Manyan Kurakuran Adafta 5 da ke Haifar da Asarar Hakori a kan Masu Hakora na Caterpillar J300 Series a Aikin Hakora Mai Tasiri

Layin Pin Boss: Yanayin Rashin Daidaita Adafta Mafi Yawa

Babban fil shine fitowar silinda akan adaftar da fil ɗin kullewa ke ratsawa don riƙe haƙorin. A cikin zagayowar lodin ma'adinai inda bokitin ke tasiri a mita 0.5 zuwa 1.2 a kowace daƙiƙa, babban fil ɗin yana fuskantar nauyin yankewa mai zagaye na 80 zuwa 180 kN a kowace zagaye. Bayan awanni 1,500 zuwa 2,500 na aikin ma'adinai na yau da kullun, diamita na boss boss na iya faɗaɗa da mm 2.5 zuwa 4.0 daga lalacewa mai ƙarfi, yana barin fil ɗin ya canza ƙarƙashin kaya.

Da zarar fil ɗin ya yi ƙaura daga wurin da yake zaune, riƙe haƙori zai ragu zuwa kusan kashi 40 cikin ɗari na ƙayyadaddun ƙira. Sannan fil ɗin zai iya fita gaba ɗaya a ƙarƙashin zagayen ɗaukar nauyi na gaba, yana sakin tsakiyar haƙori. Ƙungiyarmu ta ƙarfe ta auna lalacewar boss bore akan adaftar J300 guda 47 da aka dawo da su kuma ta gano cewa adaftar da aka ƙera daga ƙarfen ƙarfe na 30CrNiMo8 da aka kashe zuwa 42-46 HRC sun nuna ƙarancin lalacewar boss da kashi 62 cikin ɗari fiye da adaftar daga ƙarfen carbon na 40Cr a 35-39 HRC. Matrix ɗin alloy na chromium-nickel-molybdenum yana tsayayya da shigar barbashi masu abrasive sosai fiye da ƙarfen carbon mai sauƙi.

Karyewar Rike Zobe

Yawancin masu adaftar J300 suna amfani da zoben riƙewa mai cike da maɓuɓɓuga wanda ke shiga cikin rami a kan hancin adaftar. Ramin zoben yana aiki azaman abin ɗaga damuwa da aka ƙera a cikin yanayin adaftar. A cikin haƙa duwatsu masu ƙarfi inda ƙarfin kololuwa ya wuce 250 kN, ƙananan fasa suna farawa a radius na tushen ramin cikin awanni 300 zuwa 500 na aiki. Bayanan filin daga ma'ajiyar duwatsu 12 na Australiya sun nuna cewa kashi 23 cikin 100 na duk gazawar adaftar J300 ya faru ne sakamakon karyewar tsagi-da-hanci, tare da rabuwar haƙori gaba ɗaya yana faruwa cikin ƙasa da awanni 50 daga fashewar farko da aka gani.

Maganinmu shine tsarin tsagi mai gyara tare da radius na 1.5 mm a tushen (idan aka kwatanta da radius na 0.5 mm na yau da kullun) tare da taurin saman 48-52 HRC ta hanyar maganin zafi daban-daban. Wannan yana ƙara fara fashewa zuwa fiye da awanni 1,800 a cikin gwajin da aka sarrafa. A cikin yanayin ma'adinai muna ba da shawarar tazara na dubawa na awanni 25 saboda ƙimar yaɗuwar fasa a cikin ƙarfe 40Cr shine 0.08 zuwa 0.15 mm a cikin zagayowar 100 da zarar an fara.Tsaron kyanwaka'idoji suna ba da shawarar a duba ramin a kowane sa'o'i 50, amma a cikin aikin hakar ma'adinai, taga fara fasawa ta fi guntu kuma ana yin bincike akai-akai ta hanyar tsananin sakamakon gazawar.

Fashewar Kujerar Adafta daga Yankin da Weld ke Shafar Zafi

Wurin zama na adaftar shine fuskar tsaye inda adaftar ke haɗuwa da leben bokiti. A lokacin aikin walda, yankin da zafi ya shafa a cikin ƙarfen tushe na adaftar zai iya kaiwa digiri 725 zuwa 850 na C, wanda ke haifar da ƙaiƙayi da samuwar martensite a cikin ƙarfe masu matsakaicin carbon. Waɗannan yankunan HAZ suna da ƙimar tasirin Charpy ƙasa da 8 zuwa 12 J a digiri 20 na C, idan aka kwatanta da 27 zuwa 35 J ga ƙarfe na iyaye. Lokacin da wannan yanki mai ƙyalli ya fuskanci lokutan lanƙwasawa na haƙa ma'adinai, fashewar gajiya ta fara a iyakar HAZ kuma ta yaɗu zuwa ƙasa ta cikin kauri na adaftar.

Sau da yawa ba a iya ganin tsagewar daga waje saboda tana farawa ne daga ƙasan fuskar kujera. A cikin wani akwati da aka rubuta daga wani wurin haƙa dutse na Burtaniya, wani injin haƙa mai nauyin tan 40 wanda ke aiki da kashi 85 cikin ɗari na kwararar ruwa ya yanke adaftar J300 ta cikin HAZ bayan sa'o'i 1,100 na aiki ba tare da wata alama ta gani ba. Don kawar da tarkacen HAZ, muna ƙera adaftar J300 daga ƙarfe mai ƙarancin carbon bainitic (kashi 0.18-0.22 cikin ɗari C, kashi 0.8-1.2 cikin ɗari Mn) wanda ke kiyaye ƙimar Charpy sama da 27 J ko da bayan kwaikwayon walda a digiri 850 C. Kafin a fara dumamawa zuwa digiri 200-250 C kafin a yi walda da kuma rage damuwa bayan walda a digiri 300 C na tsawon mintuna 30 yana ƙara rage taurin HAZ ƙasa da 350 HV.

Tsarin Kullewa Yana Ragewa A Lokacin Girgizar Zagaye

Ko da tsarin zahiri ya kasance ba tare da matsala ba, hanyar kullewa na iya sassautawa akan lokaci saboda girgiza mai yawa. Binciken girgiza na injin haƙa J300 a cikin aikace-aikacen haƙa dutse yana nuna mitoci masu rinjaye tsakanin 15 zuwa 45 Hz a lokacin ɓangaren fashewa na zagayowar haƙa, tare da girman hanzari ya kai 5 zuwa 8 g a cikin bokiti. Ma'aunin karfin juyi akan tsarin kulle J300 mai nau'in sukurori ya nuna cewa ƙarfin shigarwa na farko na 350 Nm ya lalace zuwa 180 Nm bayan awanni 120 na aiki a cikin yanayin busassun haƙa. Kasa da 200 Nm, ƙimar dawowar sukurori yana ƙaruwa sosai.

Gwajin da muka yi ya nuna cewa amfani da mahaɗin kulle zare (Loctite 270 ko makamancin haka) a kan sukurin kullewa kafin shigarwa, tare da ƙarfin juyawa na farko na 420 Nm, yana kiyaye ƙimar ƙarfin juyawa sama da Nm 300 bayan awanni 300. Muna ba da shawarar cewa ƙungiyoyin kula da ma'adinai su aiwatar da tazara ta duba karfin juyi na awanni 50 don tsarin kulle J300, wanda zai rage zuwa awanni 25 idan ba a yi amfani da mahaɗin kulle zare ba. A cikin yanayin gogewa, ya kamata a wargaza hanyar kullewa kuma a tsaftace ta kowace awa 500 don cire tarar da ta tara wanda zai iya haifar da karanta karfin juyi na karya.OSHAJagororin kula da kayan aiki masu nauyi suna ba da shawarar tabbatar da ƙarfin juyi a lokaci-lokaci, kuma tsarin kulle J300 yana buƙatar kulawa akai-akai fiye da tsarin yau da kullun saboda yanayin girgiza mafi girma a aikin hakar ma'adinai.

Gajiya ta Kayan Aiki: Yanayin Rashin Nasara da Aka Boye

Gajiya a cikin adaftar J300 yana bayyana azaman hanyoyin sadarwa na fasawa masu ƙananan ƙwayoyin cuta waɗanda ke yaɗuwa ta hanyar simintin sassa a kan dubban zagayowar kaya. A cikin adaftar da aka yi daga ƙarfe na 40Cr na yau da kullun, abubuwan haɗawa da ƙananan ramuka a cikin kewayon micron 50 zuwa 200 suna aiki azaman wuraren fara fasawa. Gwajin gajiya da aka gudanar akan adaftar 30CrNiMo8 (an kashe kuma an daidaita su zuwa 42-46 HRC) idan aka kwatanta da adaftar ƙarfe na 40Cr (35-39 HRC) ya nuna cewa ƙarfen ƙarfe ya cimma zagaye miliyan 1.2 zuwa gazawa a matsin lamba na lanƙwasa 120 MPa, idan aka kwatanta da zagaye 340,000 na ƙarfen carbon.

Abubuwan da ke cikin nickel a cikin 30CrNiMo8 (kashi 1.2-1.6 cikin ɗari Ni) suna taimakawa wajen rage yawan yaɗuwar fasawa ta hanyar ƙaruwar zamewar da ke faruwa a cikin matrix ɗin martensite mai zafi. Ma'anar da ake amfani da ita: adaftar ƙarfe na carbon J300 a cikin aikin haƙar ma'adinai mai ci gaba suna kaiwa ga ƙarancin gajiya a cikin awanni 3,000 zuwa 4,000. Adaftar ƙarfe na ƙarfe na ƙarfe suna tsawaita wannan zuwa awanni 6,000 zuwa 8,000. Duba gani ba zai iya gano gajiya a matakin farko ba. Tsarin da aka tsara kawai shine maye gurbin a tazara na awanni 4,000 don adaftar ma'adinai mai ƙarfi, ba tare da la'akari da yanayin da ake gani ba.

Kwatancen Ƙarfe: Alloy da Carbon Steel

Dangane da gwajin da muka yi na adaftar J300 da aka dawo da su da kuma gwaje-gwajen lalacewar dakin gwaje-gwaje da aka sarrafa, zaɓin ƙarfe shine abu mafi tasiri wajen hana dukkan yanayin gazawa guda biyar.9N4302Hakoran maye gurbin J300, idan aka haɗa su da adaftar ƙarfe mai tauri yadda ya kamata, suna samun tsawon rai na tsawon lokaci sau 2.1 a aikace-aikacen haƙoran dutse idan aka kwatanta da haƙoran iri ɗaya akan adaftar ƙarfe na carbon. Taurin hanci na 48-52 HRC akan adaftar ƙarfe da aka yi wa magani da zafi yana hana lalacewar ramukan fil, yayin da taurin tasirin Charpy sama da 27 J yana hana tsagewar kujera da karyewar tsagi. Muna ba da shawarar masu aikin haƙoran su ƙayyade adaftar ƙarfe na ƙarfe don duk wani mai haƙowa da ke aiki a cikin kayan da ke da ƙarfin matsi sama da 150 MPa ko tare da babban nauyin tasiri.

Game da [Ningbo Yinzhou Join Machinery Co., Ltd.]

Muna ƙera cikakken tsarin GET, gami datsarin haƙoran bokitikumaNingbo Yinzhou Join Machinery Co., Ltd.Adaftar bokiti don Caterpillar J300 da sauran manyan samfuran haƙa rami. Tuntuɓi ƙungiyar injiniyanmu tare da lambar serial na injin ku don takamaiman takamaiman adaftar. Muna tallafawa ayyukan haƙa rami a cikin ƙasashe 40 tare da takaddun sutura da aka ƙera bisa ga ƙa'idodin girma na ISO.

Tambayoyin da ake yawan yi akai-akai

Mene ne yanayin gazawar adaftar J300 da aka fi sani?Lalacewar fil boss ita ce mafi yawan lokuta, wanda ke haifar da kusan kashi 35 cikin 100 na duk gazawar adaftar J300 a aikace-aikacen ma'adinai. Yana faruwa ne sakamakon yawan yankewar cyclic na 80-180 kN tare da haɗakar barbashi masu abrasive a cikin ramin fil.

Shin adaftar J300 na bayan kasuwa za su iya daidaita rayuwar gajiya ta OEM?Eh. Idan aka ƙera shi daga ƙarfen ƙarfe mai ƙarfe 30CrNiMo8 tare da ingantaccen maganin zafi na kashewa da zafin jiki zuwa 42-46 HRC, adaftar bayan kasuwa za su iya daidaita ko wuce lokacin gajiyar OEM. Dole ne haƙurin girma ya dace da bayanan hanci na OEM a cikin ƙari ko rage 0.1 mm.

Sau nawa ya kamata a maye gurbin adaftar J300?Ana ba da shawarar maye gurbin da aka tsara a tazara ta sa'o'i 4,000 ga masu amfani da na'urorin haƙa ma'adinai masu ƙarfi, ba tare da la'akari da yanayin da ake gani ba. Ya kamata a duba gani a kowane sa'o'i 25-50 na aiki.

Shawarar Tsarin Dubawa don Adaftar Ma'adanai na Quarry

Dangane da bincikenmu na dubban adaftar J300 da aka dawo da su, muna ba da shawarar yin amfani da tsarin duba matakai uku don ayyukan haƙa ma'adinai. Mataki na 1 shine duba gani na yau da kullun ta mai aiki kafin zagayowar haƙa ta farko: duba tsagewar da ake gani a kan kujerar adaftar da hanci, tabbatar da haɗakar fil ko zoben riƙewa, da kuma sauraron sautuka marasa daɗi yayin ɓangaren fashewa na zagayowar. Mataki na 2 shine aunawa na mako-mako: yi amfani da ma'aunin ramin pin don auna diamita na ramin boss a wurare huɗu (sama, ƙasa, hagu, dama) kuma yi rikodin ƙimar. Ƙara 2.0 mm daga tushe yana nuna buƙatar jadawali na maye gurbin. Mataki na 3 shine duba rini-shigar HAZ na walda, fuskar kujera, da ramin zobe mai riƙewa kowane wata. Wannan tsari, wanda aka aiwatar a cikin ayyukan haƙa ma'adinai 14 ta amfani da adaftar mu, ya rage abubuwan da suka faru na asarar haƙori da kashi 78 cikin ɗari a cikin lokacin bin diddigin watanni 12.

Mafi kyawun Ayyuka na Shigarwa don Rayuwar Adafta Mafi Girma

Kyakkyawan tsarin shigarwa yana da tasiri mai kyau akan rayuwar sabis na adaftar. Ƙungiyar hidimar filinmu ta rubuta cewa adaftar da aka sanya tare da sigogin walda mara kyau suna rasa kashi 30 zuwa 50 cikin 100 na tsawon lokacin gajiya da ake tsammani. Shawarar sigogin walda don adaftar J300 zuwa lebe na bokitin haƙa sun haɗa da: E7018 ƙarancin hydrogen electrode, zafin zafin zafin da aka riga aka yi zafi 200-250 digiri C da aka shafa a yankin 75 mm a kusa da yankin walda, zafin interpass bai wuce digiri 350 ba, jerin beads na walda farawa daga tsakiya da aiki waje don sarrafa karkacewa, da kuma sanyaya a hankali bayan walda a ƙarƙashin bargo mai rufi don cimma ƙimar sanyaya ƙasa da digiri 50 C a kowace awa. Girman fillet ɗin walda ya kamata ya zama mm 8 zuwa 10 a saman da ƙasan wurin zama na adaftar. Binciken walda ya kamata ya haɗa da gwajin ƙwayoyin maganadisu cikin awanni 24 bayan kammalawa da kuma sake bayan sa'o'i 100 na sabis don tabbatar da sahihancin walda a ƙarƙashin kaya.

Binciken Farashi-Aikin ta hanyar Adafta Kayan Matsayi

Ga masu aikin haƙar ma'adinai waɗanda ke kimanta haɓakawa daga ƙarfen carbon 40Cr zuwa adaftar ƙarfe na ƙarfe na 30CrNiMo8 J300, tattalin arzikin ya dogara ne da yanayin aiki. A aikace-aikacen haƙar ma'adinai na granite inda abun ciki na silica ya wuce kashi 25 cikin ɗari da matsakaicin ƙarfin matsi sama da 200 MPa, farashin kowace awa na aiki ga adaftar 40Cr shine kusan $0.38 a kowace awa (bisa ga farashin siye na $380 da tsawon lokacin sabis na sa'o'i 1,000 akan lalacewar ramin pin kawai, ba wai la'akari da haɗarin karyewa ba). Ga adaftar ƙarfe na ƙarfe na 30CrNiMo8 akan farashin siye na $520 da matsakaicin tsawon lokacin sabis na sa'o'i 2,800, farashin kowace awa ya faɗi zuwa $0.19. Adaftar ƙarfe na ƙarfe na ƙarfe yana ba da raguwar kashi 50 cikin ɗari a kowace awa yayin da kusan kawar da haɗarin gazawar da ke haifar da lokacin hutu ba tare da an shirya ba. Ana dawo da ƙimar ƙarfe na ƙarfe na ƙarfe a cikin sa'o'i 1,400 na farko na aiki a yanayin haƙar ma'adinai na granite. A cikin aikace-aikacen da ba su da tasiri kamar haƙa yumbu, fa'idar farashi tana raguwa amma har yanzu tana fifita ƙarfen ƙarfe mai ƙarancin farashi kusan kashi 25 cikin ɗari a kowace awa ta aiki.

Lalacewar Hanci Mai Adafta da Tasirinsa ga Riƙe Hakori

Hancin adaftar shine saman da aka yi da injin daidai wanda ke haɗuwa kai tsaye da haƙorin bokiti. Fiye da dubban zagayowar kaya a cikin yanayin haƙori, yanayin hanci yana lalacewa a hankali, yana canza yanayin hulɗa tsakanin adaftar da haƙori. Binciken girman da muka yi na adaftar da aka dawo da shi bayan sa'o'i 2,000 na aikin haƙorin dutse ya nuna cewa faɗin hanci ya ragu da matsakaicin 1.8 mm daga ƙayyadaddun asali, kuma tsayin hanci ya ragu da 1.2 mm. Waɗannan canje-canjen girma suna haifar da sassauci tsakanin adaftar da haƙori, suna gabatar da wasa wanda ke hanzarta lalacewa ta fil kuma yana rage ingantaccen yankin canja wurin kaya. Lokacin da share hanci zuwa haƙori ya wuce 0.5 mm, haɗarin gazawar yanke fil yana ƙaruwa da kashi uku. Mafita ba wai kawai a ƙera adaftar don ƙara juriya na farko ba ne, amma a tsara bayanin hanci adaftar tare da tsarin lalacewa wanda ke kula da ingantaccen yanki na hulɗa koda kuwa saman hanci yana lalacewa. Na'urorin adaftar J300 ɗinmu sun haɗa da matsewar digiri 2 a gefen hanci wanda ke ba da damar daidaita kansa yayin da hanci ke lalacewa, yana kiyaye ingancin canja wurin kaya a tsawon rayuwar sabis na adaftar.

Tsarin Kula da Zafi don Ingancin Adafta Mai Daidaito

Abu mafi mahimmanci a cikin ingancin kera adaftar J300 shine sarrafa tsarin sarrafa zafi. Layin maganin zafi namu na adaftar ƙarfe mai ƙarfe ya haɗa da tashar dumama kafin digiri 350 na Celsius na mintuna 30 don rage girgizar zafi, tanda mai kunna wuta a digiri 860 tare da ƙarin ko rage daidaiton zafin jiki na digiri 5 a duk faɗin yankin kaya, tsarin kashe mai tare da girgiza mai sarrafawa wanda ke kiyaye ƙimar kashewa na digiri 55 a kowace daƙiƙa ta hanyar canjin martensite, da kuma tanda mai dumamawa a digiri 450 na Celsius na mintuna 90 don cimma maƙasudin taurin HRC na 42-46. Kowane rukunin maganin zafi ya haɗa da takaddun gwaji guda uku waɗanda aka raba, aka goge, aka goge, aka duba su a ƙarƙashin na'urar hangen nesa ta ƙarfe don tabbatar da cewa tsarin martensite mai zafi ya cika ƙa'idodi. Duk wani rukunin da ke nuna austenite da aka riƙe sama da kashi 3 cikin ɗari ko kuma samuwar hanyar sadarwa ta carbide ana ƙin amincewa da shi kuma ana sake yin maganinsa. Wannan matakin sarrafa tsari, wanda ake ci gaba da shi a cikin sama da rukunin samarwa 10,000 kowace shekara, yana tabbatar da cewa kowane adaftar J300 da ke barin wurinmu ya cika daidai gwargwado na aiki ba tare da la'akari da ranar samarwa ko girman rukunin ba.

Jimlar Kudin Mallaka: Karfe Mai Kauri da Adaftar Karfe Mai Kauri J300

Cikakken jimlar kuɗin nazarin mallakar adaftar J300 a cikin aikin haƙar ma'adinai dole ne ya haɗa da ɓangarorin farashi guda shida: farashin farko na siye, aikin shigarwa, tsawon lokacin aiki a lokutan aiki, farashin lokacin aiki ba a tsara ba (wanda ya bambanta da girman mai haƙa ma'adinai da ƙimar samarwa), farashin maye gurbin idan adaftar ta gaza kafin ƙarshen lalacewa, da kuma dawo da garanti. Ga adaftar ƙarfe 40Cr na carbon a farashin siye na $380, tsawon lokacin sabis ɗin da ake tsammani shine awanni 1,200 a cikin yanayin ma'adinai mai matsakaici, tare da yuwuwar kashi 12 na gazawar da wuri (kafin awanni 800) bisa ga bayanan filinmu daga adaftar da aka bi diddigin su 1,400. Jimlar farashin kowane adaftar gami da haɗarin shigarwa da lokacin aiki shine kimanin $580. Ga adaftar ƙarfe 30CrNiMo8 mai ƙarfe a farashin siye na $520, tsawon lokacin sabis ɗin da ake tsammani shine awanni 3,600 tare da yuwuwar gazawar da wuri na kashi 2. Jimlar farashin kowane adaftar gami da shigarwa da haɗarin dakatarwa shine kusan $720. Duk da cewa adaftar ƙarfe mai ƙarfe mai ƙarfe yana da ƙarin kashi 24 cikin ɗari na jimlar kuɗin aiki, farashinsa a kowace sa'a ɗaya shine $0.20 idan aka kwatanta da $0.48 ga ƙarfe mai carbon, raguwar kashi 58 cikin ɗari. Ga ma'aikatan hakar ma'adinai 10 da ke aiki da injin haƙa ma'adinai waɗanda ke amfani da adaftar a wannan ƙimar, tanadin da aka yi a shekara ya wuce $14,000.