拧紧技术-与工具

EBtools&FasteningStrategies电动工具及其拧紧策略«MoreThanProductivity»Content内容•EBtoolandImpactwrench电动工具和气扳机•Tighteningintroduction•拧紧介绍•Fasteningapplications拧紧应用INTRODUCTION前言•Thebadqualityoffasteningcostalotofmoney劣质的螺栓扭紧会损耗大量钱财IMPACTTOOLS冲击工具IMPACTTOOLS冲击工具Tensionincrements张力增量Time时间Torquesignal扭矩信号Installedtorque/tension安装扭矩/张力1-2ms20-40msImpactTool–noISOstandardtomeasuredynamicpulsetorque冲击工具－没有国际标准来测量动态的脉冲扭矩2optionsfor100%traceability两个选择可以做到100%的可追朔性Option1选择1Airpoweredtool气动工具Manualtorquewrench扭力扳手Pen笔Wecanassuretorqueoverthetarget,butneverknowtherealvalue确保扭力超过目标值，但无法知道确切值Option2选择2(fullsupervision全方位监管)Transducerizedelectriccontinuousdrivenutrunnertool带传感器的连续驱动的电动螺母拧紧工具IMPACTTOOLS-Whatisthenicemansweight?冲击工具－人的最佳体重是多少？85kgMoredifficulttosaybecausethereisnostandardforhowtoreadthescale,anddifferentmenwilljumpindifferentways.更难确定的是这里没有一个标准尺度来衡量，而且不同的人跳的方法也不同。90kg40kg90kg90kg90kg130kgAction1-fasten第一步，扭紧Action2-control第二步，检查Whatabout?怎么样？Action3-mark第三步，记录Action2第二步Action3第三步Action1第一步TOTALtraceability=Appliedtorqueverified100%全部可追朔性＝实用扭矩100%的校验Torqueauditvalidatestorquevalues&process扭矩监控确保扭矩值和工艺过程Appliedtorqueisverifiedto100%应用扭矩可以100%的校验Toolwithtransducer,rundown&带有传感器的电动工具Calibrationdatastoredforeachtool标定仪器可以保存每一把工具的标定数据ResultstoredinCVIandCVINET工作结果存储在CVI和CVINETAdvantagesofEBtools电动工具的优势•Accuracy精度•Productivity生产效率•Repeatable可重复性好•Traceability拧紧数据可存储，可追溯性，方便以后提高装配工艺•Goodcommunication可与外部设备进行通讯•Lowmaintenancecostandtoollife维护成本和工具寿命•Quiet,nooilandlowenergyconsumptionTIGHTENINGINTRODUCTION拧紧介绍PRESENTATIONTorque&Tension螺栓的拧紧力－张力张力张力夹紧力夹紧力GENERALDESCRIPTION简介•Strainsandforces张力和其他力:–torsionstrain扭转张力–shearforce剪切力–tensionforce拉伸力•Atorquemustbeapplied一定要施加扭矩Tension张力（拉伸力）Shear剪切torsion扭转TheinstalledTORQUE安装扭矩Controloftheclampingforceinproduction控制生产中的夹紧力•Nopracticalmethodhasyetbeendeveloped目前还没有可行的手段•Tocontrolotherparameterswhichinfluencetheclampingforcewecanonlyuse:控制影响夹紧力的其他参数，我们只能用：Physicaldefinitionofthetorque扭矩的物理定义臂长力1m1kgTorque扭矩=臂长x力1mx1kg=1kgm=9.8Nm简单来说就是拧紧过程作用力与作用距离的乘积。Torque-linkedparameters扭矩相关的参数•Clampingforce夹紧力:F(10%)•Frictions摩擦力:µ(90%)Theydependon摩擦力取决于:–surfacecondition.表面条件（如光洁度）–componentgeometry部件的几何形状.–lubrication润滑油.•Elasticityofthejoint接合处弹性:K•T=KµFFrictions摩擦力50%40%Linearrelationship:Angle/Tension角度和张力/夹紧力的关系T=To+DT=To+p.aE.360aturningangleofthebolt螺栓旋转角度ppitchoftheboltthread螺栓齿距Eelasticitycoefficientofjoint连接处的弹性系数DTtensionincreasingDT拉伸力的增加360°PitchaCoefficientoffrictioninthethread螺纹上的摩擦力的相关特性表BoltsurfacetreatmentNutsurfacetreatmentDryLightlyoiledUntreatedUntreated0.18-0.350.14-0.26PhosphoruscoatedUntreated0.25-0.400.17-0.30ElectroZincplatedUntreated0.11-0.360.11-0.20PhosphoruscoatedPhosphoruscoated0.13-0.240.11-0.17ElectroZincplatedElectroZincplated0.18-0.420.13-0.22Frictionsmaybeundesirable,buttheypreventtheboltfromlooseningwithvibrations.摩擦力可能不符合需要，但它可以防止螺栓因震动引起的松动螺栓表面处理螺母表面处理干性轻微浸油无处理无处理0.18-0.350.14-0.26涂磷无处理0.25-0.400.17-0.30电镀锌无处理0.11-0.360.11-0.20涂磷涂磷0.13-0.240.11-0.17电镀锌电镀锌0.18-0.420.13-0.22ACCURACY-Torque/Tension扭矩/拉伸力TorqueNm扭矩TensionKN拉伸力10202030405060406080100120medium-oiled中度浸油well-oiled充分浸油rough/nooiled无浸油tensiondispersal±50%TOSUMUP总结Itisimportanttorealisethatthereislittlepointcontrollingtorqueiftherestoftheprocessisnotcontrolled如果其它工艺没有得到控制，那么控制扭矩是无济于事的认识到这点很重要Solutionsforapplication现场应用解决方案Application’sneed应用需求•Boltsize螺栓尺寸：M18-M30•Torque扭矩：200-1200NmStatusofpresentsolution目前的解决方法•Pre-fasteningmanually手动预拧Verylongtime需要很长的时间•Clickwrench咔哒扳手Notprecise(Dependsonperson)不精确（很大程度依赖于操作者）Notsafe(bothforoperatorandparts)不安全（对操作者和工件都不安全）CP’saddedValueCP解决方案带来的价值•ECPHTrange高扭矩电动拧紧枪ECPHT系列•Moreproductivity生产效率更高•Moresafety更安全•Moreprecise更精确•Moreadvancedassemblytechnology(makeyourproductmorecompetitive)更好的装配技术（使得您的产品更具优势）Dynapac’srollerapplicationbefore丹纳派克先前的应用Dynapac’sapplicationnow丹纳派克现在的应用Energy\Windmills\Gearboxes能源/风电/齿轮箱Application应用CurrentTool/Issues/ConcernsDescriptionoftheApplication•8BoltsM20boltsusedtoholdthebearingflangeononeofthe3gearsintheplanetgearbox.•Torque:560Nm•1gearbox=3gears•2x8bolts/gear•2gearboxes/day.•Beabletohave1toolforseveraltypeofjoints•Getarepeatableprocess•Getavisualfeedbackandpokayoke•NoiseandrepetitivestrengthinjuriesCustomerbenefits客户收益DesoutterSolution/BenefitsQuality,Cost&Payback•anglecontrolofthetool:toassurethebearingflangeistightenedok•easyaccessforothertorques•lownoisecomparedtopneumatictools•reactionbarwithslidingspindleverygoodtoavoidinjuries•batchcounttoassureallboltsaretightenedType:ECP950-N°:6151654010+CVIC-H4Min=310Nm-Max.=950Nm115rpm-4KgweightEnergy\Windmills\Superbolts能源/风电/超级螺栓Application应用CurrentTool/Issues/Concerns•Superbolt/windturbine•CriticalLevel:Standard•Jointtype:Soft•2torques:130Nm(M52superbolt)and280Nm(M60superbolt)•Portabilityofthetool(headtotheroof)•Notenoughroomtousealargemanualhandwrench•Upto5tighteningsoneachjackbolt(x12)togettotherighttension(exhausting!)Customerbenefits客户收益DesoutterSolution/Benefits•Abilitytoaccessveryhightensionlevelswithoutsacrifyingproductivity:Shortercycletimeduetohigherspeed:5minutesvs2