Rufin Laser: wata dabarar sake farfaɗo da kore wadda ke saka "super sulfur" a cikin injunan kwal
A ƙarƙashin zurfin ma'adinan kwal, ginshiƙan tallafi na hydraulic a cikin tsarin haƙar ma'adinai na injina suna juyawa ƙarƙashin matsin lamba mai nauyin tan 10,000, magudanar ruwa masu cire ruwa suna niƙawa da gangue na kwal, yayin da silinda na hydraulic ke fama da aiki a cikin yanayi mai danshi da lalata. Waɗannan muhimman abubuwan sun samar da "tsarin ƙarfe" na ayyukan haƙar kwal, suna jure lalacewa mara iyaka, tsatsa, da tasiri a tsawon lokaci. Hanyoyin gyara na gargajiya kamar walda mai rufewa, plating chromium, ko maye gurbin gaba ɗaya ba wai kawai suna da tsada da ɗaukar lokaci ba amma kuma sun kasa biyan buƙatun haƙar kwal na zamani don ayyukan inganci, ƙarancin carbon, da kuma masu araha. Fitowar fasahar rufe laser yanzu tana haifar da "juyin juya halin sake farfaɗo da ƙarfe" mai natsuwa ga masana'antar injinan kwal.
I. Rufin Laser: "tiyata mai kyau" na sake kera injin kwal
Rufin Laser ba wani abu ne mai sauƙi ba a saman, amma wata fasaha ce ta zamani wadda ke samar da wani ƙaramin narkewa a saman kayan tare da hasken laser mai ƙarfi kuma a lokaci guda tana fesa foda na musamman don cimma haɗin ƙarfe tsakanin layin rufi da tushe. Babban darajarsa tana cikin:
Daidaitaccen gyara mai manufa: Ana iya sanya fitilar laser daidai don ya yi laushi da ramukan tsatsa, don guje wa lalacewar da ke cikin ƙasa mai lafiya, musamman don gyara lahani na gida kamar ƙyalli a kan ginshiƙan hydraulic da ƙazanta a bangon ciki na silinda.
Haɗin ƙarfe mai ƙarfi da ƙarfi: Layin rufewa da matrix suna samar da haɗin yaduwar atomic, ƙarfin haɗin yana har zuwa 400MPa, yana kawar da haɗarin barewar plating na chromium gaba ɗaya.
Aiki na musamman: Ta hanyar zaɓar ƙarfe mai jure lalacewa (kamar Stellite 6), ƙarfe mai jure lalata da nickel ko kuma ƙarfe mai ƙarfafa tungsten carbide, ana iya inganta ikon rayuwa na abubuwan da ke cikin mawuyacin hali kamar tasirin gangue na kwal da lalata tururin ruwa na acid.
II. Amfani mai amfani: Daga "share gefen" zuwa "wuce gona da iri"
1. Tallafin ruwa "juyin juya halin tsawaita rayuwa"
Bayan an cire layin chromium da ke saman ginshiƙin hydraulic, ginshiƙin yana da sauƙin tsatsa kuma ya lalace a ƙarƙashin matsin lamba mai yawa. Fasahar rufe laser na iya:
Bayan cire tsohon fenti, an saka wani Layer mai kauri mai kauri 0.8-1.5mm a saman substrate ɗin kai tsaye;
An ƙara taurin zuwa HRC 55-60 (asalin layin plating na chromium shine HRC 40-45 kawai), kuma juriyar lalacewa tana ƙaruwa da fiye da sau 3;
Ana ƙara ƙarfin juriyar tsatsa sosai. Tsawon lokacin aikin ginin ma'adinan a cikin ruwan ma'adinan acid ya kai watanni 18, wanda ya zarce sabon kayan da aka saba da shi (watanni 6-8).
2. An "sake ƙirƙiro" tsakiyar ramin injin ɗin gogewa
Sawa a ƙasan farantin tsakiyar kwano na shekara-shekara yana kaiwa har zuwa 15mm, yayin da maye gurbin gargajiya ke kashe sama da yuan 20,000 a kowace naúra. Maganin rufewa na laser yana amfani da kayan haɗin ƙarfe mai ƙarfi na tungsten carbide zuwa wuraren da ke fuskantar lalacewa a bangon kwano. Ganin cewa ya kai tauri fiye da HRC 62, wannan sabon abu yana ƙara juriyar sawa sau 5-8. Aikace-aikacen gona a wuraren haƙar ma'adinai ya nuna cewa magudanar ruwa da aka gyara ta tsakiya tana tsawaita rayuwar sabis daga watanni 6 zuwa watanni 24, yayin da farashin gyara kowace tan na kwal ke raguwa da kashi 40%.
3. "Sake ginawa" bangon ciki na silinda mai amfani da ruwa
Don magance matsalar rufewa da karcewar bangon silinda ke haifarwa: Tsarin yana amfani da hanyar ciyar da foda mai coaxial tare da bututun laser na musamman don ramuka na ciki, wanda ke ba da damar walda daidai a wurare masu iyaka. Rashin kyawun saman bayan gyara (Ra ≤ 0.8μm) ya zarce sabbin ƙa'idodin injinan kayan aiki. Gwaje-gwajen da aka yi a masana'antar injinan kwal sun nuna cewa silinda da aka gyara sun cimma daidaiton aikin rufewa 100% yayin da suke kashe kashi 30% kawai na samar da silinda.
III. Sauyi Uku: Tattalin Arziki, Inganci da Canjin Kore
| girma | Hanyoyin gargajiya | Sake gyaran fenti na Laser | Amfanin canji |
|---|---|---|---|
| farashi | Sabbin kayan aiki masu tsada don siye | Kudin gyara (20%-50%) | Ɗaya daga cikin ma'auni ya ceci yuan 150,000 |
| Lokaci | Sabuwar gyare-gyaren oda (kwanaki 30 +) | Gyara a wurin (kwanaki 3-5) | Rufe kayan aiki ya ragu da kashi 70% |
| aiki | Mayar da shi zuwa yanayin farko | Inganta juriya ga lalacewa/tsatsa | Tsawon rayuwa ya ƙaru da kashi 200%-300% |
| Kare Muhalli | Gurɓatar da wutar lantarki (chromium ions) | Kusan babu gurɓatawa | Sauya tsarin electroplating mai guba |
IV. Daga gyara zuwa haɓakawa: makomar sake kera injunan kwal mai wayo
Tare da haɗakar fasahohin zamani, rufin laser yana kaiwa ga sabbin matsayi a aikace-aikacen injinan kwal: 1) Tashoshin aiki na robotic masu sarrafa kansu suna ba da damar gyara sassan kamar ginshiƙai da silinda daidai gwargwado, wanda ke ƙara inganci da kashi 50%; 2) Kula da kayan aiki tagwaye na dijital suna sa ido kan lalacewa ta hanyar na'urori masu auna sigina don yin gyaran rufi kafin lalacewa ta faru; 3) Kayan aiki masu aiki na gradient suna haɓaka yadudduka masu haɗa rufi tare da saman waje masu tauri don juriya ga lalacewa da kuma manyan yadudduka na ciki masu juriya ga fashe-fashe, waɗanda ke magance yanayin aiki tare da lalacewa ta hanyar tasiri.