Ngaba iSpot Welding Machine iyakwazi ukuWeld ngokufanelekileyo izixhobo zeCopper?

Ubhedu kunye nealloys zalo zibalulekile kwimveliso yala maxesha-ukusuka kwizithuthi zamandla amatsha kunye nombane we-electronics ukuya kwi-aerospace-ngenxa yokwenziwa kombane okungaqhelekanga kunye nokuhanjiswa kwe-thermal. Okumangalisayo kukuba, ezi zakhiwo zizisa imiceli mngeni eyoyikekayo kwitekhnoloji yokumelana ne-welding eqhelekileyo. Kangangeminyaka, i-welding yobhedu ithathwa njengengxaki enkulu kwishishini.

Eli nqaku libonelela ngo{0}}uhlalutyo olunzulu lwendlela iMedium Frequency Direct Current (MFDC)umatshini wokuwelda indawo, kunye neenzuzo zayo eziguquguqukayo zetekhnoloji, iyaboyisa ngokupheleleyo obu bunzima, kwaye inikezela ngesikhokelo esisebenzayo kwabo baza kuba ngabathengi abafuna ukwenza ngcono iinkqubo zabo zokuwelda.

I-Dilemma ye-High Conductivity, i-High Thermal Diffusivity, kunye ne-Low Resistivity

Umgaqo osisiseko we-resistance spot welding ixhomekeke kwi-Joule yokufudumeza ($ Q=I^2Rt $) eyenziwa ngokudlula ngokugqitha kwi-interface yomsebenzi ukunyibilikisa isinyithi kunye nokwenza i-weld nugget. Kubhedu, imiceli mngeni iphindwe kathathu, iyenza ibe yenye yezona zinto zinzima ukuwelda usebenzisa iindlela zemveli:

1. I-Thermal Conductivity ePhezulu kakhulu:I-Copper's conductivity ye-thermal imalunga ne-398 W/(m·K), ephindwe kaninzi kune-alloys yentsimbi eqhelekileyo. Oku kuthetha ukuba naluphi na ubushushu olwenziwa ngexesha lenkqubo ye-welding buyachitha kwizinto ezisisiseko ezijikelezayo kwizinga elikhawuleza kakhulu. Ngenxa yoko, kunzima ukuba ubushushu bommandla we-weld bufikelele ngokukhawuleza kwindawo yokunyibilika, ngokuqhelekileyo kuthintela ukubunjwa kwe-weld nugget ezinzileyo kunye nobukhulu obaneleyo. Le lahleko ikhawulezayo yobushushu ifuna igalelo lamandla eligxile kakhulu nelikhawulezayo.
2. Ukuqhuba koMbane okuPhezulu ngokuBanzi (uKuxhathisa okuphantsi):Ukuxhathisa kombane okuphantsi kweCopper kuthetha ukuba kwixesha elifanayo langoku kunye nexesha elide, ubushushu beJoule obuveliswayo buncinci kakhulu kunezixhobo ezinokumelana okuphezulu. Ukufikelela kubushushu obufunekayo bokunyibilika, kufuneka kufakwe umsinga wokuwelda ophezulu kakhulu. Le mfuno ibeka umthwalo omkhulu kwaye uhlala ungenzeki kwisixhobo somthombo wamandla kunye nesekethe yewelding yonke.
3. Ifestile yeWelding emxinwa:Ngelixa umsantsa phakathi kwendawo yokunyibilika kobhedu (malunga. 1083 neqondo) kunye nendawo yokufunxa kwayo (malunga. 2567 neqondo) inkulu, i-thermal diffusivity yayo ephezulu inciphisa kakhulu ixesha lefestile phakathi kokuqalisa kokunyibilika kunye nesehlo sokugxothwa (ubushushu obugqithisileyo kunye ne-splatter). Oku kufuna ukuchaneka okuphezulu kakhulu ekulawuleni i-welding yangoku kunye nexesha, okwenza inkqubo ivakale kakhulu kwiiyantlukwano zeparameter.

Unyino koomatshini bokuWelding be-AC abaqhelekileyo

Ilayini yesiqhelo{0}}i-frequency Alternating Current (AC) oomatshini bokuwelda bamabala, abadla ngokusebenza kwi-50Hz okanye 60Hz, baneziphene ezibulalayo xa bezama ukuwelda imathiriyeli yobhedu:

1. I-Zero yangoku{0}}Isenzeko esiNqamkileyo:Imo yamaza yangoku ye-AC ngokwendalo inqumla i-zero kabini kumjikelo ngamnye. Oku kubangela imveliso yobushushu engazinzanga kwaye engapheliyo. Kwikopolo esebenza kakhulu kwaye epholisa ngokukhawuleza, ubushushu buyalahleka ngokukhawuleza ngexesha le-zero{2}}ixesha lokuwela, okubangela ubushushu be-weld behle kakhulu. Oku kuphazamisa kakhulu ukubunjwa kunye nokuhambelana kwe-weld nugget.
2. Ukusasazwa kwamandla kunye nobushushu obukhulu{0}}iNdawo eChaphazelekayo:Iiwelder zeAC zifuna ixesha elide lokuwelda ukuqokelela ubushushu obaneleyo. Obu bude bexesha bandisiweyo buvumela ubushushu ukuba busasazeke ngokubanzi kwimathiriyeli ejikelezileyo, kudala ubushushu obukhulu-iNdawo eChaphazelekileyo (HAZ). I-HAZ enkulu inokukhokelela ekukhuleni okuziinkozo kubhedu, nto leyo ethob' isidima iipropathi zoomatshini kunye nengqibelelo epheleleyo edibeneyo.
3. Ukuguquguquka kweGridi yaMandla:Iiwelder ze-AC zitsala imisinga enkulu encopho ngoko nangoko ukusuka kwigridi yamandla ngexesha lokusebenza. Oku kubangela ukuguquguquka okubalulekileyo komthwalo wegridi yamandla, okunokuthi kube nefuthe elibi ekusebenzeni okuzinzileyo kwezinye izixhobo ezinovakalelo eziqhagamshelwe kwintambo yombane efanayo.

Ukufika komatshini wokuwelda we-Medium Frequency Direct Current (MFDC) uye wasombulula imingeni yokuwelda ubhedu, ewumisela njengobuchwephesha obukhethwayo kumashishini asemgangathweni aphezulu afana nokuveliswa kwamandla amatsha kunye nokuveliswa kwe-elektroniki ephezulu.

I-Milisecond-Ulawulo oluchanekileyo lweNqanaba: Imveliso ye-DC kunye noGuquko oluPhezulu{1}}

Undoqo weteknoloji ye-MFDC ilele -kuguqulo lwamaxesha amaninzi kunye nemveliso ye-DC. Inkqubo kuqala ilungisa kwaye ijike umgca oqhelekileyo{2}}umbane we-AC oqhelekileyo (50/60Hz) ubephakathi{5}}umlinganiselo we-AC wangoku ukusuka kwi-1kHz ukuya kwi-4kHz. Le yangoku iye yehliswe yi-transformer kwaye ilungiswe ngokukhawuleza ibe yimveliso ye-DC egudileyo, ezinzileyo.

• I-advanteji ye-DC Output:I-DC yangoku iphelisa i-zero-into yokuwela ekhoyo kumandla we-AC, iqinisekisa ukuba ngokuqhubekayo kunye nozinzo welding yangoku. Oku kuthetha ukuba imveliso yobushushu ayiguquguquki kwaye iyafana, ichasene ngokufanelekileyo nokuchithwa kobushushu obukhawulezayo bobhedu kunye nokuqinisekisa ukubunjwa okungaguqukiyo kwe-weld nugget.
• -Uguqulo oluQhelekileyo kunye nempendulo eKhawulezayo:I-MFDC isebenza ngamaxesha angama-20 ukuya kuma-80 aphezulu kuneentsimbi ze-AC zemveli. Olu phawu luphezulu- lwefrikhwensi lubonelela ngempendulo yolawulo olukhawulezayo ngokugqithisileyo, ivumela ulungelelwaniso oluchanekileyo lwangoku ngaphakathi koluhlu lwemillisecond (ngokuqhelekileyo 3-8ms). Lo mandla wokuphendula ngokukhawuleza, ukuya kumaxesha angama-20 ngokukhawuleza kunezixhobo eziqhelekileyo, uqinisekisa ukuba amandla agxininiswe kwindawo ye-weld ngokukhawuleza, ngaphambi kokuba ilahleko enkulu yobushushu ingenzeka.

Ukoyisa i-Thermal Bottleneck: Umgaqo "oPhezulu okhoyo, ixesha elifutshane, amandla aphezulu".

Ukujongana ngokuphumelelayo ne-conductivity ephezulu ye-thermal yobhedu, iteknoloji ye-MFDC ihambelana ngokugqibeleleyo nemigaqo emiselweyo ye-welding yobhedu: "Ixesha eliPhezulu, ixesha elifutshane, i-High Force."

Ukutsiba kuMgangatho weWeld: Multi{0}}Inqanaba lokufudumeza kunye noLawulo lwangoku

Oomatshini bokuwelda amabala be-MFDC bakholisa ukuba nezigaba ezininzi zemisebenzi yokufudumeza (-ubushushu, iWeld, iPost-ubushushu/ubushushu), ebaluleke kakhulu ekuphumezeni{3}}izinga eliphezulu leentsimbi zobhedu:

• Phambi-ubushushu:Umsinga omncinci usetyenziswa phambi kweweld engundoqo ukufudumeza-kwangaphambili indawo, ukususa iioksidi zomphezulu, kunye nokunciphisa i-thermal gradient yokuqala yobhedu. Oku kudala iimeko ezilungele ngakumbi ukubunjwa kwe-weld nugget.
• Weld:Eyona nto ikhoyo ngoku isetyenziselwa ukwenza ngokukhawuleza i-weld nugget.
• Thumela-ubushushu (Ubushushu):Emva kokuba i-weld igqityiwe, umsinga omncinci usetyenziselwa ukupholisa okucothayo. Oku kusebenza njengonyango lobushushu, ukulungelelanisa ukwakhiwa kweenkozo ze-weld nugget kwaye, ngokugqithiseleyo, ukukhulula uxinzelelo lwangaphakathi. Oku kwandisa kakhulu ukuqina kunye namandla omatshini we-weld joint.

Ngaphaya koko, i-MFDC isebenzisa -ulawulo lwengxelo yeluphu evaliweyo ukujonga iwelding yangoku{1}}ngexesha lokwenyani. Ilungisa ngokuzenzekelayo imveliso ngokusekwe kwizinto ezifana nokunxiba kwe-electrode kunye nokutshintsha komphezulu we-workpiece, ukuphumeza iSiphumo sangoku saKhoyo esiyinyani. Esi sikhundla siqinisekisa iSivuno sokuQala sokuQala esiphezulu kakhulu, esihlala singaphezulu kwama-99.5%.

Amandla kunye nokuNzuzwa kokusiNgqongileyo: Ukusetyenziswa okuNcitshisiweyo kunye nokuzinza kweGridi

Abashiseli be-MFDC bazuza ukonga umbane kakhulu ngobuchwepheshe babo obusebenza kakuhle be-inverter. Idatha yobungqina ibonisa ukuba i-MFDC inokonga i-30% ukuya kwi-50% kusetyenziso lwamandla xa kuthelekiswa nelayini yesiqhelo{3}}i-welders zefrikhwensi. Kwiindawo ezinkulu-zemveliso, ezifana nendibano yebhetri yemoto entsha yamandla, oku kusetyenzwa kwamandla kuguqulela kugcino lweendleko zokusebenza.

Ngaphezu koko, amandla abo aphezulu anciphisa impembelelo kwigridi yamandla, ehambelana neemfuno zale mihla zemizi-mveliso yokwenziwa kohlaza kunye nozinzo.

Ukusebenza okuphezulu koomatshini bokuwelda bamabala be-MFDC kwizicelo zobhedu kubenze ubumbeko olusemgangathweni kuwo wonke amashishini achanekileyo-achanekileyo.

Izithuthi zaMandla amatsha (IiBattery Packs, Electrodes, Busbars)

Iipakethi zebhetri zamandla kwiZithuthi zaMandla amatsha (NEVs) ziqulathe unxibelelwano oluninzi phakathi kweebhasi zobhedu, amaphepha obhedu, kunye nezixhobo ze-aluminium. Olu nxibelelwano lufuna ukuthembeka okuphezulu kakhulu kunye nokusebenza kombane.

• Ukudityaniswa kweMetal okungafaniyo (Ubhedu{0}}iAluminiyam):Ulawulo lwamandla oluchanekileyo lwe-MFDC luvumela ukudityaniswa okuthembekileyo kweentsimbi ezahlukeneyo njengobhedu kunye ne-aluminiyam, ukuthomalalisa ngokufanelekileyo ukusekwa kwezigaba ezibhityileyo ze-intermetallic ezihlala zibonwa kwiwelding eqhelekileyo.
• Ibhetri Electrode Welding:Kudibaniso lweethebhu zeeseli zebhetri (ngokuqhelekileyo ubhedu okanye i-aluminium) kwi-busbar, i-MFDC iqinisekisa amandla e-weld anokufikelela ngaphezu kwe-90% yamandla esiseko. Okubaluleke kakhulu, iqinisekisa ukuxhathisa okuphantsi kakhulu kwangaphakathi, okubalulekileyo ekusebenzeni kwebhetri kunye nokukhupha.
• UFanelo lweMveliso:Umvelisi okhokelayo we-NEV osebenzisa i-MFDC welders ukuwelda i-electrode yobhedu uhlala eqhuba ngaphezulu kwama-5,000 amabala e-weld yonke imihla, egcina i-First Pass Yield (FPY) ngaphezulu kwe-99.5%. Oku kuqinisekisa ukuthembeka kobuchwepheshe kwimveliso-ephezulu,{5}echanekileyo.

IZixhobo zoMbane kunye nezoMbane (iFoil yeKopolo, iintambo zokubopha iintambo, abafowunelwa)

Kushishino lombane, iMFDC ifanelekile kwimicro-usetyenziso lwewelding apho Ubushushu{1}}Izowuni eChaphazelekayo kufuneka ibencinci.

• Ibhodi yeSekethe yoQhagamshelwano lweFoil yeCopper:Ixesha -elifutshane,{1}}ubushushu obuphantsi-impawu zegalelo le-MFDC livumela ukuwelda okuchanekileyo kwefoyile yobhedu njenge-0.1mm. Oku kuhlangabezana neemfuno ze-micro-welding kunye ne-HAZ encinci, ukukhusela izinto ezirhangqe ezinobuthathaka ze-elektroniki.
• Udlulise kwaye utshintshe abafowunelwa:Ukudibanisa imidibaniso yesilivere kwisiseko sobhedu kufuna indawo eyomeleleyo ye-weld enokumelana okuphantsi kakhulu. I-MFDC's multi-inqanaba lokufudumeza umsebenzi olawula ngokufanelekileyo inkqubo, ukuthintela ukunyibilika okugqithisileyo kunye nokugxothwa kwezinto zesilivere.

I-Aerospace kunye noKuchaneka kweMveliso

Kwiindawo ezifuna eyona migangatho iphezulu yokusebenza kwemathiriyeli kunye nobulungisa bolwakhiwo, iinzuzo ze-MFDC zibonakala ngakumbi.

• {{0}I-Welding yeThubhu yeKhopha eNikiweyo:Ukudibanisa{0}}iityhubhu zobhedu ezishinyeneyo, amandla aphezulu kunye -nenkqubo yolawulo loxinzelelo lwenqanaba leMFDC inokufikelela kumlinganiselo ongaphantsi kwe-0.5%. Oku kuqinisekisa ukunyaniseka kokutywinwa kunye nokuchaneka kwejometri efunekayo kwimibhobho yamanzi kwiinkqubo ezibalulekileyo.

Kwiinkampani ezijonge ukwamkela itekhnoloji yeMFDC ukomeleza umgangatho wazo we-welding yobhedu, ukukhetha izixhobo ezifanelekileyo yeyona nto ibalulekileyo. Nazi izinto ezibalulekileyo ekufuneka ziqwalaselwe ngexesha lenkqubo yokuthenga:

Ukuqwalaselwa kweeNgcaciso eziPhambili zobuGcisa

1.Esona siphumo sangoku kunye nokuQhosha:

• Okwangoku: Khetha ubuninzi obufanelekileyo bemveliso yangoku ngokusekwe kubunzima bemathiriyeli yobhedu ojonge ukuweld. Ukuwelda ubhedu olutyebileyo kufuna umthamo omkhulu wogcino lwangoku.
• Ukuphindaphinda: Khetha isixhobo esine-frequency yokusebenza kuluhlu lwe-1kHz ukuya kwi-4kHz. Iifrikhwensi eziphezulu zivumela ulawulo lwangoku olucikizekileyo, oluluncedo ngakumbi-kwigeyiji yesixhobo sokuwelda.

2.Isistim yokulawula kunye neValiweyo{1}}Iindlela zeLoop:

• Umatshini we-MFDC ophezulu wokuwelda indawo kufuneka unike iindlela ezininzi ezivaliweyo zokulawula iluphu, kuquka iConstant Current, Constant Voltage, kunye neConstant Power, ekwaziyo ukuzitshintsha ngokuzenzekelayo okanye ngesandla ngokusekelwe kumsebenzi wokuwelda. Imowudi yangoku ngowona msebenzi ungundoqo wokuqinisekisa umgangatho we-weld yobhedu.

3.Ulawulo loxinzelelo lweDynamic:

• Kwiwelding yentsimbi engafaniyo (umzekelo, ubhedu{2}}i-aluminiyam) okanye{3}}usetyenziso oluchanekileyo, kuyacetyiswa kakhulu ukuba ukhethe intloko yokuwelda exhotyiswe nge-servo motor drive kunentloko ye-pneumatic yendabuko. Iinkqubo ze-Servo zibonelela nge-millisecond -yenqanaba lokuphendula loxinzelelo kunye neeprofayili zoxinzelelo ezicwangcisiweyo (umzekelo, ukusebenzisa uxinzelelo oluphezulu ekuqaleni, ukucutha kancinci ngexesha le-weld, kwaye emva koko usebenzise uxinzelelo lokubamba). Olu lawulo oluguqukayo lungundoqo ekucinezeleni ukugxothwa kunye nokuphucula umgangatho we-weld nugget.

Ukuqinisekiswa koMgangatho weMicimbi enguNdoqo

• Iimodyuli ze-IGBT: ISango le-Insulated Bipolar Transistor (IGBT) yintliziyo ye-inverter. Beka kuqala izixhobo ezisebenzisa iimodyuli ze-IGBT ezivela kwiibrendi ezaziwayo kumazwe ngamazwe (ezifana ne-Infineon okanye iFuji). Umgangatho we-IGBT umisela ngokuthe ngqo ukuzinza kunye nobomi benkonzo yomatshini.
• Isiguquli: Jonga ukuba ngaba isiguquli sizisebenzisa zonke-izijikelezi-langa zobhedu kunye nenkqubo yokuphosa intlaka ye-epoxy. -Iziguquli zodidi oluphezulu ziqinisekisa{3}}uguqulo oluphezulu lwamandla kunye nokulahla ubushushu obuphezulu.
• Izinto ze-Electrode: Kwi-welding yobhedu, i-electrode material ibalulekile. Kunconywa ukusebenzisa i-Chromium Zirconium Copper (CuCrZr) okanye i-Dispersion Strengthened Copper electrodes. Ezi mathiriyeli zigcina ukuhanjiswa kombane okuphezulu ngelixa zinobulukhuni obuphezulu kunye -nokumelana nobushushu obuphezulu, ngokufanelekileyo zinciphisa ukunxiba kwe-electrode kunye nokuncamathela.

Ukubaluleka Emva{0}}kweNkxaso yoThengiso kunye nobuGcisa beNkqubo

Ukuthenga umatshini we-welding we-MFDC ayikokufumana nje intwana yehardware; ityala imali kwisisombululo se-welding.

• Uvimba weDatha weNkqubo: Buza ukuba ngaba umboneleli ubonelela -ngelayibrari yenkqubo emiselweyo yokuseta eyenzelwe imathiriyeli yakho ethile (umzekelo, i-T2 yobhedu esulungekileyo, i-H62 yobhedu,-ikhopha ze-aluminiyam). I-database yenkqubo evuthiweyo inokunciphisa kakhulu ukugunyaziswa kwezixhobo kunye nexesha lokusetha.
• UQeqesho lobuGcisa kunye neNkxaso: Kuba ukuseta iparameter ye-welding ye-MFDC inzima kakhulu kwaye i-nuanced kune-AC welding, uqeqesho lobugcisa kunye{0}}nenkxaso yenkqubo yesayithi enikezelwa ngumboneleli zibalulekile ekuqinisekiseni{1}}umsebenzi ozinzileyo wexesha elide kunye{2}}nemveliso yemveliso.

Ukuqukumbela

Ukujongana nemingeni yobugcisa be-welding ye-copper material, i-Medium Frequency Direct Current (MFDC) i-spot welding machine iye yavela njengesisombululo esithandwayo nesiqhelekileyo kwishishini lanamhlanje. Oku kungenxa yolawulo lwayo oluchanekileyo lobushushu, imveliso ye-DC ezinzileyo, i-millisecond{1}}inqanaba lokuphendula isantya, kunye nokusebenza kakuhle kwamandla.

Kumashishini okuvelisa azama ukusebenza kakuhle, ukungaguquguquki okuphezulu, kunye nokusetyenziswa kwamandla aphantsi, utyalo-mali kumatshini wokuwelda okumgangatho ophezulu we-MFDC ayilophuculo lobuchwepheshe{1}sisiqinisekiso esithembekileyo semveliso yexesha elizayo kunye nomgangatho wemveliso. Ngokulandela esi sikhokelo sibanzi somthengi, iinkampani zinokuqinisekisa ukuba zikhetha ezona zixhobo zifanelekileyo ngokweemfuno zazo, zigcina umda okhuphisanayo kumaza ombane amatsha kunye nokwenziwa ngokuchanekileyo.

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