馬頭牌扭力扳手

1、Tightening Technics & Tools基本的扭緊技術(shù)和工具,What you will learn 我們將學(xué)到什么,Basis on tightening technics 基本的扭緊技術(shù)Tool technologies 工具的扭緊技術(shù)How to select the right tool 如何選擇扭緊工具,2,Introduction 引子,,Tightening of threaded fast

2、eners is found almost everywhere there is an industrial activityfrom maintenance in chemical process plantsto manufacture of lap top computers,3,Introduction 引子,Reasons for using screw joints使用螺栓連接的原因,4,Introduction 引

3、子,Small screws,Self drilling, thread forming screws,Wood screws,Screws for thread cutting in brittle plastics,Screws with different type surface treatment and, with different material quality,HOLDING parts inside househo

4、ld appliances,Sheet metal designs, aluminum boxes, fixing labels, etc.,Furniture, wood industry,Assemblies in plastic housings,Appearance and not to cause corrosion,For:,5,Agenda 內(nèi)容,Basis on tightening technics基本的扭緊技術(shù)T

5、ool technologies工具的扭緊技術(shù)How to select the right tool如何選擇扭緊工具,6,A joint 連接,7,在工業(yè)領(lǐng)域大量采用 優(yōu)于其它的連接方法,Torque definition 扭矩的定義,8,螺栓的夾緊力－螺栓張力,CLAMPING FORCE夾緊力,Clamping force 夾緊力,,TENSION張力,,TORSION扭力,TENSION張力 = CLAMPI

6、NG FORCE夾緊力,Objective目的Create a CLAMPING FORCE創(chuàng)建一個夾緊力,10,張力與夾緊力：大小相等，方向相反！,,TENSION產(chǎn)生張力 10%,,TORSION扭力100％,THREAD FRICTION 螺紋摩擦力40%,Efforts Repartition 影響因素,,,,,,,,,,,,,,,CLAMPING FORCE夾緊力,HEAD FRICTION 螺帽摩擦力50 %

7、,只有10％的扭矩被用來產(chǎn)生了張力！,TORQUE = TENSION + FRICTION,100％＝ 10% ＋ 90%,11,,,扭矩 張力 摩擦力,,,Friction evolution 影響摩擦力的因素,Coefficient of friction on the thread 螺紋間的摩擦系數(shù),12,Torque versus T

8、ension 扭矩和張力,,,,,Torque扭矩Nm,Tension張力 KN,10,,20,,,,20,30,40,50,60,40,,60,,80,,100,,120,,medium-oiled, 輕度浸油,well-oiled, 充分浸油,rough/not oiled 原始狀態(tài),,,Tension dispersal張力的散布誤差 ± 50%,,Final torque目標(biāo)扭矩 ± 2%,,,由此得出

9、一個重要的結(jié)論： 如果其它的因素不能控制，僅僅控制扭矩是遠(yuǎn)遠(yuǎn)不夠的！,13,Minimum torque 最小扭矩,最小扭矩需求,,,部件之間的夾緊力必須大于其外部負(fù)載。,還需留有安全余量，考慮:振動摩擦力的變化 材料的尺寸扭緊的精度,14,Maximum torque 最大扭矩,,施加過大的扭矩勢必加大螺栓的塑性變形,安全余量應(yīng)考慮:扭緊方法的精度螺栓的質(zhì)量,最大的螺栓允許扭矩,15,最大扭矩點,,ISO5393 連接的

10、硬度,硬連接α 720°,扭矩,100%,螺栓開始受力,<30°,>720°,,,α, 角度,,,,,,,,,,,硬,軟,0,5%,達(dá)到目標(biāo)扭矩,,,,16,,Tightening cycle 螺栓扭緊過程分析,Fastener finding (Search socket)尋帽Run down快速旋進(jìn)Elastic area.線性區(qū)Semi-elastic area.半線性區(qū)Pl

11、astic zone.塑變區(qū),,Run down 快速旋進(jìn),Torque扭矩,Angle角度,Elastic area線性區(qū),constant slope 斜率,,,,,,,,,,Finding尋帽,yield point 屈服點,,,,,ΔT,Δα,,,,Plastic zone塑變區(qū),Final 最終扭緊,17,螺栓扭緊過程 - 貼合面,快速旋進(jìn),最終扭緊,扭矩測量,動態(tài)扭矩 在螺栓擰緊的同時用在線式扭矩傳感器測量

12、，如右圖。靜態(tài)扭矩 螺栓安裝后用扭矩扳手測量，如下圖,靜態(tài)扭矩,T (Nm),時間,降落原因：靜態(tài)摩擦力,扭力扳手(靜態(tài)扭矩),工具輸出(動態(tài)扭矩),120-110-100-80-60-40-20-10-0-,,使用扭力扳手時可能會出現(xiàn)的問題,只能檢查扭矩是否太低同時受靜態(tài)摩擦力影響操作者不喜歡使用(生產(chǎn)效率低、人機(jī)工程問題)必須定期校準(zhǔn)測力扳手的誤差較大,In a summary 小結(jié),1

13、) The tightening torque has to be accurate,Conditions to achieve a good clamping force :,24,What you will learn,Basis on tightening technicsTool technologies 工具的技術(shù)How to select the right tool,25,螺栓擰緊過程中的防錯及糾錯,目的,你需要

14、了解和解釋如下:當(dāng)今生產(chǎn)中面臨的挑戰(zhàn)裝配中面臨的常見問題Desoutter五個等級零出錯擰緊詳述,生產(chǎn)面臨的挑戰(zhàn),無論裝配哪種產(chǎn)品，無論是小扭矩或者是大扭矩，個人使用或者工業(yè)生產(chǎn)，其結(jié)果是一樣的，都必須要滿足產(chǎn)品的工藝規(guī)格，也必須保證產(chǎn)品的質(zhì)量！,所有生產(chǎn)廠家面臨同樣的問題,質(zhì)量是生產(chǎn)中的最重要和最主要的因素,產(chǎn)品質(zhì)量低，意味浪費質(zhì)量影響品牌產(chǎn)品質(zhì)量和市場競爭力息息相關(guān)高額的質(zhì)保期費用影響品牌裝配相關(guān),,,從源頭發(fā)現(xiàn)錯誤

15、：提高生產(chǎn)力和質(zhì)量，減少支出,發(fā)現(xiàn)錯誤成本：10-30分鐘操作時間 +材料成本,發(fā)現(xiàn)錯誤成本： > 30分鐘操作時間 + 材料成本或廢次品,發(fā)現(xiàn)錯誤成本： <2分鐘操作時間,,,,客戶發(fā)現(xiàn)錯誤成本：產(chǎn)品價值， 未來的銷售，良好的品牌形象,,錯誤的扭矩,遺漏螺絲/螺栓,壞螺紋,錯誤的螺絲/螺栓,遺忘器件,提早松手,發(fā)生在裝配行業(yè)的一些常見的問題,這些問題要得以發(fā)現(xiàn)和消除,螺栓連接的防錯和糾錯,,,,,,,,,,,,,

16、,,,,Torque OK Pre-determined torque,,Batch of Torques OK Pneumatic Qualifier / Electric Qualifier,,Joint OK Current or Transd. Tool with Angle monitoring,,Multiple Joints OK Current or Transd. Tool with Socket Trays

17、 / Barcode Scanner / Stack light / HMI,Desoutter 六步防錯法,,,Sequence of Joints OK Current or Transd. Tool with Sequence Fastening Process (SFP) + Socket Trays / Barcode Scanner / Stack light / HMI,Sequence + Position of Jo

18、ints OK Current or Transd. Tool with Sequence Fastening Process (SFP) & Encoders or POSCO system + Socket Trays / Barcode Scanner / Stack light / HMI,,,,,,,,,,,,COM = NO ERGO = HANDHELD CLASS = STANDARD,COM = NO

19、ERGO = HANDHELD CLASS = STANDARD,COM = NO/DATA/LOOP ERGO = HANDHELD/ARM/SYSTEM CLASS = STANDARD/ CRITICAL/ SAFETY,COM = DATA/LOOP ERGO = HANDHELD/ARM/SYSTEM CLASS = CRITICAL/ SAFETY,COM = DATA/LOOP ERGO = HANDHELD/

20、ARM/SYSTEM CLASS = CRITICAL/ SAFETY,COM = DATA/LOOP ERGO = HANDHELD/ARM/SYSTEM CLASS = CRITICAL/ SAFETY,,1,2,3,4,5,6,Impact tools 沖擊扳手,精度 : ±30 to ±50%,,,,,硬連接,中性連接,軟連接,流行度,<30,30-360,>360,主要優(yōu)勢.較寬的扭矩范

21、圍 (3.2 to 2850Nm)較低的反作用力高功率重量比,通過沖擊器輸出旋轉(zhuǎn)加沖擊，具有較高的功率重量比,,,,,,反作用力,功率重量比,振動,環(huán)境清潔度,噪音,,,34,Impulse tools 液壓脈沖氣扳機(jī),精度 : ±10 to ±15%,,,,,<30,30-360,>360,主要優(yōu)勢.較寬的扭矩范圍 (3.2 to 450Nm)無反作用力高的功率重量比扭矩可調(diào),,,,,,

22、由高壓油脈沖沖擊扳軸產(chǎn)生旋轉(zhuǎn)加沖擊的效果,35,反作用力,功率重量比,振動,環(huán)境清潔度,噪音,硬連接,中性連接,軟連接,流行度,Shut-off nutrunners 離合器工具,精度: ±7 to ±10%,,,,,<30,30-360,>360,,,,,,主要優(yōu)勢.多用途的工具易于維護(hù)精度高,通過機(jī)械離合器調(diào)節(jié)輸出扭矩,36,硬連接,中性連接,軟連接,流行度,反作用力,功率重量比,振動,環(huán)境清潔

23、度,噪音,Current control 電流型電動扭緊系統(tǒng),,,,,<30,30-360,>360,,,,,,精度 : ±5 % to ±7%,主要優(yōu)勢.多扭緊策略輸出結(jié)果環(huán)保,利用電流來控制扭矩的工具,37,反作用力,功率重量比,振動,環(huán)境清潔度,噪音,硬連接,中性連接,軟連接,流行度,Torque control 傳感器型電動扭緊系統(tǒng),,,,,<30,30-360,>360,,,,

24、,,精度 : ±3% to ±5%,主要優(yōu)勢.保證扭矩質(zhì)量真實的扭矩顯示多扭緊策略環(huán)保,利用內(nèi)置傳感器來控制扭矩的工具,38,反作用力,功率重量比,振動,環(huán)境清潔度,噪音,硬連接,中性連接,軟連接,流行度,Classification of assembly system連接分級,39,Desoutter tools positionning 工具的定位,,扭矩 OK,扭矩+ 批次 OK,連接 + 批次 OK

25、,連接 +批次OK +存儲,100 % 確保,連接 OK,氣動工具，扭矩OK,電流控制 – 連接OK,存儲結(jié)果,連接 OK,40,More Than Productivity,工具選擇,Basis on tightening technicsTool technologiesHow to select the right tool 任何選擇扭緊工具,42,Conclusion,Criticity of the joint (st

26、andard, critical or safety critical)Automatic control needed (OK, NOK)Type of joint (hard, medium or soft)Energy (Pneumatic or Electric)Environment (noise, clean)Torque level,Tool technology must be choosen regardin