TL;DR —Masana'antun kayan lantarki na Japan suna yin odar sandunan bakin karfe masu sanyi daga China don ma'aunin ma'aunin bazara da ma'aunin tambari na tashar haɗawa suna tilasta duba girma da ƙarfe guda biyar waɗanda suka wuce ƙa'idodin ASTM A240 ko JIS G 4305. ƙin yarda da rukuni da na gani daga ƙungiyoyin QA na Japan a matakin dubawa mai zuwa shine daidaiton tauri - tsiri na 1/4H da aka ƙayyade a HV 250–310 bai kamata ya sami faɗaɗa fiye da ±15 HV a tsawon ma'aunin ba (ana ɗaukar yaduwar HV 60 ta yau da kullun da faɗi sosai ga maɓuɓɓugar hulɗa ta ƙarshe wanda ke buƙatar maimaita ƙarfin da aka riga aka ɗora na ±5%). Tsananin saman dole ne ya kasance ƙasa da Ra 0.5 μm a gefen ma'aunin ma'aunin, kuma haƙurin kauri dole ne a riƙe shi zuwa ±0.03 mm don ma'aunin suna na 0.3 mm - bambancin kauri na 0.05 mm yana haifar da bambancin 0.3 mm a cikin tsayin da aka samar na maɓuɓɓugar bazara, wanda ke canza matsin lamba da 1.2–1.5 N daga ƙimar da aka ƙayyade. Wannan labarin ya ƙunshi sigogi guda biyar na dubawa waɗanda ke da mahimmanci lokacin da kamfanin OEM na kayan lantarki na Japan ya sanya odar maimaitawa don tsiri na bakin karfe mai sanyi.

Masana'antar haɗa kaya da masana'antar tashar jiragen ruwa ta Japan - kamar JAE (Japan Aviation Electronics), Hirose Electric, da kuma sashen kayan lantarki na Yazaki - suna cinye dubban tan na bakin karfe mai kama da na'urar sanyaya sanyi a kowace shekara don abubuwan da aka buga: madaurin bazara wanda ke riƙe rabin mahaɗin haɗin (yawanci kauri 0.2–0.4 mm, zafi 1/2H, matakin 301 ko 304), da kuma sigina ko tashoshin wutar lantarki mai kauri 0.15–0.30 mm a cikin zafin 1/4H. Madaurin ya shiga madaurin buga kaya a 50–200 m/min, yana samar da tashoshi 50,000–200,000 a kowace awa ta hanyar injin bugawa mai ci gaba tare da buƙatun haƙuri da aka auna a cikin micrometers. Ana mayar da madaurin da ya gaza binciken da ake yi a masana'antar kayan lantarki ta Japan ga mai samar da kaya akan farashin mai samarwa, tare da da'awar dakatar da layin samarwa na ¥200,000–¥500,000 a kowace awa don injin buga kaya mara aiki. Muna samar da tsiri mai bakin karfe mai sanyi zuwa wannan kasuwa, kuma wannan labarin ya ƙunshi bincike guda biyar da injiniyan QA na Japan ke yi akan kowace na'ura mai shigowa. Don samfuranmu na na'urar ...Shafin samfurin bakin karfe mai sanyiDomin samun damar aiwatarwa a fannin kera tsiri mai daidaito, ziyarcidaidaici bakin karfe tsiri category.

Daidaito Mai Tauri — Me Yasa ±15 HV Yake Da Muhimmanci Ga Magudanar Ruwa

Masana'antun kayan lantarki na Japan sun ƙayyade yanayin tsiri na bakin karfe mai naɗewa mai sanyi bisa ga ma'auni guda biyu da ke aiki a layi ɗaya: JIS G 4313 (tsinri na bakin karfe mai naɗewa mai sanyi don maɓuɓɓuga) da kuma ƙayyadaddun ASTM A240/A480 don daidaitattun yanayin zafi. Ga tsiri na 1/4H a cikin bakin karfe 304, kewayon tauri ga kowace JIS G 4313 shine HV 250–310 (faɗin maki 60). Ga tsiri na 1/2H a cikin bakin karfe 301, kewayon shine HV 310–370 (kuma maki 60). Ma'aunin shinekewayon tauri don samar da injin niƙa— yana rufe bambancin tsari na yau da kullun na zafin wutar lantarki mai rage zafi (±10°C a fadin faɗin tsiri a cikin tanda mai ci gaba da rage zafi) da kuma bambancin rage sanyi (±2% a cikin wucewa ta ƙarshe a injin niƙa na Sendzimir). Amma ga masana'antar tashar jiragen ruwa ta Japan, yaduwar tauri mai maki 60 ya yi faɗi sosai ga tashar jiragen ruwa wacce dole ne ta samar da ƙarfin hulɗa mai daidaito a kan tambarin 500,000.

Ƙarfin hulɗar tashar maɓalli ta bazara ya yi daidai da ƙarfin yawan tsiri a radius ɗin lanƙwasa da aka yi. Ga wani maɓalli mai kauri 0.3 mm 1/2H 301 bakin ƙarfe mai lanƙwasa a radius na ciki na 0.3 mm (rabo na R/t = 1.0 - lanƙwasa mai ƙarfi don maɓalli), kusurwar maɓalli tana canzawa da 0.5° ga kowane 10 HV ƙaruwa a cikin taurin tsiri. Bambancin HV na 60 a kan maɓalli yana nufin kusurwar maɓalli ta bambanta da 3° - tsayin da ba shi da maɓalli ya bambanta da 0.2 mm a kan maɓalli, kuma ƙarfin haɗuwa yana canzawa daga ƙayyadadden N 8 zuwa tsakanin 6.5 N da 9.5 N. Abokin ciniki na Japan ya ƙi duk wani tsari inda taurin ya bambanta da fiye da ±15 HV a kan maɓalli (tagar maki 30). Mun cika wannan buƙata ta hanyar sarrafa injin niƙa mai birgima a raguwar sarrafawa a kowane wucewa da kuma ɗaukar samfurin taurin a wurare biyar (gefen hagu, kwata na hagu, tsakiya, kwata na dama, gefen dama) akan kowane maɓalli a cikin rukuni, muna rikodin karkacewar da aka saba. Idan daidaitaccen karkacewar ya wuce 8 HV, za a rage na'urar zuwa aikace-aikacen da ba daidai ba. Ana nuna kewayon samfurin tsiri mai sanyi a kanshafin tsiri mai sanyi.

Taushin Sama — Ra 0.5 μm don Daidaitowar Juriya ga Hulɗa

Rashin ƙarfin saman tsiri mai sanyi da aka naɗe a gefen taɓawa na tashar yana ƙayyade ainihin yankin taɓawa tsakanin tashar da fil ɗin haɗuwa. Tashar da ke ɗauke da 3 A na siginar lantarki tare da juriyar hulɗa na 20 mΩ tana buƙatar ainihin yankin taɓawa na akalla 0.01 mm² a ƙarfin taɓawa na musamman (8 N). Idan ƙarfin saman tsiri shine Ra 1.0 μm maimakon Ra 0.5 μm, rashin ƙarfin (kololuwa) a saman ya fi tsayi da 0.5 μm - nakasar filastik na waɗannan asperities a ƙarƙashin ƙarfin hulɗa yana ƙirƙirar ainihin yankin taɓawa wanda ya fi ƙanƙanta da 30-40%, yana tura juriyar hulɗa daga 20 mΩ zuwa 30-35 mΩ. A 3 A, wargajewar wutar lantarki a wurin hulɗa (I²R = 9 × 0.035 = 0.315 W) a cikin gidan haɗin da aka iyakance ba tare da iska ba yana haifar da hauhawar zafin jiki na gida na 15-25°C sama da yanayi. A cikin injin mota mai haɗin 60, zafi mai tarin yawa yana rage yanayin bazara na tashar - matsin lamba na ƙarfe mai nauyin 1/2H yana sassautawa da kashi 10–15% a 100°C sama da awanni 3,000, yana rage ƙarfin hulɗa da ƙara juriyar hulɗa a cikin zagayowar gazawar da ke ƙarfafa kai.

Rashin ƙarfin saman tsiri ya dogara da abubuwa huɗu: kammala saman aikin mirgina (ƙarshen ƙasa Ra 0.1 μm don wucewa ta ƙarshe), tsaftar mai mai birgima (tsarin matattarar 5 μm wanda ke hana barbashi masu tauri shiga saman tsiri), tashin hankalin tsiri a lokacin wucewa ta ƙarshe (wanda aka kiyaye a cikin ±3% na wurin da aka saita ta hanyar sarrafa ƙarfin juyi na madauri mai rufewa), da kuma yanayin tanderu mai cike da annealing (yanayin rage hydrogen-nitrogen a 1,050°C don maki 304 da 301 yana hana hazo da iskar carbonide a saman). Muna auna tsauraran saman a wurare uku a faɗin faɗin tsiri akan kowane na'ura ta amfani da ma'aunin lamba bisa ga ISO 25178. Ra na yau da kullun shine 0.35-0.45 μm a gefen haske da 0.45-0.55 μm a gefen matte - abokin ciniki yana zaɓar gefen don saman hulɗa. Don iya samar da tsari mai tauri, dubaShafin samfurin tsiri mai tauri mai tauri.

Juriyar Kauri — ±0.03 mm Yana Sarrafa Tsayin Lanƙwasa na Lanƙwasa

An ƙayyade juriyar kauri a cikin tsararren tsiri mai sanyi bisa ga ASTM A480 a matsayin ±10% na ma'aunin da aka ƙayyade don faɗi har zuwa mm 600. Ga kauri mai girman mm 0.30, wannan shine ±0.030 mm. Masana'antun kayan lantarki na Japan suma suna tilasta wannan haƙurin, amma suna kuma auna bambancin kauri a faɗin faɗin tsiri (bayanin kambi) da kuma tare da tsawon tsiri (bambancin ma'aunin ma'auni). Kambin - bambancin kauri tsakanin tsakiyar tsiri da gefen tsiri - bai kamata ya wuce 0.010 mm ba don faɗin tsiri mai girman mm 200 akan ma'aunin suna na 0.30 mm. Bambancin ma'aunin ma'auni - bambancin kauri na lokaci-lokaci tare da tsawon da ke haifar da rashin daidaituwar bearings na bayan injin Sendzimir - bai kamata ya wuce 0.005 mm akan tsawon mita 10 ba.

Me yasa wannan matakin daidaito na madaurin bazara? Lanƙwasa madaurin bazara mai tambari a radius na 0.5 mm tare da kauri na tsiri na 0.30 mm (R/t = 1.67) yana da tsayin da ba shi da tsari na 4.5 mm. Idan kauri na tsiri ya kai 0.33 mm (iyakar sama ta ±0.03 mm), yanayin madaurin bazara yana canzawa saboda lokacin rashin ƙarfin ɓangaren giciye (I = b × t³ / 12) yana ƙaruwa da (0.33/0.30)³ = sau 1.33 - madaurin da aka samar ya fi tauri 33% a lanƙwasa, kuma tsayin da ba shi da tsari na madaurin yana ƙaruwa da 0.3 mm zuwa 4.8 mm. Ƙarfin shigar da fil ɗin haɗuwa yana canzawa daga ƙayyadaddun 8 ± 1 N zuwa 10 ± 1.5 N - sama da iyakar sama ta abokin ciniki ta 9 N. Irin wannan tasirin a baya yana faruwa idan kauri yana ƙasa da iyaka ta 0.27 mm. Juriyar kauri na ±0.03 mm kai tsaye tana fassara zuwa bambancin ƙarfi na ±0.25 N a cikin madaurin bazara - kuma taga karɓar abokin ciniki shine ±1 N. Muna riƙe kauri zuwa ±0.02 mm a tsakiyar madaurin da ±0.03 mm a gefuna ta hanyar ma'aunin ma'auni na atomatik mai rufewa akan mashin niƙa na ƙarshe na Sendzimir. Don samfuran tsiri na bakin ƙarfe gabaɗaya, dubaShafin rukuni na tsiri na bakin karfe.

Edge Burr - Tsarin Rayuwa na Punch-and-Die

Ana yanke tsiri mai sanyi daga naɗin da aka naɗe shi zuwa ƙananan tsiri (faɗin mm 20-200, ya danganta da faɗin tashar da kuma tsarin mannewa) a kan layin yankewa da wuƙaƙe masu juyawa. Tsarin yankewa yana haifar da ƙura a gefen da aka yanke - leɓen da aka ɗaga na kayan da aka cire wanda ya fito sama da saman tsiri da mm 0.02-0.15 ya danganta da kaifi na wuka, izinin yankewa (rata tsakanin wukake na sama da na ƙasa, wanda aka saita a kashi 5-10% na kauri na tsiri don yankewa daidai), da kuma tashin hankali a wurin sake yankewa. Ga mannewa mai tambarin Japan wanda ke gudana a bugun 200 a minti ɗaya tare da izinin bugawa na 0.020 mm (7% na kauri na tsiri 0.30 mm), mannewa da ke gefen tsiri mai shigowa shine abu na farko da ke taɓa saman mannewa. Tsawon burr sama da 0.05 mm zai yi wa saman murhun wuta a cikin bugun 50,000 - murhun yana haifar da ƙazanta a kan ƙasar murhun wanda ke canzawa zuwa kowace tashar da ke gaba, yana haifar da tudu mai tsayi a saman tashar wanda ke hana tashar zama a cikin gidan mahaɗin.

Muna sarrafa tsayin burar gefen ta hanyar takamaiman ma'auni uku: an saita haɗin wukar a kashi 30% na kauri na tsiri (0.09 mm don tsiri 0.30 mm), sharewar gefe shine kashi 8% na kauri na tsiri (0.024 mm), kuma ana kiyaye radius na gefen wukar a ƙasa da 0.01 mm - ana sake niƙa wukar yankewa lokacin da radius na gefen ya wuce 0.02 mm, wanda ke faruwa bayan tan 30-50 na yankewa a kowane saitin wuka. Ana auna tsayin burar da alamar dial a mita na farko da mita na ƙarshe na kowane tsiri na tsiri. Ana cire tsayin burar da ya wuce 0.05 mm ta hanyar tashar cire burar (saitin tubalan carbide masu cike da bazara waɗanda ke tsallake gefen burar da 0.03 mm daga kowane gefe) a hanyar fita daga layin yankewa. Aikin cire kayan lantarki yana kashe mu ¥0.30 a kowace mita mai layi ɗaya na tsiri - amma kuɗin gyaran injinan lantarki na injinan lantarki na Japan mai tashoshi shida shine ¥150,000–¥300,000, tare da lokacin dakatar da layin samarwa. An haɗa aikin cire kayan lantarki a matsayin misali akan duk odar tsiri mai sanyi da aka yi wa kwastomomin lantarki na Japan, ba tare da ƙarin kuɗi ba.

Marufi da Isarwa — Bukatun JIT Coil

Masana'antun tashar jiragen ruwa ta Japan suna aiki akan kwararar kayan aiki na lokaci-lokaci (JIT). Ana karɓar na'urar 500 kg na 0.30 × 100 mm mai daidaiton birgima mai sanyi tare da matsakaicin tsawon tsiri na 2,100 m kuma an sanya ta kai tsaye akan maɓallin biyan kuɗi na mashinan tambari mai zamewa da yawa - babu ajiya mai tsaka-tsaki, babu riƙewa na dubawa. Dole ne na'urar ta kasance ba tare da alamun naɗewa ba (ɓangaren da na'urar na waje ke yi akan naɗewa na ciki yayin juyawa da sarrafawa), saboda ƙoƙon zurfin 0.02 mm a saman tsiri yana haifar da ɗaukar tasirin mutu a mashin ɗin tambari - bugun ya haɗu da ƙarin juriya na 0.02 mm a wannan matsayin, ƙoƙon mashin ɗin ya karkata, kuma gefen bugun ya fashe yana samar da tashar tarkace.

Bayanin marufi na na'urorin da aka fitar zuwa Japan ya haɗa da: maƙallin ƙarfe (diamita na ciki na mandrel 300 mm, diamita na waje 450 mm, flanges na gefe 150 mm), maƙallin yana rauni a ƙarƙashin matsin lamba akai-akai (50 N a kowace 10 mm na faɗin tsiri - 500 N don faɗin tsiri 100 mm), kowane naɗi ya raba da takardar polyethylene mai 0.10 mm don hana ƙura-ƙura, maƙallin an rufe shi a cikin jakar shinge mai danshi mai amfani da silica gel desiccant (ƙarfe ba ya tsatsa, amma dole ne a ajiye takardar da ke tsakanin ganye ƙasa da kashi 10% na danshi don hana acid ɗin takardar tabo daga saman tsiri yayin jigilar kaya a teku), da kuma maƙallin a cikin akwati na katako tare da tushen kumfa mai danshi. Adadin haɗin walda a cikin na'urar - kowanne na'urar an samar da ita ne ta hanyar walda layukan na'urar mai girman tan 5 da yawa daga ƙarshen zuwa ƙarshe a layin yankewa - an iyakance shi ga haɗin walda 1 a kowace mita 500 don odar Japan, idan aka kwatanta da ma'aunin masana'antu na 1 a kowace mita 300. Yankin haɗin walda an yi masa alama da layin fenti mai launin rawaya 30 cm kafin da kuma 30 cm bayan haɗin, kuma an umurci mai sarrafa buga tambari ya yanke kuma ya watsar da yankin walda a jagorar shigarwar latsawa.

An jera cikakken kewayon samfuran da muke bayarwa don aikace-aikacen stamping daidai akanShafin kundin samfura.

Jerin Abubuwan da Za a Yi Don Binciken QA na Japan

Don ƙayyadaddun bayanai na fitarwa na yanzu da farashin daidai gwargwado na bakin karfe mai sanyi,Shafin samfurin tsiri mai tauri daidaitacceya haɗa da yanayin zafi da iyakokin girma. Don fahimi mai faɗi game da sarrafa tsiri na bakin ƙarfe,Shafin samfurin da aka yi wa sanyiya bayyana kayan aikin samarwa da matakan aiwatarwa.

Tsarin Ka'idojin Masana'antu na Japan yana ba da tsarin kayan aiki -Jigunan bakin karfe na JIS G 4313 masu sanyi don maɓuɓɓugan ruwashine mizani mai dacewa don yanayin zafi na 1/4H da 1/2H da ake amfani da shi a cikin tambarin hulɗar bazara ta lantarki. Don amfani na ƙasashen duniya kan gwajin haɗin gwiwa,Ka'idojin gwajin tashar haɗin haɗin SAE ta ƙasa da ƙasaƙayyade hanyar auna juriyar hulɗa da yanayin gwaji don tashoshin haɗin da ake amfani da su a cikin kayan lantarki.

Tambayoyin da Ake Yawan Yi