Cishe yonke inqubo yokuhlanganisa ingenziwa ngezindlela ezimbalwa.Inketho umkhiqizi noma umdidiyeli ayikhethayo ukuze kube nemiphumela engcono kakhulu ngokuvamile ehambisana nobuchwepheshe obufakazelwe nohlelo lokusebenza oluthile.
I-Brazing ingenye yenqubo enjalo.I-Brazing iyinqubo yokuhlanganisa insimbi lapho izingxenye ezimbili noma ngaphezulu zensimbi zihlanganiswa ngokuncibilika kwensimbi yokugcwalisa bese igeleza ehlangene.I-filler metal inephuzu eliphansi lokuncibilika kunezingxenye zensimbi eziseduze.
Ukushisa kwe-brazing kungahlinzekwa ngamathoshi, izithando zomlilo noma amakhoyili wokungeniswa.Ngesikhathi sokufakwa kwe-induction, ikhoyili yokungeniswa idala inkambu kazibuthe eshisa i-substrate ukuze incibilike insimbi yokugcwalisa.I-Induction brazing ifakazela ukuthi iyisinqumo esingcono kakhulu senani elikhulayo lezinhlelo zokusebenza zomhlangano.
"I-induction brazing iphephe kakhulu kunokubhsa kwethoshi, ishesha kunokubhsa kwesithando somlilo, futhi iphindaphindeka kunakho kokubili," kusho uSteve Anderson, umphathi wesayensi yokuhlola nokuhlola e-Fusion Inc., umdidiyeli oneminyaka engu-88 ubudala e-Willoughby, e-Ohio Said, ugxile kakhulu ezindleleni ezihlukahlukene zokuhlanganisa, okuhlanganisa ukubrasa.Uma kuqhathaniswa nezinye izindlela ezimbili, okudingayo ngempela ugesi ojwayelekile.”
Eminyakeni embalwa edlule, i-Fusion yakha umshini weziteshi eziyisithupha ozishintshayo ngokugcwele wokuhlanganisa ama-carbide burrs angu-10 okusebenza kwensimbi nokwenza amathuluzi. Ama-burrs enziwa ngokunamathisela izikhala ze-cylindrical ne-conical tungsten carbide ku-shank yensimbi. Izinga lokukhiqiza liyizingxenye ezingu-250 ngehora, futhi izingxenye ezihlukene zethreyi zingabamba izibambi ezingu-144.
U-Anderson uyachaza: “Irobhothi eliyi-four-axis i-SCRA lithatha isibambo ethreyini, lisilethe kumshini wokukhipha ama-solder paste, bese lisilayisha esidlekeni sokubamba,” kuchaza u-Anderson.I-induction brazing yenziwa kusetshenziswa ikhoyili kagesi egoqa iqonde ezingxenyeni ezimbili futhi ilethe insimbi yokugcwalisa isiliva ezingeni lokushisa elingu-liquidus elingu-1,305 F. Ngemva kokuba ingxenye ye-burr iqondaniswe futhi ipholisiwe, ikhishwa nge-chute yokukhipha futhi iqoqwe ukuze kuqhutshekwe nokucubungula.”
Ukusetshenziswa kwe-induction brazing yomhlangano kuyanda, ikakhulukazi ngoba kudala ukuxhumana okuqinile phakathi kwezingxenye ezimbili zensimbi futhi ngenxa yokuthi kuphumelela kakhulu ekujoyineni izinto ezingafani.Ukukhathazeka kwemvelo, ubuchwepheshe obuthuthukisiwe, kanye nezinhlelo zokusebenza ezingezona ezendabuko nazo ziphoqelela onjiniyela bokukhiqiza ukuba bahlolisise i-induction brazing.
I-induction brazing ibilokhu ikhona kusukela ngawo-1950, nakuba umqondo wokushisa kokungeniswa (usebenzisa i-electromagnetism) watholwa ngaphezu kwekhulu leminyaka ngaphambili usosayensi waseBrithani uMichael Faraday.Amathoshi ezandla ayewumthombo wokuqala wokushisa wokushisa, okulandelwa izithando zomlilo ngawo-1920. Phakathi neMpi Yezwe II, izindlela ezisekelwe esithandweni zazivame ukusetshenziselwa ukukhiqiza izingxenye ezinkulu zensimbi kanye nenani elincane lensimbi.
Isidingo sabathengi se-air conditioning ngeminyaka yawo-1960 kanye nawo-1970 sakha izinhlelo zokusebenza ezintsha zokugqama kwe-induction. Eqinisweni, ukugqama kwe-aluminiyamu ngasekupheleni kwawo-1970 kwaholela ezingxenyeni eziningi ezitholakala ezinhlelweni zanamuhla zokupholisa umoya ezimotweni.
“Ngokungafani nokukhanyisa ithoshi, i-induction brazing ayithinteki futhi inciphisa ingozi yokushisisa ngokweqile,” kuphawula u-Rick Bausch, umphathi wezentengiso we-Ambrell Corp., inTEST.temperature.”
Ngokuka-Greg Holland, umphathi wezokuthengisa nokusebenza kwa-eldec LLC, isistimu ye-induction brazing evamile iqukethe izingxenye ezintathu.Lawa amandla kagesi, ikhanda elisebenzayo elinekhoyili yokungeniswa kanye nesistimu epholile noma yokupholisa.
Ukunikezwa kwamandla kuxhunywe enhlokweni yomsebenzi futhi amakhoyili enziwe ngokwezifiso aklanyelwe ukuhambisana nendawo ehlangene.Ama-inductors angenziwa ngezinti eziqinile, izintambo eziguquguqukayo, amabhilidi omshini, noma i-3D ephrintiwe kusuka kuma-alloys ethusi ayimpuphu. ukwakheka kwamakhoyili ngenxa yokuba khona njalo kwamandla ashintshayo kanye nomphumela wokudlulisa ukushisa okungasebenzi kahle.
“Ngezinye izikhathi i-concentrator egelezayo ifakwa kukhoyili ukuze kuqiniswe amandla kazibuthe endaweni eyodwa noma ngaphezulu lapho kuhlangana khona,” kuchaza u-Holland.” Izinto ezigxilisa ingqondo ezinjalo zingaba uhlobo lwe-laminate, oluhlanganisa izinsimbi zikagesi ezincanyana ezihlanganiswe ndawonye, ​​​​noma amashubhu e-ferromagnetic aqukethe i-ferromagnetic eyimpuphu namabhondi e-dielectric acindezelwe ngaphansi kwengcindezi ephezulu.Sebenzisa noma yikuphi Inzuzo ye-concentrator ukuthi inciphisa isikhathi somjikelezo ngokuletha amandla engeziwe ezindaweni ezithile zejoyinti ngokushesha, kuyilapho igcina ezinye izindawo zipholile.”
Ngaphambi kokubeka izingxenye zensimbi ze-induction brazing, u-opharetha udinga ukusetha ngokufanele izinga lemvamisa namandla esistimu.Imvamisa ingasukela ku-5 kuye ku-500 kHz, uma iphezulu i-frequency, lapho ingaphezulu lishisa ngokushesha.
Izimpahla zamandla ngokuvamile zikwazi ukukhiqiza amakhulukhulu ama-kilowatts kagesi.Nokho, ukubhula ingxenye elingana nesundu ngemizuzwana eyi-10 kuya kweyi-15 kudinga kuphela ama-kilowatts angu-1 kuya kwangu-5. Uma kuqhathaniswa, izingxenye ezinkulu zingadinga ama-kilowatts angu-50 kuya kwangu-100 futhi zithathe imizuzu emi-5 ukuze zibhuqe.
"Njengomthetho ojwayelekile, izingxenye ezincane zisebenzisa amandla amancane, kodwa zidinga amaza aphezulu, njenge-100 kuya ku-300 kilohertz," kusho u-Bausch.
Kungakhathaliseki ukuthi zingakanani, izingxenye zensimbi zidinga ukumiswa ngendlela efanele ngaphambi kokuba ziboshwe.Ukunakekelwa kufanele kuthathwe ukuze kugcinwe igebe eliqinile phakathi kwezinsimbi eziyisisekelo ukuze kuvunyelwe isenzo esifanele se-capillary ngensimbi yokugcwalisa egelezayo.Izingxube ze-Butt, i-lap kanye ne-butt lap ziyindlela engcono kakhulu yokuqinisekisa lokhu kuvunyelwa.
Okuvamile noma ukuzilungisa ngokwakho kuyamukeleka.Izinto ezijwayelekile kufanele zenziwe ngezinto ezingaphenduki kangako njengensimbi engagqwali noma i-ceramic, futhi zithinte izingxenye kancane ngangokunokwenzeka.
Ngokuklama izingxenye ezinama-seams ahlanganisiwe, ama-swaging, ama-depressions noma ama-knurls, ukuzilungisa kungafinyelelwa ngaphandle kwesidingo sokusekelwa kwemishini.
Khona-ke amalunga ahlanzwa nge-emery pad noma i-solvent ukuze kukhishwe ukungcola okufana namafutha, amafutha, ukugqwala, isikali kanye ne-grime.Lesi sinyathelo sithuthukisa nakakhulu isenzo se-capillary yensimbi encibilikisiwe yokugcwalisa ezidonsa ngokwayo ngokusebenzisa izindawo eziseduze zejoyinti.
Ngemuva kokuthi izingxenye zihlezi kahle futhi zihlanzwe, opharetha usebenzisa inhlanganisela ehlangene (ngokuvamile i-paste) ehlangene.Inhlanganisela iyinhlanganisela yensimbi yokugcwalisa, i-flux (ukuvimbela i-oxidation) kanye ne-binder ebamba insimbi futhi ixube ndawonye ngaphambi kokuncibilika.
Izinsimbi zokugcwalisa kanye nama-fluxes asetshenziswa ekubrazini akhiwe ukuze amelane namazinga okushisa aphakeme kunalawo asetshenziswa ekuhlanganiseni.Izinsimbi zokugcwalisa ezisetshenziselwa ukuqinisa ziyancibilika emazingeni okushisa okungenani angu-842 F futhi zinamandla uma zipholile.Zihlanganisa i-aluminium-silicon, ithusi, ithusi-isiliva, ithusi, ithusi, igolide-isiliva, isiliva, nama-alloys e-nickel.
Umsebenzisi ube esebeka ikhoyili yokungeniswa, eza ngemiklamo ehlukahlukene.Amakhoyili angama-Helical anomumo oyindilinga noma ayi-oval futhi azungeza ingxenye, kuyilapho amakhoyili emfologo (noma ipincer) abekwe ohlangothini ngalunye lwehuku yejoyinti kanye nehhuku yamashaneli engxenye.Amanye amakhoyili ahlanganisa Ububanzi Bangaphakathi (ID), I-ID/I-Diameter Engaphandle (OD), I-OpenPosition, i-Pancake, ne-Pancake.
Ukushisa okufanayo kubalulekile ekuxhumekeni kwe-brazed kwekhwalithi ephezulu.Ukwenza lokhu, umqhubi udinga ukuqinisekisa ukuthi ibanga eliqondile phakathi kweluphu yekhoyili yokungeniswa lincane nokuthi ibanga lokuhlanganisa (ububanzi begebe ukusuka ku-coil OD ukuya ku-ID) lihlala lifana.
Okulandelayo, u-opharetha uvula amandla okuqalisa inqubo yokushisisa ilungu.Lokhu kuhilela ukudlulisa ngokushesha amandla ashintshayo amaphakathi noma aphezulu asuka emthonjeni wamandla aye kusihlinzeki ukuze adale inkambu kazibuthe eshintshanayo elizungezile.
Inkambu kazibuthe idala i-current ebusweni bendawo ehlangene, ekhiqiza ukushisa ukuze kuncibilike insimbi yokugcwalisa, ukuyivumela ukuthi igeleze futhi imanzise ubuso bengxenye yensimbi, idale isibopho esiqinile.Ngokusebenzisa amakhoyili anezikhundla eziningi, le nqubo ingenziwa ezingxenyeni eziningi ngesikhathi esisodwa.
Kunconywa ukuhlanzwa kokugcina nokuhlolwa kwengxenye ngayinye ye-brazed.Izingxenye zokugeza ngamanzi ashiswe okungenani ku-120 F kuzosusa izinsalela ze-flux kanye nanoma yisiphi isikali esakhiwe ngesikhathi sokubhula.Ingxenye kufanele ifakwe emanzini ngemva kokuba insimbi yokugcwalisa iqinile kodwa umhlangano usashisa.
Kuye ngengxenye, ukuhlola okuncane kungalandelwa ukuhlolwa okungabhubhisi nokulimazayo.Izindlela ze-NDT zihlanganisa ukuhlola okubukwayo kanye ne-radiographic, kanye nokuhlola ukuvuza nobufakazi.Izindlela zokuhlola ezivamile ezilimazayo ziyi-metallographic, ikhasi, i-tensile, i-shear, ukukhathala, ukudluliswa, nokuhlolwa kwe-torsion.
"Ukufakwa kwe-induction brazing kudinga ukutshalwa kwezimali okukhulu ngaphambili kunendlela yethoshi, kodwa kuyafaneleka ngoba uthola ukusebenza kahle nokulawula okwengeziwe," kusho u-Holland.” Ngokufakwa, lapho udinga ukushisa, uvele ucindezele.Uma ungakwenzi, uyacindezela.”
I-Eldec ikhiqiza imithombo yamandla ehlukahlukene yokufaka i-induction brazing, njenge-ECO LINE MF intermediate frequency line, etholakala ekucushweni okuhlukahlukene ukuze ivumelane kangcono nesicelo ngasinye. Lawa mandla anikezwa amandla atholakala ngezilinganiso zamandla asukela ku-5 ukuya ku-150 kW namaza asuka ku-8 kuye ku-40 Hz. Wonke amamodeli angahlonyiswa nge-opharetha yamandla engeziwe ukuze akhulise amandla angu-10%. I-50% phakathi kwemizuzu engu-3. Ezinye izici eziyinhloko zihlanganisa ukulawulwa kwezinga lokushisa kwe-pyrometer, irekhodi lokushisa kanye nesango elifakiwe le-bipolar transistor power switch.Lezi zinto ezisetshenziswayo zidinga ukunakekelwa okuncane, zisebenza ngokuthula, zinezinyathelo ezincane, futhi zihlanganiswe kalula nezilawuli ze-workcell.
Abakhiqizi ezimbonini eziningana baya ngokuya besebenzisa i-induction brazing ukuze bahlanganise izingxenye.I-Bausch ikhomba ku-automotive, i-aerospace, imishini yezokwelapha kanye nabakhiqizi bemishini yezimayini njengabasebenzisi abakhulu be-Ambrell induction brazing equipment.
"Inombolo yezingxenye ze-aluminium e-induction brazed embonini yezimoto iyaqhubeka nokukhula ngenxa yezinhlelo zokunciphisa isisindo," kusho u-Bausch. "Emkhakheni we-aerospace, i-nickel nezinye izinhlobo zokugqoka zokugqoka ngokuvamile ziboshwe ngama-jet blades.Zombili lezi zimboni ziphinde zifake amapayipi ensimbi ahlukahlukene.”
Zonke izinhlelo eziyisithupha ze-EasyHeat ze-Ambrell zinebanga lemvamisa lika-150 kuya ku-400 kHz futhi zilungele ukugxilwa kokungeniswa kwezingxenye ezincane zejometri ehlukahlukene.Ama-compact (0112 kanye no-0224) anikeza amandla okulawula ngaphakathi kokulungiswa kwama-watts angu-25;amamodeli ochungechungeni lwe-LI (3542, 5060, 7590, 8310) anikeza ukulawula ngaphakathi kwesinqumo samawathi angama-50.
Zombili uchungechunge zinekhanda lomsebenzi elikhiphekayo elingafika kumamitha ayi-10 ukusuka emthonjeni wamandla.Izilawuli zephaneli yangaphambili yesistimu ziyahleleka, okuvumela umsebenzisi wokugcina ukuthi achaze amaphrofayli afinyelela kwamane ahlukene okushisisa, ngalinye linezinyathelo ezifika kweziyisihlanu namandla.Ukulawula amandla esilawuli kude kuyatholakala ukuze kuthintwayo noma okokufaka kwe-analog, noma imbobo yedatha yomkhiqizo ozikhethela yona.
“Amakhasimende ethu ayinhloko e-induction brazing abakhiqizi bezingxenye eziqukethe ikhabhoni, noma izingxenye ezinkulu eziqukethe ingxenye enkulu yensimbi,” kuchaza u-Rich Cukelj, i-Fusion Business Development Manager.” Ezinye zalezi zinkampani zisebenzela izimboni zezimoto nezasemkhathini, kuyilapho ezinye zenza izibhamu, ukuhlanganisa amathuluzi okusika, ompompi bamapayipi namadrayini, noma amabhulokhi okusabalalisa amandla namafusi.”
I-Fusion ithengisa amasistimu ajikelezayo angokwezifiso angakwazi ukufaka i-braze izingxenye eziyi-100 kuya kwezingu-1,000 ngehora.Ngokusho kwe-Cukelj, isivuno esiphezulu singenzeka kuhlobo olulodwa lwengxenye noma uchungechunge oluthile lwezingxenye.Lezi zingxenye zihluka ngobukhulu kusuka ku-2 kuya ku-14 amayintshi skwele.
"Uhlelo ngalunye luqukethe inkomba evela kwa-Stelron Components Inc. enezindawo zokusebenza eziyi-8, 10 noma eziyi-12," kuchaza uCukelj."Ezinye izindawo zokusebenzela zisetshenziselwa ukuqinisa, kanti ezinye zisetshenziselwa ukuhlolwa, kusetshenziswa amakhamera okubona noma imishini yokulinganisa i-laser, noma ukwenza izivivinyo zokudonsa ukuze kuqinisekiswe amalunga aqinile asezingeni eliphezulu."
Abakhiqizi basebenzisa ugesi ojwayelekile we-eldec we-ECO LINE ezinhlobonhlobo zezinhlelo zokusebenza ze-brazing zokungeniswa, njengama-rotor anciphayo namashafti, noma ukujoyina izindlu zezimoto, kusho u-Holland. Muva nje, imodeli ye-100 kW yale generator isetshenziswe ohlelweni lwezingxenye ezinkulu ezibandakanya ukubethelwa kwamasongo esekethe yethusi ukuze kuxhunywe umpompi kagesi we-hydro.
I-Eldec iphinde ikhiqize izinsiza zamandla ze-MiniMICO eziphathwayo ezinganyakaziswa kalula efekthri ngezinga lemvamisa lika-10 kuya ku-25 kHz. Eminyakeni emibili edlule, umkhiqizi wamashubhu okushintshanisa ukushisa kwezimoto wasebenzisa i-MiniMICO ukuze kufakwe i-braze yokubuyisela izindololwane kushubhu ngayinye.Umuntu oyedwa wenza konke ukubhuqa, futhi kuthathe imizuzwana engaphansi kwe-30 ukuhlanganisa ishubhu ngalinye.
UJim ungumhleli omkhulu EMHLANGANENI onolwazi lokuhlela lweminyaka engaphezu kwengu-30.Ngaphambi kokujoyina UMHLANGANO, u-Camillo wayengu-PM Engineer, umhleli we-Association for Equipment Engineering Journal kanye ne-Milling Journal.UJim uneziqu zesiNgisi zaseDePaul University.
Thumela Isicelo Sesiphakamiso (i-RFP) kumthengisi ozikhethele wona bese uchofoza inkinobho enemininingwane yezidingo zakho
Phequlula umhlahlandlela womthengi wethu ukuze uthole abahlinzeki bazo zonke izinhlobo zobuchwepheshe bokuhlanganisa, imishini nezinhlelo, abahlinzeki bezinsizakalo nezinhlangano zohwebo.
I-Lean Six Sigma ibilokhu ishayela imizamo yokuthuthukisa eqhubekayo amashumi eminyaka, kodwa ukushiyeka kwayo kuye kwabonakala.Ukuqoqwa kwedatha kudinga abasebenzi futhi kungathatha amasampula amancane kuphela.Idatha manje ingathwetshulwa isikhathi eside futhi ezindaweni eziningi ngengxenyana yezindleko zezindlela ezindala ezenziwa ngesandla.
Amarobhothi ashibhile futhi asebenziseka kalula kunangaphambili.Lobu buchwepheshe butholakala kalula ngisho nakubakhiqizi abancane nabaphakathi.Lalela le ngxoxo ekhethekile enabaphathi abaphuma kubahlinzeki bemishini bamarobhothi abane abaphambili baseMelika: i-ATI Industrial Automation, Epson Robots, FANUC America, kanye namaRobhothi e-Universal.