Walda tankin mai na mota (wanda aka yi shi da ƙaramin ƙarfe{0}}carbon ko aluminum) ta amfani da akabu waldi injiyana buƙatar daidaito don tabbatarwaleak -hujja, dorewa, da tsaga{1}magudanar ruwa. A ƙasa akwai mataki - ta - jagorar mataki na masana'antu:
1. Material & Design Prep
- Kayan abu:
Tankunan Karfe: Yi amfani da ƙaramin ƙarfe - ƙarfe (misali, SAE 1006/1010) don daidaitawa.
Tankuna na Aluminum: Yi amfani da allo 3003/5052 (kauce wa jerin 7000).
- Tsabtace Sama:
Degewa tare da mai tsabtace alkaline → Cire oxides ta hanyar goge baki (karfe) ko etching sinadarai (aluminum).
- Tsarin haɗin gwiwa:
Haɗin gwiwa tare da10-12 mm zoba(don kabu waldi).
Haƙurin daidaita flange:± 0.2mm.
2. Injin Welding SeamSaita
| Siga | Tankunan Karfe | Aluminum Tank |
|---|---|---|
| Welding Current | 15-25 kA | 20-35 kA |
| Ƙarfin Electrode | 3-6 kN | 2-4 kN |
| Gudun walda | 1-3 m/min | 0.5-2 m/min |
| Tsawon Pulse | Zagaye 10-30 (AC) | Zagaye 5-15 (MFDC) |
| Sanyi | Jiragen ruwa na waje | Na ciki lantarki H₂O sanyaya |
Lura:
- KarfeYi amfani da AC ko MFDC (Matsakaici Mitar Kai tsaye Yanzu).
- Aluminum: MFDC kawai(yana guje wa mannewa lantarki).
- Electrodes: Cu-Cr alloy wheels (nisa=1.5× kauri).
3. Tsarin walda
- Loading Tsayawa:
Matsa tanki rabi a cikin arotary kayan aiki(don madauwari) kolinzamin kwamfuta tracker(don madaidaicin seams).
- Taka Welding:
Spot{0}} waldi ya ƙare a50% ikodon hana rashin daidaituwa.
- Kabu Welding:
Shiga ƙafafun lantarki → Aiwatar da ƙarfi → Fara bugun bugun jini + jujjuyawar dabaran.
Mahimmanci: Matsa tabo ta25–30%don ci gaba da hatimin hermetic.
- Buga -Cooling Weld:
Busa matsewar iska akan yankin walda don rage murdiya.
4. Key Quality Checks
- Gwajin Leak:
Matsa tanki zuwa0.5 bar→ Nitsewa cikin ruwa; duba kumfa (duba 100%).
- Gwajin lalata:
Yanke samfurin → Aunafaɗin ƙugiya(ya zama mafi girma ko daidai da √𝑡, inda 𝑡=kaurin takardar).
- Visual/Dye Penetrant:
Bincika ga fasa, porosity, ko alamomin lantarki.
5. Matsalolin gama gari & Gyarawa
| Lalabi | Dalili | Magani |
|---|---|---|
| Leaks | Ƙananan zoba/na yanzu | ↑ Yanzu ta kashi 10%; ↓ gudun 20% |
| Craters/Crats | Rashin kula da lantarki | Tufafin lantarki kowane welds 50 |
| Warping | Shigar da zafi mai yawa | ↑ Gudu; amfani da pulsed sanyaya |
| Danko (Al) | Electrode alloy rashin daidaituwa | Yi amfani da Cu{0}Zr electrodes + MFDC |
6. Haɗin kai ta atomatik (Maɗaukaki{1}} Samar da ƙara)
- Kwayoyin Kafa na Robotic:
6-axis mutummutumi tare da lesar bin diddigin kabu (misali FANUC ArcMate).
- A cikin-Masu Gwajin Leak na Layi:
Na'urori masu lalata matsi na atomatik → ƙin tankuna mara kyau a ciki<20 sec.
Auto{0}}daidaita halin yanzu/karfi dangane da sa ido na juriya na lokaci.
7. Tsaro & Biyayya
- Samun iska: Cire hayakin walda (karfe: Mn/Cr oxides; Al: Al₂O₃).
- Matsayi:
TS EN ISO 3834 Bukatun inganci don waldawar Fusion
FMVSS 301 (daidaitaccen tankin mai don abubuwan hawa).
Me yasaKabu Welding(vs. Alternatives)?
| Hanya | Batu | Amfanin Welding Seam |
|---|---|---|
| MIG/TIG | Sannu a hankali; gwaninta{0} dogara | Babban gudun(3x sauri) |
| Dangantaka na m | Ragewar man fetur/mai | Kemikal juriya |
| Laser Welding | Babban farashin kayan aiki | Ƙananan farashidon tankuna masu kauri |
