Sarrafa Inganci a Samar da Sarkar Naɗaɗɗe

Sarrafa Inganci a Samar da Sarkar Na'ura: Babban Layin Tsaro don Ƙarfafa Gasar Samfura

A fannin watsa labarai na masana'antu,sarƙoƙi na nadimuhimman abubuwa ne don watsa wutar lantarki da motsi. Ingancinsu kai tsaye yana ƙayyade kwanciyar hankali na aiki, tsawon lokacin sabis, har ma da amincin samarwa na kayan aikin injiniya. Ga kasuwancin kasuwanci na ƙasashen waje, sarƙoƙin naɗawa masu inganci ba wai kawai tushe ne na samun karbuwa a kasuwa ta duniya ba, har ma da mabuɗin gina amincewar abokan ciniki na dogon lokaci. Tun daga lokacin da kayan aiki suka shiga masana'anta har zuwa lokacin da aka aika samfurin ƙarshe zuwa ga abokan ciniki na duniya, kula da inganci a kowane mataki na samarwa yana da mahimmanci kamar gears na kayan aiki na daidai - kowane haɗin yana da alaƙa kuma yana da mahimmanci. Wannan labarin zai zurfafa cikin mahimman hanyoyin inganci a duk lokacin samar da sarƙoƙin naɗawa, yana ba da cikakkiyar fahimta game da yadda za a iya amfani da sarrafawa mai tsari don ƙirƙirar sarƙoƙin naɗawa masu inganci waɗanda suka dace da ƙa'idodin duniya da magance yanayi daban-daban na aikace-aikace.

I. Kula da Tushe: Binciken Kayan Danye—Mataki Na Farko na Inganci

Ana ƙayyade aiki da tsawon lokacin sabis na sarƙoƙin nadi daga matakin zaɓin kayan. Ko da tare da sarrafa daidai, ƙarancin kayan da aka yi amfani da su ba zai samar da samfuri mai inganci ba kuma yana iya haifar da matsalolin sarƙoƙi a matakan samarwa na gaba, wanda ke ƙara farashi. Mun kafa tsarin "duba-bincike" mai tsauri don tantance kayan da aka yi amfani da su, tare da tabbatar da cewa kowane rukuni na kayan da aka yi amfani da su ya cika ƙa'idodin ƙasa da ƙasa (kamar ISO, ANSI, DIN, da sauransu) kuma ya cika buƙatun da aka keɓance.

1. Zaɓin Kayan Aiki na Musamman

Manyan abubuwan da ke cikin sarkar naɗawa sun haɗa da faranti na sarka, naɗawa, bushings, fil, da washers. Bukatun kayan da ake buƙata ga kowane sashi sun bambanta sosai dangane da halayen kayan da ake buƙata da kuma buƙatun aiki:

Faranti na sarka: A matsayin muhimman sassan da ke ɗauke da ƙarfin tauri, dole ne su kasance suna da ƙarfi mai yawa, ƙarfi mai yawa, da kuma juriyar gajiya mai kyau. Mun fi son ƙarfe masu tsari na ƙarfe 20Mn2 ko 30Mn2. Bayan an kashe su da kuma daidaita su, waɗannan ƙarfe na iya samun ƙarfin tauri fiye da 800MPa, suna jure karyewar gajiya da ta faru sakamakon ɗaukar nauyi na dogon lokaci kuma sun dace da aikace-aikacen ƙarfi mai yawa kamar injinan gini da kayan haƙa ma'adinai.

Filo da bushing: Waɗannan suna samar da haɗin sarkar da ke juyawa kuma suna buƙatar kyakkyawan juriya ga lalacewa da tasiri. Yawanci ana amfani da ƙarfe mai tauri na 20CrMnTi. Ta hanyar yin carburizing da kashewa, taurin saman zai iya kaiwa HRC58-62, yayin da zuciyar ke riƙe da wani tauri don hana lalacewa ko karyewa yayin juyawa mai yawa.

Na'urorin Tayi: Waɗannan suna haɗuwa kai tsaye da sprockets kuma suna buƙatar juriya mai kyau ga lalacewa da santsi na saman. Ana amfani da ƙarfe 10# ko 20# gabaɗaya. Maganin Carbonitriding yana ƙara tauri a saman yayin da yake tabbatar da daidaito tsakanin bangon ciki da hannun riga, yana rage gogayya yayin aiki.

2. Cikakken Gwajin Kayan Da Aka Shigo Da Su

Kowace rukunin kayan da ake shigowa ana yin gwaje-gwaje masu tsauri kafin a kawo su domin hana kayan da ba su cancanta shiga tsarin samarwa:

Gwajin Haɗaɗɗen Siminti: Ana amfani da na'urorin auna karatu kai tsaye don yin nazarin sinadaran ƙarfe daidai don tabbatar da cewa abubuwan da ke cikin ƙarfe kamar carbon, manganese, chromium, da titanium sun cika ƙa'idodi na yau da kullun, suna hana lalacewar kayan abu saboda bambancin siminti.

Gwajin Kadarorin Inji: Ana amfani da injunan gwajin tauri da tasiri don gwada ƙarfin tauri na ƙarfe, ƙarfin samarwa, tsayi, da kuma ƙarfin tasiri don tabbatar da cewa kayan aikin injin ɗin sun cika buƙatun sarrafawa da amfani na gaba. Bayyanar da Duba Girma: Ana duba kayan da aka yi amfani da su sosai don ganin an gama saman, karkacewar diamita, da madaidaiciyar su don hana lahani a saman ko kurakuran girma daga shafar daidaiton sarrafawa na gaba.

Gudanar da Tushe: Kowace rukunin kayan aiki an ba ta lambar gano abubuwa ta musamman, tana tattara bayanan masu samar da kayayyaki, rahotannin dubawa, da lokacin isowa. Wannan yana tabbatar da gano matsalolin inganci cikin sauri kuma yana ba da damar daidaitawa kan dabarun haɗin gwiwar masu samar da kayayyaki cikin lokaci.

II. Sarrafa Tsarin Aiki: Tsarin Samarwa - "Injinin" Inganci

Samar da sarkar na'ura mai juyi ya ƙunshi matakai da yawa, ciki har da ƙirƙira, yin tambari, gyaran zafi, da haɗa su. Daidaiton sigogin tsari a kowane mataki yana shafar ingancin samfurin ƙarshe kai tsaye. Ta hanyar kwararar tsari mai daidaito, sa ido kan kayan aiki masu wayo, da kuma kula da ma'aikata masu kyau, muna samun cikakken iko kan tsarin samarwa, muna tabbatar da cewa kowane samfuri ya cika ƙa'idodin inganci.

1. Injin Daidaito: Sarrafa Girma da Daidaito
Tambarin Takardar Sarka: Ana amfani da injunan hudawa masu saurin gudu don yin tambarin faranti na ƙarfe, don tabbatar da cewa daidaiton wurin ramin farantin sarka da karkatar da siffa ana sarrafa su cikin ±0.05mm. Kulawa da maye gurbin mold akai-akai (duba lalacewar mold a kowane tambari 100,000) yana hana karkacewar girman farantin sarka da lalacewar mold ke haifarwa. Bayan an yi tambari, ana cire faranti na sarka ta amfani da injin niƙa girgiza don cire burrs daga ramuka da gefuna don tabbatar da santsi a saman da kuma hana karce a kan wasu abubuwan yayin haɗuwa.

Injin fil, hannun riga, da na'urar birgima: Ana amfani da injinan CNC don juyawa daidai, don tabbatar da cewa an sarrafa juriyar diamita na fil a cikin matakin H6 (tsakanin juriya ±0.011mm), kuma ana sarrafa juriyar ciki da waje na hannun riga da na'urar birgima a cikin matakin H7. Wannan yana tabbatar da cewa rabe-raben da ke tsakanin sassan sun cika buƙatun ƙira (yawanci 0.01-0.03mm). Bayan juyawa, ana niƙa diamita na waje na fil da na'urorin birgima ta amfani da injin niƙa mara tsakiya don ƙara inganta tsatsauran saman (Ra ≤ 0.8μm) da rage asarar gogayya yayin aiki.

2. Maganin Zafi: Ingantaccen Kayan Aiki
Maganin zafi muhimmin mataki ne na inganta halayen injinan abubuwan da ke cikin sarkar nadi. Abubuwa daban-daban suna buƙatar hanyoyin magance zafi da aka tsara don tabbatar da daidaiton tauri, tauri, da juriyar lalacewa:
Maganin zafi na farantin sarka: Ana yin aikin kashewa da zafin jiki mai zafi a cikin tanderu mai ci gaba da kashewa da dumamawa. Ana sarrafa zafin kashewa a 880-920°C, kuma ana sarrafa zafin zafin zafi a 560-600°C. Wannan yana tabbatar da cewa farantin sarka ya kai tauri na HRC28-32, yana samar da isasshen ƙarfi yayin da yake riƙe da ƙarfi mai kyau don guje wa karyewar karyewa a ƙarƙashin matsin lamba. Maganin zafi na fil da hannun riga: Ana amfani da tsarin kashewa da zafin zafi mai ƙarancin zafi. Zafin carburetion shine 900-930°C, kuma ana daidaita lokacin riƙewa gwargwadon kauri na kayan (galibi awanni 2-4). Wannan yana tabbatar da zurfin Layer mai kauri na 0.8-1.2mm. Zafin kashewa shine 850-870°C, kuma zafin zafin zafi mai ƙarancin zafi shine 180-200°C. Taurin saman ƙarshe ya kai HRC 58-62, kuma taurin zuciyar ya kai HRC 30-35, yana cimma juriyar lalacewa da juriyar tasiri.
Maganin zafi na birgima: Ana amfani da Carbonitriding a zafin jiki na 850-880°C da kuma lokacin riƙewa na awanni 3-5. Wannan yana haifar da wani babban tauri, mai jure lalacewa (kauri 0.01-0.03mm) a saman abin nadi, yana inganta daidaito tsakanin bangon ciki da hannun riga da kuma rage haɗarin kamawa yayin aiki. Kula da Ingancin Maganin Zafi: Kowace rukunin abubuwan da aka yi wa zafi magani ana yin gwajin tauri (ta amfani da na'urar gwajin tauri ta Rockwell ko Vickers), gwajin zurfin Layer na carburized (ta amfani da na'urar hangen nesa ta ƙarfe), da gwajin nakasa (ta amfani da alamar dial ko micrometer) don tabbatar da cewa sakamakon maganin zafi ya cika ƙa'idodi. Bugu da ƙari, gwajin daidaiton zafin wutar tanda (kowace kwata) yana tabbatar da cewa bambance-bambancen zafin jiki a cikin tanda mai maganin zafi bai wuce ±5°C a cikin kowane yanki ba don hana bambance-bambancen aikin kayan aiki da bambancin zafin jiki ya haifar.

3. Tattarawa: Tabbatar da Daidaito Gabaɗaya

Haɗawa muhimmin mataki ne wajen haɗa sassan zuwa cikakken sarkar naɗawa, wanda ke shafar daidaiton sautin sarkar, sassauci, da kuma kwanciyar hankali na aiki.

Tsaftace Kayan Aiki: Kafin a haɗa dukkan kayan aiki, ana yin amfani da ultrasonic tsaftacewa don cire mai a saman, ƙazanta, da sikelin, don tabbatar da tsabtar saman da kuma hana ƙazanta daga haifar da farfadiya ko ƙaruwar lalacewa.

Haɗawa Daidai: Ana amfani da injin haɗa sarka mai cikakken atomatik don haɗawa. Motar servo tana sarrafa ƙarfi da zurfin matse fil ɗin, tana tabbatar da daidaito tsakanin fil, bushing, da na'urar birgima, da kuma sarrafa karkacewar siffa a cikin ±0.1mm. Ga manyan sarƙoƙi (fitila ≥ 25.4mm), ana amfani da haɗa sarƙoƙi da hannu. Ana yin gwajin siffa a kowane mahaɗi 10, wanda ke ba da damar daidaita sigogin haɗuwa akan lokaci.

Tsarin Tsaftace Sarka: Bayan haɗawa, ana shimfiɗa sarkar da ƙarfi daidai da kashi 30%-50% na ƙarfin da aka kimanta na tsawon awanni 1-2 don kawar da nakasar roba ta farko, tabbatar da kwanciyar hankali a sautin, da kuma rage tsayi yayin amfani da gaske.

Duba Bayyanar Siffa: Bayan haɗawa, sarkar za ta yi cikakken duba yanayinta don tabbatar da cewa faranti masu haɗin ba su da nakasa ko tsagewa, fil ɗin ba su da sassauƙa ko fitowa, na'urorin juyawa suna juyawa cikin 'yanci, kuma saman sarkar ba shi da ƙazanta, tsatsa, da sauran lahani.

III. Duba Kayayyakin da aka Kammala: Dubawa Mai Kyau - "Layin Kariya na Ƙarshe" don Inganci

Ko da bayan an yi amfani da tsauraran matakan zaɓi na kayan da aka ƙera da kuma sarrafa su, duba kayayyakin da aka ƙera ya kasance muhimmin mataki wajen tabbatar da cewa ingancin sarkar na'ura ya cika ƙa'idodi. Mun kafa tsarin duba kayayyakin da aka ƙera da yawa wanda ya shafi halayen zahiri, daidaiton geometric, da kuma aikin aiki. Kowane rukuni na samfuran yana yin gwaji mai zurfi kuma ba a sake shi ba har sai ya wuce binciken.

1. Gwajin Aiki na Jiki
Gwajin Ƙarfin Tashin Hankali: Ana gwada sarƙoƙi don samun ƙarfin tashin hannu ta amfani da injin gwajin kayan duniya. Dangane da ƙayyadaddun sarƙoƙi da ƙa'idodin da aka saba amfani da su, ana amfani da ƙarfin tashin hannu, kuma ana yin rikodin ƙarfin tashin hannu da tsayi. Ana tabbatar da cewa ƙarfin tashin hannu bai gaza sau 1.2 ba, kuma ana sarrafa tsawon tashin hannun tsakanin 2%-5% (wannan na iya bambanta kaɗan tsakanin ƙayyadaddun bayanai da ƙa'idodi).

Gwajin Rayuwar Gajiya: Ana yin gwajin rayuwar gajiya ta amfani da injin gwajin gajiya na sarka, yana kwaikwayon yanayin aiki na gaske (kamar nau'ikan kaya da saurin canzawa). Ana yin aikin sarkar na dogon lokaci kuma ana rubuta lokacin da gajiya ta gaza don tabbatar da cewa rayuwar gajiya ta cika ƙa'idodin duniya (misali, ISO 606 ya tanadar cewa rayuwar gajiya ta sarkar jerin A a ƙarƙashin nauyin da aka kimanta ba ta ƙasa da zagayowar miliyan 1 ba).

Gwajin Juriya da Sawa: Mai gwajin sawa yana kwaikwayon gogayya tsakanin sarkar da sprocket, yana auna sawar sarkar a cikin wani takamaiman lokaci. Ana ƙididdige yawan sawa don tabbatar da cewa sawar sarkar a ƙarƙashin yanayin aiki mai ƙima bai wuce awanni 0.1mm/1000 ba, wanda ke tabbatar da kwanciyar hankali na dogon lokaci.

2. Duba Daidaito na Geometric

Duba Daidaiton Sauti: Ana amfani da kayan aikin auna sauti don auna sautin kowace hanyar haɗin sarka, yana yin rikodin karkatar da sautin kowace hanyar haɗin. Tarin karkacewar sauti na dukkan sarkar bai wuce jimillar adadin hanyoyin haɗin × 0.05mm ba. Wannan yana hana rashin daidaiton haɗin gwiwa da sprocket yayin aiki saboda karkacewar sauti, wanda zai iya haifar da hayaniya ko girgiza.

Dubawar Kambi: Ana shimfida sarkar a kan teburin gwaji na kwance kuma ana auna matakin kambin sarkar da ke ƙarƙashin nauyinsa. Ana tabbatar da cewa kambin a kowace mita bai wuce 5mm ba. Wannan yana hana sarkar gudu yayin aiki.

Diamita na Naɗi da Duba Zagaye: Ana amfani da ma'aunin diamita na laser don auna diamita na naɗi da zagaye. Ana tabbatar da cewa bambancin diamita da zagaye na naɗin bai wuce ±0.03mm ba kuma kuskuren zagaye bai wuce 0.02mm ba, wanda ke tabbatar da daidaiton haɗin tsakanin naɗin da sprocket.

3. Gudanar da Duba Aiki
Duba Sauƙin Sauƙi: An ɗora sarkar a kan madaidaicin maƙallin kuma ana juya maƙallin da hannu don jin juriyar sarkar. Wannan yana tabbatar da cewa sarkar tana juyawa cikin 'yanci ba tare da ɗaurewa ko hayaniya mara kyau ba. Ana kuma amfani da na'urar gwada ƙarfin juyi don auna ƙarfin juriyar sarkar yayin aiki don tabbatar da cewa bai wuce ƙimar da aka ƙayyade ba (galibi ≤5 N·m, an daidaita shi bisa ga ƙayyadaddun bayanai).

Gwajin Hayaniya: A dakin gwaje-gwajen hayaniya, ana sanya sarkar a kan benci na gwaji kuma ana aiki da ita a gudu daban-daban (misali, 100 rpm, 500 rpm, da 1000 rpm). Ana auna matakin hayaniyar ta amfani da na'urar auna hayaniyar don tabbatar da cewa bai wuce 75 dB(A) ba, wanda hakan ya cika ka'idar hayaniyar kayan aikin masana'antu.

Gwajin Juriyar Tsatsa: Ga sarƙoƙi da aka yi niyya don amfani a cikin yanayi mai danshi da gurɓatawa (kamar waɗanda ake amfani da su a cikin injunan sarrafa abinci da kayan aikin ruwa), ana yin gwajin fesa gishiri (bisa ga ISO 9227, gwajin fesa gishiri mai tsaka tsaki na awanni 48) don gwada juriyar tsatsa a saman sarkar da kuma tabbatar da babu tsatsa ko ɓarna a saman bayan gwajin.
IV. Tabbatar da Tsarin: Takaddun Shaida na Inganci da Ci gaba da Ingantawa - "Tsarin Dogon Lokaci" don Inganci

Kayayyakin sarkar nadi masu inganci ba wai kawai suna buƙatar cikakken iko a kan kowane tsari ba, har ma da cikakken tsarin inganci a matsayin tushe. Mun ɗauki tsarin kula da inganci na duniya mai ci gaba, mun sami takaddun shaida daga ƙungiyoyi masu iko, kuma mun kafa tsarin ci gaba da ingantawa don ci gaba da inganta hanyoyin samar da kayayyaki da ƙa'idodin inganci, tare da tabbatar da daidaito da gasa na samfuranmu.

1. Takaddun Shaidar Tsarin Inganci na Ƙasa da Ƙasa
Mun sami takardar shaidar tsarin kula da inganci na ISO 9001, takardar shaidar tsarin kula da muhalli na ISO 14001, da kuma takardar shaidar tsarin kula da lafiya da tsaro na aiki na OHSAS 18001, inda muka haɗa tsarin kula da inganci cikin dukkan tsarin ƙira, samarwa, tallace-tallace, da sabis bayan tallace-tallace. Bugu da ƙari, samfuran sarkar na'urorinmu sun cika ƙa'idodi da yawa na duniya, kamar ISO 606 (ma'aunin ƙasa da ƙasa), ANSI B29.1 (ma'aunin Amurka), DIN 8187 (ma'aunin Jamusanci), da JIS B1801 (ma'aunin Japan). Za mu iya samar da rahotannin takaddun shaida masu dacewa akan buƙatar abokin ciniki don biyan buƙatun samun kasuwa a ƙasashe da yankuna daban-daban.

2. Ra'ayoyin Abokan Ciniki da Ci gaba da Ingantawa
Mun kafa cikakken tsarin ra'ayoyin abokan ciniki. Ta hanyar tashoshi kamar sake dubawa kan dandamalin cinikayyar ƙasashen waje, ziyarar dawowar abokan ciniki, da sabis a wurin, muna tattara ra'ayoyin abokan ciniki cikin sauri kan batutuwan inganci da shawarwarin haɓakawa yayin amfani. Don ra'ayoyin abokan ciniki, muna kafa ƙungiyoyin haɓaka inganci na musamman don gudanar da cikakken bincike na kayan aiki, hanyoyin samarwa, da ƙa'idodin gwaji, haɓaka matakan haɓakawa da aka yi niyya, da bin diddigin sakamakon haɓakawa don tabbatar da cikakken warwarewa. Misali, don mayar da martani ga korafin abokin ciniki na Turai game da raguwar sassaucin sarkar a cikin yanayin ƙarancin zafin jiki, mun inganta tsarin mai don fil da bushings (ta amfani da man shafawa na roba tare da ingantaccen aikin ƙarancin zafin jiki) da kuma daidaita sigogin maganin zafi don inganta ƙarfin tushen. Bayan gwaje-gwaje da tabbatarwa da yawa, aikin samfurin a -30°C ya inganta sosai, wanda ya sami babban yabo ga abokin ciniki.

3. Horar da Ma'aikata da kuma wayar da kan jama'a game da Inganci

Ma'aikata su ne masu aiwatar da tsare-tsaren inganci kai tsaye, kuma ƙwarewarsu ta ƙwararru da sanin ingancinsu suna shafar ingancin samfura kai tsaye. Muna shirya horon kula da inganci ga ma'aikata akai-akai, wanda ya shafi batutuwa kamar ƙa'idodin ISO, mahimman hanyoyin samarwa, hanyoyin gwaji, da kuma nazarin matsalolin inganci da warware su, don tabbatar da cewa kowane ma'aikaci ya saba da ƙa'idodin inganci da hanyoyin aiki. A lokaci guda, ta hanyar ayyuka kamar "Watan Inganci" da "Gasar Inganci", muna ƙarfafa wayar da kan ma'aikata game da ingancinsu kuma muna ƙarfafa su su gano da warware haɗarin inganci a cikin tsarin samarwa, don haka suna ƙirƙirar yanayi mai kyau inda "kowa yana mai da hankali kan inganci kuma kowa yana shiga cikin inganci."