Ikarita y'ubushakashatsi: Guhitamo ibyuma bya aluminiyumu n'uburyo bwo kuvura ubushyuhe kuri adaptateri z'indobo zishaje

A Adaptateri y'amenyo ya Komatsu mu ndoboni isano iri hagati y’inkombe y’indobo yo gucukura n’umutwe w’iryinyo ushobora gusimburwa. Ifata imbaraga zose zo gucukura — ku imashini yo gucukura ya PC200 ishobora kugera kuri 140 kN ku mutwe w’iryinyo ry’indobo — ikayikura mu ryinyo inyuze kuri adaptateri ikayishyira mu munwa w’indobo. Iyo adaptateri yacitse cyangwa yangiritse ku mwobo w’ipine, umutwe w’iryinyo uratakara maze umukozi agomba guhagarika gucukura, akagarura iryinyo, hanyuma agasimbuza adaptateri — akazi k’iminota 25 ku madolari 2–3 ku munota mu giciro cy’imashini idakoresha.

Mu ruganda rwacu rwo muri JM Ubushinwa, dukoresha adaptateri za Komatsu mu byuma bito bya martensitic — ubusanzwe 30CrMnSi cyangwa 35CrMo — kuko izi alloys zigera ku bukomere busabwa bwa HRC 45–52 nyuma yo kuzimya no gushyushya amavuta mu gihe zigumana ubukomere buhagije bwo gukurura ibintu mu kazi ko gucukura. Uburyo bwo gucukura bukoresha ifuro ryatakaye hamwe n’umucanga wa silica. Nyuma yo gucukura, buri adaptateri irashyirwa kuri 920°C mu gihe cy’amasaha 2, ikabikwa kuri ubushyuhe bw’icyumba, hanyuma ikavugururwa kuri 250°C mu gihe cy’amasaha 3 kugira ngo igere ku bukomere bukenewe. Intambwe yo gushyushya ni ingenzi: kuyireka maze adaptateri iracikagurika kuri HRC 58–60, ishobora kuvunika ku ibuye rya mbere. Ishyushye cyane kuri 350°C kandi ubukomere bugabanuka bukagera kuri HRC 38–42, bigabanya igihe cyo kwangirika ho 40%.

Dufite uburyo bwo gukanika bwa HRC 48 ± 3 kuri adaptateri zisanzwe za Komatsu na HRC 52 ± 2 kuri verisiyo ikomeye yagenwe n'abashinzwe gusenya. Ubukana bwemezwa n'ibipimo bitatu bya Rockwell C kuri adaptateri: kimwe ku mutwe w'izuru (agace gafata iryinyo), ikindi ku giti cy'amenyo (agace gafata pin yo kubika), n'ikindi ku gice cyo hejuru (agace gasudira cyangwa gafata ku munwa w'indobo). Ubukana bw'umutwe w'izuru bugomba kuba mu ngingo 2 za HRC z'igiti cy'amenyo - bitabaye ibyo, gukanika hagati y'ubuso bwombi byihutisha kurekura kw'amenyo. Niba umutwe w'izuru woroshye (HRC 42) mu gihe pin boss ikomeye (HRC 50), umutwe w'izuru urambara vuba 30% kandi iryinyo rikagira umupira wo ku ruhande nyuma y'amasaha 120. Umukoresha ntashobora kumva uku gukanika muri kabine - ariko pin yo kubika ubu irimo gutwara umutwaro wo ku ruhande itari yagenewe, kandi gukata pin itaragera igihe birashoboka.

Muri Mutarama 2025, twagerageje adaptateri 50 zo mu itsinda rishya ry’ibikoresho byo gukata ugereranyije na 50 zo mu musaruro wacu uriho ubu. Itsinda rishya — ryakozwe mu bushyuhe butandukanye gato bwa 35CrMo — ryagaragaje ubukana bw’ubukana bwa 3.8 HRC mu mpuzandengo, ugereranije na 1.6 ku itsinda ririho ubu. Impamvu nyamukuru ni ubushyuhe bw’amavuta yo gukata bungana na 15°C ku munsi wa mbere w’itsinda rishya ry’ibikoresho byo gukata, byagabanyije ubukana bwa quench ku mutwe w’izuru rito ariko ntabwo byari ku mwanya munini w’imashini. Twasubije amavuta yo gukata ubukana kuri 45°C maze twemeza ko ubukana bwa quench bwasubiye ku mpuzandengo ya 1.6 mu minsi ine yakurikiyeho y’ibikorwa. Adaptateri 50 zo mu itsinda ridasanzwe zagabanutse zikajya ku "musoro usanzwe" kandi zigurishwa ku giciro gito ku bikorwa bidasaba imbaraga nyinshi.

Raporo y'umusaruro: Guca, Gutunganya Ubushyuhe, no Kwemeza mu buryo bw'ibipimo by'ama-adaptateri ya Komatsu K-Series

Imiterere ya Komatsu K-series pin — ikoreshwa kuri PC30 kugeza kuri PC800 excavator models — igaragaza agace gato k’agapira gafite inguni ya 2° iri ku myobo yo hejuru n’iyo hasi, umurambararo wa pin wihariye (12 mm kuri PC50 kugeza kuri 30 mm kuri PC650), n’intera iri hagati kuva ku zuru kugeza ku ndunduro itandukana bitewe n’ingano ya adaptateri. Gutandukana kwa mm zirenga 0.3 mu mwanya w’agapira pin bivuze ko agapira gafata kadashobora gushyirwa mu ryinyo no mu myobo ya adaptateri — kandi adaptateri yose ni ibisigazwa. Ubu buhanga bugerwaho binyuze mu guhuza CNC machining nyuma yo gucukura hamwe n’igikoresho cyihariye kigaragaza urwego rw’ibanze rw’adaptateri.

Dukoresha buri adaptateri mu buryo bumwe ku gice cy’imashini gihagaze gifite umurongo une. Urukurikirane rw’imikorere ni: (1) kureba aho ifatizo rishyirwa - yerekeza ku ngingo zigaragaza aho ifuro ryatakaye; (2) gucukura no gukata agace k’impini hakurikijwe ubushobozi bwa H8 (urugero, 20.0 +0.033/0.000 mm kuri adaptateri ya PC200); (3) gusya umuyoboro wo gufata amenyo ku mutwe w’izuru; na (4) gucukura umwobo unyuze mu gasanduku k’impini kugira ngo habeho imashini ifata. Nyuma yo gukora, buri adaptateri igenzurwa ku mashini ipima (CMM) ifite ubushobozi bwa mm 0.005. Ibipimo by’ingenzi - umurambararo w’agace k’impini, intera iri hagati y’agace k’impini n’isura, n’ubugari bw’agace k’izuru - bipimwa kandi bigashyirwa mu nyandiko ijyanye n’ibyoherezwa byose bigezwa ku bacuruzi b’Abayapani.

Mu 2024, twakoze adaptateri 38.000 zihuye na Komatsu mu ngano 20. Igipimo cyo kwangwa cyari 1.1%, bivuze ko adaptateri 418 zananiwe kugenzura CMM kandi zarakuweho cyangwa zigasubirwamo. Ikosa ryakunze kugaragara - 62% by'ibyanze byose - ni aho pin bore iherereye: intera yo hagati kugera ku idirishya ryo kwihanga yari hanze y'idirishya rya ± 0.3 mm. Ibi twabikurikiranye ku ihindagurika ry'ubushyuhe mu mashini zisanzwe: castings zari zarakonje buhoro mu ibumba (kubera ubushuhe bwinshi bw'umucanga) zagaragaje 0.15-0.2 mm yiyongereye ku mutwe w'izuru, zihindura aho pin bore iherereye ugereranyije n'aho yerekeza. Umuti wo gushongesha kwari ugushyira mu bikorwa gukonjesha ibumba rigenzurwa rya 180 ± iminota 10 mbere yo gukonjesha - mbere, igihe cyo gukonjesha cyaterwaga n'ubushobozi bw'umukoresha kandi cyari hagati y'iminota 120 na 240. Nyuma yo gushyira mu bikorwa gukonjesha gugenzurwa, igipimo cyo kwangwa aho pin bore iherereye cyagabanutse kuva kuri 0.68% kigera kuri 0.19%.

Ku bacuruza ibikoresho by’ubwubatsi b’Abayapani — basanzwe bafite ububiko bw’ibikoresho biri hagati ya 200 na 500 kuri buri ngano — sisitemu yo gukurikirana ibikoresho dutanga ituma bashobora kumenya adapter iyo ari yo yose hakurikijwe umubare wayo no kubona raporo y’uburyo bwo gukata, imbonerahamwe yo gutunganya ubushyuhe, na raporo y’ingano ya CMM. Ubu buryo bwo gukurikirana ibikoresho bukomeje gukurikizwa na sisitemu zo gucunga ubuziranenge z’ibigo by’ubwubatsi by’Abayapani, zisaba ko ibice byose byangirika bitangwa kuriIshyirahamwe ry'ibikoresho by'ubwubatsi mu Buyapaniamasosiyete y’abanyamuryango afite inyandiko zuzuye z’amateka y’inganda.

Amakuru yo mu murima: Imikorere ya sisitemu yo kubika PIN mu gihe cyo gushyiramo uruziga

Sisitemu yo kubika pin - icupa ry'icyuma cyangwa polyurethane rifunga pin ikomeza - ni cyo gice gito cyane cy'iteranya ry'adaptateri ariko ni cyo gikunze gutuma umurima unanirwa. Iyo icyuma gihagarika pin gicitse cyangwa kidakora neza, pin ikomeza pin ikora neza bitewe n'ihindagurika ry'imashini, maze umutwe w'iryinyo ugwa kuri adaptateri mu gihe cy'amasaha 10-20 yo gukora. Iryinyo ryatakaye ahantu hasenywe mu mujyi wa Tokyo rwagati - aho icyuma gicukura PC350 cyamenaga ibyuma bya sima - bivuze ko imashini igomba guhagarara, uyikoresha agomba kumanuka, agashaka iryinyo mu kirundo cy'imyanda (bishobora gufata iminota 10 ahantu huzuye), akarigarura, hanyuma akarishyiraho icyuma gishya cyo kubika pin. Ku giciro cy'imashini kingana na $80 ku isaha yo gukora no guhagarara iminota 30 bitateganyijwe, buri gutakaza iryinyo rimwe ritwara $40 mu gihe cy'imashini idakora - hiyongereyeho ikiguzi cy'umukozi n'umugenzuzi w'umutekano w'aho hantu.

Twagerageje ibikoresho bitatu byo gukata amenyo ku mashini ikora akazi ko gupakira amenyo mu kigo cyacu cya Zhengzhou mu 2024: (1) icyuma cy’impeshyi cya 65Mn, gishyushye gikoresheje HRC 44–48; (2) icyuma cy’impeshyi cya 60Si2Mn, gishyushye gikoresheje HRC 46–50; na (3) ubukana bwa polyurethane 95A Shore. Ikizamini cyanyuze muri buri gice mu mizingo 50.000 yo gukuramo amenyo ku muvuduko wa 0.5 Hz - biganisha ku ihinduka ry’amenyo ryose mu gihe cy’imyaka 2. Udupapuro twa 65Mn twagaragaje ko imbaraga za clip force zangiritseho 22% nyuma y’amasaha 50.000 - kuva kuri 280 N ya mbere ya force retention force kugeza kuri 218 N. Udupapuro twa 60Si2Mn twagaragaje ko 15% byangiritse - kuva kuri 300 N kugeza kuri 255 N. Udupapuro twa polyurethane twagaragaje ko 35% byangiritse - kuva kuri 200 N kugeza kuri 130 N - naho dutatu muri 20 twa polyurethane twacitse aho clip-to-pin ihurira hagati y’amasaha 30.000 na 38.000.

Dushingiye kuri ibi bisubizo, ubu dukoresha uduce tw'icyuma twa 60Si2Mn nk'ibisanzwe ku ngano zose za adaptateri za Komatsu ziri hejuru ya PC200, kandi dutanga uduce twa 65Mn ku ngano nto za PC70 na PC130 aho umuvuduko wo hasi w'uduce uhagije ku mutwaro ntarengwa w'amenyo wa 20 kN. Uduce twa polyurethane turacyaboneka mu bikorwa bitari ngombwa nko gusuzuma amenyo y'indobo ariko ntibyemewe mu gusenya cyangwa gucukura amabuye. Dufite itsinda ry'uduce icumi tw'inyongera two kubikamo uduce hamwe na buri pallet y'uduce 50 twoherezwa ku bacuruzi b'Abayapani - igikorwa cyakiriwe neza kuko uduce ari two dukunze gutakaza igice gito mu bikorwa byo gusana umurima.

Ibisubizo by'ikizamini: Igereranya ry'ubudahangarwa bw'uburibwe mu byiciro by'ubukomere

Twakoze ikizamini cyo gushwanyagurika gicungwa ku buryo bugenzurwa tugereranya icyuma cya adaptateri ku rwego rune rw'ubukomere: HRC 38, HRC 45, HRC 50, na HRC 55. Buri cyitegererezo cyari isahani ya 50 mm × 50 mm × 12 mm yaciwe kuri adaptateri y'umusaruro ku gice cyo ku mpera y'izuru. Ikizamini cyakoresheje igikoresho cy'umucanga wumye n'umucanga kuri buri ASTM G65 - uburyo D, umutwaro wa kg 5, revolutions 1.000 - kandi twapimye igihombo cy'ingano muri milimetero kibe.

Ibisubizo: HRC 38 yatakaje 85 mm³. HRC 45 yatakaje 62 mm³ — yazamutseho 27% ugereranyije n’icyitegererezo cyoroshye cyane. HRC 50 yatakaje 48 mm³ — yazamutseho 23% ugereranyije na HRC 45 na 44% ugereranyije n’icyitegererezo cyoroshye cyane. HRC 55 yatakaje 41 mm³ — yazamutseho 15% ugereranyije na HRC 50 ariko yazamutseho 7 mm³ gusa. Itegeko ryo kugabanya umusaruro riragaragara: kwiyongera k’ubudahangarwa kuva kuri HRC 50 kugera kuri HRC 55 ni gato, mu gihe gutakaza imbaraga z’ingaruka ari ingenzi. Ikizamini cya Charpy V-notch ku ngero zimwe cyagaragaje ko ingufu z’ingaruka zagabanutse kuva kuri 24 J kuri HRC 50 kugera kuri 14 J kuri HRC 55 — yagabanutseho 42%. Mu ikoreshwa ryo gusenya aho adaptateri igomba kwihanganira gukubitwa n’amabuye mu buryo butaziguye, ibyago byo kuvunika kuri HRC 55 biruta kwiyongera k’ubuzima bwo kwangirika kwa 15%.

Aya makuru y’igerageza ayobora inama zacu ku bicuruzwa. Ku bijyanye no kwimura ubutaka mu butaka bw’umucanga cyangwa butose — aho gushwanyagurika ari bwo buryo bukunze kwangirika — turasaba HRC 50–52 kugira ngo irambe igihe kirekire cyo kwangirika nta butose butemerwa. Ku bijyanye no gusenya cyangwa gucukura amabuye — aho gukurura ibintu bikomeye — turasaba HRC 46–48 kugira ngo igumane ubukomezi mu gihe ikomeza kugera ku bukomezi butemerwa. Abashoramari bo mu Buyapani bo mu isoko rya Tokyo na Osaka bashyizeho uburyo bwa HRC 46–48 bwo gukoresha 60Si2Mn retainer clips, kandi ikoreshwa ryazo buri mwaka kuri PC350 excavator rikoresha 36 adaptateurs — imwe isimburwa buri masaha 10 y’akazi — ugereranije na adaptateurs 48 ku mwaka kuri HRC 38–42 ziturutse ku isoko ry’umuhiganwa.

Ibitekerezo by'abakiriya: Ingamba zo kubika ibicuruzwa by'abacuruza ibicuruzwa n'isesengura ry'isubizwa ry'ingwate

Umucuruzi w’umuyapani ukorera i Yokohama afite ingano 18 z’udupira tw’amenyo twa Komatsu duturuka mu ruganda rwacu. Batanga abakiriya bagera kuri 350 bo mu bwoko bw’udupira two mu bwoko bwa “cukumbuzi” mu karere ka Kanto, batanga udupira duto (PC30–PC70) two gusana amazu kugeza ku dupira tunini two gusenya inyubako ndende (PC490–PC800). Udupira dutumiza mu byiciro bya buri gihembwe udupira 5,000–8,000. Muri 2024, bavuze ko batanze garanti ya 1.2% ku dupira twacu — udupira 96 ​​kuri 8,200 twoherejwe — ugereranije n’igipimo cya 3.8% cy’umucuruzi wabo wa mbere.

Twasesenguye adapter 96 zasubijwe. Isesengura: adapter 42 zari zarashaje cyane ku kigero kiri hejuru y’ikigereranyo - byagaragaye ko ari abakiriya bazikoreshaga mu gucukura amabuye nta rwego rukomeye. Adaptateri 31 zari zifite agace k’ipine kacitse cyangwa kagoranye - byagaragaye ko ari abakoresha bakoreshaga imbaraga z’indobo kugira ngo bakure ibuye mu mwobo ufunze, bigatuma habaho umwanya wo kunama kuri pin boss warenze ubushobozi bwo kunama bwa 180 kN bwa adaptateri ya PC200. Adaptateri 12 zari zatakaje iryinyo kubera ikibazo cyo gufunga - ku matsinda yoherejwe mbere yuko duhindura 60Si2Mn clips. Adaptateri 11 mu by’ukuri ntabwo ari ibicuruzwa byacu - zari adaptateri zihanganye zashyizwe mu bubiko bw’umucuruzi mu buryo butari bwo. Nyuma yo gukosora ku bicuruzwa bitari ibyacu, igipimo nyacyo cyo kugarura garanti cyari 1.04%. Umuyobozi ushinzwe kugura umucuruzi yarambwiye ati: “Twakoreshaga ingengo y’imari ya 5% by’ikiguzi cyo kugura adaptateri cyo gusimbuza garanti. Ku bicuruzwa byawe, turi kuri 1.2%. Ibyo ni ukwizigamira kw’ibintu mu buryo nyabwo.”

Ku isoko ry'Ubuyapani, imiterere isanzwe yo gutumiza adaptateri ikurikiza imiterere y'ibihe. Ubusabe bugera ku rwego rwo hejuru muri Mata (mu ntangiriro z'umwaka w'ingengo y'imari, igihe ingengo y'imari y'ubwubatsi izaba ari nshya) no mu Ukwakira (mu ntangiriro y'igihe cy'izuba cyo gusenya). Itegeko ry'umutekano ry'umucuruzi ni: nibura 3.000 ku ngano esheshatu zigenda vuba (PC78, PC128, PC138, PC200, PC228, PC400), 1.500 ku ngano zo hagati, na 500 ku ngano nini cyane. Dufite igihe cyo kwiyandikisha cy'iminsi 45 ku ngano zisanzwe na 60 ku ngano zikomeye. Ibi byemerera umucuruzi gukora afite ingano 4.5 ku mwaka - hejuru y'impuzandengo y'inganda ya 3 - twishingikirije ku buryo gahunda yacu yo gukora iteganyagihe.

Inyigo: Itsinda ry’Abasenye amenyo rya Tokyo ryagabanyije 75% by’ingaruka z’ihungabana ry’amenyo

Isosiyete isenya i Tokyo yari ikora imashini umunani zo gucukura za PC350 n'izindi eshatu zo gucukura za PC490 yasenye impuzandengo y'inyubako 14 za sima zikomejwe ku mwaka - inyubako z'ibiro, aho guparika imodoka, n'amazu yo guturamo kugeza ku magorofa arindwi. Mbere ya 2024, bashakaga ibyuma bitanga amenyo y'indobo ku mucuruzi mukuru wo muri Osaka. Igipimo cy'amenyo y'imashini yatakaye cyari 0.14 kuri buri mashini ku munsi w'akazi - bivuze ko imashini zatakaye amenyo zabagaho buri minsi 4.2 y'akazi muri izo mashini 11. Buri gikorwa cyasabaga guhagarara iminota 35-45 (kugira ngo haboneke kandi hagarurwe umutwe w'iryinyo ryatakaye, harebwe icyuma gitanga amenyo, kandi hashyirweho ikindi gisimbura), bamara amasaha 3.2 y'abakozi ku munsi muri izo mashini.

Muri Mutarama 2024, umuyobozi w’ubwikorezi bw’imodoka yatwandikiye nyuma yo kumenya ibisobanuro byacu mu imurikagurisha rya JCEA. Twatanze adapter 500 zikomeye (HRC 50 ifite 60Si2Mn clips) ku ruganda rwa PC350 na 200 ku ruganda rwa PC490 - zose zifite icyemezo cya CMM kandi zishobora gukurikirana neza. Twanatanze amahugurwa y’iminsi ibiri yo gushyiraho aho hantu: (1) torque ikwiye yo gufata pin na clip - 45 Nm kuri PC350 na 75 Nm kuri PC490, ipimwa hakoreshejwe torque, ntabwo ari "feel"; (2) ibipimo byo kugenzura amaso ku bijyanye no kwambara adapter - bisimbura iyo ubugari bw'izuru bwamaze kwangirikaho mm 5 uvuye ku gipimo cya mbere; na (3) gahunda yo gusimbuza clip - buri masaha 200 y'akazi hatitawe ku miterere y'amaso.

Mu mezi 12 nyuma y’impinduka, igipimo cy’amenyo y’ubwikorezi bw’ubwikorezi cyagabanutse kiva kuri 0.14 ku munsi w’imashini kigera kuri 0.035 - igabanuka rya 75%. Guhagarara kw’amenyo ku buryo butateganijwe byagabanutse biva kuri 511 mu 2023 bigera kuri 128 mu 2024. Igihombo cy’amasaha y’abakozi cyagabanutse kiva kuri 3.2 ku munsi kigera kuri 0.8 ku munsi - kigaruza ikiguzi cy’abakozi cya $46.000 buri mwaka. Umuyobozi w’ubwikorezi yavuze ko ebyiri muri PC350 zanyuze mu mushinga wose wo gusenya - amezi ane y’iminsi 14 - nta gutakaza iryinyo na rimwe. Yagize ati: “Ibyo ntibyigeze bibaho ku byuma byabanje bya adapters.”Amabwiriza y'inyubako ya OSHAKu bijyanye no gukoresha ibikoresho biremereye no gukoresha ibikoresho biremereye, bishimangira akamaro ko kubungabunga neza ibikoresho byo mu butaka, no kugabanya gutakaza amenyo bitunguranye bigira uruhare mu buryo butaziguye mu bikorwa byo gusenya amenyo mu buryo bwizewe binyuze mu gukuraho aho imashini zihagarara hafi y’aho zisenya.

Ku bacuruza ibikoresho by'Abayapani n'abakiriya babo b'amato, ubutumwa buva muri ubu bushakashatsi ni ubu: ikiguzi cya adaptateri — ¥3.500–¥8.000 kuri buri gice bitewe n'ingano — si cyo gipimo gikwiye. Igipimo gikwiye ni ikiguzi ku isaha imwe y'akazi. Adaptateri ya PC350 igura ¥6.000 kandi imara amasaha 250 mbere yo kuyisimbuza igura ¥24 ku isaha. Adaptateri ihanganye kuri ¥4.500 imara amasaha 150 igura ¥30 ku isaha. Adaptateri nziza cyane izigama ¥6 ku isaha — kandi ku mashini ikora amasaha 2.500 ku mwaka, ni ukuvuga ¥15.000 kuri buri mashini ku mwaka. Iyo umuyobozi w'amato akubye ibyo ku mashini 350 zicukura abakiriya b'umucuruzi, ubushobozi bwo kuzigama buri mwaka ni ¥5.25 miliyoni — kandi ibyo ni mbere yo kubara amafaranga yagabanutse mu gihe cyo gutakaza amenyo make.

Ibibazo Bikunze Kubazwa