Ukuwelda okungazinzanga? MFDC vs AC Spot Welder Isikhokelo sokuKhetha

Kumhlaba wemveliso yala maxesha-uMzimba weemoto onwenwayo{1}}kwi-Mhlophe (BIW), iitreyi zebhetri yeSisithuthi saMandla eNtsha (NEV),{3}}indawo ezivaliweyo zesixhobo esiphezulu, kunye nezakhiwo ze-aerospace{4}}I-Resistance Spot Welding (RSW) ihlala iyinkqubo yekona. Nangona kunjalo, abaphathi bemveliso bahlala bejongana ne-paradox ephazamisayo: ngaphandle kokulungiswa ngokupheleleyo koxinzelelo, okwangoku, kunye neeparamitha zexesha, umgangatho we-weld uyaqhubeka nokuguquguquka. Imiba eqhelekileyo efana nedayamitha ye-nugget engahambelaniyo, ukugxothwa okugqithisileyo (ukutshiza), kunye ne-welds ebandayo ephindaphindiweyo okanye "ukuvuthela{7}}ukutyhutyha" kwintsimbi ephezulu{8}}yokuqina iyaqhubeleka.
Ngelixa abasebenzi besiza bahlala begxeka ungcoliseko olungaphezulu okanye ukutenxa kwindawo, oyena nobangela wokungazinzi uhlala ungaphakathi "kwibhokisi emnyama" yesixhobo: umthombo wamandla wokuwelda. Kumxholo weSpot Welding Machine yangoku, ukukhetha umthombo wamandla kukukhetha ngokufanelekileyo imo yemveliso yangoku. Esi sikhokelo siphonononga iiyantlukwano ezingundoqo phakathi kweMedium Frequency Direct Current (MFDC) kunye neesistim zeAlternative Current (AC) zesintu ukuze zikuncede wenze isigqibo sokuthenga unolwazi.

Ukuqonda ukuba kutheni iintlobo zemithombo yamandla ziyalela iziphumo, kufuneka siphinde sijonge umthetho osisiseko wokuxhathisa ukuwelda, uMthetho kaJoule:
Q = I² × R × t

Kulo mlinganiso, i-Q imele ubushushu obuveliswayo, mna ndingumatshini we-welding, i-R iyonke yokumelana nesekethe (kubandakanywa nokumelana noqhagamshelwano), kwaye lixesha lokuhamba ngoku.
Ngokwezibalo, okwangoku ndichaphazela igalelo lobushushu ngesikwere salo. Ngenxa yoko, nokuguquguquka okuncinci okanye ukubambezeleka kwindlela yamaza yangoku ikhuliswa ngokwejometri kuyilo lokugqibela lwe-nugget. Ukuba imveliso yangoku ayizinzile, igalelo lobushushu liba yinto engalindelekanga, kungakhathaliseki ukuba i-electrode pressure ichanekileyo kangakanani. Esi sisiseko esibonakalayo sobungangamsha obugqithisileyo bemithombo yamandla ye-MFDC ngaphezu kweeyunithi ze-AC zemveli.

Iimpazamo zeNdalo ze-50/60Hz AC Output

Abashiseli bamabala be-AC bemveli baxhomekeke kumaza e-sine asemgangathweni. Le waveform ifumana "zero{1}}ukuwela" 100 ukuya 120 amaxesha ngomzuzwana. Ngalo lonke ixesha i-current idlula kwi-zero, igalelo lamandla liyayeka ngokufanelekileyo. Oku kufudumeza okwethutyana kukhokelela koku:

• Ukuchithwa kweThermal kunye nokuguquguquka:Intsimbi ekwindawo yeweld idlula kwizigaba zokupholisa ezimfutshane kuzo zonke ii-zero-ezinqumlayo, ezikhokelela ekukhuleni okungaqhubekiyo kwe-nugget kunye nokwakheka kweenkozo ezirhabaxa.
• Uxinzelelo oluphezulu lwangoku:Ukubuyekeza ilahleko yamandla ngexesha -lokuwela, iiwelder zeAC kufuneka zikhuphe imisinga ephezulu. Ezi pulses zinobundlobongela zingoyena nobangela wokugxothwa, ngakumbi kwiintsimbi ezigqunyiweyo (njengamashiti afakwe igalvanized), ezonakalisa umphezulu womgangatho kwaye ikhawulezise ukunxiba kwe-electrode.

UZinzo oluluncedo lweMphumo yeMFDC

Iiwelder ze-MFDC zisebenzisa ubuchwepheshe be-inverter ukulungisa ezintathu-inqanaba le-AC kwi-high{1}}i-frequency current (1000Hz ukuya kwi-4000Hz), ethi emva koko iguqulwe kwaye ilungiswe ibe yimveliso ye-DC egudileyo. Iinzuzo eziphambili ziquka:

• Ungeniso lwamandla oluqhubekayo:Imveliso ye DC iphantse yasicaba engenaziro -ezinqumlayo. Ubushushu buqokelelana ngokufanayo kwi weld zone. Idatha ibonisa ukuba ukusebenza kobushushu be-MFDC kumalunga ne-20% ngaphezulu kwe-AC phantsi kweemeko ezifanayo.
• Ultra-I-Factor yeRipple ePhantsi:Iinkqubo ze-MFDC zigcina i-ripple yangoku engaphantsi kwe-5%. Olu uzinzo olugqithisileyo luvumela ukubunjwa kwe-nugget elawulwa kakhulu. Xa i-welding 1.2mm yentsimbi ye-galvanized, ukuphambuka okusemgangathweni kwe-nugget ye-diameter inokubanjwa ngaphakathi kwe-± 0.15mm, xa kuthelekiswa ne-± 0.40mm ye-AC welders.

Imveliso yale mihla isebenzisa iintsimbi eziPhezulu{0}eziPhezulu (i-AHSS, ezifana ne-DP980, i-QP1180) kunye neengxube ze-aluminiyam. Ezi zixhobo zifuna ukuchaneka kotyando kwigalelo lobushushu.

Ukubaluleka kwexesha lokunyuka ngokukhawuleza

Isantya apho ikhoyo ngoku ifikelela kwixabiso layo elibekiweyo (iXesha lokuKhuphuka) libalulekile. Imithombo yamandla yoguqulo lwe-MFDC iphendula malunga ne-1ms, ngelixa iinkqubo ze-AC zifuna i-10ms ukuya kwi-20ms. Impendulo ekhawulezayo ivumela i-current ukuba ingene kwi-oxides yomhlaba okanye i-coatings ngokukhawuleza, ukuseka indlela eqhubayo ezinzileyo kunye nokuthintela "i-arcing" okanye ukuxoshwa ekuqaleni kwe-weld.

Phezulu-Ukuchaneka kuvalwe{1}}Ingxelo yeLoop

Abalawuli bale mihla be-MFDC babonisa iisampulu eziphezulu zezakhelo ezibeka esweni utshintsho loxhathiso lwesekethe ngexesha lokwenyani kwaye babuyekeze ukutenxa kwangoku kwii-milliseconds. Olu "hlengahlengiso olutshintshayo" luyimfuneko kwizixhobo eziphezulu{2} zokuqhuba ezifana ne-aluminiyam. I-Automotive Tier - ababoneleli be-1 baye baxela ukuba ukutshintshela kwi-MFDC kwimizila yentsimbi ephezulu yaphucula i-CPK yabo (i-Process Capability Index) ukusuka kwi-0.88 ukuya kwi-1.75, ihambisa inkqubo ibe yi "Six Sigma" ukuzinza.

Abathengi abaninzi bathintelwa lixabiso eliphezulu lokuqala lezixhobo zeMFDC. Nangona kunjalo, uhlahlelo lweTotal Cost of Ownership (TCO) lubonisa uqoqosho oluphezulu- lwexesha elide.

Ugcino lwamandla olubalulekileyo

Ngenxa yokuba iinguqu ze-MFDC zisebenza kwiifrikhwensi eziphezulu, ilahleko yamagnetic incinci, kwaye iiyunithi ziyi-1/3 ukuya kwi-1/5 ubukhulu be-AC transformers.

• Ufaniso olusebenzayo:I-AC welders isebenza kwi-50-60% esebenzayo, ngelixa iinkqubo ze-MFDC zifikelela kwi-85-90%.
• Unciphiso lweendleko:Kumgca wemveliso onama-welders angama-20, ukonga amandla kunokufikelela kumashumi amawaka eedola ngonyaka.

Ubomi obuphindwe kabini be-Electrode

Ukugxothwa "ngumbulali" wee-electrodes. Ukushisa okugudileyo, okugxininisiweyo kwe-MFDC kunciphisa ukukhukuliseka kwe-thermal kunye nokugqoka komatshini kwii-electrode caps.

• Iziphumo zommandla:Kwizicelo zentsimbi, iiwelder ze-AC zifuna ukunxitywa kwe-electrode yonke indawo engama-500-800. Nge-MFDC, amaxesha okunxiba anokwandiswa ukuya kumabala angama-2,000-3,000, ukunciphisa kakhulu iindleko ezisetyenziswayo kunye nexesha lokuphumla.

Ngexesha le-Smart Manufacturing, umatshini we-welding awusesona sixhobo esizimeleyo kodwa i-node yokuqokelela idatha.

Ukungafihli kweDatha kunye nokulandelelwa

Abalawuli be-MFDC banokurekhoda okwangoku, i-voltage, uxinzelelo, kunye neejika zamandla kwi-weld nganye. Le datha idluliselwa nge-Ethernet ukuya kwi-MES (IiNkqubo zokuSebenza zokuSebenza). Ukuba kuvela inkxalabo yomgangatho, abaphathi banokutsala iprofayile yamandla ethe ngqo yelo bhetshi, besusa uqikelelo kwingcambu{2}}uhlalutyo lwesizathu.

Intelligent Parameter Storage

Iinkqubo zanamhlanje zixhasa amakhulu "IiShedyuli ze-Welding." Ukutshintsha phakathi kobunzima bemathiriyeli eyahlukeneyo okanye iindidi ngumsebenzi omnye-wokuchukumisa, obaluleke kakhulu-kumxube, ukuveliswa kwevolumu esezantsi{3}}kunye neeseli zerobhothi.

Iimeko apho i-MFDC inyanzelekile:

• Ukhuseleko-Izahlulo zeMoto eziBalulekileyo: izakhiwo ze-BIW, imiqadi yokuntlitheka, kunye neendawo ezivaliweyo zebhetri.
• Izinto eziSensitive Materials: Ialuminiyam, iialloyi zobhedu, intsimbi engatyiwayo, kunye namashiti enziwe ngegalvanized.
• Ephakamileyo -Intsimbi Yamandla (AHSS): Kwiintsimbi ezingaphezulu kwe-590MPa, i-MFDC yeyona nto ikhethiweyo yokungena okungaguqukiyo.
• Imigca yeRobhothi ezenzekelayo: Ubume obukhaphukhaphu beenguqu ze-MFDC buphucula ukukhawuleza kwerobhothi kunye nokunciphisa amaxesha okujikeleza.

Iimeko apho i-AC inokwanela:

• Ulwakhiwo oluLula:{0}iicingo zentsimbi yekhabhoni ephantsi okanye izibiyeli ezisisiseko.
• -Ulungiso lwamaxesha aphantsi: Iivenkile zogcino apho ukhuseleko{1}}isiqinisekiso somgangatho singekho mfuneko.
• Izithintelo zoHlahlo-lwabiwo-mali ezigqithisileyo: Xa welding elula, intsimbi yekhabhoni engqindilili kwimithamo ephantsi.

Xa kuvavanywa aUmatshini we-Spot Welding, jonga ngaphaya kwethegi yexabiso kwaye uqinisekise ezi nkcukacha zobugcisa:

• Ukuchaneka koLawulo lwangoku:-izixhobo ezikumgangatho ophezulu kufuneka zinike ±1% ukuchaneka.
• Uyilo lweNkqubo yokupholisa:Qinisekisa ukuba iimodyuli ze-transformer kunye ne-SCR zineesekethe zokupholisa ezizimeleyo ukuthintela ukucinywa kwe-thermal ngexesha -lomjikelo ophezulu womsebenzi.
• I-Software Intuition:Ngaba ujongano luyaxhasa{0}}ixesha lokwenyani umboniso kunye nenkxaso yeelwimi ezininzi{1}}?
• UbuGcisa boBuchule bomthengisi:Khetha ababoneleli ababonelela ngeenkonzo zovavanyo lwe-weldability kwaye babe nerekhodi eqinisekisiweyo kumacandelo eemoto okanye ebhetri.

Isiphelo: Ukukhetha uMthombo waMandla oLungileyo linyathelo lokuqala lokuzinza

Kwi-welding yokumelana, uzinzo luvela kulawulo olupheleleyo kwinkqubo yomzimba. Itekhnoloji yeMFDC imele utshintsho ukusuka "kuvavanyo-kunye{2}}nempazamo" ukulungiswa kweparamitha ukuya "kwisixhobo{3}}esiqhutywayo" ukungaguquguquki. Ngelixa utyalo-mali lokuqala luphezulu, i-ROI ebonelelwa ngezivuno eziphezulu, amatyala aphantsi amandla, kunye nedatha-nolawulo lomgangatho oluqhutywayo luyenza ibe lukhetho oluqinisekileyo lwemveliso ekhuphisanayo.
Ngaphambi kokuba uchithe ixesha elingakumbi ulungisa iiparitha ukulungisa iiwelds ezingazinzanga, zibuze: Ngaba umthombo wam wamandla ngowona ufanelekileyo kulo msebenzi?

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