Embonini yokukhiqiza izimoto, ikhwalithi yokushisela inomthelela oqondile ekuphepheni kwesakhiwo semoto, ukusebenza kahle kokukhiqiza, kanye nezindleko zokukhiqiza zizonke. Lokhu kuyiqiniso ikakhulukazi ezinsizeni ezifana nezimoto zikagesi, izindawo ezivalekile zamabhethri, kanye nomzimba-ekuhlanganiseni{2}}okumhlophe (BIW), lapho ukuzinza kwe-welding kudlala indima ebalulekile ekuthembekeni komkhiqizo. Idatha yemboni ibonisa ukuthi imoto yabagibeli ejwayelekile iqukethe3,000 kuya ku-5,000 ama-spot welds, eziningi zazo zitholakala ezindaweni zesakhiwo nokuphepha-ezibalulekile zendikimba yemoto. Ngenxa yalokhu, ngisho nephesenti elincane leziphambeko zokushisela lingaholela ezingozini eziphawulekayo zekhwalithi lapho umthamo wokukhiqiza ufinyelela amakhulu ezinkulungwane zamayunithi ngonyaka.
Njengoba idizayini yezimoto iya ngokuya ihlanganisa izinto ezingasindi kanye{0}}nezinsimbi ezinamandla aphezulu, imigqa yokukhiqiza nayo isiye yasebenza ngokuzenzakalelayo. Ngaphansi kwalezi zimo, zendabukoImishini yokushisela indawo ye-AC ukumelanangokuvamile kunzima ukuhlangabezana nezidingo zesimanje zokukhiqiza. Izinkinga ezifana ne-welding current engazinzile, i-spatter eyeqile, kanye nekhwalithi yokushisela engahambisani kungaholela ekushintshashintsheni kwesivuno sokukhiqiza kanye nezindleko zokuphinda zisebenze.
Ngalesi sizathu, abakhiqizi bezimoto abaningi nabahlinzeki be-Tier 1 bathuthukisa izinhlelo zabo zokushisela. IUmshini wokushisela indawo we-MFDC (Medium Frequency Direct Current).kuvele njengesixazululo esithandwayo ngenxa yokuphuma kwayo okuzinzile kwe-DC, isikhathi sokuphendula esisheshayo, namandla okulawula inqubo ethuthukisiwe. Ekukhiqizweni kwezimoto ezinkulu-, le mishini inikeza izinzuzo ezicacile ekuzinzeni kokushisela, ukungaguquguquki kwekhwalithi, nokuhlanganiswa nemigqa yokukhiqiza ezenzakalelayo.
Ukuqonda i-MFDC Spot Welding Technology
Isimiso esiyisisekelo se-medium frequency inverter welding
Kusetshenziswa umshini wokushisela indawo we-MFDCubuchwepheshe be-inverter{0}}ephakathi nendawoukuguqula amandla kagesi abe umsinga wokushisela ozinzile futhi olawulekayo. Inqubo ngokuvamile ilandela izigaba ezimbalwa.
Okokuqala, engenayoAmandla angu-50/60 Hz AC asuka kugridi kagesi alungiswa abe wamanje oqondile (DC). Okulandelayo, imojula ye-inverter-imvamisa esekelwe kubuchwepheshe be-IGBT{2}}iguqula amandla e-DC abemedium-ifrequency AC cishe ngo-1,000 Hz. Lokhu okuphezulu-i-frequency current ithunyelwa nge-medium{2}}frequency welding transformer lapho i-voltage yehliswa ifike ezingeni elifanele lokushisela. Ekugcineni, i-current iyalungiswa futhi ukuze kukhiqizwe aezinzile DC Welding okukhiphayo.
Lo mklamo uhluke kakhulu ezinhlelweni ezijwayelekile zokushisela i-AC. Imishini evamile incike ngokuqondile-ekugcineni kwe-AC yamanje ephansi, eshintshashintsha ngokwemvelo phakathi nomjikelezo kagesi ngamunye. Ngokuphambene, izinhlelo ze-MFDC zinikeza iphrofayili yamanje ezinzile, evumela ukulawula okunembe kakhudlwana kwenqubo yokushisela.
Ngokombono wezobuchwepheshe, lesi sakhiwo sinikeza izinzuzo ezimbalwa ezingokoqobo:
- Ukulawula okunembe kakhudlwana kwe-welding current
- Ukusabela okusheshayo okuguquguqukayo phakathi nomjikelezo wokushisela
- Ukusebenza kahle kwamandla okuphezulu
- Ukuhambisana okuthuthukisiwe nezinhlelo zokukhiqiza ezizenzakalelayo
Ngenxa yalezi zinzuzo, imishini yokushisela indawo ye-MFDC isetshenziswa kabanzi hhayi kuphela ekukhiqizeni izimoto kodwa nasezimbonini ezifana nemishini yasendlini, ukukhiqizwa kwamabhethri, kanye nokwakhiwa kwensimbi okunembayo.
Okuphumayo kwe-DC Okuzinzile Kuthuthukisa Ikhwalithi Yokushisela
Iqeda ukushintshashintsha kwamanje ekushiseleni kwe-AC
Omunye wemikhawulo eyinhloko yemishini yokushisela indawo ye-AC yendabukouziro{{0}isenzakalo sokuwela. Phakathi nomjikelezo ngamunye wamandla ashintshayo, amandla kagesi ehla ngezikhathi ezithile aze afike kuqanda ngaphambi kokuba akhuphuke futhi. Lokhu kuphazamiseka kokugeleza kwamanje kungadala ukushintshashintsha kokufaka ukushisa phakathi nenqubo yokushisela.
Lapho ushisela izinto ezibucayi noma amashidi ensimbi azacile, lokhu kushintshashintsha kungaholela ekwakhekeni kwama-nugget okungahambisani. Ngenxa yalokho, amandla e-weld angase ahluke kusuka iphuzu kuya kwelinye.
Imishini yokushisela indawo ye-MFDC ixazulula le nkinga ngokuletha aokukhiphayo okuzinzile kwamanje. Ngenxa yokuthi i-current ayidluli ngokuphindaphindiwe endaweni eyiziro, okokufaka kokushisa kuhlala kufana kuwo wonke umjikelezo wokushisela. Lokhu kuvumela i-weld nugget ukuthi yakheke ngaphansi kwezimo ezilawulwa kakhulu.
Ezimweni zangempela zokukhiqiza, lokhu kuzinza kwamanje okuthuthukisiwe ngokuvamile kubangela:
- I-spatter ye-welding encishisiwe
- Usayizi we-nugget ongaguquki
- Ukwehluka okuphansi kwamandla e-weld
- Ukubukeka kwe-weld okuthuthukisiwe
Ngezakhiwo zomzimba wezimoto lapho izinkulungwane zokushisela kufanele zisebenze ngokuthembekile, ukugcina leli zinga lokungaguquguquki kubalulekile.
Ukusebenza okungcono ngensimbi{0}}ephezulu nezinto ezimboziwe
Izakhiwo zezimoto zesimanje zithembele kakhulu kuzohigh-insimbi enamandla (HSS) neshidi lensimbiukunciphisa isisindo ngenkathi ugcina ubuqotho besakhiwo. Lezi zinto zinzima kakhulu ukushisela ngoba zidinga ukufaka ukushisa okunembile kanye nokulawula okuqinile kwenqubo yokushisela.
Imishini yokushisela indawo ye-MFDC ifaneleka kakhulu kulezi zinhlelo zokusebenza. Impendulo yabo yamanje esheshayo kanye nokulawulwa kwamandla okunembile kuvumela ukushisela ukuthi kuqedwe ngesikhathi esifushane kuyilapho kugcinwa ukusatshalaliswa kokushisa okuzinzile.
Ngenxa yalokho, amasistimu e-MFDC asetshenziswa kabanzi kwizicelo zokushisela ezifana nalezi:
- Izingxenye zesakhiwo somzimba wezimoto
- Imihlangano yezindlu zebhethri
- Izihlalo zohlaka lwezakhiwo
- Amantongomane kanye ne-stud welding eshidini lensimbi elincanyana
Kuphrojekthi eyodwa yokukhiqiza uhlaka lwezihlalo zezimoto, isibonelo, umenzi washintsha amashisela avamile e-AC ngemishini yokushisela indawo ye-MFDC. Ngemuva kokuthuthukiswa, i-izinga lokushisela elingasebenzi lehle lisuka ku-0.5% laya ku-0.02%, futhi ukuchezuka okujwayelekile kwamandla wokudonsa kwe-weld kwehle cishe50%. Lokhu kuthuthukiswa kukhulise kakhulu ukuvumelana kokukhiqiza okuphelele futhi kwehlise izindleko zokuphinda zisebenze.
Kuvaliwe-I-Loop Control Iqinisekisa Imiphumela Engaguquguquki Yokushisela
Ukuqapha{0}}kwangempela kwesikhathi kwamapharamitha angukhiye wokushisela
Abakhiqizi bezimoto namuhla abadingi ama-welds aqinile kuphela kodwa futhiizinqubo zokushisela eziphindaphindekayo futhi ezilandelekayo. Ngalesi sizathu, imishini yesimanje yokushisela indawo ye-MFDC ngokuvamile ihlanganisa okuthuthukileavaliwe-amasistimu okulawula iluphu.
Phakathi nomjikelezo wokushisela, uhlelo lokulawula luqapha amapharamitha ambalwa abalulekile ngesikhathi sangempela, okuhlanganisa:
- Welding current
- Welding voltage
- Amandla kagesi
- Ukukhishwa kwe-Electrode
Ngokuqhubeka nokuhlaziya lezi zimpawu, isilawuli singakwazi ukulungisa amapharamitha wokushisela ngamandla ukuze kugcinwe okokufaka kwamandla okungaguquki kuyo yonke i-weld.
Izinhlelo zokushisela ezithuthukisiwe ze-MFDC zivame ukufezaukuphindaphinda kwamandla ngaphakathi ±2%, kuyilapho amasistimu wokushisela we-AC avamile ngokuvamile asebenza phakathi kwebanga elingu-cishe±5%. Emkhiqizweni wezimoto{1}wevolumu ephezulu, lo mehluko ungaba nomthelela omkhulu kuyo yonke ikhwalithi yomkhiqizo nokuvumelana.
Ukuqoshwa kwedatha yokushisela kanye nokulandeleka kwekhwalithi
Omunye umkhuba obalulekile ekukhiqizeni izimoto ukugcizelela okwandayoUkuphathwa kwekhwalithi{0}eqhutshwa yidatha. Amazinga afanaI-IATF 16949zidinga abakhiqizi ukuthi bagcine amarekhodi okukhiqiza alandelekayo ngezinqubo ezibalulekile.
Ngakho-ke imishini eminingi yesimanje ye-MFDC yokushisela amabala ihlanganisa-amasistimu akhelwe ekuqapheni nawokuloga idatha. Lawa masistimu avumela abakhiqizi ukuthi:
- Rekhoda imingcele yokushisela kuwo wonke amaphoyinti e-weld
- Thola izimo zokushisela ezingavamile ngesikhathi sangempela
- Hlaziya amathrendi ekhwalithi yokushisela ngokuhamba kwesikhathi
- Hlanganisa idatha yokushisela nge-MES noma amasistimu okuphatha embonini
Ngalolu lwazi, abakhiqizi bangakwazi ukuhlonza izinkinga zenqubo ezingaba khona kusenesikhathi futhi benze{{0}ukuthuthukiswa okusekelwe kudatha ekusebenzeni kwabo kokushisela.
I-Modular Design Ithuthukisa Ukuhlanganiswa Komugqa Wokukhiqiza
Ukuhambisana ne-robotic welding systems
Imisebenzi eminingi yesimanje yokushisela izimoto incike kakhulu ekuzishintsheni kwerobhothi. Ukusekela lezi zinhlelo, imishini yokushisela indawo ye-MFDC ivame ukuklanywa nge-i-architecture ye-modular.
Izingxenye zesistimu ezijwayelekile zifaka:
- Welding amandla module module
- I-Madium-i-frequency transformer
- Imojula yesistimu yokulawula
Ukuhlukanisa lezi zingxenye zibe amamojuli azimele kwenza ukufakwa nokugcinwa kube lula kuyilapho kwenza isistimu ibe lula ukuhlanganisa emigqeni yokukhiqiza ezenzakalelayo.
Izinhlelo eziningi zokushisela ze-MFDC nazo zisekela izivumelwano zokuxhumana ezisetshenziswa kabanzi ezimbonini, njenge:
- Inzuzo
- I-modbus
- I-Ethernet/IP
Lezi zindawo zokusebenzelana zivumela imishini yokushisela ukuthi ixhumane ngokuqondile namarobhothi, abalawuli be-PLC, nezinhlelo ze-MES, okuvumela ukusebenza kwefekthri okuphumelelayo nokuhlakaniphe kakhudlwana.
Ukufakwa okusheshayo nokusetshenziswa
Kumaphrojekthi amakhulu okukhiqiza izimoto, isikhathi esidingekayo ukuze kufakwe futhi kugunyazwe okokusebenza kokukhiqiza sithinta ngokuqondile ijubane lokukhiqiza{0}}irempu phezulu. Amasistimu okushisela endabuko ngokuvamile adinga izintambo ezenziwe ngokwezifiso, ukumiswa kwe-pneumatic, kanye nokulungiswa okubanzi-kusayithi.
Ngokuphambene, amasistimu wokushisela we-MFDC angenza lezi zinqubo zibe lula kakhulu. Ngenxa yokuthi izingxenye eziyinhloko -zakhiwe ngaphambili futhi zimisiwe, ukufakwa kuyashesha futhi ukuhlanganiswa kwesistimu kubonakala kakhulu.
Kumaphrojekthi ambalwa wokukhiqiza izingxenye zezimoto, ukuthuthukela kuma-modular welding we-MFDC kuholele kulokhu:
- 60-70% isikhathi esifushane sokusebenza
- Ulayini wokukhiqiza usuwonkeI-OEE idlula u-90%
Lokhu kuthuthukiswa kuvumela abakhiqizi ukuthi balethe imigqa yokukhiqiza emisha ku-inthanethi ngokushesha okukhulu ngenkathi begcina ukusebenza kahle okuphezulu.
Ungawukhetha Kanjani Umshini Wokushisela Ofanele Wendawo Wokukhiqiza Kwezimoto
Kubakhiqizi abahlela ukuthuthukisa imishini yabo yokushisela, ukukhetha umshini wokushisela wamabala we-MFDC ofanele kudinga ukuhlolwa ngokucophelela kwezinto ezimbalwa zobuchwepheshe.
Okokuqala, ukuzinza kokunikezwa kwamandla okushisela kubalulekile. Imishini ngeukunemba kokulawula kwamanje ngaphakathi ±3%futhiukuphindaphinda kwamandla ngaphakathi ±2%ngokuvamile kunconywa izinhlelo zokusebenza zezimoto lapho ukuhambisana kwe-weld kubalulekile.
Okwesibili, amakhono wesistimu yokulawula ukushisela kufanele acatshangelwe. Isilawuli{1}}esiklanywe kahle kufanele sisekele amashejuli amaningi wokushisela,{2}}ukuqapha inqubo yesikhathi sangempela, kanye nokuqoshwa kwedatha yokushisela. Lezi zici zisiza ukuqinisekisa ikhwalithi yokushisela engaguquki futhi zinike amandla ukulandeleka kuyo yonke inqubo yokukhiqiza.
Okokugcina, ukuhambisana nezinhlelo ezizenzakalelayo kuya ngokuya kubaluleke kakhulu. Imishini esekela izimiso zokuxhumana ezijwayelekile zezimboni zingahlanganisa kalula nezinhlelo zokushisela zamarobhothi nezinkundla ze-MES zasembonini, zehlise izindleko zokuhlanganisa nokwenza lula ukuthuthukiswa okuzayo.
Isiphetho
Njengoba imboni yezimoto iqhubeka nokuguqukela ezimotweni zikagesi, izakhiwo ezingasindi, kanye nokukhiqizwa okuzenzakalelayo, izidingo zemishini yokushisela ziya zidingeka kakhulu. Imishini yokushisela indawo ye-AC yendabuko ivamise ukuthwala kanzima ukuletha ukuzinza nokunemba okudingekayo ezindaweni zokukhiqiza zesimanje.
Imishini yokushisela indawo ye-MFDCukubhekana nalezi zinselele ngokuhlanganisa okukhiphayo kwe-DC okuzinzile,{0}}ukunemba okuphezulu okuvalwe{1}}ukulawula iluphu, kanye nomklamo wesistimu we-modular. Lawa makhono awathuthukisi ikhwalithi yokushisela kuphela kodwa futhi asekela ukuhlanganiswa okuphumelelayo nemigqa yokukhiqiza ezenzakalelayo.
Kubakhiqizi abahlose ukuthuthukisa ukuthembeka kokushisela, ukunciphisa ukusebenza kabusha, kanye nokwandisa ukusebenza kahle kokukhiqiza, ukutshala imali kubuchwepheshe bokushisela indawo be-MFDC sekuya ngokuya kuba yisinqumo esisebenzisekayo namasu. Njengoba ukukhiqiza okuhlakaniphile kuqhubeka nokuthuthuka, amasistimu wokushisela ahlinzeka ngokulawula okunembayo, ukucaca kwenqubo, kanye nokuhlanganiswa okuzenzakalelayo okuzenzakalelayo kuzodlala indima ebalulekile esikhathini esizayo sokukhiqizwa kwezimoto.
