Phantse yonke inkqubo yokuhlanganisa inokwenziwa ngeendlela ezahlukeneyo. Ukhetho olukhethwa ngumvelisi okanye ngumdibanisi ukuze afumane iziphumo ezilungileyo ludla ngokuba lolo luhambelana netekhnoloji eqinisekisiweyo nesicelo esithile.
Ukuqhotsa yinkqubo yokudibanisa isinyithi apho iindawo ezimbini okanye ngaphezulu zesinyithi zidityaniswa ngokunyibilikisa isinyithi esizalisa isinyithi size siyifake kwijoyinti. Isinyithi esizalisa isinyithi sinendawo yokunyibilika ephantsi kuneendawo zesinyithi ezikufutshane.
Ubushushu bokugquma bunokubonelelwa ngeetotshi, ii-oven okanye ii-induction coils. Ngexesha lokugquma, i-induction coil idala i-magnetic field efudumeza i-substrate ukuze inyibilikise isinyithi esizalisayo. Ukugquma ngokukhupha kubonakala ukuba lolona khetho lulungileyo kwinani elikhulayo lezicelo zokuhlanganisa.
“Ukugquma i-induction kukhuselekile kakhulu kunokugquma i-torch, kukhawuleza kunokugquma i-furnace, kwaye kuyaphindaphindeka ngaphezu kwazo zombini,” utshilo uSteve Anderson, umphathi wesayensi yentsimi kunye novavanyo kwiFusion Inc., i-integrator eneminyaka engama-88 ubudala eWilloughby, eOhio Said, ugxile kwiindlela ezahlukeneyo zokuhlanganisa, kuquka ukugquma i-induction.” Ngaphezu koko, ukugquma i-induction kulula. Xa kuthelekiswa nezinye iindlela ezimbini, into oyifunayo ngokwenene ngumbane oqhelekileyo.”
Kwiminyaka embalwa eyadlulayo, iFusion yaphuhlisa umatshini ozenzekelayo onezikhululo ezintandathu wokudibanisa ii-carbide burrs ezili-10 zokusebenza ngentsimbi kunye nokwenziwa kwezixhobo. Ezi burrs zenziwa ngokuncamathisela ii-tungsten carbide blanks ezisilinda nezikhonkwane kwi-shank yentsimbi. Izinga lemveliso liziinxalenye ezingama-250 ngeyure, kwaye itreyi yeendawo ezahlukeneyo inokuthwala ii-blanks ezili-144 kunye nezibambi zezixhobo.
“Irobhothi ye-SCARA enemijikelo emine ithatha isiphatho kwitreyi, isinike isixhobo sokukhupha intlama, ize isifake kwindlwane yegripper,” ucacisa uAnderson. “Irobhothi emva koko ithatha iqhekeza elingenanto kwitreyi ize ilibeke esiphelweni sesiqu apho incamathiselwe khona. I-induction brazing yenziwa kusetyenziswa i-electric coil ejikeleza ngokuthe nkqo iindawo ezimbini ize izise isilivere filler metal kubushushu obuyi-1,305 F. Emva kokuba i-burr component ilungelelaniswe kwaye ipholisiwe, ikhutshwa nge-discharge chute ize iqokelelwe ukuze iqhubeke nokucutshungulwa.”
Ukusetyenziswa kwe-induction brazing xa kuhlanganiswa kuyanda, ikakhulu kuba kudala unxibelelwano oluqinileyo phakathi kwamacandelo amabini esinyithi kwaye kuba kusebenza kakhulu ekudibaniseni izinto ezahlukeneyo. Iinkxalabo zokusingqongileyo, ubuchwepheshe obuphuculweyo, kunye nokusetyenziswa okungaqhelekanga nazo zinyanzela iinjineli zokuvelisa ukuba zijonge ngokusondeleyo i-induction brazing.
Ukugquma izibane zokungenisa umoya (induction brazing) bekukho ukususela ngeminyaka yoo-1950, nangona ingcamango yokufudumeza umoya (ukusebenzisa i-electromagnetism) yafunyanwa kwiminyaka engaphezu kwenkulungwane ngaphambili ngusosayensi waseBritane uMichael Faraday. Iitotshi zezandla zazingumthombo wokuqala wobushushu bokugquma, zalandelwa zizitofu ngeminyaka yoo-1920. Ngexesha leMfazwe Yehlabathi yesiBini, iindlela ezisekelwe kwisithando somlilo zazisetyenziswa rhoqo ukwenza iindawo ezininzi zesinyithi ngaphandle kwemisebenzi emininzi kunye neendleko ezincinci.
Imfuno yabathengi yomoya opholileyo ngeminyaka yoo-1960 noo-1970 yadala usetyenziso olutsha lokufaka i-induction brazing. Enyanisweni, i-aluminium mass brazing ngasekupheleni kweminyaka yoo-1970 yabangela uninzi lwezinto ezifumaneka kwiinkqubo zomoya opholileyo zeemoto zanamhlanje.
“Ngokungafaniyo nokugquma itotshi, ukugquma itotshi akusebenzi kwaye kunciphisa umngcipheko wokutshisa kakhulu,” uphawula uRick Bausch, umphathi wentengiso we-Ambrell Corp., kwi-TEST.temperature.”
Ngokutsho kukaGreg Holland, umphathi wentengiso kunye nemisebenzi kwi-eldec LLC, inkqubo eqhelekileyo yokugquma umbane iqulathe izinto ezintathu. Ezi zizixhobo zombane, intloko yokusebenza ene-induction coil kunye nenkqubo yokuphola okanye yokuphola.
Umbane uqhagamshelwe entlokweni yokusebenza kwaye iikhoyili zenzelwe ngokwezifiso ukuba zilingane nejoyinti. Ii-inductors zingenziwa ngeentonga eziqinileyo, iintambo eziguquguqukayo, iibhilethi ezenziwe ngomatshini, okanye eziprintiweyo ze-3D ezivela kwii-alloys zobhedu oluyimpuphu. Nangona kunjalo, ngokwesiqhelo, zenziwe ngeetyhubhu zobhedu ezingenanto, apho amanzi ahamba khona ngezizathu ezahlukeneyo. Esinye kukugcina ikhoyili ipholile ngokuthintela ubushushu obubonakaliswa ziindawo ngexesha lenkqubo yokugquma. Amanzi aqukuqelayo akwathintela ukwakheka kobushushu kwiikhoyili ngenxa yokubakho rhoqo kombane otshintshanayo kunye nokudluliselwa kobushushu okungasebenzi kakuhle.
“Ngamanye amaxesha i-flux concentrator ifakwa kwi-coil ukuze kuqiniswe amandla emagnethi kwindawo enye okanye ezingaphezulu kwindawo yokuhlangana,” ucacisa uHolland. “Ezi concentrator zinokuba zezohlobo lwe-laminate, eziquka iintsimbi zombane ezincinci ezihlanganiswe ngokuqinileyo, okanye iityhubhu ze-ferromagnetic eziqulethe izinto ze-ferromagnetic ezicoliweyo kunye neebhondi ze-dielectric ezicinezelwe phantsi koxinzelelo oluphezulu. Sebenzisa nayiphi na inzuzo ye-concentrator kukuba inciphisa ixesha lokujikeleza ngokuzisa amandla amaninzi kwiindawo ezithile zejoyinti ngokukhawuleza, ngelixa igcina ezinye iindawo zipholile.”
Ngaphambi kokubeka iindawo zesinyithi kwindawo yokufakelwa kwe-induction brazing, umqhubi kufuneka amisele ngokufanelekileyo amanqanaba e-frequency kunye namandla enkqubo. I-frequency ingasukela kwi-5 ukuya kwi-500 kHz, okukhona i-frequency iphezulu, kokukhona umphezulu ushushu ngokukhawuleza.
Izixhobo zamandla zihlala zikwazi ukuvelisa amakhulu ee-kilowatts zombane. Nangona kunjalo, ukubethela inxalenye enobukhulu besundu kwimizuzwana eli-10 ukuya kweli-15 kufuna i-kilowatts e-1 ukuya kwezi-5 kuphela. Xa kuthelekiswa, iindawo ezinkulu zinokufuna ii-kilowatts ezingama-50 ukuya kwezi-100 zamandla kwaye kuthatha imizuzu emi-5 ukubethela.
“Njengomthetho jikelele, izinto ezincinci zisebenzisa amandla amancinci, kodwa zifuna amaza aphezulu, njenge-100 ukuya kwi-300 kilohertz,” utshilo uBausch. “Ngokwahlukileyo koko, izinto ezinkulu zifuna amandla amaninzi kunye namaza aphantsi, ngesiqhelo angaphantsi kwe-100 kilohertz.”
Nokuba zingakanani na ubukhulu bazo, iindawo zesinyithi kufuneka zibekwe ngokuchanekileyo ngaphambi kokuba zibotshelelwe. Kufuneka kuqatshelwe ukugcina umsantsa oqinileyo phakathi kweentsimbi ezisisiseko ukuvumela ukusebenza kakuhle kwee-capillary yintsimbi egelezayo. Izihlanganisi ze-butt, i-lap kunye ne-butt lap zezona ndlela zilungileyo zokuqinisekisa ukuba oku kuvuleka.
Izinto zemveli okanye ezizilungisa ngokwazo ziyamkeleka. Izinto ezisemgangathweni kufuneka zenziwe ngezinto ezingahambisi kakhulu ezifana nentsimbi engagqwaliyo okanye iseramikhi, kwaye zichukumise izinto ezincinci kangangoko.
Ngokuyila iindawo ezinee-seams ezidibeneyo, ukujijeka, ukuxinwa okanye ii-knurls, ukuzilungisa ngokwakho kunokufezekiswa ngaphandle kwesidingo senkxaso yoomatshini.
Emva koko amalungu acocwa nge-emery pad okanye isinyibilikisi ukususa izinto ezingcolisayo ezifana neoyile, igrisi, umhlwa, isikali kunye nokungcola. Eli nyathelo liphucula ngakumbi ukusebenza kwe-capillary yentsimbi enyibilikisiweyo yokuzalisa izitsalela kwiindawo ezikufutshane zelungu.
Emva kokuba iindawo zihlaliswe kakuhle kwaye zicociwe, umqhubi ufaka i-joint compound (ngesiqhelo i-paste) kwi-joint. I-compound ngumxube we-filler metal, i-flux (ukuthintela i-oxidation) kunye ne-binder ebamba i-metal kwaye i-flux kunye ngaphambi kokuba inyibilike.
Iintsimbi zokuzalisa kunye neefluxes ezisetyenziswa kwibrazing zenzelwe ukumelana namaqondo obushushu aphezulu kunezo zisetyenziswa kwi-soldering. Iintsimbi zokuzalisa ezisetyenziselwa ibrazing ziyanyibilika kumaqondo obushushu angama-842 F ubuncinane kwaye zinamandla xa zipholile. Ziquka i-aluminium-silicon, i-copper, i-copper-silver, i-brass, i-bronze, i-gold-silver, isilivere, kunye nee-nickel alloys.
Emva koko umqhubi ubeka ikhoyili yokungenisa, eza ngeendlela ezahlukeneyo. Iikhoyili zeHelical zijikelezile okanye zimile okweqanda kwaye zijikeleze ngokupheleleyo indawo leyo, ngelixa iikhoyili zefolokhwe (okanye zepincer) zibekwe kwicala ngalinye lejoyinti kwaye iikhoyili zetshaneli zixhumeka kwindawo leyo. Ezinye iikhoyili ziquka i-Inner Diameter (ID), i-ID/Outer Diameter (OD), iPancake, iVulekile, kunye ne-Multi-Position.
Ubushushu obufanayo bubalulekile kwiintambo zokudibanisa ezisemgangathweni ophezulu. Ukuze wenze oku, umqhubi kufuneka aqinisekise ukuba umgama othe nkqo phakathi kwe-induction coil loop nganye umncinci kwaye umgama wokudibanisa (ububanzi besithuba ukusuka kwi-coil OD ukuya kwi-ID) uhlala ufana.
Okulandelayo, umqhubi uvula umbane ukuze aqalise inkqubo yokufudumeza ijoyinti. Oku kuquka ukudlulisa ngokukhawuleza umbane ojikelezayo ophakathi okanye ophezulu ukusuka kumthombo wamandla ukuya kwi-inductor ukuze kudalwe intsimi yemagnethi ejikelezayo.
I-magnetic field ibangela umsinga kumphezulu wejoyinti, nto leyo evelisa ubushushu bokunyibilikisa isinyithi esizalisayo, esivumela ukuba sihambe kwaye simanzise umphezulu wenxalenye yesinyithi, nto leyo edala unxibelelwano oluqinileyo. Ukusebenzisa iikhoyili zeendawo ezininzi, le nkqubo inokwenziwa kwiindawo ezininzi ngaxeshanye.
Ukucoca nokuhlola okokugqibela kwenxalenye nganye efakwe ibrashi kuyacetyiswa. Ukuhlamba iindawo ngamanzi ashushu ukuya kwi-120 F ubuncinane kuya kususa iintsalela zeflux kunye nalo naliphi na ixolo elenziwe ngexesha lebrashi. Inxalenye kufuneka ifakwe emanzini emva kokuba intsimbi yokuzalisa iqinile kodwa indibano isashushu.
Ngokuxhomekeke kwicandelo, uvavanyo oluncinci lunokulandelwa luvavanyo olungonakalisiyo nolutshabalalisayo. Iindlela ze-NDT ziquka ukuhlolwa okubonakalayo kunye nokwe-radiographic, kunye novavanyo lokuvuza kunye nobungqina. Iindlela zovavanyo ezitshabalalisayo eziqhelekileyo zii-metallographic, peel, tensile, shear, fatigue, transfer, kunye novavanyo lwe-torsion.
“Ukugquma i-induction kufuna utyalo-mali olukhulu oluphambili kunendlela yetotshi, kodwa kufanelekile kuba ufumana ukusebenza kakuhle kunye nolawulo olongezelelweyo,” utshilo uHolland. “Nge-induction, xa ufuna ubushushu, ucinezela nje. Xa ungabufuni, ucinezela.”
I-Eldec ivelisa uluhlu olubanzi lwemithombo yamandla yokufakelwa kwe-induction brazing, efana nomgca we-ECO LINE MF intermediate frequency line, ofumaneka kwiindlela ezahlukeneyo zokulungiselela usetyenziso ngalunye. Ezi zixhobo zamandla ziyafumaneka kwiireyithingi zamandla ukusuka kwi-5 ukuya kwi-150 kW kunye neefrequencies ukusuka kwi-8 ukuya kwi-40 Hz. Zonke iimodeli zinokuxhotyiswa ngesici sokunyusa amandla esivumela umqhubi ukuba anyuse ireyithingi yomsebenzi oqhubekayo ye-100% nge-50% eyongezelelweyo kwimizuzu emi-3. Ezinye iimpawu eziphambili ziquka ulawulo lobushushu be-pyrometer, irekhoda yobushushu kunye neswitshi yamandla ye-bipolar transistor efakwe kwi-insulated gate. Ezi zinto zisetyenziswayo azifuni ulondolozo oluncinci, zisebenza ngokuthula, zinomlinganiselo omncinci, kwaye zidityaniswa ngokulula nabalawuli be-workcell.
Abavelisi kwimizi-mveliso emininzi baya besebenzisa ngakumbi i-induction brazing ukuhlanganisa iindawo. IBausch ikhomba abavelisi bezithuthi, abaqhubi beenqwelo-moya, izixhobo zonyango kunye nezixhobo zemigodi njengabasebenzisi abakhulu bezixhobo ze-Ambrell induction brazing.
“Inani lezinto ze-aluminium ezifakwe i-induction brased kwishishini leemoto liyaqhubeka nokwanda ngenxa yemizamo yokunciphisa ubunzima,” utshilo uBausch. “Kwicandelo leenqwelo-moya, i-nickel kunye nezinye iintlobo zee-wear pads zihlala zifakelwa i-brased ukuya kwii-jet blades. Zombini ezi nkampani zikwafakela i-induction brased ezahlukeneyo kwii-fittings zentsimbi.”
Zonke ezintandathu iinkqubo ze-Ambrell's EasyHeat zinoluhlu lwee-frequency oluqala kwi-150 ukuya kwi-400 kHz kwaye zilungele ukubethelwa kwezinto ezincinci zejometri ezahlukeneyo. Iicompacts (0112 kunye ne-0224) zibonelela ngolawulo lwamandla ngaphakathi kwesisombululo se-25 watts; iimodeli ezikuluhlu lwe-LI (3542, 5060, 7590, 8310) zibonelela ngolawulo ngaphakathi kwesisombululo se-50 watts.
Zombini ezi ngcelele zinentloko yokusebenza esuswayo ukuya kuthi ga kwiimitha ezili-10 ukusuka kumthombo wamandla. Ulawulo lwephaneli yangaphambili yenkqubo lunokucwangciswa, okuvumela umsebenzisi wokugqibela ukuba achaze ukuya kuthi ga kwiiprofayili ezine ezahlukeneyo zokufudumeza, nganye inexesha ukuya kuthi ga kwiinyathelo ezintlanu zamandla. Ulawulo lwamandla olukude luyafumaneka ukuze lufakwe kunxibelelwano okanye kwi-analog, okanye kwi-port yedatha ye-serial ekhethiweyo.
“Abathengi bethu abaphambili bokufaka ibrazing kwi-induction ngabavelisi beendawo ezinekhabhoni, okanye iindawo ezinkulu ezinobunzima obuphezulu bentsimbi,” ucacisa uRich Cukelj, uMphathi woPhuhliso lweShishini leFusion.”Ezinye zezi nkampani zikhonza amashishini eemoto kunye neendiza, ngelixa ezinye zenza izibhamu, zisika izixhobo, iimpompo zemibhobho kunye nemisele yamanzi, okanye iibhloko zokusasazwa kombane kunye neefusi.”
I-Fusion ithengisa iinkqubo ezijikelezayo ezenziwe ngokwezifiso ezinokufaka iinxalenye ezili-100 ukuya kwi-1,000 ngeyure. Ngokutsho kukaCukelj, isivuno esiphezulu sinokwenzeka kuhlobo olunye lwenxalenye okanye kuthotho oluthile lwenxalenye. Ezi nxalenye zinobukhulu obuqala kwi-2 ukuya kwi-14 square intshi.
“Inkqubo nganye ine-indexer evela kwiStelron Components Inc. eneendawo zokusebenza ezisi-8, ezili-10 okanye ezili-12,” ucacisa uCukelj. “Ezinye iindawo zokusebenza zisetyenziselwa ukurhawuzelela, ngelixa ezinye zisetyenziselwa ukuhlolwa, kusetyenziswa iikhamera zokubona okanye izixhobo zokulinganisa nge-laser, okanye ukwenza uvavanyo lokutsala ukuqinisekisa ukuba amalungu arhawuzelelweyo asemgangathweni ophezulu.”
Abavelisi basebenzisa izixhobo zamandla ze-ECO LINE eziqhelekileyo ze-eldec kwiintlobo ngeentlobo zezicelo ze-induction brazing, ezifana nee-rotors kunye nee-shafts ezifakelwayo, okanye ii-joining motor housings, utshilo uHolland. Kutshanje, imodeli ye-100 kW yale generator isetyenzisiwe kwisicelo esikhulu seendawo esibandakanya ukubethela iiringi zesekethe yobhedu kwiintambo zombhobho zombane kwiijenereyitha zamadama e-hydroelectric.
I-Eldec ikwavelisa izixhobo zombane zeMiniMICO eziphathekayo ezinokufuduselwa ngokulula kumzi-mveliso ngoluhlu lwamaza oluqala kwi-10 ukuya kwi-25 kHz. Kwiminyaka emibini eyadlulayo, umenzi weetyhubhu zokutshintsha ubushushu beemoto wasebenzisa iMiniMICO ukubuyisela iingqiniba kwityhubhu nganye. Umntu omnye wenza yonke i-brazing, kwaye kwathabatha ngaphantsi kwemizuzwana engama-30 ukuhlanganisa ityhubhu nganye.
UJim ungumhleli omkhulu kwi-ASSEMBLY onamava angaphezu kweminyaka engama-30 yokuhlela. Ngaphambi kokuba ajoyine i-ASSEMBLY, uCamillo wayenguNjineli weNkulumbuso, umhleli we-Association for Equipment Engineering Journal kunye ne-Milling Journal. UJim unesidanga sesiNgesi kwiYunivesithi yaseDePaul.
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Iirobhothi zitshiphu kwaye kulula ukuzisebenzisa kunangaphambili. Le teknoloji ifumaneka lula nakubavelisi abancinci nabaphakathi. Mamela le ngxoxo yephaneli ekhethekileyo equka abaphathi abavela kubathengisi abane abaphambili beerobhothi eMelika: i-ATI Industrial Automation, i-Epson Robots, iFANUC America, kunye ne-Universal Robots.