Cishe yonke inqubo yokuhlanganisa ingenziwa ngezindlela eziningana. Inketho ekhethwa umenzi noma umhlanganisi ukuze athole imiphumela emihle kakhulu ivame ukuba yileyo efanisa ubuchwepheshe obuqinisekisiwe nohlelo lokusebenza oluthile.
Ukushisisa kungenye yenqubo enjalo. Ukushisisa kuyinqubo yokuhlanganisa insimbi lapho izingxenye ezimbili noma ngaphezulu zensimbi zihlanganiswa khona ngokuncibilikisa insimbi yokushisisa bese igeleza iye ejoyintini. Insimbi yokushisisa inephuzu lokuncibilika eliphansi kunezingxenye zensimbi eziseduze.
Ukushisa kokushiswa kunganikezwa ngamathoshi, izitofu noma amakhoyili okufakwa. Ngesikhathi sokushiswa kokufakwa, ikhoyili yokufakwa idala insimu yamagnetic efudumeza i-substrate ukuze incibilikise insimbi yokugcwalisa. Ukushiswa kokufakwa kokufakwa kubonakala kuyindlela engcono kakhulu yenani elikhulayo lezicelo zokuhlanganisa.
“Ukushiswa kwe-induction kuphephile kakhulu kunokushiswa kwethoshi, kushesha kakhulu kunokushiswa kwe-furnace, futhi kuyaphindaphindeka ngaphezu kwakho kokubili,” kusho uSteve Anderson, umphathi wesayensi yensimu kanye nokuhlolwa kwa-Fusion Inc., i-integrator eneminyaka engu-88 ubudala eWilloughby, e-Ohio Said, ugxile ezindleleni ezahlukene zokuhlanganisa, okuhlanganisa nokushiswa kwe-induction.” Ngaphezu kwalokho, ukushiswa kwe-induction kulula. Uma kuqhathaniswa nezinye izindlela ezimbili, okudingayo ngempela ugesi ojwayelekile.”
Eminyakeni embalwa edlule, i-Fusion yasungula umshini ozenzakalelayo ngokuphelele oneziteshi eziyisithupha wokuhlanganisa ama-carbide burrs ayi-10 okusebenza ngensimbi nokwenza amathuluzi. Ama-burrs enziwa ngokunamathisela ama-tungsten carbide blanks asindilinga nayi-conical e-shank yensimbi. Izinga lokukhiqiza liyizingxenye ezingu-250 ngehora, kanti ithreyi yezingxenye ezihlukene ingaphatha ama-blanks angu-144 kanye nezibambi zamathuluzi.
“Irobhothi le-SCARA elinama-axis amane lithatha isibambo kuthreyi, lisinikeze umshini wokunamathisela i-solder paste, bese lisifaka esidlekeni se-gripper,” kuchaza u-Anderson. “Irobhothi libe selithatha ingxenye engenalutho kuthreyi bese liyibeka ekugcineni kwe-shank lapho inamathiselwe khona. I-induction brazing yenziwa kusetshenziswa ikhoyili kagesi egoqa ngokuqondile izingxenye ezimbili bese iletha insimbi yesiliva ekushiseni kwe-liquidus okungu-1,305 F. Ngemva kokuba ingxenye ye-burr iqondaniswe futhi ipholisiwe, ikhishwa nge-discharge chute bese iqoqwa ukuze icutshungulwe kabanzi.”
Ukusetshenziswa kwe-induction brazing ekuhlanganiseni kuyanda, ikakhulukazi ngoba kudala ukuxhumana okuqinile phakathi kwezingxenye ezimbili zensimbi futhi ngoba kusebenza kahle kakhulu ekuhlanganiseni izinto ezingafani. Izinkinga zemvelo, ubuchwepheshe obuthuthukisiwe, kanye nezinhlelo zokusebenza ezingezona ezendabuko nazo ziphoqa onjiniyela bokukhiqiza ukuthi bahlolisise i-induction brazing.
Ukushiswa kwe-induction bekulokhu kukhona kusukela ngawo-1950, yize umqondo wokushiswa kwe-induction (kusetshenziswa i-electromagnetism) watholakala eminyakeni engaphezu kwekhulu ngaphambili ngusosayensi waseBrithani uMichael Faraday. Izibani zesandla zaziwumthombo wokuqala wokushisa we-induction, kwalandela izitofu ngawo-1920. Ngesikhathi seMpi Yezwe II, izindlela ezisekelwe esithandweni zazivame ukusetshenziswa ukukhiqiza izingxenye eziningi zensimbi ngobuningi babasebenzi kanye nezindleko ezincane.
Isidingo sabathengi se-air conditioner ngawo-1960 nawo-1970 sakha izinhlelo zokusebenza ezintsha ze-induction brazing. Eqinisweni, i-aluminium mass brazing ngasekupheleni kwawo-1970 yabangela izingxenye eziningi ezitholakala ezinhlelweni ze-air conditioner zezimoto zanamuhla.
“Ngokungafani nokushisa kwethoshi, ukushisa kwe-induction akuthinteki futhi kunciphisa ingozi yokushisa ngokweqile,” kuphawula uRick Bausch, umphathi wezokuthengisa we-Ambrell Corp., ku-TEST.temperature.”
Ngokusho kukaGreg Holland, umphathi wezokuthengisa nokusebenza kwa-eldec LLC, uhlelo olujwayelekile lwe-induction brazing luqukethe izingxenye ezintathu. Lezi yi-power supply, ikhanda lokusebenza eline-induction coil kanye ne-cooler noma uhlelo lokupholisa.
Ugesi uxhunywe ekhanda lomsebenzi futhi amakhoyili aklanyelwe ngokwezifiso ukulingana eduze kwejoyinti. Ama-inductor angenziwa ngezinduku eziqinile, izintambo eziguquguqukayo, ama-billet akhiwe ngomshini, noma aphrintiwe nge-3D kusuka kuma-alloy ethusi aphuciwe. Nokho, ngokuvamile, enziwa ngamapayipi ethusi angenalutho, lapho amanzi ageleza khona ngezizathu eziningana. Esinye iwukugcina ikhoyili ipholile ngokulwa nokushisa okubonakaliswa yizingxenye ngesikhathi senqubo yokubhoboza. Amanzi agelezayo avimbela nokwakheka kokushisa kumakhoyili ngenxa yokuba khona njalo kwamandla ashintshanayo kanye nokudluliselwa kokushisa okuphumelelayo okubangelwa yilokhu.
“Ngezinye izikhathi i-flux concentrator ifakwa ku-coil ukuze kuqiniswe insimu yamagnetic endaweni eyodwa noma ngaphezulu endaweni yokuhlangana,” kuchaza uHolland. “Ama-concentrator anjalo angaba uhlobo lwe-laminate, oluqukethe izinsimbi zikagesi ezincane ezihlanganiswe ndawonye, ​​noma amashubhu e-ferromagnetic aqukethe izinto ze-ferromagnetic eziphuphuthekile kanye nezibopho ze-dielectric ezicindezelwe ngaphansi kwengcindezi ephezulu. Sebenzisa noma yikuphi Inzuzo ye-concentrator ukuthi inciphisa isikhathi sokujikeleza ngokuletha amandla engeziwe ezindaweni ezithile zejoyinti ngokushesha, kuyilapho igcina ezinye izindawo zipholile.”
Ngaphambi kokubeka izingxenye zensimbi ze-induction brazing, umqhubi udinga ukusetha kahle amazinga emvamisa kanye namandla esistimu. Imvamisa ingaba phakathi kuka-5 no-500 kHz, uma imvamisa iphakeme, kulapho ubuso bushisa khona ngokushesha.
Izinsiza zikagesi zivame ukukwazi ukukhiqiza amakhulu ama-kilowatts kagesi. Kodwa-ke, ukufaka ingxenye engangesundu ngemizuzwana eyi-10 kuya kweyi-15 kudinga ama-kilowatts ayi-1 kuya kwayi-5 kuphela. Uma kuqhathaniswa, izingxenye ezinkulu zingadinga ama-kilowatts angama-50 kuya kwayi-100 amandla futhi kuthathe imizuzu emi-5 ukuyifaka.
“Njengomthetho ojwayelekile, izingxenye ezincane zisebenzisa amandla amancane, kodwa zidinga imvamisa ephezulu, njenge-100 kuya ku-300 kilohertz,” kusho uBausch. “Ngokuphambene nalokho, izingxenye ezinkulu zidinga amandla amaningi kanye nemvamisa ephansi, ngokuvamile engaphansi kwe-100 kilohertz.”
Kungakhathaliseki ukuthi zingakanani, izingxenye zensimbi zidinga ukufakwa kahle ngaphambi kokuba ziboshwe. Kufanele kuqashelwe ukuthi kugcinwe isikhala esiqinile phakathi kwezinsimbi eziyisisekelo ukuze kuvunyelwe ukusebenza kahle kwe-capillary ngensimbi egelezayo. Amajoyinti e-Butt, lap kanye ne-butt lap ayindlela engcono kakhulu yokuqinisekisa lokhu kuvuleka.
Izinto zendabuko noma ezizilungisa ngokwazo ziyamukeleka. Izinto ezijwayelekile kufanele zenziwe ngezinto ezingadingi ugesi kakhulu njengensimbi engagqwali noma i-ceramic, futhi zithinte izingxenye kancane ngangokunokwenzeka.
Ngokuklama izingxenye ezinezithungo ezixhumene, ukugoba, ukugoba noma ama-knurls, ukuzilungisa kungafinyelelwa ngaphandle kwesidingo sokusekelwa ngomshini.
Amajoyinti abe esehlanzwa nge-emery pad noma i-solvent ukuze kususwe ukungcola okufana namafutha, amafutha, ukugqwala, isikali kanye nokungcola. Lesi sinyathelo sithuthukisa kakhulu ukusebenza kwe-capillary kwensimbi encibilikisiwe edonsa ngokwayo ezindaweni eziseduze kwejoyinti.
Ngemva kokuba izingxenye sezihlanzwe kahle futhi zahlanzwa, umqhubi ufaka inhlanganisela ehlangene (ngokuvamile i-paste) engxubeni. Inhlanganisela iyinhlanganisela yensimbi yokugcwalisa, i-flux (ukuvimbela i-oxidation) kanye ne-binder ebamba insimbi bese ixubana ndawonye ngaphambi kokuncibilika.
Izinsimbi zokugcwalisa kanye nama-flux asetshenziswa ekushiseni aklanyelwe ukumelana namazinga okushisa aphezulu kunalawo asetshenziswa ekushiseni. Izinsimbi zokugcwalisa ezisetshenziswa ekushiseni ziyancibilika emazingeni okushisa okungenani angu-842 F futhi ziqine kakhulu uma zipholile. Zihlanganisa i-aluminium-silicon, ithusi, ithusi-isiliva, ithusi, ithusi, igolide-isiliva, isiliva, kanye nama-alloy e-nickel.
Umqhubi ube esebeka ikhoyili yokungenisa, eza ngemiklamo eyahlukahlukene. Amakhoyili e-Helical ayindilinga noma ayindilinga futhi azungeze ingxenye ngokuphelele, kuyilapho amakhoyili efoloko (noma ama-pincer) etholakala ohlangothini ngalunye lwejoyinti futhi amakhoyili esiteshi axhumeka engxenyeni. Amanye amakhoyili afaka phakathi i-Inner Diameter (ID), i-ID/Outer Diameter (OD), i-Pancake, i-Open, kanye ne-Multi-Position.
Ukushisa okufanayo kubalulekile ekuxhumeni okune-brashed okusezingeni eliphezulu. Ukuze enze lokhu, umqhubi udinga ukuqinisekisa ukuthi ibanga eliqondile phakathi kwe-induction coil loop ngayinye lincane nokuthi ibanga lokuxhuma (ububanzi besikhala kusuka ku-coil OD kuya ku-ID) lihlala lifana.
Okulandelayo, umqhubi uvula amandla ukuze aqale inqubo yokushisa ijoyinti. Lokhu kuhilela ukudlulisa ngokushesha ugesi oshintshashintshayo ophakathi noma ophezulu kusuka emthonjeni wamandla uye ku-inductor ukuze kudalwe insimu kazibuthe eshintshashintshayo ezungezile.
Insimu yamagnetic ibangela ugesi ebusweni bejoyinti, okukhiqiza ukushisa okuncibilikisa insimbi yokugcwalisa, okuvumela ukuthi igeleze futhi imanzise ubuso bengxenye yensimbi, okudala isibopho esiqinile. Kusetshenziswa amakhoyili anezikhundla eziningi, le nqubo ingenziwa ezingxenyeni eziningi ngasikhathi sinye.
Kunconywa ukuhlanza nokuhlola kokugcina kwengxenye ngayinye efakwe i-brass. Ukugeza izingxenye ngamanzi afudumele okungenani ku-120 F kuzosusa izinsalela ze-flux kanye nanoma yisiphi isikali esakhiwe ngesikhathi se-brass. Ingxenye kufanele ifakwe emanzini ngemva kokuba insimbi yokugcwalisa isiqinile kodwa inhlanganisela isashisa.
Kuye ngengxenye, ukuhlolwa okuncane kungalandelwa ukuhlolwa okungabhubhisi nokubhubhisayo. Izindlela ze-NDT zifaka phakathi ukuhlolwa okubonakalayo kanye ne-radiographic, kanye nokuhlolwa kokuvuza nokufaka ubufakazi. Izindlela ezivamile zokuhlola okubhubhisayo yi-metallographic, i-peel, i-tensile, i-shear, i-fatigue, i-transfer, kanye ne-torsion testing.
“Ukufaka i-induction brazing kudinga ukutshalwa kwezimali okukhulu kusengaphambili kunendlela yethoshi, kodwa kuyafaneleka ngoba uthola ukusebenza kahle nokulawula okwengeziwe,” kusho uHolland. “Nge-induction, uma udinga ukushisa, umane ucindezele. Uma ungakudingi, ucindezela.”
I-Eldec ikhiqiza imithombo eminingi yamandla yokufakelwa kwe-induction brazing, njengomugqa wemvamisa ephakathi we-ECO LINE MF, otholakala ngezindlela ezahlukahlukene ukuze uvumelane kahle nohlelo ngalunye. Lezi zinto zamandla zitholakala ngezilinganiso zamandla ezisukela ku-5 kuya ku-150 kW kanye namaza asukela ku-8 kuya ku-40 Hz. Wonke amamodeli angafakelwa isici sokukhulisa amandla esivumela umqhubi ukuthi andise isilinganiso somsebenzi oqhubekayo esingu-100% ngo-50% owengeziwe kungakapheli imizuzu emi-3. Ezinye izici ezibalulekile zifaka phakathi ukulawulwa kokushisa kwe-pyrometer, irekhoda yokushisa kanye neswishi yamandla ye-bipolar transistor efakwe i-insulated gate. Lezi zinto ezisetshenziswayo azidingi ukulungiswa okuningi, zisebenza buthule, zinezinyathelo ezincane, futhi zihlanganiswa kalula nezilawuli ze-workcell.
Abakhiqizi ezimbonini eziningana basebenzisa kakhulu i-induction brazing ukuhlanganisa izingxenye. I-Bausch ikhomba abakhiqizi bezimoto, izindiza, imishini yezokwelapha kanye nemishini yezimayini njengabasebenzisi abakhulu bemishini ye-Ambrell induction brazing.
“Inani lezingxenye ze-aluminium ezifakwe i-induction braze embonini yezimoto liyaqhubeka nokukhula ngenxa yezinhlelo zokunciphisa isisindo,” kusho uBausch. “Emkhakheni wezindiza, i-nickel nezinye izinhlobo zama-wear pad zivame ukufakwa i-braze kuma-jet blades. Zombili lezi zimboni nazo zisebenzisa i-induction braze fittings ehlukahlukene yensimbi.”
Zonke izinhlelo eziyisithupha ze-Ambrell's EasyHeat zinebanga lemvamisa elisukela ku-150 kuya ku-400 kHz futhi zilungele ukufakwa kwe-induction brazing kwezingxenye ezincane zejiyometri ezahlukahlukene. Ama-compact (0112 kanye no-0224) anikeza ukulawula kwamandla ngaphakathi kwesisombululo sama-watts angu-25; amamodeli ochungechungeni lwe-LI (3542, 5060, 7590, 8310) anikeza ukulawula ngaphakathi kwesisombululo sama-watts angu-50.
Zombili lezi chungechunge zinekhanda lomsebenzi elisuswayo elifinyelela kumamitha ayi-10 ukusuka emthonjeni wamandla. Izilawuli zephaneli yangaphambili zesistimu zingahlelwa, okuvumela umsebenzisi wokugcina ukuthi achaze amaphrofayili okushisa afinyelela kwamane ahlukene, ngalinye linezinyathelo zesikhathi ezifika kwezinhlanu namandla. Ukulawula amandla okude kuyatholakala ukuze kufakwe oxhumana naye noma i-analog, noma i-port yedatha ye-serial ongayikhetha.
“Amakhasimende ethu amakhulu okufaka i-induction brazing ngabakhiqizi bezingxenye eziqukethe ikhabhoni ethile, noma izingxenye ezinkulu eziqukethe iphesenti eliphezulu lensimbi,” kuchaza uRich Cukelj, uMphathi Wokuthuthukiswa Kwebhizinisi le-Fusion.” Ezinye zalezi zinkampani zikhonza izimboni zezimoto nezindiza, kanti ezinye zenza izibhamu, zisika amathuluzi okuhlanganisa, ompompi bamapayipi kanye namapayipi okuhambisa amanzi, noma amabhlogo okusabalalisa ugesi kanye nama-fuse.”
I-Fusion ithengisa izinhlelo ezijikelezayo ezenziwe ngokwezifiso ezingabamba izingxenye eziyi-100 kuya kweziyi-1,000 ngehora. Ngokusho kukaCukelj, kungenzeka ukuthi kube nokukhiqiza okuphezulu kohlobo olulodwa lwengxenye noma uchungechunge oluthile lwezingxenye. Lezi zingxenye zisukela ngobukhulu obungamasentimitha angu-2 kuya kwangu-14.
“Uhlelo ngalunye luqukethe inkomba evela ku-Stelron Components Inc. enezindawo zokusebenza ezingu-8, 10 noma 12,” kuchaza uCukelj. “Ezinye izindawo zokusebenza zisetshenziselwa ukubhula, kanti ezinye zisetshenziselwa ukuhlola, ukusebenzisa amakhamera okubona noma imishini yokulinganisa nge-laser, noma ukwenza izivivinyo zokudonsa ukuqinisekisa ukuthi amalunga abhula asezingeni eliphezulu.”
Abakhiqizi basebenzisa izinsiza zikagesi ze-ECO LINE ezijwayelekile ze-eldec ezinhlotsheni ezahlukene zezicelo ze-induction brazing, njenge-shrink-fitting rotors kanye ne-shafts, noma ukujoyina ama-motor housings, kusho uHolland. Muva nje, imodeli engu-100 kW yale generator isetshenziswe ekusetshenzisweni kwezingxenye ezinkulu okuhilela ukufaka i-brazing rings yesekethe yethusi kuya ekuxhumekeni kwempompi yethusi kuma-generator edamu lamanzi.
I-Eldec iphinde ikhiqize izinsiza zikagesi ze-MiniMICO eziphathekayo ezingathuthwa kalula embonini ngebanga lemvamisa eliyi-10 kuya ku-25 kHz. Eminyakeni emibili edlule, umkhiqizi wamashubhu okushintshanisa ukushisa kwezimoto wasebenzisa i-MiniMICO ukuze abuyisele izingqiniba eshubhini ngalinye. Umuntu oyedwa wenza konke lokhu, futhi kwathatha imizuzwana engaphansi kwengu-30 ukuhlanganisa ishubhu ngalinye.
UJim ungumhleli omkhulu e-ASSEMBLY onolwazi lokuhlela iminyaka engaphezu kwengu-30. Ngaphambi kokujoyina i-ASSEMBLY, uCamillo wayenguNjiniyela we-PM, umhleli we-Association for Equipment Engineering Journal kanye ne-Milling Journal. UJim uneziqu zesiNgisi eDePaul University.
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I-Lean Six Sigma ibilokhu iqhuba imizamo yokuthuthukisa eqhubekayo amashumi eminyaka, kodwa ukushiyeka kwayo sekusobala. Ukuqoqwa kwedatha kudinga umsebenzi omningi futhi kungabamba amasampula amancane kuphela. Idatha manje ingabanjwa isikhathi eside futhi ezindaweni eziningi ngentengo encane kunezindlela ezindala zesandla.
Amarobhothi ashibhile futhi kulula ukuwasebenzisa kunanini ngaphambili. Lobu buchwepheshe butholakala kalula ngisho nakubakhiqizi abancane nabaphakathi. Lalela le ngxoxo ekhethekile yephaneli equkethe abaphathi abavela kubahlinzeki abane abaphezulu bamarobhothi eMelika: i-ATI Industrial Automation, i-Epson Robots, i-FANUC America, kanye ne-Universal Robots.