Ukwenziwa kombhobho okanye umbhobho ngempumelelo nangokufanelekileyo kufuna ukuphuculwa kweenkcukacha ezili-10,000, kuquka nokugcinwa kwezixhobo. Ngenxa yeentlobo ngeentlobo zezinto ezihambayo kuzo zonke iintlobo zomatshini wokugaya kunye nesixhobo ngasinye esingaphandle, ukunamathela kwishedyuli yokukhusela ecetyiswayo ngumvelisi akuyonto ilula. Ifoto: T & H Lemont Inc.
Inqaku loMhleli: Le yinxalenye yokuqala yochungechunge olunezigaba ezimbini malunga nokuphucula ukusebenza kwetyhubhu okanye ipayipi. Funda inxalenye yesibini.
Ukuvelisa iimveliso zetyhubhu kunokuba nzima, nokuba imeko intle kangakanani na. Iifektri ziyinkimbinkimbi, zifuna ukugcinwa rhoqo, kwaye kuxhomekeke kwinto eziyivelisayo, ukhuphiswano lunzima. Abavelisi abaninzi beepayipi zesinyithi baphantsi koxinzelelo olukhulu lokwandisa ixesha lokusebenza ukuze bafumane ingeniso eninzi, bengenalo nexesha elibalulekileyo lokulungisa rhoqo.
Akukho meko ilungileyo kushishino kule mihla. Izixhobo zibiza kakhulu kwaye ukuhanjiswa okungaphelelanga akuqhelekanga. Ngoku kunanini na ngaphambili, abavelisi beepayipi kufuneka basebenzise ixesha elininzi kwaye banciphise izinto ezilahliweyo, kwaye ukufumana ukuhanjiswa okungaphelelanga kuthetha ukunciphisa ixesha lokusebenza. Ukuhamba okufutshane kuthetha ukutshintsha rhoqo, okungekuko ukusetyenziswa kakuhle kwexesha okanye umsebenzi.
“Ixesha lokuvelisa liphezulu kakhulu ngoku,” utshilo uMark Prasek, uMphathi weNtengiso yeeTubing zaseNorth American kwi-EFD Induction.
Ingxoxo neengcali zoshishino malunga neengcebiso kunye namaqhinga okusebenzisa kakuhle isityalo sakho ityhile ezinye zezihloko eziphindaphindayo:
Ukusebenzisa isityalo ngendlela esebenza kakuhle kuthetha ukuphucula izinto ezininzi, uninzi lwazo ezisebenzisana nezinye, ngoko ke ukuphucula ukusebenza kwesityalo akulula kangako. ILizwi Elingcwele lombhali wephephandaba iTube & Pipe Journal uBud Graham unika umbono othile: “Isixhobo sokugawula iityhubhu sisixhobo esigcina izixhobo.” Ukukhumbula esi sicatshulwa kunceda ukugcina izinto zilula. Ukuqonda oko kwenziwa sisixhobo ngasinye, indlela esisebenza ngayo, kunye nendlela isixhobo ngasinye esisebenzisana ngayo nezinye izixhobo kumalunga nesithathu sedabi. Ukugcina yonke into igcinwe kwaye ilungelelanisiwe sesinye isithathu sayo. Isithathu sokugqibela siquka iinkqubo zoqeqesho lwabaqhubi, amaqhinga okusombulula iingxaki, kunye neenkqubo ezithile zokusebenza ezikhethekileyo kumvelisi ngamnye wepayipi okanye wepayipi.
Eyona nto iphambili ekufuneka iqwalaselwe xa kuqhutywa umtshini ngempumelelo kukuba umtshini awuxhomekekanga kwizixhobo ezisetyenzisiweyo. Ukufumana imveliso ephezulu kwimtshini kuthetha ukufumana imveliso ephezulu kwikhoyili nganye ethunyelwa kumtshini. Kuqala ngesigqibo sokuthenga.
ubude bekhoyili. UNelson Abbey, umlawuli weFives Bronx Inc. Abbey Products, uthe: “Iityhubhu zemibhobho ziyachuma xa iikhoyili zinde. Ukwenza iikhoyili ezimfutshane kuthetha ukwenza iikhoyili ezininzi. Isiphelo ngasinye sekhoyili sifuna i-butt weld. I-butt weld ivelisa i-scrap.
Ubunzima apha kukuba iikhoyili ezinde kangangoko zinokuthengiswa ngexabiso eliphantsi. Iikhoyili ezimfutshane zinokufumaneka ngamaxabiso angcono. Iiarhente zokuthenga zisenokufuna ukonga imali, kodwa oku akuhambelani nembono yabasebenzi bomgangatho wokuvelisa. Phantse wonke umntu oqhuba umzi-mveliso angavuma ukuba umahluko wexabiso kuya kufuneka ube mkhulu ukuze kulungiswe ilahleko yemveliso enxulumene nokuvalwa okongezelelweyo komzi-mveliso.
Enye into ekufuneka iqwalaselwe, utshilo u-Abbey, kukwazi kwe-decoiler kunye nayo nayiphi na eminye imiqobo ekungeneni kwefektri. Kungafuneka ukutyala imali kwizixhobo zokungena ezinomthamo ophezulu ukuze kuphathwe iikhoyili ezinkulu nezinzima ukuze kuxhamle iingenelo zokuthenga iikhoyili ezinkulu.
I-slitter nayo ibalulekile, nokuba i-slitting yenziwa ngaphakathi okanye ngaphandle. Ii-slitter zinobunzima kunye nobubanzi obukhulu abanokusingatha, ngoko ke ukufumana ulungelelwaniso olufanelekileyo phakathi kwee-coil kunye nee-slitter kubalulekile ukuze kuphunyezwe kakhulu.
Ngamafutshane, kukunxibelelana phakathi kwezinto ezine: ubungakanani kunye nobunzima bekhoyili, ububanzi obufunekayo be-slitter, umthamo we-slitter, kunye nomthamo wezixhobo zokungenisa.
Ububanzi bekhoyili kunye nemeko yayo. Kwivenkile, kuyacaca ukuba iikhoyili kufuneka zibe nobubanzi obufanelekileyo kunye negeyiji efanelekileyo yokwenza imveliso, kodwa iimpazamo ziyenzeka ngamanye amaxesha. Abaqhubi beefektri badla ngokubuyisela ububanzi bemicu emincinci kakhulu okanye emikhulu kakhulu, kodwa oku kuxhomekeke kwinqanaba elithile. Kubalulekile ukuqaphela ububanzi bemicu ye-slit.
Imeko yomphetho westrip nayo yeyona nto ibalulekileyo. Ukubonakaliswa komphetho okuzinzileyo, ngaphandle kwe-burrs okanye naluphi na olunye ukungalingani, kubalulekile ekugcineni ii-welds ezihambelanayo kubude bestrip, utshilo uMichael Strand, umongameli we-T&H Lemont. Ukujijeka kokuqala, ukunqumla kunye nokubuyela umva nako kuyadlala indima. Iikhoyili ezingaphathwanga ngononophelo zinokugoba, nto leyo eyingxaki. Inkqubo yokwenza eyenziwe ziinjineli ze-roll die iqala ngestrip esithe tyaba endaweni yestrip egobileyo.
Amanqaku eZixhobo. “Uyilo oluhle lwesikhunta luphucula imveliso,” utshilo uStan Green, umphathi jikelele we-SST Forming Roll Inc. Ubonisa ukuba akukho cebo linye lokwenza iityhubhu, kwaye ke ngoko akukho cebo linye lokwenza iisikhunta. Ababoneleli bezixhobo zeroli bayahluka kwindlela abazicubungula ngayo iityhubhu kunye neemveliso zabo. Iimveliso nazo ziyahluka.
“Irediyasi yomphezulu weroli itshintsha rhoqo, ngoko ke isantya sokujikeleza kwesixhobo siyatshintsha kumphezulu wesixhobo,” utshilo. Kakade ke, ityhubhu idlula kwisixhobo sokugawula ngesantya esinye kuphela. Ke ngoko, uyilo luchaphazela isivuno. Uyilo olubi luchitha izinto xa isixhobo sisitsha, kwaye luya lusiba lubi ngakumbi njengoko isixhobo siguga, wongezelela.
Kwiinkampani ezingalandeli indlela yoqeqesho nokugcinwa kwezityalo, ukuphuhlisa icebo lokuphucula ukusebenza kakuhle kwezityalo kuqala ngezinto ezisisiseko.
“Kungakhathaliseki ukuba uhlobo lomzi-mveliso kunye neemveliso ezenzayo, zonke iifektri zinezinto ezimbini ezifanayo—abaqhubi kunye neenkqubo zokusebenza,” utshilo uAbbey. Ukuqhuba umzi-mveliso rhoqo kangangoko kunokwenzeka ngumbandela wokubonelela ngoqeqesho oluqhelekileyo kunye nokulandela iinkqubo ezibhaliweyo, utshilo. Ukungangqinelani koqeqesho kunokukhokelela kumahluko ekusetweni nasekusombululeni iingxaki.
Ukuze ufumane okuninzi kwisityalo, ukusuka kumqhubi ukuya kumqhubi, i-shift ukuya kwi-shift, umqhubi ngamnye kufuneka asebenzise iinkqubo zokuseta ezihambelanayo kunye neenkqubo zokusombulula iingxaki. Naluphi na umahluko wenkqubo uhlala ubangelwa kukungaqondani, imikhwa emibi, iindlela ezimfutshane, kunye neendlela zokusombulula iingxaki. Ezi zinto zihlala zenza kube nzima ukuqhuba isityalo ngokufanelekileyo. Ezi ngxaki zinokukhuliswa ekhaya okanye zingeniswe xa abaqhubi abaqeqeshiweyo beqeshwa kubakhuphisana nabo, kodwa umthombo awubonisi mahluko. Ukungqinelana kubalulekile, kuquka nabaqhubi abanamava.
“Kuthatha iminyaka ukuqeqesha umqhubi we-tube mill, kwaye awunakuthembela kwisicwangciso esifanela wonke umntu,” utshilo uStrand. “Yonke inkampani ifuna inkqubo yoqeqesho ehambelana nomzi-mveliso wayo kunye nemisebenzi yayo.”
“Iindlela ezintathu zokusebenza kakuhle kukugcinwa koomatshini, ukugcinwa kwezinto ezisetyenziswayo kunye nokulinganiswa,” utshilo uDan Ventura, umongameli weVentura & Associates. “Umatshini unezinto ezininzi ezihambayo – nokuba yimatshini ngokwayo okanye izinto ezikwicala lokungena okanye lokuphuma, okanye itafile yokutshaya, okanye yintoni onayo – kwaye ukugcinwa rhoqo kubalulekile ukugcina umatshini ukwimeko entle.”
UStrand uyavuma. “Ukusebenzisa inkqubo yokujonga ulondolozo lokuthintela kulapho yonke into iqala khona,” utshilo. “Inika ithuba elihle lokuqhuba umzi-mveliso ngenzuzo. Ukuba umvelisi wemibhobho usabela kuphela kwiimeko ezingxamisekileyo, akalawuleki. Ixhomekeke kwingxaki elandelayo.”
“Zonke izixhobo ezikwifektri kufuneka zilungelelaniswe,” utshilo uVentura. “Kungenjalo, umzi-mveliso uza kuzilwela.”
“Kwiimeko ezininzi, xa imiqulu idlula ixesha layo lokusetyenziswa, isebenza nzima ize ekugqibeleni iqhekeke,” utshilo uVentura.
“Ukuba imiqulu ayigcinwanga ikwimeko entle ngokulungiswa rhoqo, ngoko ke kufuneka ilungiswe ngokukhawuleza,” utshilo uVentura. Ukuba izixhobo bezinganakwa, ukuzilungisa kuya kufuna ukususa izinto eziphindwe kabini ukuya kathathu ezifunekayo ukuba bazisuse, utshilo. Kuthatha ixesha elide kwaye kubiza ngaphezulu.
UStrand waphawula ukuba ukutyala imali kwizixhobo zokuncedisa kunokunceda ekuthinteleni iimeko ezingxamisekileyo. Ukuba esi sixhobo sisetyenziswa rhoqo ekusebenzeni ixesha elide, kuya kufuneka iindawo ezingaphezulu kunezo zingasetyenziswa rhoqo ekusebenzeni ixesha elifutshane. Umsebenzi wesixhobo ukwachaphazela inqanaba lokugcina. Iifins zinokuphuma kwisixhobo sefin kwaye ii-weld rolls zinokuchaphazeleka bubushushu bebhokisi ye-weld, imiba engaphazamisi ukwakheka kunye nobungakanani bee-rolls.
“Ukugcinwa rhoqo kulungele izixhobo, kwaye ukulungelelaniswa okufanelekileyo kulungile kwiimveliso ezizenzayo,” utshilo. Ukuba ezi azinakwa, abasebenzi bomzi-mveliso bachitha ixesha elininzi bezama ukulungisa loo nto. Eli xesha lingasetyenziselwa ukwenza iimveliso ezilungileyo nezithengiswa kakhulu. Ezi zinto zimbini zibaluleke kakhulu kwaye zihlala zinganakwa okanye zinganakwa kangangokuba, ngokombono kaVentura, zibonelela ngethuba elihle lokufumana okuninzi kwisityalo, ukwandisa isivuno kunye nokunciphisa inkunkuma.
IVentura ifanisa ukulungiswa kwemizila kunye nezinto ezisetyenziswayo kunye nokugcinwa kwemoto. Akukho mntu uza kuqhuba imoto kangangeekhilomitha ezininzi phakathi kokutshintshwa kweoyile ngamatayara angenanto. Oku kuya kukhokelela kwizisombululo ezibizayo okanye ekutshatyalalisweni, nokuba kwizityalo ezinganyangeki kakuhle.
Ukuhlolwa rhoqo kwesixhobo emva kokusetyenziswa ngakunye nako kuyimfuneko, utshilo. Izixhobo zokuhlola zinokutyhila iingxaki ezifana nokuqhekeka kwemigca emincinci. Umonakalo onjalo ufunyanwa kwangoko emva kokuba isixhobo sisusiwe kwindawo yokusila, endaweni yokuba sifakwe kwangoko ngaphambi kokuba isixhobo sisetyenziswe kwixesha elilandelayo, nto leyo enika ixesha elininzi lokwenza isixhobo esitsha.
“Ezinye iinkampani zisebenza ngexesha lokuvalwa okucwangcisiweyo,” utshilo uGreen. Wayesazi ukuba kuya kuba nzima ukuthobela ukuvalwa okucwangcisiweyo kule meko, kodwa wabonisa ukuba kuyingozi kakhulu. Iinkampani zokuthumela impahla kunye nezokuthutha impahla zixinene kakhulu okanye azinabasebenzi baneleyo, okanye zombini, kangangokuba ukuhanjiswa kwezinto akufikeleli ngexesha kule mihla.
“Ukuba kukho into ephukileyo kumzi-mveliso kwaye kufuneka u-odole enye entsha, uza kwenza ntoni ukuze iziswe?” wabuza. Ewe kona, ukuhanjiswa ngenqwelo moya kusoloko kuyindlela, kodwa kunokunyusa iindleko zokuthunyelwa.
Ukugcinwa kwe-mill kunye ne-roll kungaphezulu nje kokulandela ishedyuli yokugcinwa, kodwa kukulungelelanisa ishedyuli yokugcinwa kunye neshedyuli yemveliso.
Kuzo zontathu iindawo – imisebenzi, ukusombulula iingxaki kunye nokugcinwa kwazo, ububanzi kunye nobunzulu bamava bubalulekile. UWarren Wheatman, usekela-mongameli we-T&H Lemont's Die Business Unit, uthe iinkampani ezinemizila enye okanye ezimbini kuphela zokuvelisa iityhubhu zazo zihlala zinabantu abambalwa abazinikele ekugcinweni kwemizila kunye neefektri. Nangona abasebenzi bokugcinwa benolwazi, amasebe amancinci anamava amancinci kunamasebe amakhulu okugcinwa kwezinto, nto leyo ebeka abasebenzi abancinci kwimeko embi. Ukuba inkampani ayinalo isebe lobunjineli, isebe lokugcinwa kwezinto kufuneka lizenzele ukusombulula iingxaki kunye nokulungiswa kwazo.
UStrand wongeze ngelithi uqeqesho lwamasebe okusebenza nokugcinwa ngoku lubaluleke ngakumbi kunangaphambili. Ukwanda kwabantu abathatha umhlalaphantsi abanxulunyaniswa nokwaluphala kweentsana ezisandul’ ukuzalwa kuthetha ukuba ulwazi lwesizwe olwalukade lushukumisa iinkampani luyaphela. Nangona abavelisi abaninzi beetyhubhu besenokuxhomekeke kwingcebiso kunye neengcebiso zabathengisi bezixhobo, nobu buchule abuninzi njengoko babunjalo ngaphambili kwaye buyancipha.
Inkqubo yokuwelda ibaluleke njengayo nayiphi na enye inkqubo eyenzekayo xa kusenziwa umbhobho okanye umbhobho, kwaye indima yomatshini wokuwelda ayinakugqithiswa.
Ukuwelda ngokunyusa. “Namhlanje, malunga nesibini kwisithathu see-odolo zethu zezokulungiswa kwakhona,” utshilo uPrasek. “Zihlala zithatha indawo yabawelda abadala, abaneengxaki. Ukuphuma kwe-throughput yeyona nto iphambili ngoku.”
Uthe uninzi lwabo lusemva kweenjongo ezisibhozo kuba izinto eziluhlaza zifike emva kwexesha. “Ngokwesiqhelo xa izinto ziphuma ekugqibeleni, umthungi uyawa,” utshilo. Inani elimangalisayo labavelisi beetyhubhu basebenzisa oomatshini abasekelwe kubuchwepheshe beetyhubhu zevacuum, oko kuthetha ukuba basebenzisa oomatshini abaneminyaka engama-30 ubudala ukunyamekela. Ulwazi lwenkonzo koomatshini abanjalo alubanzi, kwaye iityhubhu ezitshintshayo ngokwazo kunzima ukuzifumana.
Umceli mngeni kubavelisi beepayipi abasasebenzisayo kukuba zikhula njani. Azisileli ngendlela eyingozi, kodwa ziwohloka kancinci. Esinye isisombululo kukusebenzisa ubushushu obuncinci bokuwelda kunye nokusebenzisa umzi-mveliso ngesantya esiphantsi ukuze kulungiswe, nto leyo enokuthi iphephe ngokulula imali echithwa kutyalo-mali kumatshini omtsha. Oku kudala ingcamango ephosakeleyo yokuba yonke into ilungile.
Utyalo-mali kumthombo omtsha wamandla okufakelwa kwe-induction welding lunokunciphisa kakhulu ukusetyenziswa kombane kwesi sityalo, utshilo uPrasek. Amanye amazwe—ingakumbi lawo anabantu abaninzi kunye neegridi ezixineneyo—abonelela ngezaphulelo zerhafu ezinkulu xa kuthengwa izixhobo ezisebenzisa umbane kakuhle. Esinye isizathu sokutyala imali kwiimveliso ezintsha kukuba amathuba emveliso emitsha anokubakho, wongezelela.
“Ngokwesiqhelo, iyunithi entsha yokuwelda isebenza kakuhle kakhulu kunendala, kwaye ingonga amawaka eedola ngokubonelela ngomthamo ongaphezulu wokuwelda ngaphandle kokuphucula inkonzo yombane,” utshilo uPrasek.
Ukulungelelaniswa kwekhoyili yokungenisa kunye ne-resistor nako kubalulekile. UJohn Holderman, umphathi jikelele we-EHE Consumables, uthi ikhoyili yokungenisa ekhethiweyo nefakelweyo inendawo efanelekileyo xa kuthelekiswa neroli yokuhambisa, kwaye kufuneka igcine indawo efanelekileyo nehambelanayo ejikeleze ityhubhu. Ukuba icwangciswe ngendlela engalunganga, ikhoyili iya kusilela ngaphambi kwexesha.
Umsebenzi wesithinteli ulula – sithintela ukuhamba kombane, siwuqondise kumphetho wesithinteli – kwaye njengayo yonke into ekwisitshili, ukubeka indawo kubaluleke kakhulu, utsho. Indawo echanekileyo ikwincopho yentsimbi, kodwa ayisiyonto yodwa ekufuneka iqwalaselwe. Ukufakela kubaluleke kakhulu. Ukuba ibotshelelwe kwi-mandrel engaqinanga ngokwaneleyo ukuyixhasa, indawo yesithinteli inokutshintsha, itsala i-ID ezantsi kwetyhubhu.
Ukusebenzisa iindlela ezithandwayo zoyilo olusetyenziswayo lokuwelda, ingcamango ye-split coil inokuba nefuthe elikhulu kwixesha lokusebenza kwe-mill.
“Iifektri ezinkulu ezinobubanzi obude bezisoloko zisebenzisa uyilo lweekhoyili eziqhekekileyo,” utshilo uHaldeman. “Ukutshintsha iqhekeza elinye lekhoyili yokungenisa kufuna ukusika umbhobho, ukutshintsha ikhoyili kunye nokuyiphinda uyifake umsonto,” utshilo. Uyilo lwekhoyili eqhekekileyo luza ngamacandelo amabini, nto leyo ekongela lonke ixesha lakho kunye nomzamo wakho.
“Ziye zasetyenziswa kwiifektri ezinkulu zokuqengqeleka, kodwa kuthathe ubunjineli obuphambili ukusebenzisa lo mgaqo kwiikhoyili ezincinci,” utshilo. “Imisebenzi embalwa kakhulu kumenzi.” Iikhoyili ezincinci ezineziqwenga ezimbini zinezixhobo ezikhethekileyo kunye nee-clamps ezenziwe ngobuchule,” utshilo.
Ngokuphathelele inkqubo yokupholisa ye-blocker, abavelisi beepayipi baneendlela ezimbini zemveli: inkqubo yokupholisa ephakathi kumzi-mveliso okanye inkqubo yamanzi eyahlukileyo, enokuba nexabiso eliphantsi.
“Kungcono ukupholisa i-resistor nge-coolant ecocekileyo,” utshilo uHolderman. Ngenxa yesi sizathu, utyalo-mali oluncinci kwinkqubo yokucoca i-choke eyenzelwe ukupholisa i-mill lunokwandisa kakhulu ubomi be-choke.
Isixhobo sokupholisa umatshini sidla ngokusetyenziswa kwi-choke, kodwa isixhobo sokupholisa umatshini siqokelela ii-fines zesinyithi. Nangona bezama yonke into yokubamba ii-fines kwisihluzo esiphakathi okanye ukuzibamba ngenkqubo yemagnethi ephakathi, abanye abantu bayadlula baze bafumane indlela eya kwindawo ethintelayo. Asikuko oku indawo yee-powders zesinyithi.
“Ziyafudumala kwindawo yokungenisa umoya zize zizitshise zingene kwindawo yokumelana nomoya kunye ne-ferrite, nto leyo ebangela ukungaphumeleli kwangethuba ize ivale ukuze kuthathelwe indawo i-resistor,” utshilo uHolderman. “Zikwakhula nakwii-coil zokungenisa umoya kwaye ekugqibeleni zibangele umonakalo ngenxa yokungqubana apho.”