步增机制在焊点质量提升中的应用  

Application of Step-Up Mechanism in Quality Improvement of Solder Joints

作　　者：彭其飞 潘远安 刘鑫 杨大宇 张林阳 肖冰[2] PENG Qifei;PAN Yuan'an;LIU Xin;YANG Dayu;ZHANG Linyang;XIAO Bing(China FAW Group Corporation,Changchun 130011,China;Changchun Automobile Industry Institute,Changchun 130013,China)

机构地区：[1]中国第一汽车集团有限公司,吉林长春130011 [2]长春汽车工业高等专科学校,吉林长春130013

出　　处：《热加工工艺》2023年第1期131-134,140,共5页Hot Working Technology

基　　金：中国职业技术教育学会课题(2020B0885)。

摘　　要：电极端面的磨损致其直径增大,焊接面电流密度降低,焊点质量衰减,严重影响汽车车身质量。以0.6 mm厚的镀锌钢板为研究材料,设定了步增机制参数,并对步增机制应用前后电极的端面磨损和焊点质量进行对比分析。结果表明,在步增机制下随着焊接过程的持续,焊接电流不断增加,电极端面直径增加的速度更快,焊接面电流密度降低更慢,焊点表面粗糙度更好,同时焊点的合格率更高。并在A平台、M平台两款新车型进行步增机制的应用试验和成本分析。应用试验表明:与未应用步增机制的相比,步增机制的应用使焊点质量合格率提升0.52%,消除了由于电极端面尺寸不断增加所带来的焊点质量衰减问题,点焊电极使用次数由4000点提升至6000点,节约了电极帽费用和人工更换电极帽的成本,约204万元/年。The wear of electrode end face causes its diameter to increase, the current density of welding surface decreases, and the welding spot quality decreases, which seriously affects the quality of automobile body. Taking 0.6 mm thick galvanized steel sheet as the research object, the step-up mechanism parameters were set, and a comparison analysis of the wear of the end face of the electrode and the quality of the solder joint before and after the application of the step-up mechanism was carried out. The results show that under the step-up mechanism, with the welding process continues, the welding current increases, the electrode end diameter increases faster, the current density of welding surface decreases more slowly, the surface roughness of the solder joint is better, and the qualified rate of the solder joint is higher. The application test and cost analysis of step-up mechanism were carried out in two new models of A platform and M platform. The application test shows that the qualified rate of solder joint is increased by 0.52% and the welding spot quality attenuation caused by the increasing size of electrode end face is eliminated, and the number of spot welding electrode is increased from 4000 to 6000, and the cost of electrode cap and manual replacement of electrode cap are saved, about ￥2.04 million/a.

关 键 词：电极磨损 点焊 镀锌钢板 伺服焊钳 步增机制 

分 类 号：TG47[金属学及工艺—焊接] TG438.2