Pafupifupi njira iliyonse yopangira zinthu ingachitike m'njira zingapo. Njira yomwe wopanga kapena wophatikiza amasankha kuti apeze zotsatira zabwino nthawi zambiri imakhala yogwirizana ndi ukadaulo wotsimikizika ndi pulogalamu inayake.
Kusungunula zitsulo ndi njira imodzi yotere. Kusungunula zitsulo ndi njira yolumikizira zitsulo momwe zigawo ziwiri kapena zingapo zachitsulo zimalumikizidwa mwa kusungunula zitsulo zodzaza ndikuzilowetsa mu cholumikizira. Chitsulo chodzaza chimakhala ndi malo otsika osungunula zitsulo kuposa zigawo zachitsulo zomwe zili pafupi.
Kutentha kwa brazing kungaperekedwe ndi ma tochi, ng'anjo kapena ma induction coils. Pa nthawi ya induction brazing, induction coil imapanga mphamvu yamaginito yomwe imatenthetsa substrate kuti isungunuke chitsulo chodzaza. Induction brazing ikuoneka kuti ndiyo chisankho chabwino kwambiri pa ntchito zambiri zomangira.
"Kupangira magetsi pogwiritsa ntchito induction brazing ndikotetezeka kwambiri kuposa kupangira magetsi pogwiritsa ntchito tochi, mwachangu kuposa kupangira magetsi pogwiritsa ntchito ng'anjo, komanso kobwerezabwereza kuposa zonse ziwiri," adatero Steve Anderson, manejala wa sayansi ya sayansi yamunda ndi mayeso ku Fusion Inc., wophatikiza wazaka 88 ku Willoughby, Ohio Said, katswiri pa njira zosiyanasiyana zopangira magetsi, kuphatikizapo kupangira magetsi pogwiritsa ntchito induction brazing. "Kuphatikiza apo, kupangira magetsi pogwiritsa ntchito induction brazing ndikosavuta. Poyerekeza ndi njira zina ziwiri, chomwe mukufunikira ndi magetsi wamba."
Zaka zingapo zapitazo, Fusion idapanga makina odziyimira okha okhala ndi malo asanu ndi limodzi okonzera ma carbide burrs 10 opangira zitsulo ndi zida. Ma burrs amapangidwa polumikiza ma tungsten carbide blanks ozungulira ndi ozungulira ku chitsulo. Chiŵerengero cha kupanga ndi magawo 250 pa ola limodzi, ndipo thireyi yosiyana imatha kusunga ma blanks 144 ndi zogwirira zida.
"Loboti ya SCARA yokhala ndi ma axis anayi imatenga chogwirira kuchokera mu thireyi, n’kuchipereka kwa chotulutsira phala chosungunula, n’kuchiyika mu chisa cha gripper," akutero Anderson. "Kenako lobotiyo imatenga chidutswa chopanda kanthu kuchokera mu thireyi n’kuchiika kumapeto kwa shank komwe chimamatiridwa. Kuyika kwa induction kumachitika pogwiritsa ntchito coil yamagetsi yomwe imazungulira molunjika mbali ziwirizo ndikubweretsa chitsulo chodzaza siliva kutentha kwa 1,305 F. Gawo la burr likayikidwa bwino ndikuziziritsidwa, limatulutsidwa kudzera mu chute yotulutsira madzi ndikusonkhanitsidwa kuti likonzedwenso."
Kugwiritsa ntchito makina opangira zinthu zoyambitsa ...
Kuwotcha kwa induction kwakhalapo kuyambira m'ma 1950, ngakhale lingaliro la kutentha kwa induction (pogwiritsa ntchito magetsi) linapezeka zaka zoposa zana zapitazo ndi wasayansi waku Britain Michael Faraday. Miyuni yamanja inali gwero loyamba la kutentha kwa induction, kutsatiridwa ndi ng'anjo m'ma 1920. Pa Nkhondo Yachiwiri Yapadziko Lonse, njira zopangira ng'anjo nthawi zambiri zinkagwiritsidwa ntchito popanga zitsulo zambirimbiri popanda ntchito yambiri komanso ndalama zambiri.
Kufunika kwa ogula kwa mpweya woziziritsa m'zaka za m'ma 1960 ndi 1970 kunapanga njira zatsopano zopangira chitsulo choziziritsa. Ndipotu, chitsulo choziritsa cha aluminiyamu kumapeto kwa zaka za m'ma 1970 chinapangitsa kuti pakhale zinthu zambiri zomwe zimapezeka m'makina amakono amakono oziziritsira mpweya m'magalimoto.
"Mosiyana ndi kuunikira kwa tochi, kuunikira kwa induction sikugwirizana ndi kutentha kwambiri," akutero Rick Bausch, manejala wogulitsa wa Ambrell Corp., inTEST.temperature.
Malinga ndi Greg Holland, manejala wogulitsa ndi ntchito ku eldec LLC, makina okhazikika opangira magetsi okhala ndi zinthu zitatu. Izi ndi magetsi, mutu wogwirira ntchito wokhala ndi coil yopangira magetsi komanso makina oziziritsira kapena oziziritsira.
Mphamvu yamagetsi imalumikizidwa ku mutu wa ntchito ndipo ma coil amapangidwa mwapadera kuti agwirizane mozungulira cholumikizira. Ma inductor amatha kupangidwa ndi ndodo zolimba, zingwe zosinthika, ma billet opangidwa ndi makina, kapena kusindikizidwa ndi 3D kuchokera ku ma alloy a mkuwa wophwanyidwa. Komabe, nthawi zambiri amapangidwa ndi mapaipi amkuwa opanda kanthu, omwe madzi amadutsamo pazifukwa zingapo. Chimodzi mwa izi ndi kusunga coil kuzizira polimbana ndi kutentha komwe kumawonetsedwa ndi zigawo panthawi ya brazing. Madzi oyenda amaletsanso kutentha komwe kumawonjezeka mu ma coil chifukwa cha kupezeka pafupipafupi kwa alternating current komanso kusamutsa kutentha kosagwira ntchito bwino.
“Nthawi zina chosungira madzi chimayikidwa pa coil kuti chilimbikitse mphamvu ya maginito pamalo amodzi kapena angapo pamzere wolumikizirana,” akutero Holland. “Zosungira zimenezi zitha kukhala za mtundu wa laminate, zopangidwa ndi zitsulo zamagetsi zopyapyala zolumikizidwa pamodzi, kapena machubu a ferromagnetic okhala ndi zinthu zopangidwa ndi ferromagnetic ndi ma bond a dielectric opanikizidwa pansi pa kupanikizika kwakukulu. Gwiritsani ntchito chilichonse mwa izi. Ubwino wa chosungira madzi ndikuti chimachepetsa nthawi yozungulira pobweretsa mphamvu zambiri m'malo enaake a cholumikizira mwachangu, pomwe chimasunga malo ena ozizira.”
Asanayike zida zachitsulo kuti zigwiritsidwe ntchito popangira induction brazing, wogwiritsa ntchitoyo ayenera kuyika bwino kuchuluka kwa ma frequency ndi mphamvu za dongosololi. Ma frequency amatha kuyambira 5 mpaka 500 kHz, ma frequency akakwera, kutentha kwa pamwamba kumawonjezeka mwachangu.
Magetsi nthawi zambiri amatha kupanga ma kilowatts mazana ambiri a magetsi. Komabe, kuyika gawo lofanana ndi kanjedza m'masekondi 10 mpaka 15 kumafuna kilowatts imodzi mpaka 5 zokha. Poyerekeza, zigawo zazikulu zimatha kufunikira ma kilowatts 50 mpaka 100 a mphamvu ndipo zimatenga mphindi 5 kuti zigwiritsidwe ntchito.
"Mwachizolowezi, zigawo zazing'ono zimagwiritsa ntchito mphamvu zochepa, koma zimafuna ma frequency apamwamba, monga 100 mpaka 300 kilohertz," adatero Bausch. "Mosiyana ndi zimenezi, zigawo zazikulu zimafuna mphamvu zambiri ndi ma frequency otsika, nthawi zambiri osakwana 100 kilohertz."
Kaya ndi kukula kwake kapena ayi, ziwalo zachitsulo ziyenera kuyikidwa bwino musanazimangirire. Samalani kuti pakhale mpata wolimba pakati pa zitsulo zoyambira kuti zitsulo zodzaza zigwire bwino ntchito. Mapaipi a m'mbuyo, m'chiuno ndi m'chiuno ndi njira yabwino kwambiri yotsimikizira kuti pali kusiyana kumeneku.
Zipangizo zachikhalidwe kapena zodzikonzera zokha ndizovomerezeka. Zipangizo zokhazikika ziyenera kupangidwa ndi zinthu zosagwiritsa ntchito mphamvu zambiri monga chitsulo chosapanga dzimbiri kapena ceramic, ndipo zisakhudze zipangizozo pang'ono momwe zingathere.
Mwa kupanga ziwalo zokhala ndi mipata yolumikizana, kugwedezeka, kugwetsa kapena kugoba, kudzikonza nokha kumatha kuchitika popanda kufunikira thandizo la makina.
Kenako malo olumikizirana mafupa amatsukidwa ndi emery pad kapena solvent kuti achotse zinthu zodetsa monga mafuta, mafuta, dzimbiri, mamba ndi litsiro. Gawoli limawonjezera mphamvu ya capillary ya chitsulo chosungunuka chomwe chimakoka chokha pamwamba pa malo olumikizirana mafupa.
Zigawozo zikayikidwa bwino ndikutsukidwa, wogwiritsa ntchito amaika cholumikizira (nthawi zambiri chimakhala phala) pa cholumikiziracho. Cholumikiziracho ndi chisakanizo cha chitsulo chodzaza, flux (kuti chiteteze kusungunuka kwa okosijeni) ndi chomangira chomwe chimagwira chitsulocho ndikusuntha pamodzi chisanasungunuke.
Zitsulo zodzaza ndi ma fluxes omwe amagwiritsidwa ntchito popangira zitsulo zimapangidwa kuti zipirire kutentha kwambiri kuposa zomwe zimagwiritsidwa ntchito popangira zitsulo. Zitsulo zodzaza zomwe zimagwiritsidwa ntchito popanga zitsulo zimasungunuka kutentha kwa osachepera 842 F ndipo zimakhala zolimba zikazizira. Zikuphatikizapo aluminiyamu-silicon, mkuwa, mkuwa-siliva, mkuwa, mkuwa, golide-siliva, siliva, ndi nickel alloys.
Kenako wogwiritsa ntchito amaika cholembera cha induction, chomwe chimabwera m'njira zosiyanasiyana. Ma coil a helical ndi ozungulira kapena ozungulira ndipo amazungulira gawo lonselo, pomwe ma coil a foloko (kapena pincer) ali mbali zonse ziwiri za cholumikizira ndipo ma coil a channel amalumikizana ndi gawolo. Ma coil ena ndi Inner Diameter (ID), ID/Outer Diameter (OD), Pancake, Open, ndi Multi-Position.
Kutentha kofanana n'kofunika kwambiri pakugwirizanitsa kwapamwamba kwambiri. Kuti achite izi, wogwiritsa ntchitoyo ayenera kuonetsetsa kuti mtunda woyima pakati pa kuzungulira kulikonse kwa coil yolowetsa ndi wochepa komanso kuti mtunda wolumikizira (m'lifupi mwa kusiyana kuchokera ku coil OD kupita ku ID) ukhalebe wofanana.
Kenako, wogwiritsa ntchito amayatsa magetsi kuti ayambe kutenthetsa cholumikiziracho. Izi zimaphatikizapo kusamutsa mwachangu mphamvu yamagetsi yapakatikati kapena yapamwamba kuchokera ku gwero lamagetsi kupita ku inductor kuti apange mphamvu yamagetsi yosinthasintha mozungulira.
Mphamvu ya maginito imayambitsa mphamvu yamagetsi pamwamba pa cholumikizira, zomwe zimapangitsa kutentha kusungunula chitsulo chodzaza, zomwe zimapangitsa kuti chiziyenda ndikunyowetsa pamwamba pa gawo lachitsulo, ndikupanga mgwirizano wolimba. Pogwiritsa ntchito ma coil okhala ndi malo ambiri, njirayi ikhoza kuchitika pazigawo zingapo nthawi imodzi.
Kuyeretsa komaliza ndi kuyang'ana gawo lililonse lopangidwa ndi chitsulo cholimba kumalimbikitsidwa. Kutsuka ziwalo ndi madzi otentha mpaka madigiri 120 Celsius kudzachotsa zotsalira za flux ndi mamba aliwonse omwe amapangidwa panthawi yopangidwa ndi chitsulo cholimba. Gawolo liyenera kumizidwa m'madzi chitsulo chodzaza chikadali cholimba koma chomangiracho chikadali chotentha.
Kutengera ndi gawo, kuwunika kochepa kumatha kutsatiridwa ndi kuyesa kosawononga komanso kowononga. Njira za NDT zimaphatikizapo kuwunika kowoneka ndi ka X-ray, komanso kuyesa kutulutsa madzi ndi kutsimikizira. Njira zodziwika bwino zoyesera zowononga ndi metallographic, peel, tensile, shear, fatigue, transfer, and torsion testing.
"Kuyika magetsi pogwiritsa ntchito induction brazing kumafuna ndalama zambiri zoyambira kuposa njira ya tochi, koma ndikoyenera chifukwa mumapeza luso komanso ulamuliro wowonjezera," adatero Holland. "Ndi induction, mukafuna kutentha, mumangokanikiza. Mukapanda kutero, mumangokanikiza."
Eldec imapanga magwero osiyanasiyana amagetsi opangira induction brazing, monga mzere wa ma frequency apakati a ECO LINE MF, womwe umapezeka m'makonzedwe osiyanasiyana kuti ugwirizane ndi ntchito iliyonse. Ma power supplies awa amapezeka m'ma rating amagetsi kuyambira 5 mpaka 150 kW ndi ma frequency kuyambira 8 mpaka 40 Hz. Mitundu yonse imatha kukhala ndi mphamvu yowonjezera mphamvu yomwe imalola wogwiritsa ntchito kuwonjezera 100% continuous duty rating ndi 50% yowonjezera mkati mwa mphindi zitatu. Zina mwazinthu zazikulu ndi monga pyrometer temperature control, temperature recorder ndi insulated gate bipolar transistor power switch. Ma consumable awa safuna kukonzedwa bwino, amagwira ntchito mwakachetechete, ali ndi malo ochepa, ndipo amaphatikizidwa mosavuta ndi ma workcell controllers.
Opanga m'mafakitale angapo akugwiritsa ntchito kwambiri zida zopangira zinthu zoyambira kupanga zinthu. Bausch ikuwonetsa kuti opanga magalimoto, ndege, zida zamankhwala ndi zida zamigodi ndi omwe amagwiritsa ntchito kwambiri zida zopangira zinthu zoyambira za Ambrell.
"Chiwerengero cha zida zopangira aluminiyamu zoyendetsedwa ndi induction braid mumakampani opanga magalimoto chikupitirirabe kukwera chifukwa cha njira zochepetsera kulemera," akutero Bausch. "Mu gawo la ndege, nickel ndi mitundu ina ya ma wear pad nthawi zambiri amalumikizidwa ndi jet blades. Makampani onsewa amalumikizanso induction brading zosiyanasiyana za mapaipi achitsulo."
Makina onse asanu ndi limodzi a Ambrell's EasyHeat ali ndi ma frequency range kuyambira 150 mpaka 400 kHz ndipo ndi abwino kwambiri popangira zinthu zazing'ono za geometries zosiyanasiyana. Ma compacts (0112 ndi 0224) amapereka mphamvu yolamulira mkati mwa resolution ya ma watts 25; mitundu yomwe ili mu mndandanda wa LI (3542, 5060, 7590, 8310) imapereka mphamvu yolamulira mkati mwa resolution ya ma watts 50.
Magulu onse awiriwa ali ndi mutu wogwirira ntchito wochotsedwa mpaka mamita 10 kuchokera ku gwero lamagetsi. Zowongolera za paneli yakutsogolo ya dongosololi zimatha kukonzedwa, zomwe zimathandiza wogwiritsa ntchito kusankha ma profiles anayi osiyanasiyana otenthetsera, iliyonse yokhala ndi nthawi mpaka zisanu komanso masitepe amphamvu. Kuwongolera mphamvu yakutali kulipo kuti mulowetse kapena kulowetsa analog, kapena doko la data losankhidwa.
“Makasitomala athu akuluakulu opangira zinthu zoyambira ndi opanga zida zomwe zili ndi kaboni, kapena zida zazikulu zomwe zili ndi chitsulo chambiri,” akutero Rich Cukelj, Fusion Business Development Manager. “Makampani enawa amagwira ntchito m'makampani opanga magalimoto ndi ndege, pomwe ena amapanga mfuti, kudula zida, mapaipi a mapaipi ndi njira zotulutsira madzi, kapena ma block amagetsi ndi ma fuse.”
Fusion imagulitsa makina ozungulira omwe amatha kuyika zinthu zoyambira 100 mpaka 1,000 pa ola limodzi. Malinga ndi Cukelj, zokolola zambiri zimatha kupezeka pa mtundu umodzi wa gawo kapena pa mndandanda winawake wa zigawo. Zigawozi zimakhala ndi kukula kuyambira mainchesi awiri mpaka khumi ndi anayi.
“Dongosolo lililonse lili ndi cholembera kuchokera ku Stelron Components Inc. chokhala ndi malo ogwirira ntchito 8, 10 kapena 12,” akutero Cukelj. “Malo ena ogwirira ntchito amagwiritsidwa ntchito popangira zitsulo, pomwe ena amagwiritsidwa ntchito poyang'anira, pogwiritsa ntchito makamera owonera kapena zida zoyezera laser, kapena kuchita mayeso okoka kuti atsimikizire kuti malo olumikizirana ndi zitsulo ndi abwino kwambiri.”
Opanga amagwiritsa ntchito magetsi a ECO LINE omwe amagwiritsidwa ntchito ndi eldec pa ntchito zosiyanasiyana zopangira magetsi, monga ma rotor ndi ma shaft, kapena ma joining motor housings, Holland adatero. Posachedwapa, jenereta ya 100 kW ya jenereta iyi idagwiritsidwa ntchito pakugwiritsa ntchito zida zazikulu zomwe zimaphatikizapo kupangira mphete za mkuwa ku zolumikizira za mkuwa za ma hydroelectric dam connections.
Eldec imapanganso magetsi a MiniMICO onyamulika omwe amatha kusunthidwa mosavuta mufakitale yonse ndi ma frequency a 10 mpaka 25 kHz. Zaka ziwiri zapitazo, wopanga machubu osinthira kutentha kwa magalimoto adagwiritsa ntchito MiniMICO kuyika ma braze ku chubu chilichonse. Munthu m'modzi ndiye adayika ma brazing onse, ndipo zidatenga masekondi osakwana 30 kuti asonkhanitse chubu chilichonse.
Jim ndi mkonzi wamkulu ku ASSEMBLY ndipo wakhala akugwira ntchito yolemba nkhani kwa zaka zoposa 30. Asanalowe nawo ku ASSEMBLY, Camillo anali PM Engineer, mkonzi wa Association for Equipment Engineering Journal ndi Milling Journal. Jim ali ndi digiri ya Chingerezi kuchokera ku DePaul University.
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Lean Six Sigma yakhala ikutsogolera ntchito zopititsa patsogolo zinthu kwa zaka zambiri, koma zofooka zake zaonekera. Kusonkhanitsa deta kumafuna ntchito yambiri ndipo kungathe kungotenga zitsanzo zazing'ono. Deta tsopano ikhoza kujambulidwa kwa nthawi yayitali komanso m'malo osiyanasiyana pamtengo wotsika poyerekeza ndi njira zakale zogwiritsira ntchito pamanja.
Maloboti ndi otsika mtengo komanso osavuta kugwiritsa ntchito kuposa kale lonse. Ukadaulo uwu umapezeka mosavuta ngakhale kwa opanga ang'onoang'ono ndi apakatikati. Mvetserani ku zokambirana zapaderazi zomwe zili ndi akuluakulu ochokera kwa ogulitsa ma roboti anayi apamwamba ku America: ATI Industrial Automation, Epson Robots, FANUC America, ndi Universal Robots.