Tsarin Kera Sarkar Na'ura Mai Lanƙwasa ta 12B: Bayyana Daidaiton Tsarin Samarwa na Babban Sassan Watsawa na Masana'antu
A fannin watsawa da sarrafa kayan masana'antu na duniya, sarƙoƙin na'urorin 12B, tare da ƙarfin wutar lantarki mai faɗi, ƙarfin ɗaukar kaya mai ɗorewa, da sauƙin shigarwa da kulawa, sun zama muhimmin kayan aikin watsawa ga injunan haƙar ma'adinai, kayan aikin noma, da tsarin jigilar layin haɗawa. Ingancin dogon lokaci na sarƙoƙin na'urorin 12B a ƙarƙashin aiki mai yawa da yawan aiki ya dogara ne akan tsari mai tsauri da inganci. Daga zaɓin kayan aiki zuwa isar da kayayyaki da aka gama, kulawa mai kyau a kowane mataki na aikin yana da mahimmanci don tantance tsawon rayuwar sarƙoƙin, ingancin watsawa, da juriyar haɗari. A yau, za mu zurfafa cikin cikakken tsarin kera sarƙoƙin na'urorin 12B, muna bayyana cikakkun bayanai na fasaha a bayan wannan "sarƙoƙin na'urori masu inganci."
1. Tsarin Aiki: Matsayin Daidaitacce da Tsarin Zaɓin Kayan Aiki don Sarkar Na'urar Naɗa 12B
Kafin a zurfafa cikin cikakkun bayanai kan tsarin, yana da mahimmanci a fara fayyace "ma'aunin tsari" na sarkar na'urar 12B. A matsayinta na sarkar watsawa wacce ta dace da ANSI B29.1 (ma'aunin sarkar Amurka) da ISO 606 (ma'aunin sarkar duniya), girmanta na asali, kamar faranti (19.05mm), diamita na na'urar (11.91mm), da faɗin ɓangaren ciki (12.57mm), an daidaita su kuma an daidaita su. Babban burin wannan tsari shine cimma matsakaicin aiki ta hanyar kayan aiki da fasahar sarrafawa yayin cika waɗannan ƙa'idodi.
1. Zaɓin Dacewar Tsarin Aiki na Babban Kayan Aiki
Sassan daban-daban na sarkar na'urar 12B suna buƙatar kayan aiki daban-daban da hanyoyin kafin a fara magani saboda yanayin nauyinsu daban-daban:
Fina-finai da na'urori masu birgima: A matsayin manyan abubuwan da ke cikin watsa sarkar da ke jure wa tasiri da gogayya, an zaɓi ƙarfe mai ɗauke da sinadarin SUJ2 mai yawan carbon chromium (daidai da ƙarfen GCr15 na gida). Dole ne a fara yin maganin "spheroidizing annealing" kafin a fara amfani da shi - a dumama ƙarfen zuwa 780-820°C na tsawon awanni 4-6, sannan a sanyaya shi a hankali zuwa ƙasa da 500°C. Wannan tsari yana rage taurin kayan (taurin Brinell ≤ 207 HB), yana inganta injin, kuma yana shimfida harsashi don ƙaramin tsari iri ɗaya yayin maganin zafi na gaba, yana hana tsagewa yayin kashewa.
Faranti da bushings na sarka: Ana buƙatar faranti na sarka don jure wa nauyin tururi, don haka ana amfani da ƙarfe mai ƙarancin carbon ST52-3 (ƙarfin tururi ≥ 520 MPa). Tsarin "ƙuntawa da tururi" (ƙuntawa sannan tempering mai zafi) yana kawo tauri zuwa HB220-250, yana tabbatar da ƙarfin tururi da kuma wani matakin tauri don hana karyewa. An yi bushings ɗin da ƙarfe mai ƙarfe 20CrMnTi, tare da tsarin carburizing na gaba don ƙara tauri a saman don jure gogayya mai zamiya tare da fil.
II. Tsarin Masana'antu na Musamman: Canjin Daidaito daga "Kayan Danye" zuwa "Haɗin Sarka"
Kera sarƙoƙin na'urori masu motsi na 12B ya ƙunshi manyan tsare-tsare guda takwas, kowannensu yana buƙatar cikakken iko na sigogin tsari don tabbatar da daidaito da aiki:
1. Maganin Kayan Danye Kafin A Yi Amfani Da Su: Gyara Hanyar Sarrafawa
Cire Tsatsa da Mai: Da zarar an shiga wurin aiki, ana fara ratsa dukkan ƙarfe ta cikin baho mai rage man alkaline (50-60°C, a jiƙa na tsawon mintuna 15-20) don cire man saman. Sannan a shafa masa sinadarin hydrochloric acid (15%-20% mai yawa, a jiƙa a zafin ɗaki na tsawon mintuna 8-12) don cire ƙura. A ƙarshe, ana wanke shi da ruwa mai tsabta sannan a busar da shi don hana ƙazanta shafar daidaiton sarrafa shi na gaba.
Yankewa Daidai: Dangane da girman kayan aikin, ana amfani da yanke CNC ko yanke laser don yankewa. Dole ne a sarrafa juriyar tsawon yanke fil a cikin ±0.1mm, yayin da yanke farantin sarka dole ne ya kiyaye karkacewar rabon al'amari na ≤0.05% don hana lalacewa yayin buga tambari na gaba.
2. Daidaita Ma'aikata Masu Muhimmanci: Daidaita Matsakaici na Matakan Millimeter
Tambarin farantin sarka da naushi: Ana yin tambarin farantin sarka da naushi a kan injin CNC ta amfani da "ci gaba da ci gaba da matsewa." Da farko ana fitar da tsarin farantin sarka, sannan a bi shi da ramukan fil a ƙarshen biyu. Dole ne a sarrafa juriyar matsayin rami zuwa H7 (tsakanin haƙuri 0-0.018mm), tare da kuskuren nisan tsakiya na rami na ≤0.05mm don tabbatar da daidaiton da ya biyo baya tare da fil ɗin. Ana buƙatar cirewa (ta amfani da ƙafafun niƙa ko niƙa mai girgiza) bayan an yi tambarin don hana gefuna masu kaifi daga cutar da masu aiki ko kuma su tsoma baki tare da haɗuwa. Tambarin Sanyi Mai Juya: Ana samar da ƙarfe SUJ2 a mataki ɗaya ta amfani da injin yin tambarin sanyi mai tashoshi da yawa. Da farko ana yin tambarin, sannan a fitar da shi zuwa siffar abin naɗawa, sannan a ƙarshe a yi tambarin (don sakawa cikin hannun riga). A lokacin da ake yin ƙera kayan sanyi, dole ne a sarrafa zafin jikin mashin (≤200°C) da matsin lamba (300-400 MPa) don tabbatar da cewa kuskuren zagayen abin nadi ya kai ≤0.03mm don hana lalacewa mai yawa yayin aiki.
Kammalawa da Filo: Da farko ana yin amfani da injin niƙa mai kauri ta amfani da injin niƙa mara tsakiya (tare da juriyar diamita na waje na ±0.05mm), sannan a niƙa shi da kyau har zuwa girmansa na ƙarshe (juriya H8, 0-0.022mm) ta amfani da injin niƙa mai silinda. Ana kiyaye ƙaiƙayin saman Ra ≤0.8μm. Wannan santsi saman yana rage gogayya da zamiya tare da hannun riga, yana tsawaita tsawon lokacin aikinsa.
3. Maganin Zafi: Bayar da "Aikin Tauri" ga Abubuwan da Aka Haɗa
Tsarin Zafin Faranti na Sarka: Bayan an buga, ana sanya faranti na sarka a cikin tanderu mai ci gaba da kashewa, ana riƙe su a 850-880°C na tsawon mintuna 30, sannan a kashe su da mai. Sannan a sanya su a cikin tanderu mai zafi a 550-600°C na tsawon awanni 2. Taurin ƙarshe ya kai HB220-250, kuma ƙarfin juriyar yana ƙaruwa zuwa ≥800 MPa, yana tabbatar da cewa za su iya jure nauyin sarkar 12B (≥18.8 kN). Ƙarfin Filo da Na'urar Kashewa + Ƙarancin Zafin Jiki: Ana dumama fil da na'urorin juyawa na SUJ2 zuwa 830-850°C (zafin riƙewa na mintuna 25) a cikin tanderu mai kashe bel, an kashe mai, sannan a rage zafin jiki a 160-180°C na tsawon awanni 2, wanda hakan ke nuna taurin saman HRC 58-62 da kuma taurin zuciyar HRC 30-35. Wannan tsarin "mai tauri na waje, mai tauri na ciki" yana hana lalacewa da tasirin matashin kai, yana hana karyewa. Sleeve Carburizing and Quenching Handle: Ana sanya hannun 20CrMnTi a cikin tanderu mai amfani da carbonizing kuma ana dumama shi a 920-940°C na tsawon awanni 4-6 tare da methanol da propane (masu amfani da carbizing) don cimma sinadarin carbon a saman 0.8%-1.2%. Sannan ana kashe hannun (mai sanyaya 850°C) da kuma rage zafin jiki (180°C). Taurin saman da aka samu shine HRC 58-62, kuma zurfin layin carburized shine 0.8-1.2mm, wanda hakan ke ƙara tsawon lokacin gogayya na hannun riga akan fil ɗin.
4. Haɗakar Modular: Tabbatar da Daidaito Tsakanin Sarka
Haɗin Haɗin Ciki da Waje: Haɗin haɗin ciki ya ƙunshi hannun riga, abin nadi, da farantin haɗin ciki. Da farko, danna hannun riga a cikin ramin fil na farantin haɗin ciki (tsarin tsangwama, ƙarfin da ya dace da dannawa 5-8kN). Sannan, zame abin nadi a kan hannun riga (tsarin tsangwama, sharewa 0.02-0.05mm). Haɗin waje ya ƙunshi fil da farantin haɗin waje. Ana danna fil ɗin a cikin ramin farantin haɗin waje (tsarin tsangwama). Bayan dannawa, duba ko akwai daidaito (ɓacewa ≤ 0.5°) don hana ɗaurewa yayin aiki.
Cikakken Haɗa Sarka da Gabatar da Shi: Ana haɗa hanyoyin haɗin ciki da na waje don samar da cikakken sarka. Bayan haka sai a yi amfani da "maganin shimfiɗawa" - ana amfani da ƙarfin tensile na kashi 80% na nauyin da aka ƙididdige (kimanin 15kN) a kan injin gwaji na musamman na tsawon mintuna 30. Wannan yana kawar da tsawaita sarkar farko kuma yana ba da damar sassan su dace sosai. Wannan yana ba da damar sarrafa tsawaitawa ta gaba cikin kashi 0.5% (idan aka kwatanta da matsakaicin masana'antu na 1%-1.5%).
III. Tsarin Kula da Inganci: Duba Cikakken Tsarin Aiki don Kawar da Kayayyaki Marasa Inganci
Ana yin gwaje-gwaje masu girma dabam-dabam don tabbatar da bin ƙa'idodin ƙasashen duniya. Matakan gwaji na musamman sun haɗa da:
1. Duba Daidaito na Girma
Ana amfani da na'urar auna daidaito mai girma uku (CMM) don duba ma'auni masu mahimmanci kamar nisan tsakiyar ramin sarkar, diamita na waje na shaft ɗin fil, da diamita na nadi. Ana gudanar da samfurin guda 20 bazuwar a kowane rukuni, tare da ƙimar wucewa 100%.
Ana amfani da ma'aunin bugun dutse don duba bugun sarkar. Bambancin bugun dutse a kowace mita dole ne ya zama ≤0.3mm don tabbatar da daidaiton haɗin gwiwa tare da sprocket.
2. Gwajin Halayen Inji
Gwajin Ƙarfin Tashin Hankali: Sarkar tana fuskantar matsin lamba a kan injin gwajin tashin hankali har sai ta karye. Dole ne nauyin karyewar ya kasance ≥ 28.2kN (ya wuce nauyin da aka kimanta na 18.8kN sosai) don tabbatar da aminci idan aka yi amfani da shi fiye da kima.
Gwajin Rayuwar Gajiya: An ɗora sarkar a kan "injin gwajin gajiyar sarka" kuma an sanya ta a cikin kashi 50% na nauyin da aka kimanta (kimanin 9.4kN) a gudun 1500r/min. Dole ne tsawon lokacin gajiyar ya kasance ≥ awanni 500 (ma'aunin masana'antu shine awanni 300), wanda ke kwaikwayon aminci a ƙarƙashin yanayin ɗaukar nauyi na dogon lokaci.
3. Duba Ingancin Fuskar
Yi amfani da na'urar gwada taurin saman don duba saman fil da abin nadi; ƙimar Ra dole ne ta kasance ≤0.8μm.
Duba maganin saman (misali, yin galvanizing, yin baƙi): kauri na layin galvanizing dole ne ya kasance ≥8μm kuma bai nuna tsatsa ba bayan gwajin feshi na gishiri na awanni 48 (feshin gishiri mai tsaka tsaki, maganin NaCl 5%). Maganin yin baƙi dole ne ya kasance iri ɗaya kuma ba shi da tabo, kuma mannewa dole ne ya cika ƙa'idar GB/T 10125.
IV. Darajar Sana'a: Me yasa sana'a mai inganci ke ƙara ƙarfin kasuwar sarƙoƙin na'urori masu juyawa 12B?
Fa'idodin fasaha na sarkar na'urar juyawa ta 12B sun fassara kai tsaye zuwa daraja:
Tsawon Rai: Ta amfani da kayan SUJ2 da kuma maganin zafi daidai, sarkar tana da matsakaicin tsawon rai na awanni 8,000-10,000, fiye da 40% fiye da sarƙoƙi na gargajiya (awanni 5,000-6,000), wanda ke rage farashin maye gurbin da lokacin aiki.
Ya fi kwanciyar hankali wajen watsawa: Daidaiton girman matakin milimita da kuma shimfiɗawa kafin a fara aiki yana tabbatar da cewa sarkar ta yi aiki da ≤0.1mm, wanda hakan ke tabbatar da ingancin watsawa sama da kashi 98%, wanda hakan ya sa ya dace da aikace-aikacen sauri kamar injunan yadi da layukan haɗa kaya ta atomatik.
Mai sauƙin daidaitawa sosai: Zaɓuɓɓukan hanyoyin gyaran saman (galvanizing, blackening, da phosphating) da kuma hanyoyin magance zafi na musamman (kamar rage zafin jiki don yanayin zafi mai ƙarancin zafi) sun cika buƙatun aiki daban-daban. Misali, ana iya amfani da sarƙoƙi masu galvanized a masana'antun sarrafa abinci don hana tsatsa, yayin da sarƙoƙi masu galvanized za a iya amfani da su a cikin kayan aikin haƙar ma'adinai don juriya ga ƙura da lalacewa.
Kammalawa: Sana'a ita ce "Fa'idar Gasar da Aka Boye" ta Sarkunan Roller na 12B
A kasuwar sarkar na'urorin 12B ta duniya, "ƙarancin farashi" ba shine babban fa'ida ba. Madadin haka, "daidaitaccen tsari" da "kwanciyar hankali" sune mabuɗin samun amincewar abokan ciniki na ƙasashen waje. Daga ƙa'idodi masu tsauri a cikin zaɓin kayan masarufi, zuwa sarrafa matakin milimita a cikin tsarin masana'antu, zuwa cikakken dubawa kafin jigilar kaya, kowane tsari yana da alƙawarin tabbatar da ingancin samfura.
Lokacin Saƙo: Satumba-15-2025