Summary
This article gives guidance and suggestions for the general error-proof setting of the hand-held electric gun tightening procedure in the manufacturing assembly, and hopes to help everyone. We also welcome peer exchanges to discuss and improve together.
1 Overview
The production bolts of modern manufacturing are tightened into the assembly process, and the main tightening procedure parameters involved are torque, angle, acceleration and so on. So how do we tighten the program to prevent incorrect assembly of the bolts? How to avoid bolt mixing? How to avoid operator leakage or repeated tightening? As mentioned in the article in July last year, today, mainly from the setting of the tightening program, further elaborate on how to set up to minimize the possibility of these problems.
2, tighten the error prevention program to set the basic strategy
1) First, ensure that the anti-error setting of the tightening program has been added;
2) Continuously improve and optimize existing error-proof programs, so that the program's error-proofing effect is continuously improved;
3, tighten the program common settings basic steps
1), the basic error-proof function is turned on, and the basic conditions for error prevention are:
i, open the curve recording function, from the start of the trigger, record the entire tightening process;
Ii, open the repeat tightening recognition function, and add the angle monitoring lower limit of 10 degrees to ensure that the repeated tightening is effectively detected;
Iii. Turn on the counting function and lock the tool after the counting is completed, unless the PLC enables the unlocking tool;
Iiii. Turn on the lower rotation angle monitoring function to ensure that the lower rotation angle is completely recorded;
4, error prevention function optimization one :
How to set the tightening program to realize the error prevention of self-tapping bolt monitoring?
We need to rule out the impact of the self-tapping phase on the entire tightening process. The following curve is a typical self-tapping bolt tightening curve:
1) Method 1: Control the angle of the self-tapping phase, and monitor the torque of the self-tapping bolts is a relatively ideal choice;
2) Method 2: Control the downward rotation angle and monitor the torque during the lower rotation;
5, error prevention function optimization two :
How to solve the problem of large angle difference?
After the above error-proofing is completed, we will still find the angle data of the partial tightening station, even if the bolts that are normally tightened are very discrete. This loses the meaning of the error prevention itself.
The following is the angular distribution after a station is set, the angle varies from a few degrees to 3500 degrees:
In this regard, it is recommended to optimize and improve the program as follows:
1) Increase the torque value at the end of the lower rotation. For example, in the above example, the angle is changed to a large position, and the determination torque of the lower end is increased to 4 Nm. The effect is as follows:
2) The starting point of the lower rotation angle calculation can be changed to torque, starting from cycle start, but the cycle start value needs to be set higher than the trigger idle rotation below the bolt feed tightening. This will help to avoid the problem of excessive angle deterioration caused by the person pressing the trigger in advance.
6, other error prevention function optimization
For example, position-based torque and angle control, four-step tightening program control, etc., need to set parameters to achieve error-proofing effect for specific situations:
7, summary
The industry involved in bolt assembly and tightening is very extensive. Whether it is traditional cars, new energy vehicles, general electronics industry, aviation industry, etc., the quality of bolt assembly tightening is particularly important for product quality due to fastener problems. The recall event is not uncommon. It only relies on the optimization of the error control of the program parameters. It is impossible to completely eliminate the bolt assembly problem. It also needs to be worked hard from personnel management, parts quality control, equipment control, etc. Continuous PDCA improvements can be gradually improved to an ideal level of bolt assembly.
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