The existing steel structure is a weathered welded structure composed of steel, sheet and stamping. Welding is its primary connection. The welding quality of the sky car, the underframe and the cab in heavy-duty vehicles accounts for more than 50% of the total working hours. Undoubtedly, the electric welder is the main equipment of the manufacturers in the heavy-duty automotive industry. However, for a long time, due to the poor conditions of use, welding machine is in frequent use to maintain repair and maintenance, I believe, the main parties face is the lack of a comprehensive analysis of welding machines, coupled with the use, maintenance, management, and out of touch, not The goal of achieving the lowest equipment cycle cost and the highest comprehensive benefit has delayed the replacement of the welding machine and delayed the development of the Chinese electric welding machine industry for a long time.
Through nearly 16 years of observation, the author has focused on the current use of welding machines and maintenance status of some typical enterprises in Shaanxi, and talked about their own views on the economic life, maintenance, design and development of electric welding machines.
Basic situation of electric welding machine in existing enterprises
(1) There are many types and types of welders, and most of the models purchased are different models produced by different manufacturers. (See Table 1)
It can be seen from Table (1) that there are many varieties of electric welding machines. In terms of composition ratio, the AC welding machine and the CO2 welding machine are the main bodies in the existing welding machine. But for AC welders alone, there are as many as twelve suppliers. Many welder parts are required to be small and complete, and one welder cannot be used with one less. In addition, due to the modification, modification or closure of many welder manufacturers, many welders lacked original parts and were idle.
Type item AC welding machine DC welding machine CO2 welding machine Submerged arc welding machine Automatic welding machine Other welding machine proportion 40% 5% 40% 6% 3% 6%
Type four series 7 varieties three series 6 varieties three series 5 varieties two series three varieties seven series (data provided by Shaanxi Automobile Group Tongli Special Purpose Vehicle Company Power Equipment Division)
(2) The old and miscellaneous welders failed to be scrapped in time, and the economy was not worth the loss. (Table 2)
Type item 5 years or less, 5 years or more, 10 years or more, 10 years or more, AC welding machine, 310 sets, 127 sets, 312 sets of DC welding machines, 4 sets, 7 sets of 9 sets of CO2 welders, 137 sets, 83 sets of 153 sets of submerged arc welders, 16 sets of 16 sets. 9 sets (the above data are provided by the Equipment Power Division of Xi'an Vehicle Factory, Ministry of Railways, which produces train oil tanks)
As can be seen from the data in Table (2), welders used for more than 10 years account for a considerable portion of the total number of welders. The longer the welder is used, the more severe the damage will be. At present, the AC welding machine like the one that I overhauled to Xi'an Vehicle Factory, model BK-500, Shenyang Electric Welder Factory (produced in 1956), its material consumption is greater than the new welding machine. In addition, the BK-500 and BK2-1000 welding machines of the Shanghai Electric Welder Factory in the 1970s are still undergoing overhaul. The longer the welder is used, the more repair time and cost. The cycle repair method has made many overage welders unable to be renewed. In this way, it not only restricts the development of the electric welding machine industry, but also restricts the development of equipment renewal in the manufacturing equipment power sector. From the existing point of view, for BX1, BX6 (35% load duration) welders below 2,000 yuan, the service life should not exceed 5 years; for NBC welders (tap type) should not exceed 6 Year; for ZX5, the NB-K series should not exceed 8 years.
(3) Continuous operation time and high current are the two main causes of damage to the welder.
When the welder is welded at rated current at the rated load duration, the arc welding power source will not exceed its allowable temperature rise, but when the output current changes, the load continuation rate will change, but the bulk flow operation in the enterprise, The welding machine on the production line runs for a long time, and some even work in the rated state or exceed the rated load continuation rate, so that the insulation of the arc welding power source is destroyed, and the related devices are burned.
Repair and repair of electric welders should be carried out in an integrated manner to continuously improve the overall economic benefits. For welders that are technically inoperable or economically unsuitable for continuous use, they should be replaced by more sophisticated and economical welders. This requires a long-term perspective to study and analyze the cost of the welder over its entire life cycle. The relationship is to achieve the best results with the lowest life cycle cost. To this end, we need to start from two aspects, one is to determine the best life of the welding machine. The second is to improve the manufacturing quality of existing welders.
(1) Views on the economic life of the welder
A welder is designed, manufactured, used, and scrapped to form a life cycle. All expenses during this life cycle are mainly composed of purchase and use fees. The purchase fee is a one-time payment, and the usage fee is paid periodically or irregularly during use.
1 The repair man-hour and repair cost of the welder is directly proportional to the service life of the welder. The longer the welder is used, the more serious the damage and the higher the repair cost.
2 Using the welding machine for more than 5 years, the maintenance man-hours and costs are skyrocketing. The repair cost of the BX1, BX6 and BX3 welders, especially for more than 5 years, exceeds the net value, even the value of the new welder.
(2) Improving the quality of existing welding machines is the only way to improve the efficiency of the welding machine.
There are two concepts to improve the efficiency of the welder: one is to improve the efficiency of the welder, and the other is to reduce the inspection time of the welder.
Gradually achieve the maintenance of the welder. No repair is a good thing for operation and overhaul, but the welder has no overhaul or minor overhaul and product quality. Therefore, the only way to improve the efficiency of the welder is to improve the quality of the newly manufactured welder.
1 Improve structural design and coordinate the functional life of each component.
Unsupervised design is the highest limit of idealized design. The so-called non-repair design, that is, the same life design, so that each component reaches the same or similar service life, in addition to the consumables must be replaced, the general parts will not be replaced throughout the life cycle, and will be scrapped at the same time beyond the use period. Of course, in reality, it is difficult to achieve an ideal system, but such a concept requires that our design personnel continue to work hard and gradually realize it in stages.
2 Reform the process to ensure quality.
Whether the welding machine manufacturing process adopts new technology is a constraint to improve the performance and quality of the welding machine. Over the years, product upgrades have been slow, and process is one of the main reasons. The design of the welder is continually updated in terms of process conditions rather than obeying the need for structural reforms. In recent years, this has only improved due to the impact of advanced foreign technological conditions. In the past, the ZX5 and NBK series of primary, primary and balanced reactor windings were all disc-wound, labor-intensive, time-consuming, and costly; now, the primary is barrel-wound, and the secondary and balanced coils are used. Vertical winding, saving labor, saving time and materials. This is the ZX5-based welding machine, which reduces the weight, saves raw materials, improves the coupling coefficient, and brings new improvements in quality.
3 While welding machine manufacturers pay attention to product quality, they should strengthen the production and supply of matching parts and wearing parts to meet the needs of the market. At the same time, designers should use common, common, and good quality welder accessories.
4 At present, while the existing welder manufacturers pay more attention to the appearance, shape, and style, they should pay attention to the inherent quality of the welder, improve the load continuation rate of the welder, and produce according to the national standard.
In short, for the existing welder manufacturers, the company should go deep into the user while listening to the product, listen to the opinions of the maintenance, and feedback the information to the design and manufacturing department to promote the design and manufacture of the welder. To improve the reliability of the welder is a necessary path for our industry to be professional, focused and specialized.
Through nearly 16 years of observation, the author has focused on the current use of welding machines and maintenance status of some typical enterprises in Shaanxi, and talked about their own views on the economic life, maintenance, design and development of electric welding machines.
Basic situation of electric welding machine in existing enterprises
(1) There are many types and types of welders, and most of the models purchased are different models produced by different manufacturers. (See Table 1)
It can be seen from Table (1) that there are many varieties of electric welding machines. In terms of composition ratio, the AC welding machine and the CO2 welding machine are the main bodies in the existing welding machine. But for AC welders alone, there are as many as twelve suppliers. Many welder parts are required to be small and complete, and one welder cannot be used with one less. In addition, due to the modification, modification or closure of many welder manufacturers, many welders lacked original parts and were idle.
Type item AC welding machine DC welding machine CO2 welding machine Submerged arc welding machine Automatic welding machine Other welding machine proportion 40% 5% 40% 6% 3% 6%
Type four series 7 varieties three series 6 varieties three series 5 varieties two series three varieties seven series (data provided by Shaanxi Automobile Group Tongli Special Purpose Vehicle Company Power Equipment Division)
(2) The old and miscellaneous welders failed to be scrapped in time, and the economy was not worth the loss. (Table 2)
Type item 5 years or less, 5 years or more, 10 years or more, 10 years or more, AC welding machine, 310 sets, 127 sets, 312 sets of DC welding machines, 4 sets, 7 sets of 9 sets of CO2 welders, 137 sets, 83 sets of 153 sets of submerged arc welders, 16 sets of 16 sets. 9 sets (the above data are provided by the Equipment Power Division of Xi'an Vehicle Factory, Ministry of Railways, which produces train oil tanks)
As can be seen from the data in Table (2), welders used for more than 10 years account for a considerable portion of the total number of welders. The longer the welder is used, the more severe the damage will be. At present, the AC welding machine like the one that I overhauled to Xi'an Vehicle Factory, model BK-500, Shenyang Electric Welder Factory (produced in 1956), its material consumption is greater than the new welding machine. In addition, the BK-500 and BK2-1000 welding machines of the Shanghai Electric Welder Factory in the 1970s are still undergoing overhaul. The longer the welder is used, the more repair time and cost. The cycle repair method has made many overage welders unable to be renewed. In this way, it not only restricts the development of the electric welding machine industry, but also restricts the development of equipment renewal in the manufacturing equipment power sector. From the existing point of view, for BX1, BX6 (35% load duration) welders below 2,000 yuan, the service life should not exceed 5 years; for NBC welders (tap type) should not exceed 6 Year; for ZX5, the NB-K series should not exceed 8 years.
(3) Continuous operation time and high current are the two main causes of damage to the welder.
When the welder is welded at rated current at the rated load duration, the arc welding power source will not exceed its allowable temperature rise, but when the output current changes, the load continuation rate will change, but the bulk flow operation in the enterprise, The welding machine on the production line runs for a long time, and some even work in the rated state or exceed the rated load continuation rate, so that the insulation of the arc welding power source is destroyed, and the related devices are burned.
Repair and repair of electric welders should be carried out in an integrated manner to continuously improve the overall economic benefits. For welders that are technically inoperable or economically unsuitable for continuous use, they should be replaced by more sophisticated and economical welders. This requires a long-term perspective to study and analyze the cost of the welder over its entire life cycle. The relationship is to achieve the best results with the lowest life cycle cost. To this end, we need to start from two aspects, one is to determine the best life of the welding machine. The second is to improve the manufacturing quality of existing welders.
(1) Views on the economic life of the welder
A welder is designed, manufactured, used, and scrapped to form a life cycle. All expenses during this life cycle are mainly composed of purchase and use fees. The purchase fee is a one-time payment, and the usage fee is paid periodically or irregularly during use.
1 The repair man-hour and repair cost of the welder is directly proportional to the service life of the welder. The longer the welder is used, the more serious the damage and the higher the repair cost.
2 Using the welding machine for more than 5 years, the maintenance man-hours and costs are skyrocketing. The repair cost of the BX1, BX6 and BX3 welders, especially for more than 5 years, exceeds the net value, even the value of the new welder.
(2) Improving the quality of existing welding machines is the only way to improve the efficiency of the welding machine.
There are two concepts to improve the efficiency of the welder: one is to improve the efficiency of the welder, and the other is to reduce the inspection time of the welder.
Gradually achieve the maintenance of the welder. No repair is a good thing for operation and overhaul, but the welder has no overhaul or minor overhaul and product quality. Therefore, the only way to improve the efficiency of the welder is to improve the quality of the newly manufactured welder.
1 Improve structural design and coordinate the functional life of each component.
Unsupervised design is the highest limit of idealized design. The so-called non-repair design, that is, the same life design, so that each component reaches the same or similar service life, in addition to the consumables must be replaced, the general parts will not be replaced throughout the life cycle, and will be scrapped at the same time beyond the use period. Of course, in reality, it is difficult to achieve an ideal system, but such a concept requires that our design personnel continue to work hard and gradually realize it in stages.
2 Reform the process to ensure quality.
Whether the welding machine manufacturing process adopts new technology is a constraint to improve the performance and quality of the welding machine. Over the years, product upgrades have been slow, and process is one of the main reasons. The design of the welder is continually updated in terms of process conditions rather than obeying the need for structural reforms. In recent years, this has only improved due to the impact of advanced foreign technological conditions. In the past, the ZX5 and NBK series of primary, primary and balanced reactor windings were all disc-wound, labor-intensive, time-consuming, and costly; now, the primary is barrel-wound, and the secondary and balanced coils are used. Vertical winding, saving labor, saving time and materials. This is the ZX5-based welding machine, which reduces the weight, saves raw materials, improves the coupling coefficient, and brings new improvements in quality.
3 While welding machine manufacturers pay attention to product quality, they should strengthen the production and supply of matching parts and wearing parts to meet the needs of the market. At the same time, designers should use common, common, and good quality welder accessories.
4 At present, while the existing welder manufacturers pay more attention to the appearance, shape, and style, they should pay attention to the inherent quality of the welder, improve the load continuation rate of the welder, and produce according to the national standard.
In short, for the existing welder manufacturers, the company should go deep into the user while listening to the product, listen to the opinions of the maintenance, and feedback the information to the design and manufacturing department to promote the design and manufacture of the welder. To improve the reliability of the welder is a necessary path for our industry to be professional, focused and specialized.
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