Kutheni oomatshini bokuwelda be-MFDC banguMgangatho woShishino lwe-Auto?

Kwishishini lokuvelisa iimoto, umgangatho we-welding unefuthe elithe ngqo kukhuseleko lwesakhiwo sesithuthi, ukusebenza kakuhle kwemveliso, kunye neendleko zokuvelisa ngokubanzi. Oku kuyinyani ngokukodwa kwiinkqubo ezifana nezithuthi zombane, iindawo ezivalekileyo zebhetri, kunye nomzimba-kwindibano{2} emhlophe (BIW), apho uzinzo lwewelding ludlala indima ebalulekileyo ekuthembekeni kwemveliso. Idatha yoshishino ibonisa ukuba isithuthi esiqhelekileyo somkhweli siqulethe3,000 ukuya 5,000 indawo welds, uninzi lwazo lubekwe kulwakhiwo kunye nokhuseleko{0}}indawo ezibalulekileyo kumzimba wemoto. Ngenxa yoku, nepesenti encinci yeziphene zokuwelda kunokukhokelela kumngcipheko obalulekileyo womgangatho xa umthamo wemveliso ufikelela kumakhulu amawaka eeyunithi ngonyaka.

Njengoko uyilo lweemoto lusiya lubandakanya imathiriyeli ekhaphukhaphu kunye{0}}nezintsimbi eziphezulu zamandla, imigca yemveliso nayo iye yasebenza ngakumbi. Phantsi kwezi meko, zemveliAC ukumelana indawo oomatshini ukuweldakusoloko kunzima ukuhlangabezana neemfuno zale mihla zokwenziwa kwemveliso. Imiba efana ne-welding engazinzanga yangoku, i-spatter egqithisileyo, kunye nomgangatho we-weld ongahambelaniyo unokukhokelela ekuguquguqukeni kwemveliso yemveliso kunye nokunyuka kweendleko zokuphinda zisebenze.

Ngesi sizathu, abaninzi abavelisi beemoto kunye nababoneleli beTier 1 baphucula iinkqubo zabo zokuwelda. IMFDC (Medium Frequency Direct Direct Current) umatshini wokuwelda amabalaiye yavela njengesisombululo esithandwayo ngenxa yemveliso yayo ye-DC ezinzileyo, ixesha lokuphendula ngokukhawuleza, kunye nezakhono zokulawula inkqubo. Kwimveliso yemoto-enkulu, aba matshini babonelela ngeenzuzo ezicacileyo kuzinzo lwe-welding, ukuhambelana komgangatho, kunye nokudibanisa kunye nemigca yemveliso ezenzekelayo.

Umgaqo osisiseko we-medium frequency inverter welding

Umatshini we-welding we-MFDC osetyenziswayoubuchwephesha be-inverter{0} ephakathiukuguqula amandla ombane abe ngumsinga wokuwelda ozinzileyo kwaye olawulekayo. Inkqubo idla ngokulandela amanqanaba amaninzi.

Okokuqala, engenayoI-50/60 Hz Amandla e-AC asuka kwigridi yombane alungiswa abe ngumbane othe ngqo (DC). Okulandelayo, imodyuli yoguqulo{1}}ehlala isekwe kubuchwephesha be-IGBT{2}}iguqula amandla eDC abephakathi-i-frequency AC malunga ne-1,000 Hz. Lo msinga uphezulu-uphinda uthunyelwe nge-medium-i-frequency welding transformer apho umbane wehliswa ukuya kumgangatho ofanelekileyo wokuwelda. Ekugqibeleni, umsinga uyalungiswa kwakhona ukuvelisa aimveliso welding ezinzileyo ye-DC.

Olu luyilo luhluke kakhulu kwiinkqubo ze-welding ze-AC eziqhelekileyo. Oomatshini besintu baxhomekeke ngokuthe ngqo kwi-low{1}}i-frequency AC yangoku, eguquguqukayo ngokwendalo kumjikelo ngamnye wombane. Ngokwahlukileyo, iinkqubo ze-MFDC zibonelela ngeprofayili yangoku ezinzileyo, evumela ulawulo oluchanekileyo lwenkqubo ye-welding.

Ngokwembono yobugcisa, olu lwakhiwo lubonelela ngeenzuzo ezininzi ezisebenzayo:

• Ulawulo oluchanekileyo ngakumbi lwe-welding current
• Ukuphendula ngokukhawuleza okuguquguqukayo ngexesha lomjikelo we-welding
• Ukusebenza kwamandla aphezulu
• Ukuphucula ukuhambelana neenkqubo zokuvelisa ezizenzekelayo

Ngenxa yolu ncedo, oomatshini bokuwelda amabala be-MFDC basetyenziswa ngokubanzi kungekuphela nje ekwenzeni iimoto kodwa nakwimizi-mveliso efana nezixhobo zasekhaya, imveliso yebhetri, kunye nokwenziwa kwentsimbi echanekileyo.

Ukuphelisa ukuguquguquka kwangoku kwi-welding ye-AC

Enye imida engundoqo yemveli koomatshini welding indawo AC yizero{0}isiganeko sokuwela. Ngexesha lomjikelo ngamnye wokutshintshana kwangoku, umsinga wombane ngamanye amaxesha wehla uye kwi-zero ngaphambi kokuba uphakame kwakhona. Oku kuphazamiseka kokuhamba kwangoku kunokudala ukuguquguquka kwigalelo lobushushu ngexesha lenkqubo ye-welding.

Xa udibanisa izinto ezibuthathaka okanye iishiti zetsimbi ezibhityileyo, oku kuguquguquka kunokukhokelela ekubunjweni kwe-nugget engahambelaniyo. Ngenxa yoko, amandla e-weld anokwahluka ukusuka kwinqanaba ukuya kwinqanaba.

Oomatshini bokuwelda indawo beMFDC basombulula le ngxaki ngokuzisa aimveliso yangoku ezinzileyo. Ngenxa yokuba i-current ayidluli ngokuphindaphindiweyo kwindawo ye-zero, igalelo lokushisa lihlala lihambelana kulo lonke umjikelezo we-welding. Oku kuvumela i-weld nugget ukuba yenze phantsi kweemeko ezilawulwa ngakumbi.

Kwiimeko zokwenyani zemveliso, oluzinzo oluphuculweyo lwangoku lukhokelela ekubeni:

• Ukunciphisa i-welding spatter
• Ubungakanani obuhambelanayo be-nugget
• Ukwahluka okuncinci kumandla we-weld
• Ukuphuculwa kwenkangeleko ye-weld

Kwizakhiwo zomzimba weemoto apho amawaka e-welds kufuneka enze ngokuthembekileyo, ukugcina eli nqanaba lokuhambelana kubalulekile.

Ukusebenza ngcono ngentsimbi -yamandla aphezulu kunye nemathiriyeli egqunyiweyo

Izakhiwo zezithuthi zale mihla zithembele kakhuluphezulu -intsimbi yokuqina (HSS) kunye nentsimbi yentsimbiukunciphisa ubunzima ngelixa ugcina ingqibelelo yesakhiwo. Ezi zixhobo zinzima kakhulu kwi-weld kuba zifuna igalelo lobushushu elichanekileyo kunye nolawulo oluluqilima lwenkqubo ye-welding.

Oomatshini bokuwelda indawo be-MFDC bafaneleke ngokukodwa kwezi zicelo. Impendulo yabo yangoku ngokukhawuleza kunye nokulawulwa kwamandla okuchanekileyo kuvumela ukuba i-weld igqitywe ngexesha elifutshane ngelixa igcina ukusabalalisa ubushushu obuzinzile.

Ngenxa yoko, iinkqubo MFDC zisetyenziswa ngokubanzi izicelo welding ezifana:

• Amalungu esakhiwo somzimba weemoto
• Iindibano zezindlu zebhetri
• Izihlalo zesakhelo sezakhiwo
• I-nut kunye ne-stud welding kwiphepha lesinyithi

Kwiprojekthi yokuvelisa isakhelo sesihlalo semoto, umzekelo, umenzi watshintsha iiwelder ze-AC eziqhelekileyo ngoomatshini bokuwelda bendawo beMFDC. Emva kokuphucula, iizinga le-weld elinesiphene lehlile ukusuka kwi-0.5% ukuya kwi-0.02%, kunye nokutenxa okusemgangathweni kwamandla okutsalwa kwe-weld kwehle malunga50%. Olu phuculo lwandise kakhulu ukuhambelana kwemveliso ngokubanzi kunye nokunciphisa iindleko zokusebenza kwakhona.

Ixesha lokwenyani{0}}lokubeka iliso kwiparameters ze-welding key

Abavelisi beemoto namhlanje abafuni kuphela iiwelds ezinamandla kodwa kunyeiinkqubo zokuwelda eziphindaphindwayo nezinokulandeleka. Ngesi sizathu, oomatshini bale mihla be-MFDC beendawo zokuwelda bahlala bebandakanya phambiliivaliwe-inkqubo yokulawula iluphu.

Ngexesha lomjikelo ngamnye we-welding, inkqubo yolawulo ibeka iliso kwiiparamitha ezininzi ezibalulekileyo ngexesha lokwenyani, kubandakanya:

• Welding okwangoku
• Umbane wokuwelda
• Amandla e-Electrode
• Ukufuduswa kwe-Electrode

Ngokuqhubeka nokuhlalutya le miqondiso, umlawuli unokulungelelanisa iiparamitha ze-welding dynamically ukugcina igalelo lamandla elihambelanayo kwi-weld nganye.

Iinkqubo ze-welding ze-MFDC eziphucukileyo zihlala ziphumelelaukuphindaphindwa kwamandla ngaphakathi ±2%, ngelixa iinkqubo ze-welding ze-AC eziqhelekileyo zisebenza ngaphakathi kuluhlu malunga±5%. Kwimveliso yeemoto{1} eziphezulu, lo mahluko unokuba nefuthe elibonakalayo kumgangatho wemveliso kunye nokungaguquguquki.

Ukurekhodwa kwedatha yeWelding kunye nokulandeleka komgangatho

Omnye umkhwa ophambili kwimveliso yeemoto kukugxininisa okwandayoidatha{0}eqhutywa ulawulo lobulunga. Imigangatho efanaIATF 16949kufuna abavelisi bagcine iirekhodi zemveliso ezinokulandeleka kwiinkqubo ezibalulekileyo.

Oomatshini abaninzi bale mihla be-MFDC baquka{0}}inkqubo yokubeka iliso kunye nokuloga kwedatha eyakhelweyo. Ezi nkqubo zivumela abavelisi ukuba:

• Rekhoda iiparamitha ze-welding kuyo yonke indawo ye-weld
• Fumana iimeko zokuwelda ezingaqhelekanga ngexesha langempela
• Hlalutya iindlela zomgangatho we-welding ngokuhamba kwexesha
• Hlanganisa idatha ye-welding kunye ne-MES okanye iinkqubo zolawulo lwefektri

Ngolu lwazi, abavelisi banokuchonga imiba yenkqubo enokwenzeka kwangoko kwaye benze uphuculo olusekwe kwidatha{{0}esekwe kwimisebenzi yabo yokuwelda.

Ukuhambelana neenkqubo ze-robotic welding

Uninzi lwemisebenzi ye-welding yemoto yanamhlanje ixhomekeke kakhulu kwi-robotic automation. Ukuxhasa ezi nkqubo, MFDC indawo oomatshini ukuwelda badla ukuyilwa ngeuyilo lwemodyuli.

Amalungu enkqubo eqhelekileyo aquka:

• Imodyuli yonikezelo lwamandla eWelding
• Phakathi{0}}isiguquli samaxesha amaninzi
• Imodyuli yesistim yokulawula

Ukwahlula la macandelo kwiimodyuli ezizimeleyo kwenza lula ukufakela kunye nokugcinwa ngelixa ukwenza inkqubo ibe lula ukudibanisa kwimigca yokuvelisa ngokuzenzekelayo.

Iinkqubo ezininzi ze-welding ze-MFDC zikwaxhasa iiprothokholi zonxibelelwano ezisetyenziswa ngokubanzi, ezinje:

• Inzuzo
• Modbus
• Ethernet/IP

Olu nxibelelwano luvumela izixhobo ze-welding ukuba zinxibelelane ngokuthe ngqo neerobhothi, abalawuli be-PLC, kunye neenkqubo ze-MES, ezivumela ukusebenza kakuhle kunye nokusebenza kwefektri ekrelekrele.

Ufakelo olukhawulezayo kunye nokugunyaziswa

Kwiiprojekthi ezinkulu zokwenziwa kweemoto, ixesha elifunekayo lokufaka kunye nokugunyazisa izixhobo zokuvelisa lichaphazela ngokuthe ngqo isantya serempu yemveliso{0}}phezulu. Iisistim zewelding eziqhelekileyo zihlala zifuna iingcingo ezilungelelanisiweyo, ulungelelwaniso lwe-pneumatic, kunye nohlengahlengiso olubanzi{2}}kwisiza.

Ngokwahlukileyo, iimodyuli ze-MFDC welding systems zingenza lula ezi nkqubo. Kuba ezona nxalenye ziphambili{1}}zenziwe ngobunjineli kwaye zabekwa emgangathweni, ukufakela kuyakhawuleza kwaye nodibaniso lwesixokelelwano luqikeleleka ngakumbi.

Kwiiprojekthi ezininzi zokwenziwa kwecandelo leemoto, ukuphuculwa kweendlela zokuwelda ze-MFDC kukhokelele ku:

• 60–70% yexesha elifutshane lokugunyazisa
• Umgca wemveliso ngokubanziI-OEE ingaphaya kwe-90%

Olu phuculo luvumela abavelisi ukuba bazise imigca emitsha yemveliso kwi-intanethi ngokukhawuleza ngelixa begcina ukusebenza kakuhle okuphezulu.

Kuba abavelisi baceba ukuphucula izixhobo zabo zokuwelda, ukukhetha umatshini wokuwelda we-MFDC ofanelekileyo kufuna uphononongo olucokisekileyo lwezinto ezininzi zobugcisa.

Okokuqala, ukuzinza kokunikezelwa kombane we-welding kubalulekile. Izixhobo ngeulawulo lwangoku ukuchaneka ngaphakathi ±3%kwayeukuphindaphindwa kwamandla ngaphakathi ±2%iyacetyiswa ngokubanzi kwizicelo zeemoto apho ukuhambelana kwe-weld kubalulekile.

Okwesibini, izakhono zenkqubo yokulawula i-welding kufuneka ziqwalaselwe. Umlawuli{1}oyilwe kakuhle kufuneka axhase iishedyuli ezininzi ze-welding,{2}}ixesha lokwenyani lokujonga inkqubo, kunye nokurekhodwa kwedatha ye-welding. Ezi mpawu zinceda ekuqinisekiseni umgangatho we-weld ongaguqukiyo kwaye wenze ukuba kube nokulandeleka kuyo yonke inkqubo yemveliso.

Ekugqibeleni, ukuhambelana neenkqubo ezizenzekelayo kubaluleke kakhulu. Oomatshini abaxhasa iiprothokholi zonxibelelwano ezisemgangathweni zinokudityaniswa ngokulula kunye neenkqubo zokuwelda iirobhothi kunye namaqonga e-MES efektri, ukunciphisa iindleko zokudityaniswa kunye nokwenza lula ukuphuculwa kwexesha elizayo.

Ukuqukumbela

Njengoko ishishini leemoto liqhubeka nokuguqukela kwiimoto zombane, izakhiwo ezikhaphukhaphu, kunye nemveliso ezenzekelayo, iimfuno zezixhobo ze-welding ziya ziba nzima ngakumbi. Oomatshini bokuwelda bendawo be-AC bemveli bahlala besokola ukuzisa uzinzo kunye nokuchaneka okufunekayo kwiindawo zale mihla zokwenziwa.

Oomatshini bokuwelda indawo be-MFDCukujongana nale mingeni ngokudibanisa imveliso yeDC ezinzileyo, -echanekileyo evaliweyo{1}}ulawulo lwelophu, kunye noyilo lwemodyuli yenkqubo. Ezi zakhono aziphuculi kuphela umgangatho we-weld kodwa zixhasa ukuhlanganiswa okusebenzayo kunye nemigca yokuvelisa ngokuzenzekelayo.

Kubavelisi abajolise ekuphuculeni ukuthembeka kwe-welding, ukunciphisa ukusebenza kwakhona, kunye nokwandisa ukusebenza kakuhle kwemveliso, utyalo-mali kwi-MFDC yetekhnoloji ye-welding yebala iya isiba lukhetho olusebenzayo nolucwangcisiweyo. Njengoko ukwenziwa kobuchule kuqhubela phambili, iinkqubo zokuwelda ezibonelela ngolawulo oluchanekileyo, ukucaca kwenkqubo, kunye nokudityaniswa kwe-automation engenamthungo kuya kudlala indima ebalulekileyo kwikamva lemveliso yeemoto.

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