Iziseko zale mihla zijongene nokhetho olunzima: imveliso yesikali ngaphandle kokuncama ukuchaneka-okanye ukuwela ngasemva kwimizi-mveliso apho izindlu zempompo kufuneka zitywinwe kwibar ye-400, imizimba yevalvu ixhathisa ukhukuliseko lwe-cobalt-alloy kwiiyure zokusebenza ezingama-12,000, kwaye i-winch shafts ithwala imithwalo eguquguqukayo phantsi kokuvezwa kwesitshizi setyuwa. Impendulo ayingomsebenzi wezandla ongaphezulu. yi i-automated sand casting factory-kungekhona njenge-bolt-on upgrade, kodwa njengokwakhiwa ngokutsha kwemveliso.
Sifake kwaye sigunyazise imigca emithandathu enjalo ukususela ngo-2021-emithathu kwizityalo ze-hydraulic component, izixhobo ezimbini ze-oilfield ze-OEMs, kwaye enye idityaniswe ngokuthe ngqo kwi-Tier-1 yeemoto zobunjineli kwikhampasi yomthengisi. Oko sikufundileyo kwakungekho ngqiqweni. Yayiyinto ebambekayo: lutshintsha njani uxinzelelo olungundoqo xa ukufuma kwe-ambient kunyuka ngaphezulu kwe-65%, kutheni i-pitch yokuhambisa umngundo kufuneka icuthe nge-3.2 mm xa utshintshela kwintsimbi engwevu ukuya kwi-AMS 5387 cobalt alloy molds, kwaye kutheni "i-automated ngokupheleleyo" ingaphumeleli ukuba indawo yokugcina ipateni ayinayo i-RFID-triggeration. I-automation yokwenyani iqala apho isigwebo somntu siphela-kwaye apho ukuphinda-phinda kuqala khona.
IiNqaku eziNtathu ezingaxoxiswanayo zeNyaniso ezenzekelayo
Abathengisi abaninzi bathengisa “i-automated sand casting” njengeengalo zerobhothi ezigalela isanti eluhlaza. Leyo yintshukumo yomgangatho womphezulu-hayi inkqubo yolawulo. Umsebenzi osebenzayo i-automated sand casting factory Ihlala kumaleko amathathu adibeneyo:
- Ukuzimela kokwenza umngundo: Hayi nje i-robotic ramming, kodwa i-real-time density mapping ngokusebenzisa i-piezoresistive sensors efakwe kwibhokisi nganye yokubumba, kunye nokulungiswa kwe-loop evaliweyo yamandla okudibanisa kwindawo nganye-ebaluleke kakhulu xa uphosa izindlu ze-cylinder ezinqabileyo ezinodonga oluyi-2.1 mm ubukhulu kunye ne-± 0.15 mm GD & T callouts.
- Ubukrelekrele bezinto eziphathekayo: Ukuhlaziywa kwesanti akuyiyo i-batch recycling-luhlalutyo oluqhubekayo lwe-spectral. Sibeka iliso kwilahleko ye-bentonite, ukuguquguquka kokufuma, kunye nokuqina rhoqo kwimizuzwana engama-90 kusetyenziswa ukubonakaliswa kwe-infrared ekufutshane. Xa umxholo we-silica wehla ngaphantsi kwe-92.7%, inkqubo ye-auto-triggers binder dosing-kungekhona kwi-timer, kodwa kwimfuno yangempela.
- Iokhestration eshushu: Ixesha le-Shakeout alilungiswanga. Iyatshintsha. Igridi yethu ye-thermocouple edityaniswe kwisithando somlilo ifunda ubushushu bolusu ngapha kwamanqaku angama-48 kumngundo ngamnye. Ukuba izinga lokupholisa liwela ngaphandle kwe-1.8-2.3 ° C / min yefestile ye-ASTM A48 Iklasi ye-35 yentsimbi, umgca uyema i-shakeout kwaye uphinde ubuyisele isikhunta kwindawo elawulwayo yomoya-ukuthintela i-microcracks eya kuthi kamva ingaphumeleli ukuhlolwa kwe-X-ray.
Oku akuyontelekelelo. Yiyo eyenza ukuba omnye umenzi wempompo waseYurophu anqumle inkunkuma enxulumene nokuphosa ukusuka kwi-8.4% ukuya kwi-1.9% phakathi kweenyanga ezine-ngelixa inyusa imveliso yemihla ngemihla ukusuka kwi-62 ukuya kwi-97 yezindlu eziyinkimbinkimbi.
Kutheni iHybrid Casting-Machining Beats “Casting-Only” Automation
Abanye bayaphikisana: zenzele kuqala ukuphosa, umatshini kamva. Kodwa ekusebenzeni, oko kudala ukungahambi kakuhle. Umbhobho owenziwe ngoomatshini kwizindlu ezenziwe ngesanti akukhona nje ukunyamezelana-kumalunga nokushiyeka koxinzelelo, ukuqhubeka kokuhamba kweenkozo, kunye nembali yobushushu. Xa ukuphosa kunye nomatshini kusebenza njenge-silos eyahlukileyo, ufumana iinxalenye ezidlula iitshekhi ze-CMM kodwa zisilele uvavanyo lwe-hydrostatic kwi-1.5 × uxinzelelo lokusebenza.
Sizinzise imiphezulu yedatum elungele i-CNC *kuyilo lokungunda-ayongezwanga emva kokuphosa. Iindlela zethu ze-toolpaths ze-akhawunti yokugqwesa okuxelwe kwangaphambili ngokuqiniswa kokulinganisa (usebenzisa i-MAGMAsoft v7.1 i-thermal-mechanical coupling). Emva koko, amaziko ethu oMatshini we-axis amahlanu enza ukusikwa kwesiqingatha sokugqiba *phambi* konyango lokugqibela lobushushu-ukunciphisa umngcipheko we-warpage nge-63% ngokuchasene nolandelelwano lwemveli. Oku kuhamba komsebenzi we-hybride kutheni izindlu zethu zempompo zepiston ziphumelela I-Rz ≤ 3.2 μm ebusweni bokutywinwa okubalulekileyo-ngaphandle kokugaya okwesibini.
Eyona nto uyihlawulayo (kunye nento ongayihlawuliyo)
Ukuphosa isanti ngokuzenzekelayo kuthwala iindleko zangaphambili-kodwa indleko yokwenyani ifihla kwenye indawo. Nantsi into ebalulekileyo:
- Akukho rhafu yengeniso efihliweyo: Imigca yelifa isoloko ifuna ukuqiniswa kolwakhiwo, izowuni entsha ye-HVAC, okanye ukuphuculwa kwesitishi sombane. Iiseli zethu zemodyuli zidibanisa kwiindawo ezikhoyo zokuphakama kwe-6.5 m-akukho miqadi ye-crane, akukho siseko sokuthulula.
- Akukho Phantom downtime: Abathengisi bathembisa "i-95% yexesha lokuphumla." Yinyani? I-Sensor calibration drift ibangela i-alamu zobuxoki. Sisebenzisa i-self-diagnostics: i-robot nganye iqinisekisa isikhundla sayo sokuphindaphinda ngokuchasene ne-laser-tracked granite masters rhoqo kwiiyure ze-8-akukho kungenelela komsebenzisi ofunekayo.
- Akukho tyala lesiqinisekiso: ISO 9001: Ukuthotyelwa kwe-2015 akusiso isatifikethi eludongeni. I-ID yesanti elandelekayo idityaniswe neengxelo zovavanyo lwe-tensile, iilog zobushushu zokungunda ezivumelaniswe kwii-odolo zomsebenzi we-ERP, kunye neerekhodi ezipheleleyo zamawele edijithali kuzo zonke izinto zokuphosa-ezifumanekayo kuphicotho phantsi kwemizuzwana eyi-17.
Olu qeqesho lusivumela ukuba siqinisekise ukuhanjiswa kweefestile zemitsi ephakathi-nomthamo ongekho mgangathweni njengesixhobo esisekwe kwi-cobalt ye-T800, apho ukunyibilika kokungaguquguquki kuchaphazela ngokuthe ngqo ubomi bokudinwa kwiziko le-winch ye-offshore shaft rollers.
Apho Ukuchaneka Kudibana nenjongo
An i-automated sand casting factory ayithethi ngokutshintsha abantu. Imalunga nokuqondisa ngokutsha ubuchwephesha: ukusuka kwiigeyiji zokubek' esweni ukuya ekutolikeni i-thermal gradients, ukusuka kukulungelelaniswa kwepateni yesandla ukuya ekuqinisekiseni izitaki ze-GD&T ngokuchasene nokulinganisa iifiziksi ezininzi, ukusuka kuhlengahlengiso olusebenzayo lokuhlela ukuya kwimodeli yemveliso yesinyithi.
QINGDAO QIANGSENYUAN TECHNOLOGY CO., LTD. wakha ezi nkqubo kungekhona njengomthengisi wezixhobo-kodwa njengeqabane lexesha elide lokuvelisa. Siphuhlisa amacebo okudlala ngokubambisana ngexesha lesigaba sakho se-DFMEA. Siqinisekisa iijiyometri ze-AMS 5387 zombhobho ngokuchasene nokhukuliseko lweemephu-hayi nje imizobo. Sifumana imathiriyeli ekrwada eqinisekisiweyo ngeengxelo zovavanyo lokusila ezibotshelelwe kubushushu obubodwa-kwaye sigcina ezo rekhodi iminyaka eli-15.
Ikamva lelemizi-mveliso apho isanti ingagcini nje ukumila—inika ingxelo. Apho ukuphosa akusiyo inyathelo kwinkqubo, kodwa isiseko esikrelekrele sayo yonke into elandelayo. Ayiyonto i-automation leyo. Sisiqinisekiso eso.
