Kera Sassan Motoci: Nazarin Misali Kan Haɗawa Mai Inganci Ta Amfani da Robot Mai Aiki Uku

Kera Sassan Motoci: Nazarin Misali Kan Haɗawa Mai Inganci Ta Amfani da Robot Mai Aiki Uku

Na farko, Gabatarwa: Ma'aunin Ciwo da Maganin Haɗa Sassan Motoci

A matsayin ginshiƙin masana'antar kera motoci, kera sassan motoci yana sanya buƙatu masu tsauri kan daidaito, inganci, da kwanciyar hankali a cikin tsarin haɗa motoci. Dole ne a sarrafa juriyar haɗa tubalan injin a cikin ±0.02mm, kuma zagayowar haɗa kayan watsawa dole ne ya cika buƙatun samarwa sama da raka'a 30 a minti ɗaya. Haɗa hannu ba wai kawai yana fuskantar ƙalubalen inganci da ke tattare da matakan ƙwarewa masu canzawa da aiki mai maimaitawa ba, har ma yana fama da biyan buƙatun musamman na haɗa kayan lantarki marasa tsatsauran ra'ayi da rashin mai a cikin sabon zamanin motar makamashi.

Tare da manyan fa'idodin "matsayi mai inganci + amsawa mai sauri + daidaitawa mai sassauƙa," robot masu aiki uku sun zama babban kayan aiki don magance waɗannan matsalolin. Wannan labarin zai yi nazari kan yadda suke cimma nasara a cikin inganci da inganci ta hanyar amfani da kayan haɗin motoci guda uku na yau da kullun.

Dacewar Robots na Servo na Axis na Biyu da na Uku don Haɗa Sassan Motoci

Kafin a fara nazarin shari'o'in, yana da mahimmanci a gano muhimman fannoni inda fasalolin fasaha suka dace da buƙatun masana'antu:

Daidaita Daidaito: Amfani da injin servo na Panasonic na Japan da kuma injin ball sukurori, robot ɗin yana cimma nasarar maimaitawa na ±0.01mm, yana biyan buƙatun dacewa da matsi da haɗawa don daidaiton abubuwan da aka haɗa kamar bearings da gears.

Fa'idar Sauri: Matsakaicin saurin da ba a cika ɗaukar kaya ba ya kai 1.2m/s, tare da lokacin hanzari na ≤0.3s, wanda ya dace da zagayowar taro mai ci gaba bayan an yi tambari da kuma ƙera allura.

Sauƙin Sauƙi: Ana iya sauya shirye-shiryen haɗawa cikin sauri ta amfani da Koyar da Pendant, yana tallafawa haɗakar samfuran sassa daban-daban guda 3-5 (misali, jagororin bawul don injunan da ke da matsuguni daban-daban) akan layin samarwa iri ɗaya.

Dacewar Muhalli: Matsayin kariya na IP65 yana jure yanayin mai na shagon injin, kuma zaɓin haɗa wuyan hannu na anti-static ya cika buƙatun haɗa kayan lantarki na mota.

Na uku, Zurfin Bincike na Nazarin Haɗa Abubuwa Uku na Musamman

Shari'a ta 1: Haɗa Murfin Bulo na Silinda na Injin Mai Aiki da Kai (Mai Kaya na Mataki na 1 na Jamus)
1. Bayanin Aikin
Tsarin haɗa kayan aiki na "mutum biyu + kayan aiki mai sauƙi na pneumatic" na abokin ciniki ya gabatar da mahimman abubuwan zafi guda uku: ① Ƙarfin matsewa mara daidaituwa na bolts ɗin murfin ɗaukar kaya (zagayen canjin ± 5 N·m), wanda ya haifar da ƙarar injin 1.2%; ② Kula da tubalin silinda da hannu (kowanne yana da nauyin kilogiram 35) yana da yuwuwar kamuwa da cuta, wanda ya haifar da ƙimar tarkace na 0.8%; ③ Ƙarfin samar da sau ɗaya raka'a 800 ne kawai, ba su iya cika buƙatun isar da OEM na raka'a 1,200 a kowane sauyi ba.
2. Robot Mai Aiki Uku-Axis Mafita
Tsarin Kayan Aiki: Tafiya ta axis X 1800mm, axis Y 800mm, axis Z 600mm, sanye take da sukudireba na lantarki mai sarrafa karfin juyi da kuma injin tsotsawa na ƙarshen kofin tsotsa;
Inganta Tsarin Taro:
The Robot MuMatsayin hangen nesa na es don kama jikin silinda da kuma jigilar shi zuwa tashar haɗuwa (daidaitaccen matsayi ± 0.02mm);
Sukudirin lantarki mai tuƙi na Z-axis yana ƙara matse ƙusoshin a matakai uku bisa ga shirin da aka riga aka saita (ƙara matsewa 5N·m → sake matsewa 18N·m → ƙara matsewa ta ƙarshe 25N·m), yana ba da ra'ayoyin bayanai na ainihin lokaci;
Bayan an haɗa, ana duba lanƙwasa murfin mai ɗaukar kaya ta atomatik kuma ana ƙin samfuran da ke da lahani ta atomatik.

3. Sakamakon Aiwatarwa
An rage yawan canjin ƙarfin matsewa na Bolt zuwa ±0.5N·m, kuma an rage yawan hayaniyar injin zuwa 0.15%;
An kawar da lalacewar karo a Zhi, kuma an rage yawan tarkacen zuwa 0.03%;
Ƙarfin samar da kayayyaki na aiki ɗaya-lokaci ya ƙaru zuwa raka'a 1,350, kuma an rage farashin aiki da kashi 60%.

Shari'a ta 2: Haɗa Haɗin Ƙwallon Tuƙi na Tuƙi don Sabuwar Chassis ɗin Motar Makamashi (Sabuwar Masana'antar Tallafawa Motocin Makamashi)
1. Bayanin Aikin
A matsayin wani ɓangare na aminci, haɗin ƙwallon ƙafa na sitiyari yana buƙatar tsari mai haɗawa: "haɗa ƙwallon fil + haɗa murfin ƙura + gwajin ƙarfin juyi." Tsarin da ke akwai yana da matsaloli kamar haka: ① Rashin daidaitaccen ikon latsawa (yana iya lalacewa saboda matsin lamba ko sassautawa saboda matsin lamba); ② Haɗa murfin ƙura yana da saurin wrinkles, wanda ya haifar da rashin kyawun rufewa mai hana ruwa shiga; kuma ③ Ba a iya gano bayanan gwajin ba, wanda ya kasa cika buƙatun takaddun shaida na IATF16949. 2. Servo na Axis Uku Robot Smaganin
Tsarin Tsarin: An sanye shi da na'urar firikwensin matsi (± 1N daidai) da kuma tsarin taro mai sarrafa ƙarfi, wanda aka sanye shi da kayan aikin faɗaɗa murfin ƙura na musamman.
Manyan Nasarorin Fasaha:
Kulawa ta ainihin lokaci na lanƙwasa matsin lamba da ƙaura yayin aikin dasawa, nan take kashe na'urar idan lanƙwasa ta kauce daga ma'aunin da aka saba (misali, faɗuwa kwatsam).
Axis ɗin Z yana amfani da yanayin sarrafa ƙarfi mai sassauƙa, yana amfani da matsin lamba na 50N akai-akai a murfin ƙurar, yana tabbatar da cewa babu wrinkles.
Ana loda bayanan tattarawa (ƙarfin matsi, ƙarfin juyi, da lokaci) ta atomatik zuwa tsarin MES, wanda ke samar da lambar bin diddigi ta musamman.
3. Sakamakon Aiwatarwa
An rage yawan lahani na matsewa daga 2.3% zuwa 0.08%, kuma ƙimar wucewar gwajin rufe murfin ƙura ta kai 100%.
An cimma nasarar bin diddigin bayanai na cikakken tsari, inda aka samu nasarar wuce binciken IATF16949 na OEM.
An rage yawan mutane a kowace ma'aikata daga uku zuwa ɗaya, wanda hakan ya ƙara yawan aiki ga kowane mutum da kashi 220%.

Shari'a ta 3: Daidaita Gidajen Firikwensin Motoci (Kamfanin Lantarki na Motoci)
1. Bayanin Aikin
Gidan firikwensin ya ƙunshi tushe na filastik da garkuwar ƙarfe. Haɗawa yana buƙatar izinin 0.05mm kuma babu gogewa (buƙatar gama saman: Ra ≤ 0.8μm). Haɗawa da hannu, saboda man da aka yi da hannu da kuma ƙarfin da bai daidaita ba, ya haifar da lahani har zuwa 3.5%, kuma bai iya biyan buƙatun ƙarfin samarwa na yau da kullun na raka'a 20,000 ba.

2. Maganin Robot Mai Aiki Uku-Axis

Tsarin Musamman: Ana amfani da wani ƙaramin hannu mai zare na carbon (rage nauyi kashi 40%), wanda aka sanya masa kofin injin silicone da tsarin jagorar gani a ƙarshe.

Manhajar Haɗawa:

Tsarin hangen nesa yana gano ramukan da gidan ke sanyawa kuma yana jagorantar robot ɗin don kamawa daidai (lokacin sanyawa ≤ 0.2s).

Ana amfani da dabarar "jagora da farko, sannan a daidaita", inda axis na Z ke tafiya ƙasa da ƙarancin gudu na 0.1m/s don tabbatar da cewa an sanya garkuwar a cikin tushe.

Bayan an haɗa su, ana amfani da na'urar auna haske ta laser don duba gibin da kuma karce-karcen saman. 3. Sakamakon Aiwatarwa
Adadin izinin wucewar mating ya kai kashi 99.92%, kuma an rage yawan lahani na karce a saman zuwa kashi 0.05%.
Lokacin zagayowar haɗawa ya ƙaru zuwa 0.8s/saiti, tare da matsakaicin ƙarfin samarwa na saiti 21,600 a kowace rana.
Ta hanyar rage yawan mai da kuma tsaftace shi, farashin kowanne saiti ya ragu da yuan 0.8.

Na huɗu, Gano Muhimmancin Robots Masu Aiki a Axis Uku

Kamar yadda aka nuna a cikin waɗannan misalan, ƙimarsu a haɗa sassan motoci ta wuce kawai maye gurbin aikin hannu. Maimakon haka, suna cimma ingantaccen "inganci, inganci, da farashi":

Inganta Inganci: Ta hanyar "haɗakar da sauri da tsari," yawan aiki na tashar guda ɗaya yana ƙaruwa da matsakaicin kashi 80% -150%, yana biyan buƙatun isar da motoci na "Kawai-a-lokaci".

Tabbatar da Inganci: Ta hanyar maye gurbin "dogara da ƙwarewa" da "sarrafa bayanai," ƙimar lahani a cikin manyan ayyuka gabaɗaya yana raguwa zuwa ƙasa da 0.1%, yana cika ƙa'idodin ingancin matakin PPM na masana'antar kera motoci.

Inganta Kuɗi: Baya ga rage farashin aiki kai tsaye, ana kuma samun ɓoyayyen tanadin kuɗi ta hanyar rage ɓata lokaci da kuma rage lokacin aiki (rage lokacin sauyawa daga awanni 4 zuwa mintuna 15). Lokacin biyan kuɗi na saka hannun jari yawanci watanni 12-18 ne.

Na biyar, Shawarwari kan Zaɓe da Aiwatarwa

Zaɓi abubuwan da aka haɗa bisa ga halayen abubuwan da aka haɗa:
Daidaitattun kayan aikin injiniya (kamar bearings): Fi son tsari tare da amsawar karfin juyi/matsi.
Manyan kayan aiki masu nauyi (kamar silinda): Ana buƙatar injinan servo masu nauyi (an ba da shawarar ≥500W).
Abubuwan lantarki: Ana buƙatar kayan aikin anti-static da masu tasiri na ƙarshe masu tsabta.
Mayar da hankali kan haɗakar layin samarwa: Ana ba da shawarar a haɗa shi da tsarin duba gani na MES don cimma madauri mai rufewa na "haɗuwa-duba-duba-bin diddigin".
Ba da damar sassauci: Zaɓi samfurin da ke da gatari mai faɗaɗawa (yana tallafawa haɓakawa zuwa gatari huɗu/biyar) don dacewa da maimaitawar samfura na gaba.

Na shida, Kammalawa

A tsakanin sauye-sauyen da masana'antar ke yi zuwa ga samar da wutar lantarki, basira, da kuma rage nauyi, robots masu aiki uku-axis sun samo asali daga kayan aiki na zaɓi zuwa muhimman abubuwa. Ko dai haɗa injuna don motocin gargajiya masu amfani da mai ko haɗa kayan lantarki don sabbin motocin makamashi, suna sake tsara iyakokin inganci na ƙera kayan aiki tare da daidaito da inganci.