Kwimizi-mveliso efana nesitampu sesinyithi, izinto zemoto, iitheminali zamandla amatsha, iintambo zobhedu{0}}ze-aluminiyam yocingo, kunye nolwakhiwo lwamashiti entsimbi, ukuwelda indawo yokumelana kuseyeyona nto isetyenziswa kakhulu kubuchwephesha bokudibanisa. Phakathi kokhetho olukhoyo, oomatshini bokuwelda bamabala e-MFDC kunye ne-capacitor discharge (CD) koomatshini bokuwelda bendawo zimbini zezisombululo ezikhethwa ngokuqhelekileyo. Nangona bobabini bengabosapho oluxhathisayo lwe-welding kwaye benza imisebenzi efanayo yokujoyina, iindlela zabo zokuhambisa amandla, iimpawu zegalelo lobushushu, indlela yokwenza i-nugget, kunye nokuhambelana kwezinto kwahluke kakhulu. Lo mahluko uchaphazela ngqo amandla e-weld, ukusebenza kakuhle kwemveliso, uzinzo lwezixhobo, kunye neendleko zokusebenza zexesha elide-.
Kwiindawo zokwenyani zokuvelisa, iinkampani ezininzi zijolise ikakhulu kumandla alinganisiweyo okanye kwixabiso lokuqala lokuthenga xa ukhetha izixhobo zokuwelda. Nangona kunjalo, ukungahoywa kobudlelwane phakathi kweempawu zoomatshini kunye neepropathi zezinto eziphathekayo zihlala zikhokelela kumgangatho ongazinzanga we-weld, i-spatter egqithisileyo, okanye imijikelo yemveliso engahambelaniyo. Enyanisweni, izixhobo ezingahambelaniyo zingabangela uhlengahlengiso lwenkqubo ngokuphindaphindiweyo ngaphandle kokuzuza iziphumo ezizinzileyo, ekugqibeleni kwandisa iindleko zokunciphisa kunye nokugcinwa.
Ukuqonda umahluko osisiseko phakathiAbashiseli bamabala beMFDCkwayei-capacitor yokukhupha i-welders yendawoke ngoko kubalulekile kwiinjineli, abaphathi bemveliso, kunye namaqela abathengi. Ukuthelekiswa okucacileyo kobu buchwepheshe kunceda ukuqinisekisa ukuba izixhobo ezikhethiweyo zihambelana neempawu eziphathekayo, umthamo wokuvelisa, kunye neemfuno zomgangatho wesicelo.
Eli nqaku libonelela ngothelekiso olucwangcisiweyo lwemigaqo yokusebenza, ukuziphatha kokuphuma kobushushu, ukuhambelana kwezinto, ukusebenza komgangatho we-weld, kunye nezikhokelo zokhetho olusebenzayo, ezinikezela ngereferensi eziluncedo zobugcisa ukuxhasa ukhetho lwezixhobo ezinolwazi kunye nokulungiswa kwenkqubo.
1. Iiyantlukwano zoMgaqo wokuSebenza oSisiseko
Phakathi kwazo zonke izinto zokusebenza, iumgaqo wonikezelo lwamandlangowona mahluko ubalulekileyo phakathi kwe-MFDC kunye ne-capacitor discharge welding systems. Indlela amandla ombane enziwa ngayo kwaye ahanjiswe ngayo imisela ukuziphatha kwegalelo lobushushu, elichaphazela ngokuthe ngqo ukubunjwa kwe-nugget kunye nokuthembeka kwe-weld.
1.1 I-MFDC Spot Welding Machines: Imveliso eZinzileyo eZinzileyo ngoku
Oomatshini bokuwelda bamabala be-MFDC (i-Medium Frequency Direct Current welders) basebenza besebenzisa itekhnoloji ye-inverter eyilelwe ukuphucula uzinzo lwangoku kunye nokunciphisa ilahleko yamandla xa kuthelekiswa neenkqubo ze-AC zemveli. Inkqubo yokuguqula umbane ibandakanya izigaba ezininzi. Okokuqala, amandla aqhelekileyo e-AC (50 Hz okanye 60 Hz) alungiswa abe ngoku ngokuthe ngqo. La mandla eDC aze ajike abephakathi-i-frequency AC, ngokwesiqhelo kuluhlu lwe-1 kHz ukuya ku-4 kHz, ngemodyuli yoguqulo. I-medium -i-frequency current idlula kwi-welding transformer apho i-voltage yehlisiwe, kwaye ekugqibeleni, iphinde ilungiswe kwakhona ukuvelisa imveliso ye-DC ezinzileyo efanele ukuwelda.
Ngenxa yokuba le nkqubo ibonelela ngokuqhubekayo ngoku, ukuguquguquka kwangoku kuncinci, kwaye ukuzinza kwe-waveform kuhlala kuphezulu. Kwiinkqubo ezininzi zoshishino, i-ripple yangoku ingalawulwa ukuya kwi-5%, ephucula kakhulu ukuhambelana kokubunjwa kwe-nugget. Ukunikezelwa kwangoku okuzinzileyo kunciphisa ukuhluka phakathi kwamanqaku e-weld kunye nokuphucula ukuphindaphinda kwemveliso jikelele.
Kwiindawo zemveliso ezizenzekelayo, abashiseli be-MFDC bayakwazi ukusebenza ngokuqhubekayo ixesha elongeziweyo ngelixa begcina umgangatho we-weld ongaguqukiyo. Oku kuthembeka kubenza bafaneleke ngokukodwa-kwizicelo ezinkulu zokwenziwa kwemveliso ezifana nokudityaniswa kwemizimba yemoto kunye nolwakhiwo lwecandelo lolwakhiwo.
Enye inzuzo yetekhnoloji yeMFDC kukukwazi ukuphendula ngokukhawuleza. Xa ukuguquguquka kwenzeka kunikezelo lwamandla, inkqubo yokulawula inokuhlawula ngexesha langempela, iqinisekisa imveliso ehambelanayo yangoku kunye nokugcina umgangatho we-weld naphantsi kweemeko zombane ezahlukeneyo.
1.2 ICapacitor Discharge Spot Spot Machines: High{1}}Energy Pulse Output
Ukukhutshwa kwe-Capacitor discharge (CD) oomatshini beendawo zokuwelda basebenzisa indlela yonikezelo lwamandla eyahluke ngokupheleleyo ngokusekwe kugcino lwamandla kunye nokukhutshwa ngokukhawuleza. Umgaqo ongundoqo uquka ukugcina amandla ombane kwiibhanki ze-capacitor kunye nokukhulula loo mandla ngexesha elifutshane kakhulu ngexesha le-welding.
Ngexesha lokusebenza, ii-capacitors zihlawuliswa ngokuthe ngcembe kwinqanaba lombane osethiweyo. Nje ukuba i-voltage efunekayo ifikeleleke, umjikelo we-welding uyashukunyiswa, kwaye amandla agciniweyo akhutshwa phantse kwangoko ngesekethe ye-welding. Oku kudala i-pulse ephezulu kakhulu yangoku ehlala ihleli phakathi kwe-1 kunye ne-20 milliseconds.
Nangona ixesha lokukhutshwa lifutshane kakhulu, inqanaba eliphezulu langoku liphezulu kakhulu kunolo lweenkqubo zangoku eziqhubekayo. Olu nikezelo lwamandla olugxininisiweyo luvumela indawo ye-welding ukuba ifikelele kwiqondo lobushushu bokudibanisa phantse ngoko nangoko. Ngenxa yokuba ukukhutshwa kwenzeka ngokukhawuleza, kukho ixesha eliqingqiweyo lokuba ubushushu busasazeke kwizinto ezijikelezileyo, okukhokelela kubushushu obuncinane{2}}kwindawo echaphazelekayo.
Ukongezelela, ngenxa yokuba amandla agcinwa ngokuthe ngcembe kwaye akhululwe ngokukhawuleza, umthwalo kwigridi yamandla uphantsi. Olu phawu lwenza ukuba i-capacitor discharge welders ifaneleke ngokukodwa kwizibonelelo ezinomthamo omncinci wombane okanye iindawo apho oomatshini abaninzi babelana ngentambo yamandla efanayo.
2. Iimpawu zoMphumo wobushushu kunye neNugget yoKwakha iNugget
Kwi-welding yokumelana, ukubunjwa kwe-nugget yeyona nto iphambili emisela amandla e-weld kunye nokuthembeka. Iindlela ezahlukeneyo zokuhambisa ubushushu zikhokelela kwiiprofayili zobushushu ezahlukileyo, eziphembelela ubume be-weld kunye nokuziphatha okujikelezileyo.
2.1 I-MFDC Spot Welding: ukuNgenelwa kobushushu kancinci kunye noLwakhiwo lweNugget oluZinzileyo
Kwi-welding ye-MFDC, ikhoyo ngoku eqhubekayo ivumela ubushushu ukuba bakhe ngokuthe ngcembe ngaphakathi kwendawo yoqhagamshelwano kwaye bungene nzulu kwizinto eziphathekayo. Le nkqubo yokufudumeza eqhubela phambili ikhokelela ekuhanjisweni okufanayo kwamaqondo obushushu kuwo wonke ummandla weld. Ngenxa yoko, i-weld nugget ithande ukuba xinene kwaye ihambelana ngokwesakhiwo.
Amaxesha e-welding aqhelekileyo kwiinkqubo ze-MFDC aphakathi kwe-80 milliseconds kunye ne-300 milliseconds, evumela ixesha elaneleyo lokuba ubushushu bungene kwi-interface edibeneyo. Ngaphantsi kweemeko zenkqubo ezinzile, ukuhluka kwe-nugget ye-diameter kunokulawulwa ngokuqhelekileyo ngaphakathi kwe-± 0.2 mm ukuya ku-± 0.4 mm, ukubonelela ngokuhambelana okugqwesileyo kwimijikelezo ye-weld ephindaphindiweyo.
Lo mgangatho wokuhambelana ubaluleke kakhulu kumthwalo-izinto ezithwalayo. Kwimveliso yeemoto, umzekelo, amanqaku amaninzi e-weld ahlala ebelana ngemithwalo yesakhiwo. Ukuba ubungakanani be-nugget buhluka kakhulu phakathi kwee-welds, bunokuthi buyeke ukunyaniseka komatshini wendibano.
Nangona kunjalo, ngenxa yokuba ixesha lokufudumeza lilide, obunye ubushushu bunwenwela kwizinto ezingqongileyo. Ngenxa yoko, ubushushu-indawo echaphazelekayo (HAZ) bukhulu ngokubanzi kune-capacitor discharge welding. Kwizicelo ezibandakanya imathiriyeli ebhityileyo okanye iimfuno ezingqongqo zezithambiso, useto olungafanelekanga lweparamitha lunokukhokelela kumbala omncinci womphezulu okanye ukugqwetheka kwendawo.
2.2 I-Capacitor Discharge Welding: Ubushushu obuGxinisiweyo kunye nobushushu obuncinci{1}}Indawo eChaphazelekayo
I-Capacitor discharge welding ivelisa ubushushu phantse kwangoko. Xa amandla agciniweyo ekhutshwa, ukuphakama okuphezulu kwangoku kubangela ukufudumeza ngokukhawuleza kwi-weld interface. Ngenxa yokuba ixesha lokufudumeza lifutshane kakhulu, i-weld igqitywe ngaphambi kokuba ubushushu bube nexesha lokusasazeka kwiindawo ezikufutshane.
Amaxesha okuwelda asuka kwi-1 ukuya kwi-20 milliseconds, ephindwe kaninzi mfutshane kunemijikelo ye-welding ye-MFDC. Elixesha lifutshane linciphisa ukusasazwa kobushushu kwaye livumela ubushushu-indawo echatshazelweyo ukuba yehle malunga ne-30% ukuya kwi-70%, ngokuxhomekeke kwimpahla kunye nobukhulu.
Igalelo lobushushu elincitshisiweyo likwanciphisa utshintsho lwesinyithi kwizinto ezijikelezileyo, ezikhokelela kuphuculo lwenkangeleko yomphezulu kunye nokuncipha kombala. Ukusetyenziswa apho umgangatho obonakalayo ubalulekile, njengezinto eziveziweyo zensimbi ezingenasici okanye iindibano zetsimbi zokuhombisa, i-capacitor discharge welding ihlala ibonelela ngeziphumo eziphezulu.
Nangona kunjalo, le ndlela yokufudumeza ngokukhawuleza ikwabonisa imida. Xa welding imathiriyeli engqindilili, ukungena ngobushushu okwaneleyo kunokwenzeka ukuba amanqanaba ombane awahambelani ngokufanelekileyo nobungqingqwa bezinto eziphathekayo. Kwiimeko ezinjalo, umphezulu we-weld unokubonakala wamkelekile ngelixa ukudibanisa kwangaphakathi kuhlala kungaphelelanga, okunokunciphisa amandla e-weld.
3. Ukuhambelana kwezinto kunye nezicelo eziqhelekileyo
Ukukhethwa kwezinto eziphathekayo kudlala indima ebalulekileyo ekukhetheni iteknoloji ye-welding efanelekileyo. Umahluko kwi-conductivity yombane kunye ne-thermal conductivity ichaphazela kakhulu indlela ubushushu obuziphatha ngayo ngexesha le-welding.
3.1 IiMathiriyeli eziqhelekileyo kunye namashishini e-MFDC Spot Welding
Abashiseli bamabala e-MFDC bafanelene kakhulu-nemathiriyeli yokutyeba kunye namalungu olwakhiwo afuna amandla omatshini aphezulu. Izinto eziqhelekileyo ziquka i-carbon steel sheets,-intsimbi ephezulu, i-multilayer steel assemblies, kunye ne-structural metal components.
Kwizicelo zamashishini, iisistim ze-welding ze-MFDC zisetyenziswa kakhulu kwimveliso yeemoto, ngakumbi kwiipaneli zomzimba welding, iipleyiti zokuqinisa, kunye nezakhiwo ze-chassis. Ezi zixhobo ziqhelekile ukusuka kwi-1.0 mm ukuya kwi-2.5 mm ubukhulu kwaye kufuneka zimelane noxinzelelo oluqhubekayo lomatshini ngexesha lenkonzo.
Iinkqubo ze-MFDC ziqhele ukusetyenziswa kwimizi-mveliso yezixhobo zendlu kunye-nokwenziwa kwamaphepha amakhulu esinyithi, apho ukomelela kweweld engaguqukiyo kunye nemveliso ephezulu kufuneka. Ukukwazi kwabo ukugcina intsebenzo ezinzileyo phezu kokuqhubela phambili kwemveliso eyandisiweyo kubenza balungele iimeko zemveliso ezizenzekelayo.
3.2 Izinto eziqhelekileyo kunye namashishini e-Capacitor Discharge Welding
I-Capacitor discharge welding ifanelekile ngokukodwa kwizinto ezincinci kunye neentsimbi eziqhuba kakhulu ezifana nobhedu kunye ne-aluminium. Iimathiriyeli eziqhelekileyo ziquka amashiti entsimbi engatyiwa, i-nickel{1}}imathiriyeli elayitiweyo, intsimbi eyenziwe ngegalvanized, iialloyi zobhedu, iialloys ze-aluminiyam, kunye nendibaniselwano yobhedu{2}}ze-aluminiyam.
Kwicandelo lamandla amatsha, i-capacitor discharge welding isetyenziswa kakhulu ukuwelda ithebhu yebhetri kunye noqhagamshelo lwe-aluminiyam yobhedu. Ezi mathiriyeli ziqhele ukuba nobukhulu phakathi0.1 mm kunye ne-0.3 mmkwaye ifuna ulawulo oluchanekileyo lwe-thermal ukukhusela umonakalo.
Ukongeza, i-CD welding isetyenziswa rhoqo kunxibelelwano lombane, izinto ze-elektroniki, kunye neendawo ezichanekileyo zetsimbi, apho ukugqwetheka okuncinci kunye nokucoceka komphezulu kubaluleke kakhulu. Ukukwazi ukugxila kubushushu kwindawo encinci kwenza ukuba kube yinto efanelekileyo kumalungu athambileyo afuna ukunyamezela okuqinileyo.
4. Itheyibhile yokuthelekisa iParameter engundoqo
Le theyibhile ilandelayo ishwankathela umahluko ophambili phakathi kwe-MFDC kunye ne-capacitor discharge welding systems:
| Ipharamitha | MFDC Spot Welder | I-Capacitor Discharge Welder |
|---|---|---|
| Isiphumo sangoku | I-DC eqhubekayo | Phezulu{{0}I-Peak Pulse |
| Ixesha le-Welding | 80–300 ms | 1–20 ms |
| Ubushushu-Indawo eChaphazelekayo | Enkulu | Encinci |
| Ukutyeba okufanelekileyo kwezinto | Phakathi ukuya kuThire | Izinto eziphathekayo ezibhityileyo |
| Imbonakalo yoMphezulu | Kulungile | Egqwesileyo |
| Ubuchule beMveliso obuQolekileyo | Phezulu | Phakathi |
| Impembelelo yeGridi yaMandla | Phakathi | Phantsi |
5. Izikhokelo eziSebenzayo zokuKhetha i-Welding Machine efanelekileyo
Ukukhetha umatshini wokuwelda ofanelekileyo kufuna ukuvavanya zombini iimpawu zemathiriyeli kunye neemfuno zemveliso kunokuthembela kuphela kwiinkcukacha zezixhobo.
5.1 Xa i-MFDC Spot Welding iluKhetho olungcono
Iinkqubo zokuwelda amabala e-MFDC ziyacetyiswa ngokubanzi xa usebenza ngemathiriyeli-yobungqingqwa obuphakathi, ulwakhiwo lwe-multilayer, okanye amacandelo afuna amandla oomatshini aphezulu. Zifaneleke ngakumbi iindawo zemveliso apho umgangatho we-weld ongaguqukiyo kunye nokuthembeka kwexesha elide- kubalulekile.
Umzekelo, ukuwelda kolwakhiwo lweemoto kudla ngokufuna ukomelela okuzinzileyo kunye nokuphindaphindwayo kwe-weld, ukwenza iinkqubo ze-MFDC zibe yeyona ndlela ikhethwayo. Ukongeza, xa imigca yemveliso isebenza ngokuqhubekayo ixesha elongeziweyo, abashiseli be-MFDC babonelela ngokuhlala kunye nokuhambelana okuyimfuneko ukugcina imveliso.
5.2 Xa i-Capacitor Discharge Welding iluKhetho olungcono
Iinkqubo ze-Capacitor discharge welding ziqhelekileyo isisombululo esithandwayo sezinto ezincinci kunye neentsimbi eziqhuba kakhulu ezifana nobhedu okanye i-aluminium. Zikwafanelekile xa ukunciphisa ukuphazamiseka kwe-thermal kunye nokugcina ukubonakala komphezulu zizinto eziphambili eziphambili.
Kwizibonelelo ezinomthamo omncinci wombane, oomatshini bokuwelda iCD babonelela ngeenzuzo ezongezelelweyo ngenxa yokuba banyanzelisa imfuno engaphantsi kombane. Umjikelo wabo we-welding okhawulezayo uphucula ukusebenza kakuhle kwiindawo ezichanekileyo zokuvelisa apho izinto ezincinci kufuneka zicutshungulwe ngesantya esiphezulu.
Ukuqukumbela: Olona khetho lulungileyo luxhomekeke kwiiMfuno zeSicelo
Nangona i-MFDC kunye ne-capacitor discharge spot welding machines ziyinxalenye ye-welding efanayo yokumelana, iyantlukwano kunikezelo lwamandla kunye nokuziphatha kobushushu kukhokelela kuncedo olwahlukileyo lwesicelo. Iinkqubo ze-welding ze-MFDC zifaneleka ngcono kwi-medium-yobungqingqwa bezakhiwo ezifuna i-welds ezomeleleyo nezingatshintshiyo, ngelixa iinkqubo zokukhupha i-capacitor zigqwesa kwizinto ezibhityileyo kunye neentsimbi eziqhuba kakhulu apho igalelo lobushushu lincinci lifunwayo.
Xa ukhetha izixhobo ze-welding, kubalulekile ukuqwalasela uhlobo lwezinto eziphathekayo, ubukhulu bezinto eziphathekayo, iimfuno zomgangatho ophezulu kunye neemfuno zomjikelezo wemveliso. Ukukhetha izixhobo ezisekelwe kwezi zinto zisebenzayo endaweni yeendleko zokuthenga kuphela kuya kunceda ukuqinisekisa umgangatho we-weld ongaguqukiyo, ukuphuculwa kwemveliso, kunye nokunciphisa iindleko zokusebenza zexesha elide{1}}.
