Wɔ kar a wɔyɛ mu no, welding a ɛyɛ papa no nya kar nhyehyɛe ahobammɔ, sɛnea wɔyɛ no yiye, ne ne yɛ ho ka nyinaa so nkɛntɛnso tẽẽ. Eyi te saa titiriw wɔ dwumadie te sɛ anyinam ahoɔden kar, batere a wɔde abɔ ho, ne nipadua-wɔ-fitaa (BIW) nhyiamu mu, baabi a welding a ɛgyina pintinn di dwuma titire wɔ nneɛma a wɔtumi de ho to so mu. Nnwumayɛbea ho nsɛm kyerɛ sɛ kar a wɔde fa nnipa a wɔtaa de di dwuma no kura...3,000 kosi 5,000 a wɔde yɛ spot weld, a emu pii wɔ kar nipadua no mmeae a ɛho hia wɔ nhyehyɛe ne ahobammɔ-mu. Esiane eyi nti, welding mu sintɔ ɔha biara mu nkyem ketewaa bi mpo betumi de asiane kɛse aba sɛnea nneɛma te bere a nneɛma a wɔyɛ no dodow du ɔpehaha pii afe biara no.
Bere a kar nhyehyɛe de nneɛma a emu yɛ hare ne dade a ahoɔden kɛse -ayɛ ka ho kɛse no, nhama a wɔde yɛ nneɛma nso abɛyɛ nea wɔde wɔn ankasa yɛ. Wɔ tebea horow yi mu no, atetesɛmAC a ɛko tia beae welding mfirimpɛn pii no wɔpere sɛ wobedi nnɛyi nneɛma a wɔyɛ ho ahwehwɛde ahorow ho dwuma. Nsɛm te sɛ welding current a entumi nnyina, spatter a ɛboro so, ne weld quality a ɛnkɔ so pɛpɛɛpɛ betumi ama nsakrae aba wɔ nneɛma a wɔyɛ mu na ɛka a wɔbɔ wɔ adwuma a wɔsan yɛ no kɔ soro.
Esiane eyi nti, wɔn a wɔyɛ kar ne wɔn a wɔde Tier 1 ma no pii reyɛ wɔn welding nhyehyɛe ahorow no foforo. NoMFDC (Medium Frequency Direct Current) afiri a wɔde yɛ nneɛma a ɛwɔ baabiaraapue sɛ ano aduru a wɔpɛ esiane ne DC a ɛyɛ pintinn, mmuae bere a ɛyɛ ntɛm, ne tumi a ɛkɔ akyiri a ɛfa nhyehyɛe sohwɛ ho nti. Wɔ kar a wɔyɛ kɛse-mu mu no, saa mfiri yi ma mfaso a ɛda adi pefee wɔ welding a ɛyɛ den, nea ɛyɛ papa a ɛkɔ so pɛpɛɛpɛ, ne nea ɛne nneɛma a wɔde yɛ nneɛma a wɔde wɔn ankasa yɛ no bom.
MFDC Spot Welding Mfiridwuma ho ntease
Nnyinasosɛm titiriw a ɛfa medium frequency inverter welding ho
MFDC spot welding afiri bi de di dwumamedium-frequency inverter mfiridwuma ho nimdeɛsɛ wɔbɛdan anyinam ahoɔden ayɛ no welding current a ɛyɛ den na wotumi di so. Mpɛn pii no, adeyɛ no di akwan horow pii akyi.
Nea edi kan no, nea ɛba no50/60 Hz AC ahoɔden a efi anyinam ahoɔden nhama no mu no, wɔsiesie no ma ɛyɛ tẽẽ (DC) .. Afei, inverter module-a ɛtaa gyina IGBT mfiridwuma so-dannan DC tumi no kɔmedium-frequency AC a ɛwɔ bɛyɛ 1,000 Hz. Afei wɔde saa frequency a ɛkorɔn-frequency current yi fa medium-frequency welding transformer a wɔde voltage no sian kɔ fam kodu baabi a ɛfata ma welding. Awiei koraa no, wɔsan siesie current no ma ɛyɛ aDC welding a ɛyɛ den a ɛba.
Saa nhyehyɛe yi yɛ soronko koraa wɔ AC welding nhyehyɛe a wɔtaa de di dwuma no ho. Mfiri a wɔde di dwuma wɔ amanne kwan so no de wɔn ho to AC current a ɛba fam-frequency so tẽẽ, a efi awosu mu sakra wɔ anyinam ahoɔden kyinhyia biara mu. Nea ɛne eyi bɔ abira no, MFDC nhyehyɛe ahorow ma mprempren nsɛm a ɛyɛ den kɛse, na ɛma wotumi di welding nhyehyɛe no so pɛpɛɛpɛ.
Sɛ yɛhwɛ mfiridwuma mu a, saa adansi yi wɔ mfaso horow pii a mfaso wɔ so:
- Pɛpɛɛpɛ control a welding mprempren
- Faster dynamic mmuae wɔ welding kyinhyia no mu
- Ahoɔden a wɔde di dwuma yiye a ɛkorɔn
- Nkitahodi a ɛkɔ anim ne nhyehyɛe ahorow a wɔde yɛ nneɛma a wɔde wɔn ankasa yɛ
Esiane saa mfaso horow yi nti, ɛnyɛ kar a wɔyɛ nko na wɔde MFDC spot welding mfiri di dwuma kɛse, na mmom wɔ nnwuma te sɛ ofie mfiri, batere a wɔyɛ, ne dade a wɔyɛ no pɛpɛɛpɛ nso mu.
Stable DC Output Ma Welding Quality Tu mpɔn
Mprempren nsakrae a ɛba wɔ AC welding mu a wobeyi afi hɔ
Anohyeto titiriw biako a ɛwɔ atetesɛm AC spot welding mfiri mu ne...zero-crossing adeyɛ. Wɔ anyinam ahoɔden a ɛsesa no kyinhyia biara mu no, anyinam ahoɔden no kɔ fam bere ne bere mu kodu zero ansa na akɔ soro bio. Saa ntwitwiridii yi a ɛba mprempren nsu mu no betumi ama nsakrae aba ɔhyew a ɛba mu bere a wɔreyɛ welding no.
Sɛ wɔreyɛ welding nneɛma a ɛyɛ mmerɛw anaa dade a ɛyɛ tratraa a, saa nsakrae yi betumi ama nugget a ɛnyɛ pɛpɛɛpɛ aba. Ne saa nti, weld ahoɔden betumi ayɛ soronko wɔ beae biara.
MFDC spot welding mfiri di ɔhaw yi ho dwuma denam astable tẽẽ mprempren output. Esiane sɛ current no ntwam mpɛn pii wɔ zero point nti, ɔhyew a ɛba no kɔ so yɛ pɛpɛɛpɛ wɔ welding cycle no nyinaa mu. Eyi ma weld nugget no tumi yɛ wɔ tebea horow a wɔahyɛ so kɛse mu.
Wɔ mmeae a wɔyɛ nneɛma ankasa no, mprempren ahoɔden a ɛkɔ anim yi taa de:
- Welding a wɔde petepete so no so tew
- Nugget kɛse a ɛkɔ so daa kɛse
- Nsonsonoe a ɛba fam wɔ weld ahoɔden mu
- Weld hwɛbea a ɛkɔ anim
Wɔ kar nipadua nhyehyɛe ahorow a ɛsɛ sɛ weld mpempem pii yɛ adwuma wɔ ɔkwan a wotumi de ho to so ho no, ɛho hia sɛ wɔma ɛkɔ so yɛ pɛpɛɛpɛ wɔ saa gyinabea yi mu.
Adwumayɛ a eye sen biara a ɛwɔ dade a ahoɔden kɛse -yɛ ne nneɛma a wɔde akata so
Nnɛyi kar nhyehyɛe ahorow de wɔn ho to so kɛsehigh-ahoɔden dade (HSS) ne galvanized krataa dadesɛnea ɛbɛyɛ a wɔbɛtew wɔn mu duru so bere a wokura nhyehyɛe no mudi mu kura mu no. Saa nneɛma yi yɛ den kɛse sɛ wɔde weld bɛbɔ efisɛ ɛhwehwɛ sɛ wɔde ɔhyew a wɔde hyɛ mu pɛpɛɛpɛ na wɔhwɛ welding no so denneennen.
MFDC spot welding mfiri no fata yiye titiriw ma saa dwumadie yi. Wɔn mprempren mmuae ntɛmntɛm ne ahoɔden a wɔhwɛ so pɛpɛɛpɛ no ma wotumi wie weld no wɔ bere tiaa bi mu bere a wɔma ɔhyew kyekyɛ a ɛyɛ pintinn no.
Nea afi mu aba ne sɛ, wɔde MFDC nhyehyɛe ahorow di dwuma kɛse ma welding dwumadie te sɛ:
- Kar nipadua nhyehyɛe afã horow
- Batere dan nhyiam ahorow
- Nkongua frame nhyehyɛe ahorow
- Nut ne stud welding wɔ dade a ɛyɛ tratraa so
Sɛ nhwɛso no, wɔ kar nkongua ntama a wɔyɛ ho adwuma bi mu no, adwumakuw bi de MFDC mfiri a wɔde weld a ɛwɔ baabiara sesaa AC welder a wɔtaa de di dwuma no ananmu. Afei upgrade no, na...weld rate a asɛe no so tew fii 0.5% koduu 0.02% ., na standard deviation a weld twetwe ahoɔden so tew bɛyɛ50%. Saa nkɔso ahorow yi maa nneɛma a wɔyɛ no nyinaa kɔɔ soro kɛse na ɛmaa ɛka a wɔbɔ wɔ adwuma a wɔsan yɛ no so tew.
Closed-Loop Control Hwɛ sɛ Welding aba a ɛkɔ so daa
Ankasa-bere a wɔhwɛ so wɔ welding parameters atitiriw ho
Ɛnyɛ weld a ano yɛ den nko na wɔn a wɔyɛ kar nnɛ hwehwɛ, na mmom wɔhwehwɛ nsowelding akwan a wotumi san yɛ bio kɛse na wotumi hwehwɛ mu. Esiane eyi nti, nnɛyi MFDC spot welding mfiri taa de nea ɛkɔ anim ka hoclosed-loop control nhyehyɛe ahorow.
Wɔ welding cycle biara mu no, control system no hwɛ parameters a ɛho hia pii wɔ bere ankasa mu, a nea ɛka ho ne:
- Welding mprempren
- Welding ahoɔden a wɔde yɛ adwuma
- Electrode ahoɔden
- Electrode a ɛkɔ baabi foforo
Ɛdenam kɔ so hwehwɛ saa nsɛnkyerɛnne yi mu no, controller no betumi asiesie welding parameters no dynamically de akura ahoɔden a ɛkɔ so daa a wɔde hyɛ mu ma weld biara.
Advanced MFDC welding nhyehyɛe taa nyaahoɔden a wɔsan yɛ no mpɛn pii wɔ ±2% mu ., bere a AC welding nhyehyɛe ahorow a wɔtaa de di dwuma no taa yɛ adwuma wɔ bɛyɛ±5%. Wɔ kar a wɔyɛ no dodow a ɛkɔ soro mu no, saa nsonsonoe yi betumi anya nkɛntɛnso kɛse wɔ nneɛma a wɔyɛ no nyinaa mu yiyedi ne nea ɛkɔ so daa no so.
Welding data kyerɛwtohɔ ne su traceability
Ade titiriw foforo a ɛrekɔ so wɔ kar a wɔyɛ mu ne sɛnea wɔresi so dua kɛsedata-driven quality management. Gyinapɛn ahorow te sɛIATF 16949 na ɛwɔ hɔhwehwɛ sɛ wɔn a wɔyɛ nneɛma no yɛ nneɛma a wɔyɛ ho kyerɛwtohɔ a wotumi hwehwɛ mu ma nneɛma a ɛho hia.
Enti nnɛyi MFDC spot welding mfiri pii ka ho a wɔde asisi-wɔ monitoring ne data logging nhyehyɛe ahorow mu. Saa nhyehyɛe ahorow yi ma wɔn a wɔyɛ no tumi:
- Kyerɛw welding parameters ma weld point biara
- Hu welding tebea horow a ɛnteɛ wɔ bere ankasa mu
- Analyse welding quality trends bere tenten
- Fa welding data ne MES anaa adwumayɛbea sohwɛ nhyehyɛe ahorow bom
Saa nsɛm yi, adwinnanfoɔ bɛtumi ahunu dwumadie ho nsɛm a ɛbɛtumi aba ntɛm na wɔayɛ nkɔsoɔ a egyina data- so wɔ wɔn welding dwumadie mu.
Modular Design Ma Production Line Nkabom Tu mpɔn
Nea ɛne robɔt welding nhyehyɛe ahorow hyia
Nnɛyi kar welding adwuma dodow no ara de wɔn ho to robɔt a wɔde yɛ adwuma so kɛse. Sɛnea ɛbɛyɛ a wɔbɛboa saa nhyehyɛe ahorow yi no, wɔtaa yɛ MFDC spot welding mfiri ahorow no amodular nhyehyɛe a wɔde yɛ nneɛma.
Nhyehyɛe no mu nneɛma a wɔtaa yɛ no bi ne:
- Welding tumi a wɔde ma module
- Mfinimfini-frequency nsakraeɛ
- Control nhyehyɛe module
Sɛ wɔtetew saa nneɛma yi mu yɛ no module ahorow a ɛde ne ho a, ɛma ɛyɛ mmerɛw sɛ wɔde besisi hɔ ne ne siesie bere a ɛma ɛyɛ mmerɛw sɛ wɔde nhyehyɛe no bɛka nneɛma a wɔyɛ no ankasa ho no.
MFDC welding nhyehyɛe pii nso boa mfiridwuma mu nkitahodi nhyehyɛe ahorow a wɔde di dwuma kɛse, te sɛ:
- Profinet a ɛwɔ hɔ
- Modbus na ɔkyerɛwee
- Ethernet/IP a wɔde di dwuma
Saa nkitahodi ahorow yi ma welding mfiri tumi ne robɔt, PLC controllers, ne MES nhyehyɛe ahorow di nkitaho tẽẽ, na ɛma wotumi yɛ adwumayɛbea dwumadi ahorow a etu mpɔn na nyansa wom.
Faster installation ne commissioning
Wɔ kar yɛ adwuma akɛse mu no, bere a egye na wɔde ahyɛ mfiri a wɔde yɛ nneɛma mu na wɔahyɛ sɛ wɔmfa nyɛ adwuma no nya ahoɔhare a wɔde yɛ adwuma no so nkɛntɛnso tẽẽ. Amanneɛ kwan so welding nhyehyɛe taa hwehwɛ sɛ wɔyɛ nhama a wɔayɛ no sɛnea wɔpɛ, mframa nhyehyɛe, ne nsakrae kɛse wɔ-beae hɔ.
Nea ɛne eyi bɔ abira no, modular MFDC welding nhyehyɛe betumi ama saa akwan yi ayɛ mmerɛw kɛse. Esiane sɛ wɔadi kan ayɛ nneɛma atitiriw no na wɔayɛ no pɛpɛɛpɛ nti, instɔlehyɛn no yɛ ntɛmntɛm na nhyehyɛe no nkabom yɛ nea wotumi hyɛ ho nkɔm.
Wɔ kar afã horow a wɔyɛ adwuma pii mu no, nkɔso a wɔayɛ akɔ modular MFDC welding nhyehyɛe ahorow so no ama:
- 60–70% bere tiaa a wɔde hyɛ adwuma mu
- Ne nyinaa mu no, nneɛma a wɔyɛOEE a ɛboro 90% .
Saa nkɔsoɔ yi ma wɔn a wɔyɛ nneɛma no tumi de nneɛma foforɔ a wɔyɛ no ba intanɛt so ntɛmntɛm berɛ a wɔkura adwumayɛ mu mmɔdenbɔ a ɛkorɔn mu.
Sɛnea Wobɛpaw Spot Welding Machine a Ɛfata a Wɔde Yɛ Kar
Wɔ adwinnanfo a wɔreyɛ nhyehyɛe sɛ wɔbɛma wɔn welding mfiri no ayɛ foforo fam no, MFDC spot welding afiri a ɛfata a wɔbɛpaw no hwehwɛ sɛ wɔhwehwɛ mfiridwuma mu nneɛma pii mu yiye.
Nea edi kan no, sɛnea welding ahoɔden a wɔde ma no gyina pintinn no ho hia yiye. Nnwinnade a wɔdemprempren control pɛpɛɛpɛ a ɛwɔ ±3% mu .neahoɔden a wɔsan yɛ no mpɛn pii wɔ ±2% mu .wɔtaa kamfo kyerɛ sɛ wɔmfa nyɛ kar mu nneɛma a ɛho hia sɛ wɔde weld yɛ pɛpɛɛpɛ.
Nea ɛto so abien no, ɛsɛ sɛ wosusuw sɛnea welding control system no tumi yɛ ho. Ɛsɛ sɛ controller a wɔayɛ no yie{1}}boa welding nhyehyɛeɛ pii, real-bere process monitoring, ne welding data recording. Saa nneɛma yi boa ma wɔhwɛ hu sɛ weld no yɛ nea ɛkɔ so daa na ɛma wotumi traceability wɔ production nhyehyɛe no nyinaa mu.
Awiei koraa no, sɛnea ɛne automation nhyehyɛe ahorow hyia no ho hia kɛse. Mfiri a ɛboa mfiridwuma mu nkitahodi nhyehyɛe a ɛyɛ gyinapɛn no betumi ne robɔt welding nhyehyɛe ne adwumayɛbea MES nhyiam ase ayɛ biako ntɛmntɛm, na ɛtew nkabom ho ka so na ama daakye nkɔso a wɔbɛyɛ no ayɛ mmerɛw.
Awie
Bere a kar adwuma no kɔ so nya nkɔso kɔ kar a anyinam ahoɔden wom, adan a emu yɛ hare, ne nneɛma a wɔde afiri yɛ kɛse so no, nneɛma a wɔhwehwɛ wɔ mfiri a wɔde yɛ welding ho no reyɛ nea ɛho hia kɛse. Mfiri a wɔde yɛ AC spot welding a wɔde di dwuma wɔ amanne kwan so no taa di apere sɛ wɔde ahoɔden a egyina pintinn na ɛyɛ pɛpɛɛpɛ a ehia wɔ nnɛyi mmeae a wɔyɛ nneɛma no bɛma.
MFDC spot welding mfiri ahorowdi saa nsɛnnennen yi ho dwuma denam DC a ɛyɛ den a ɛba, high-precision closed-loop control, ne modular system design a wɔde bɛka abom so. Ɛnyɛ sɛ saa tumi ahorow yi ma weld no tu mpɔn nko na mmom ɛboa ma wɔde ka bom yiye ne mfiri a wɔde yɛ nneɛma a wɔde wɔn ankasa yɛ adwuma.
Wɔ adwinnanfo a wɔde wɔn ani asi so sɛ wɔbɛma welding ahotoso atu mpɔn, atew adwuma a wɔsan yɛ so, na wɔama nneɛma a wɔyɛ no yiye no akɔ soro no, sika a wɔde bɛto MFDC spot welding mfiridwuma mu no reyɛ ade a mfaso wɔ so na ɛyɛ ɔkwan a wɔfa so paw. Bere a adwinni a nyansa wom kɔ so nya nkɔso no, welding nhyehyɛe ahorow a ɛma wotumi di nneɛma so pɛpɛɛpɛ, ɛma wotumi yɛ nneɛma a ɛda adi pefee, na ɛma nneɛma a wɔde yɛ adwuma a ɛnyɛ den no bedi dwuma titiriw wɔ kar a wɔyɛ daakye mu.
