斜插阻焊机自动生产线的研究
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摘要
随着世界性能源危机的爆发,各国政府对能源的利用越来越重视,墙体节能做为建筑节能的重要组成部分也受到了广泛的关注。钢丝网架聚苯板外墙保温材料具有保温性能好、易装修、施工简单快捷、周期短、节能效果显著等优点,是目前被广泛推广的建筑墙体保温材料之一。由于其生产设备存在工艺落后、控制单一、设备结构不合理、生产效率低下、漏焊率高等问题,导致产品难以满足市场需求。
本课题以钢丝网架聚苯板的生产设备——斜插阻焊机为研究对象,在对国内外同类产品调研的基础上对生产工艺进行了细分,运用系统化设计法,把整体功能划分为牵引机构,矫直机构、斜插丝机构、断丝机构、焊接机构等几个相互耦合关系的功能模块,各个模块都有独立的驱动系统,使得各功能模块之间能按排定的工艺流程有序的工作,协同完成预定的功能,大大简化了机械结构的设计。然后在此基础上结合各个功能模块的功能进行了必要的数学分析和相关的结构设计。
其次,本论文对电阻点焊熔核形成过程的温度场进行模拟,通过提供必要的控制方程和边界条件,对焊接周期的不同阶段的温度分布进行了模拟。为了得到不同材料的焊接参数,可通过修改模型中焊接参数模拟获得,而不需要进行大量的物理实验,大大节约了成本,并为以后的焊接标准的制定提供参考。
最后,本论文就如何对产品的质量进行控制做了介绍。从生产工艺、原材料、生产设备等方面分析了产生质量问题的原因,在这些分析基础上提出了产品质量控制方案。
Along with the global energy crisis,more and more attention have given to the energy utilization. As an important part of building energy saving,energy saving walls received extensive attention. Polystyrene steel wire mesh frame of exterior insulation materials which have good insulation performance,easy to decorate, simple and quick construction ,remarkable energy-saving,is widely promoted as one of the building wall insulation materials. Because the present equipment existing backward technology, single control, unreasonable equipment structure, low production efficiency, high leakage welding rate problems, which lead to the products can not meet market demand.
Based on the extansive investigation and research,this thesis analyzed and studied the current resistance spot welding machine for polystyrene steel wire mesh frame.New automatic angle-inserting resistance spot welding machinc which is made up of pull unit,straightening uint, sheets-feeder unit,sheet cutting unit and welding unit is researched and designed. The equipment is developed by using the modular design method. Each modules have gotten independent drive system, so every function modules can work as prescribed technics procedure, then cooperate and accomplish the predetermined function.The structure of mechanical is greatly simplified.
Secondly,an invremental and coupled thermal-electro-mechanical finite element model is presented for predicting temperture distribution.By providing the necessary information and boundary conditions,simulations were preformed for different stages of welding cycle.The results provide information on the development of the weld nugget and thus predict the welding quality prior to the actual welding process.The input parameters to the model can bu adjusted to give differert size of the weld nugget.As a result ,optimum setting of the welding parameters for the desired quality and different materials of the workpiece can be obtanined through simulations,without performing large number of physical experiments.
Finally, the necessity of the product quality control is discussed in this paper.The reasons of quality problem have been researed and analyed from the production technology, raw material, production equipment ,then a scheme of controlling quality is propounded.
本课题以钢丝网架聚苯板的生产设备——斜插阻焊机为研究对象,在对国内外同类产品调研的基础上对生产工艺进行了细分,运用系统化设计法,把整体功能划分为牵引机构,矫直机构、斜插丝机构、断丝机构、焊接机构等几个相互耦合关系的功能模块,各个模块都有独立的驱动系统,使得各功能模块之间能按排定的工艺流程有序的工作,协同完成预定的功能,大大简化了机械结构的设计。然后在此基础上结合各个功能模块的功能进行了必要的数学分析和相关的结构设计。
其次,本论文对电阻点焊熔核形成过程的温度场进行模拟,通过提供必要的控制方程和边界条件,对焊接周期的不同阶段的温度分布进行了模拟。为了得到不同材料的焊接参数,可通过修改模型中焊接参数模拟获得,而不需要进行大量的物理实验,大大节约了成本,并为以后的焊接标准的制定提供参考。
最后,本论文就如何对产品的质量进行控制做了介绍。从生产工艺、原材料、生产设备等方面分析了产生质量问题的原因,在这些分析基础上提出了产品质量控制方案。
Along with the global energy crisis,more and more attention have given to the energy utilization. As an important part of building energy saving,energy saving walls received extensive attention. Polystyrene steel wire mesh frame of exterior insulation materials which have good insulation performance,easy to decorate, simple and quick construction ,remarkable energy-saving,is widely promoted as one of the building wall insulation materials. Because the present equipment existing backward technology, single control, unreasonable equipment structure, low production efficiency, high leakage welding rate problems, which lead to the products can not meet market demand.
Based on the extansive investigation and research,this thesis analyzed and studied the current resistance spot welding machine for polystyrene steel wire mesh frame.New automatic angle-inserting resistance spot welding machinc which is made up of pull unit,straightening uint, sheets-feeder unit,sheet cutting unit and welding unit is researched and designed. The equipment is developed by using the modular design method. Each modules have gotten independent drive system, so every function modules can work as prescribed technics procedure, then cooperate and accomplish the predetermined function.The structure of mechanical is greatly simplified.
Secondly,an invremental and coupled thermal-electro-mechanical finite element model is presented for predicting temperture distribution.By providing the necessary information and boundary conditions,simulations were preformed for different stages of welding cycle.The results provide information on the development of the weld nugget and thus predict the welding quality prior to the actual welding process.The input parameters to the model can bu adjusted to give differert size of the weld nugget.As a result ,optimum setting of the welding parameters for the desired quality and different materials of the workpiece can be obtanined through simulations,without performing large number of physical experiments.
Finally, the necessity of the product quality control is discussed in this paper.The reasons of quality problem have been researed and analyed from the production technology, raw material, production equipment ,then a scheme of controlling quality is propounded.
引文
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[2]钱伯章,朱建芳.建筑节能保温材料技术进展.建筑节能,2009,2:56-60
[3]宋继强,曹乾元.浅谈外墙保温与建筑节能.民营科技.2009,4:218
[4]何禹.建筑外墙外保温与内保温优势比较.中国住宅设施.2009,6: 50-52
[5]傅心静.浅议住宅房屋外墙保温节能技术应用.建筑设计,2009,3:146
[6]李静,刘琛.现浇混凝土复合EPS钢丝网架外保温系统在剪力墙结构中的运用.河南建材.2009,3:33
[7]冯金秋.外墙保温技术进展及相关问题讨论.住宅产业.2009,7: 82-87
[8]李茂.专用多点电阻焊设备结构设计及参数控制研究:[硕士学位论文].陕西:西安石油大学,2007
[9]张学军.GWC钢筋焊接网成型机.建筑技术.1997.10:110-111
[10]郝晓东,周和敏,冯光宏.连续式钢筋焊接网生产线及设备研究.机械工程与自动化. 2005,6:45-47
[11]郝晓东.连续式钢筋焊接网生产线及工艺研究.金属制品. 2005,4:19-23
[12]朱正行,严向明,王敏.电阻焊技术.北京:机械工业出版社,2000,6:49
[13] Shih-FuLing,Li-XueWan,Yoke-RungWong, et al. Input electrical impedance as quality monitoring signature for characterizing resistance spot welding. NDT&E International,2010,43:200-205
[13]赵熹华.压力焊.北京:机械工业出版社,1985.31-60
[14] J.Z.Chen ,D.F.Farson.Analytical modeling of heat conduction for small scale resistance spot welding process.Journal of Materials Processing Technology.2006,178:251-258
[15]唐廷乾.电阻点焊的热过程计算及质量控制.电焊机.1981,4:6-10
[16] Gregory Le Meur,Brahim Bourouga ,Jean-Pierre Bardon. Microscopic analysis of interfacial electrothermal phenomena——definition of a heat generation fact. International Journal of Heat and Mass Transfer.2006,79:387-401
[17]李永兵.感应磁场作用下电阻点焊熔核形成过程研究:[博士学位论文].上海:上海交通大学.2005
[18]杨尚磊.钢筋焊接网自动化生产线的研制.焊接技术.2004.8:48-51
[19]谷新珊.钢筋点焊设备与工艺.湖南:湖南科学技术出版社,1985,12:37-60
[20]成都点焊机厂.次级整流电阻焊机.四川:科学技术文献出版社,1978,12:61-88
[21]中国机械工程学会焊接学会,电阻焊专业委员会.电阻焊理论与实践.北京:机械工业出版社,1994,1:118-120
[22]潘际栾.焊接手册:(第一卷)焊接方法与设备.北京:机械工业出版社,1992
[23]张天学,张延欣,张福祥.系统工程学.四川:电子科技大学出版社,2004,8:7-15
[24]杨家本.系统工程概论.湖北:武汉理工大学出版社,2007,6:9-15
[25]王凤歧.现代设计方法.天津:天津大学出版社,2004,9:24-35
[26]于俊.现代设计方法及应用.北京:中国标准出版社.2002,9:120-138
[27]冯厚植.工程设计导论.北京:航空工业出版社.1988,7:31-37
[28]简召全.工业设计方法学.北京:北京理工大学出版社,2003,11:83-95
[29]邵国辉.现代设计方法在水泵设计中的应用.机械设计与制造.2009,8:91-93
[30]王忠祥,贾春满,陆文秀,等.系统化设计法在百叶窗帘设计中的应用.天津轻工业学院学报.1990,10:86-90
[31]李士勇.工程模糊数学及应用.哈尔滨:哈尔滨工业大学出版社.2004,8:96-105
[32]刘晓艳,姚安林,于培林.模糊综合评价法优选城市燃气储气方案.油气储运.2009,8:5
[33]裴中华.系统化设计在机械产品设计中的应用.科技信息.2008,30:333
[34]李艳莉,张海燕.常用间歇机构及其在印刷包装行业中的应用.今日印刷.2008,2:68
[35]苏州特种链条厂、中国工程机械学会链传动专业委员会.输送链与特种链工程应用手册.北京.机械工业出版社。2000,9:20-28,190-193
[36]王继中,胡国栋,华仲新.短钢筋矫直机的设计.东北重型机械学院学报.1992,3:208
[37]刘喜平,曲恩,金付英.盘圆螺纹钢筋矫直机的设计.机械设计.1997,7:31-35
[38]黄庆学.轧钢机械设计.北京:冶金工业出版社.2007,6:22-33
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