Kwimveliso yale mihla yeemoto, uMzimba -kuMhlophe (BIW) umgangatho wokuwelda umisela ngokuthe ngqo ukomelela kwesithuthi kwaye ubonisa uzinzo kumgca wemveliso. Isithuthi esiqhelekileyo sabakhweli siqulethe4,000 ukuya 6,000 indawo welds, ngelixa izithuthi zombane kunye{0}}nezakhiwo zentsimbi eziphakamileyo zinokudlula7,000 amanqaku weld. Ngenani elikhulu lee-welds, kunye nepesenti encinci yamalungu angazinzanga inokukhula ngokukhawuleza ibe yimingcipheko enzulu yomgangatho ngexesha lokuhlolwa kokugqibela. Ngesi sizathu, abavelisi beemoto badla ngokufuna kuqala{2}}ukuba baphumelele amaxabiso okwamkela i-weld ngaphezulu99.5%, kunye nemimandla ebalulekileyo yezakhiwo ezizayo99.9% ukuhambelana.
Kwimveliso yemihla ngemihla,isitshizikwayeiiwelds ezibuthathakahlala zezona zinto zimbini zixhaphakileyo ezichaphazela ukuqina kwe-weld. I-Spatter ayingcolisi nje indawo yokusebenza kwaye inyuse isithuba-ixesha lokusila, kodwa okona kubaluleke kakhulu, inokugquma iziphene zeweld yangaphakathi, yenze ukuba iiweld ezibuthathaka zibe nzima ukuzibhaqa. Xa iiwelds ezibuthathaka zidlula zingabhaqwanga kwiinkqubo zokudityaniswa komsinga, zihlala zikhokelela-kumsebenzi omkhulu kwakhona okanye izinto ezikhatywayo, ezinokuthi ziphazamise iishedyuli zemveliso kwaye zandise iindleko zokwenziwa kakhulu.
Izixokelelwano zeendawo ze-AC ezixhathisayo zikholisa ukufikelela kuqala-kumazinga okupasa kuluhlu lwe96% ukuya 98%, ubukhulu becala ngenxa yolawulo olulinganiselweyo malunga nokuzinza kwegalelo lobushushu. Ngelixa lo mgangatho wokusebenza wawamkelekile kuyilo lwangaphambili lwezithuthi kusetyenziswa intsimbi epholileyo, imibutho yezithuthi yanamhlanje ixhomekeke kakhulu{1}}kukuqina kweentsimbi, amashiti esinyithi, kunye -nezakhiwo zomaleko ezininzi. Ezi zixhobo zifuna ulawulo olungqongqo lwenkqubo, kwaye ukwandisa nje i-welding yangoku akusanele. Endaweni yoko, isitshixo sokuphucula ukuhambelana kwe-weld sileleulawulo oluchanekileyo lwe-welding waveforms, ukuqinisekisa ukuba igalelo ngalinye lamandla lihlala lizinzile kwaye liphindaphinda.
Kutheni i-Spatter kunye neeWelds ezibuthathaka ziqhubeka zisenzeka?
Kwiindawo ezininzi zokuvelisa, i-spatter kunye ne-welds ezibuthathaka zihlala zibalelwa kwizinto ezingahambelaniyo okanye izinto zabaqhubi. Nangona kunjalo, ngokwembono yobunjineli, ezi ziphene zidla ngokudityaniswa neemeko zokufaka ubushushu obungazinzanga. Xa i-welding yangoku iphakama ngokukhawuleza kakhulu okanye xa ukuchasana koqhagamshelwano kuguquguquka, isinyithi sasekhaya sinokunyibilika ngokukhawuleza kwaye sigxothwe kwindawo ye-weld ngenxa yamandla ombane we-electromagnetic, okwenza i-spatter ebonakalayo ejikeleze i-weld.
I-welds ebuthathaka, kwelinye icala, iyenzeka xa igalelo lobushushu elinganeleyo lithintela ukubunjwa kwe-weld nugget ephuhliswe ngokupheleleyo. Ezi ziphene zihlala kunzima ukuzibona ngokubonakalayo kodwa zinokunciphisa kakhulu amandla e-weld kunye nobomi bokudinwa. Kumacandelwana eemoto zesakhiwo, iiwelds ezibuthathaka zinokwenza iindawo ezingaphumeleliyo ezifihlakeleyo ezibeka esichengeni ukhuseleko lwesithuthi ngexesha elide{2}}lokusebenza okanye kwiziganeko zontlitheko.
Ukuqonda ngcono ezona ziphene zixhaphakileyo zokuwelda kunye nempembelelo yazo yemveliso, le theyibhile ilandelayo ishwankathela iimeko eziqhelekileyo:
Iziphene ze-Welding ye-Spot eqhelekileyo kunye neMpembelelo yazo
| Uhlobo lwesiphene | Imbonakalo eqhelekileyo | Unobangela weengcambu | Impembelelo yeMveliso |
|---|---|---|---|
| I-Spatter | Amasuntswana esinyithi ajikeleze i-weld | Ukunyuka kwangoku okukhawulezayo okanye uqhagamshelwano olungazinzanga | Ukunyuka kokusila kunye nokunxiba kwe-electrode |
| Weld Weld | I-weld nugget encinci | Igalelo lobushushu elingonelanga | Ukunciphisa amandla adibeneyo |
| I-Srinkage Void | Ukwakheka komngxuma wangaphakathi | Iimeko zokupholisa ezingazinzanga | Ukuncipha koxinzelelo lwe-weld |
| Tshisa{0}Ngako | Ukugqojozwa kwezinto | Ukugqithiswa kwangoku okanye uxinzelelo oluphantsi | Ukwaliwa kweworkpiece |
Idatha yemveliso evela kwimigca yewelding yemoto ibonisa ukuba i-spatter{0}}imibandela enxulumeneyo inokunyusa ukugqiba umsebenzi30% ukuya kwi-50%, ngelixa ukuphinda kusebenze okubangelwa yi-welds ebuthakathaka kunokubizaamaxesha amathathu ukuya kahlanu ngaphezulukunemisebenzi ye-welding eqhelekileyo. Kumaziko eemoto{1}omthamo ophezulu, iyure yexesha lokuphumla elingalindelekanga linokubangela ilahleko ukusuka kumawaka aliqela ukuya kumashumi amawaka eedola, nto leyo eyenza uzinzo lweweld lube ngumgangatho ophezulu kunye nokubaluleka kwezemali.
Ukuwelda kwe-MFDC: Ukusuka kwi-Right Heating ukuya kuLawulo loBubushushu obuchanekileyo
Iinkqubo zemveli ze-AC zokuwelda zisebenza50 Hz, ukuvelisa umsinga otshintshanayo owela i-zero ngexesha lomjikelo ngamnye. Oku kuphazamiseka okuphindaphindiweyo kwangoku kubangela ukuba indawo ye-weld ibe nemijikelo eqhubekayo yokupholisa kunye nokufudumeza kwakhona. Ukuguquguquka okulolo hlobo kwe-thermal kudla ngokukhokelela ekuzinzeni kwe-nugget engazinzanga kwaye kwandisa kakhulu amathuba okutshiza.
Iinkqubo zeWelding eziPhakathi eziNgqo ngokuNgqo (MFDC), ngokuchaseneyo, ziguqula amandla angenayophezulu{0}}i-frequency yangoku ngaphezulu kwe-1,000 Hz, ethi emva koko ilungiswe ibe ngumsinga othe ngqo ozinzileyo. Ngenxa yokuba yangoku ihlala iqhubekile, igalelo lobushushu liba lihambelana ngakumbi, livumela i-weld nugget ukuba iphuhlise ngokulinganayo. Olu ncedo lubaluleka ngakumbi xa udiza iintsimbi eziphakamileyo-zezintsimbi okanye imathiriyeli eyenziwe ngegalvanized.
AC vs MFDC Spot Welding Uthelekiso lokuSebenza
| Ipharamitha | AC Welding | MFDC Welding | Impembelelo Esebenzayo |
|---|---|---|---|
| Ubuninzi beziphumo | 50 Hz | 1,000–4,000 Hz | I-frequency ephezulu iphucula uzinzo |
| Uhlobo lwangoku | Iyatshintshana | Ngqo ngoku | Iphelisa uphazamiseko lwangoku |
| Ukuzinza kobushushu | Phakathi | Phezulu | Ukubunjwa kwe-nugget efanayo |
| Isantya seSpatter | Phezulu | Yehliswe ngama-60–70% | Ungcoliseko olungaphantsi komhlaba |
| Lawula Ukuchaneka | ±8–10% | Ngaphakathi ±2% | Ukuphuculwa kokuhambelana kwe-weld |
| Ukusebenza kakuhle kwamandla | Ngasezantsi | 15–25% ngaphezulu | Ukunciphisa ukusetyenziswa kwamandla |
Kwiindawo zokwenyani zemveliso, iinkqubo ze-welding ze-MFDC zibonise ukuphuculwa okuhambelanayo kumgangatho we-weld. Uninzi lwabavelisi beemoto banika ingxelo yokuba uphuculo kwi-MFDC ubuchwepheshe kunokonyusa kuqala -ukwamkelwa kwe-weld ukusuka malunga97% ukuya ngaphezulu kwama-99.5%, ukunciphisa kakhulu ukusebenza kwakhona kunye nokuphucula ukuveliswa kwemveliso.
Okuninzi -Ulawulo lweNdawo yamaza: Ukuhanjiswa kwamandla apho kubalulekileyo
Njengoko imathiriyeli yemoto isiya isiba nzima ngakumbi, kuquka -inqwaba yezinto ezixutyiweyo kunye nezinto ezixubeneyo ezifana nentsimbi enamava kunye nentsimbi ephezulu{1}}yamandla, ifestile yewelding iya icutheka ngakumbi. Ukuba i-current iphakama kakhulu, i-spatter egqithisileyo ingenzeka. Ukuba okwangoku akwanelanga, ukubunjwa kwe-nugget kunokungaphelelanga. Ukujongana nale mingeni, iinkqubo ze-welding zangoku ze-MFDC zithembelemulti-inqanaba lolawulo lwamaza, ukuvumela amandla ukuba ahanjiswe ngokuthe ngcembe nangokwesicwangciso kulo lonke umjikelezo we-welding.
Eqhelekileyo Ezintathu -zeSigaba sokuWelding Ulwakhiwo lweWaveform
| Iqonga | Umsebenzi oPhambili | Umlinganiselo wangoku | INzuzo esemgangathweni |
|---|---|---|---|
| Preheat Stage | Ukuqhawula iingubo zokugqoka | 20–40% | Yehlisa isitshizi sokuqala |
| Inqanaba leWeld eliphambili | Yenza i-weld nugget | 100% | Iqinisekisa amandla e-weld |
| Forge Stage | Compress nugget | 40–60% | Ukuphucula ukuxinana |
Ngokwesiqhelo, kubunjwe ngokufanelekileyo amaza amaninzi{0}inqanaba lamaza aphucula kakhulu uzinzo lweweld. Ngokomzekelo, kwi-welding yensimbi ye-galvanized, i-preheat stage inceda ukuphula iingubo ezingaphezulu kunye nokuzinzisa ukuchasana noqhagamshelwano, ngelixa inqanaba eliphambili liqinisekisa ukushisa okwaneleyo kwi-nugget formation. Inqanaba lokugqibela le-forge lisebenza ngoxinzelelo olulawulwayo lokuphucula ukuxinana kwe-nugget kunye nokunciphisa iziphene zangaphakathi.
Idatha yobunjineli ibonisa ukuba amaqhinga aphuculweyo e-waveform anokunciphisa iziphene zokucuthekangaphezulu kwe 80%ngelixa ugcina ukwahluka kwamandla e-weld ngaphakathi±3 N, okukhokelela ekusebenzeni okuphindaphindiweyo kwe-welding.
Ivaliwe{0}}Ulawulo lweNgxelo yeLoop luqinisekisa uZinzo lweXesha elide{1}}
Iimeko ze-welding azizange zime. Ngokuhamba kwexesha, ukunxiba kwe-electrode, ubukhulu beshiti buhluka kancinci, kwaye iimeko zokwaleka zingatshintsha. Ngaphandle kwembuyekezo{2}}yexesha lokwenyani, ezi ziguquguqukayo zithomalalisa umgangatho weweld.
Iinkqubo zanamhlanje zeMFDC zisetyenziswaivaliwe{0}}lopha ulawulo lwengxelo, ngokuqhubekayo ukubeka iliso kwi-welding yangoku, i-voltage, kunye nokumelana okuguquguqukayo. Ngokuhlalutya le miqondiso ngexesha langempela, inkqubo ilungelelanisa ngokuzenzekelayo imveliso yangoku elandelayo ukugcina iimeko ze-weld ezihambelanayo.
Kwimizila yewelding yemoto, evaliweyo{0}}ulawulo lwelophu lukholisa ukwenza:
- Ukuphindaphindwa kwamandla ngaphakathi±2%
- Ukwahluka kwamandla e-weld kuncitshiswe yi30–40%
- Okokuqala{0}amazinga okupasa azinzisiwe99.9%
Kwizityalo -eziphezulu zemoto, eli nqanaba lozinzo lwenkqubo linciphisa kakhulu ixesha lokuphumla, liphucula ukuhambelana kwemveliso, kwaye lithobe umngcipheko wokwenziwa ngokubanzi.
Ukukhetha iNkqubo ye-Welding ye-MFDC eLungileyo
Ukukhetha okulungileyoIzixhobo ze-welding ze-MFDCkubandakanya okungaphezulu kokuthelekisa umthamo wangoku oreyithiweyo. Inkqubo{1}ekhethwe kakuhle kufuneka ixhase-uzinzo lwenkqubo yexesha elide kwaye ivumele indibaniselwano yemathiriyeli.
Okokuqala, ukuguquguquka kwe-waveform kufuneka kuhlolwe ngononophelo. Ulwakhiwo lweemoto lubandakanya ukupakishwa kwemathiriyeli eyahluka-hlukeneyo, kunye nokukwazi ukucwangcisa izigaba ezininzi zamaza kuvumela abaqhubi ukuba balungise{1}}unikezelo lwamandla kwisicelo ngasinye. Iinkqubo eziswele ukuguquguquka kwamaza zihlala zisokola ukugcina ukusebenza okuzinzileyo kuzo zonke iimeko zokuwelda ezahlukeneyo.
Okwesibini, ukuchaneka kwengxelo kufuneka kuqwalaselwe. Iinkqubo zempendulo ezichanekileyo-zichaneka ngokuzenzekelayo zinokuhlawula ngokuzenzekelayo ukunxitywa kwe-electrode okanye ukwahluka kwezinto, ukunciphisa imfuno yohlengahlengiso lweparamitha yesandla kunye nokuphucula ukusebenza kakuhle kwemveliso.
Okokugqibela, amandla olawulo lwedatha abaluleke kakhulu. Iinkqubo zomgangatho weemoto ngoku zifuna ukulandelelwa ngokupheleleyo kweeparamitha ze-welding. Iinkqubo ezirekhoda ii-curves zangoku, ixesha le-welding, kunye nedatha yenkqubo ivumela iinjineli ukuba zihlolisise imbali yemveliso kwaye ziphendule ngokukhawuleza kuphicotho-zincwadi olusemgangathweni okanye imiba yentsimi.
Okwenyani-Uphononongo lweHlabathi lweMyilelo: Ukuphucula iMvuno yokuQala{1}}ukuPhuma ukusuka kuma-97% ukuya kuma-99.9%.
Kwiprojekthi ye-welding ye-automotive body welding, umenzi ekuqaleni wayethembele kwiinkqubo ze-welding ze-AC. Ngokuhamba kwexesha, iinjineli zabona ukutshiza rhoqo, ubomi obufutshane be-electrode, kunye nemiba eqhubekayo yokuphinda isebenze. Emva kokwenza uvavanyo lwenkqubo eneenkcukacha, isibonelelo siphuculwe kwiinkqubo ze-welding ye-MFDC kwaye yaphunyezwa inkqubo ye-waveform ephuculweyo.
Iziphumo bezibalulekile:
Ukusebenza kweWelding Ngaphambi nasemva koPhuculo
| Metric | Phambi koPhuculo | Emva koPhuculo |
|---|---|---|
| Okokuqala -UkuPhumelela iSivuno | 97.2% | 99.9% |
| Isantya seSpatter | 28% | 8% |
| Electrode Life | 2,500 welds | 4,500 welds |
| Ixesha lokugaya | Isiseko | Yehliswe ngama-40% |
Eli tyala libonisa ukuba ukwenziwa kwe-waveform optimization kuzisa izibonelelo zemali ezinokulinganiswa. Ngokunciphisa i-spatter kunye nokunciphisa ukusebenza kwakhona, impumelelo yemveliso iphuculwe ngelixa iindleko zokusebenza zehla kakhulu.
Ukuqukumbela
Njengoko ukuveliswa kweemoto kuqhubeleka ukuguqukela kwimathiriyeli{0}}yamandla aphezulu,{1}}ulwakhiwo oluninzi, kunye neenkqubo zemveliso ezizenzekelayo, ulawulo lobulunga bewelding lutshintshile ukusuka kuhlengahlengiso lwezandla ukuya kwidatha{2}}yobunjineli obuchanekileyo obuqhutywayo. Itekhnoloji yokuwelda indawo ye-MFDC, edityaniswe nenqanaba -lolawulo lwamaza kunye nengxelo evaliweyo -yelophu, ibonelela ngenqanaba lozinzo olufunekayo kwimveliso yemoto yanamhlanje.
I-Spatter kunye ne-welds ezibuthathaka azikho iziphene ezingenakuphepheka. Kwiimeko ezininzi, zibangelwa ukulawulwa okunganeleyo kwegalelo lokushisa kunokuba kuthintelwe izinto eziphathekayo. Xa iisistim ze-welding zikwazi ukulawula ukuhanjiswa kwamandla ngokuchanekileyo kunye nokulungelelanisa ngokuguquguqukayo ukusetyenzwa kweenguqu, umgangatho we-weld uqikeleleka kwaye uphinde uphindwe.
Kubavelisi bacwangcisa imigca emitsha yemveliso okanye ukuphucula iinkqubo ezikhoyo, utyalo-mali kwitekhnoloji yeMFDC enolawulo oluphambili lwamaza ayilophuculo lobugcisa. Imele isicwangciso sexesha elide-sokuphucula ukungaguquguquki kweweld, ukunciphisa iindleko zokusebenza, kunye nokugcina ukukhuphisana kwindawo yokuvelisa ekhulayo.
