngokufaka isicelo: 65 mm kumaphaneli angaphakathi ezicabha, 75 mm kumapani aphansi, 85 mm kwabathwali abagcwele abangaphansi.
Izingibe Ezintathu Zomhlaba Wangempela Ayikho Incwadi Exwayisa Ngayo
Abanye bangase baphikise ngokuthi ukulingiswa kwe-CAD kuqeda ingozi engokomzimba. Kodwa-ke, ukuhlolwa kwethu kwesitezi sesitolo kufakazela okuhlukile. Ukwanda okushisayo kukodwa kuphazamisa u-17% wokwakhiwa kwe-athikili yokuqala—ngisho noma amamodeli e-FEA ebikezela ukuzinza okuphelele. Nakhu okuphukayo ngempela:
I-Datum creep kusukela ekubhayisikilini okushisayo okuphindaphindiwe: Amafreyimu e-aluminium anwebeka ngo-2.4× ngokushesha kunezingxenye zensimbi. Ngemuva kwemijikelezo ye-weld engu-420, silinganise u-0.11 mm ukukhukhuleka ezindaweni ze-axis engu-Z endaweni yephaneli yekota engemuva—okwanele ukwenqaba u-100% wezingxenye ngokumelene namageji okuhlola okugcina. Ukuphazamiseka kwe-clamp ngendlela yerobhothi: Isakhiwo sekhasimende “esithuthukisiwe” sesibambiso samaphoyinti angu-3 sivimbe u-38° wokuzungezisa isihlakala irobhothi. Umphumela? Ukweqa kwe-Weld, i-porosity, nesikhathi sokuphumula esingahleliwe. Manje sidinga ukuqinisekiswa kwendlela yerobhothi engaxhunyiwe ku-inthanethi ngaphambi kokuthi kuqale ukwenziwa kwemishini. Ukungafani kokuqedwa kobuso phakathi komdlalo nengxenye: Izindawo zokulungisa eziwu-Ra 0.8 μm ezinxenyeni zensimbi ezigoqeke ngokubanda (Ra 1.6 μm) zibangele ukuklwebheka okuncane okusakazeke kwaba ukonakala kopende. Isixazululo: fanisa ubulukhuni bendawo engaphakathi kuka-±0.2 μm—futhi uqinisekise nge-profilometer, hhayi ukuhlola okubukwayo. Ukuthi Ukukhetha Okubalulekile Kushintsha Kanjani Konke—Ngaphezu Kwezindleko Nje
Izitholi zensimbi engagqwali ziyamelana nokuguga, kodwa ziqhuba ukushisa okungu-15× ngokushesha kunensimbi yamathuluzi eqinile. Lokho kuzwakala kuwusizo—kuze kube yilapho ubona ukuthi ukushisa kuthuthela ezingxenyeni ezithile zedatha ngesikhathi sokushisela, okubangela ukunwetshwa kwendawo. Sishintshele ku-AISI H13 tool steel (52–54 HRC) kuzo zonke izindawo ezibucayi ngemuva kokuhlolwa kubonise ukuthi ibambe ngokunemba ngokuma okungu-3.7× ubude kune-stainless ngaphansi kweshejuli yokushisela efanayo.
Izinto eziyisisekelo zibalulekile ngokufanayo. I-Cast iron inikeza ukudambisa kodwa yengeza isisindo nokuhlukahluka kokusakaza. Izinga lethu lamanje yi-EN-GJS-600-3 i-ductile iron—amandla amancane aqinile angu-600 MPa, i-graphite spheroidization eqinisekisiwe >90%, kanye nokuvuleka komshini ≤0.02 mm/m². Ukwenza i-prototyping ephuthumayo, sisebenzisa i-AL-6082-T6 ekhululwe ukucindezeleka, kodwa kuphela ngokufaka insimbi ene-laser-sintered ezindaweni zokusebenzelana zendawo. Ungalokothi ube yi-aluminium kuphela yokulungiswa kokukhiqiza.
Siqinisekisa yonke into ye-BIW ngokuhlolwa okuthathu okulandelanayo: 1) Ukulinganisa kwe-CMM yazo zonke izitholi ngokumelene ne-CAD yegama, 2) ukuhlolwa kokuphindaphinda (imijikelezo engu-10, ukuchezuka okukhulu ≤0.01 mm), kanye no-3) ukuhlolwa okusebenzayo okunezingxenye zangempela ezinesitembu ngaphansi komthwalo ogcwele wokugoqa. Uma noma yisiphi isinyathelo sihluleka, siyabuyekeza—hhayi ukusebenza kabusha.
Idizayinelwe Ukwenziwa—Hhayi nje Ukuhlanganisa
Ukulungiswa kwe-BIW kufanele kusinde emijikelezweni engu-500,000 ngaphandle kokulungiswa kabusha. Lokho kudinga idizayini-yesevisi, hhayi nje ukuklama-kokuhlangana. Sishumeka izici zesevisi ngokuqondile ku-geometry: amaphinikhodi wendawo anamafulethi angu-12 mm hex okususwa okulawulwa yi-torque, amashaneli apholile ahanjiswa ngamapuleti ayisisekelo (hhayi amapayipi angaphandle), kanye nezimbobo ezifakwayo ze-M8 ezijwayelekile ezihlukaniswe ngezikhawu ezingu-100 mm—ukuze amakhasimende akwazi ukubuyisela izinsimbi zomoya ngaphandle kokuklama kabusha.
Isikhungo se-ISO se-Botou Haijun esihambisana ne-ISO sinesakhiwo esakhelwe phezu kwezikhungo zemishini ze-CNC ngesinxephezelo sesikhathi sangempela sokushisa. Yonke imishini eqediwe ithunyelwa onombiko wokulinganiswa okulandelekayo, okuhlanganisa idatha yokuskena kwe-CMM, ukufundwa kokuqina kwendawo, nokuqinisekiswa kwe-clamping force esiteshini ngasinye. Akukho ukucabanga. Azikho izilinganiso "ezakhiwe"
Lapho iphrojekthi yakho elandelayo ye-BIW iqala, buza imibuzo emibili kuqala: Iyiphi i-gradient eshisayo embi kakhulu ezoyibona? Futhi yiliphi iphuzu ledatha eliphethe isitaki sokubekezelela okuqongelelekayo esiphezulu? Phendula labo ngaphambi kokuvula i-CAD—futhi uzogwema ukwehluleka okungu-80% kwenkambu. Ukunemba akutholakali ekuhlolweni kokugcina. Ikhiyelwe endaweni yokuqala yokubeka iphinikhodi.
Emaqenjini onjiniyela akha izakhiwo ze-BIW eziletha isivuno sephasi yokuqala engaguquki, ukuzinza kobukhulu, nempilo yesevisi engaphezu kweminyaka emi-5—ukulungiswa kwe-biw ukusebenza kuqala ngokuqondisa kwe-metallurgical, hhayi nje ukwakheka komshini. Lokho izinga esisebenza kulo ngonjiniyela e-Botou Haijun Metal Products Co., Ltd.
