lt焊接点焊电极的修磨与更换作业指导书_现用

1、Good is good, but better carries it.精益求精，善益求善。lt焊接点焊电极的修磨与更换作业指导书_现用上海捷众汽车冲压件有限公司上海捷众汽车冲压件有限公司Shanghai JieZhong Automotive Pressing Co., Ltd点焊电极的修磨与更换作业指导书1 主题与范围通过规定焊接点焊电极的修磨标准、修磨方式、修磨频次、回用标准、更换方式，保证焊接生产时使用的点焊电极符合焊接工艺标准，保证焊点质量。本文件适用于生产部焊接班组所使用的点焊电极。2 引用文件 （无）3 定义点焊电极的修磨：通过使用规定工具打磨点焊电极端面，保证电极端面直径符合焊

2、接工艺要求（见5.2.1.1）的过程。点焊电极的回用：对于需要修磨的点焊电极，通过使用检测工具测量电极剩余长度，来判定电极能否回用的过程。点焊电极的更换：使用规定工具拆下旧电极（不符合工艺要求的电极），装上新电极的过程。4 职责4.1 焊接班组长负责点焊电极修磨及更换工作的落实。4.2 焊接操作工负责点焊电极的拆装。4.3 夹具修理工负责点焊电极能否回用的分类工作。4.4 夹具修理工负责能够回用的点焊电极的具体修磨工作。4.5 值班长负责督促和检查点焊电极的修磨及更换工作的执行情况。5 点焊电极的修磨、回用、更换程序5.1 点焊电极5.1.1 点焊电极端面直径5.1.1.1 16mm（外表直径

3、）×23mm（长）电极：原始（机加工后）端面直径为6mm。5.1.1.2 13mm（外表直径）×20mm（长）电极：原始（机加工后）端面直径为5mm。5.1.1.3 特殊形式电极：参见具体图纸规定。5.1.2 电极墩粗：点焊电极在使用过程中由于电极端面工作区域受力及受大电流的热影响,电极端面形状发生变化，端面直径变大，接触表面产生化合物,降低焊接时焊点区域内通过的电流密度值,从而产生虚焊现象,影响焊接质量。5.2 点焊电极的修磨5.2.1 修磨标准5.2.1.1 16mm电极：电极端面直径允许范围为68mm。5.2.1.2 13mm电极：电极端面直径允许范围为57mm。5.

4、2.1.3 特殊型式电极：电极端面直径允许范围为原始直径+2mm。5.2.2 端面直径检测工具5.2.2.1 检测工具：电极卡板5.2.2.2 检测方式：将电极卡板上放在电极端面上，保证卡板上的标准孔与端面基本同心。5.2.2.3 合格判定：68的标准孔内可以看到整个电极端面，判断该电极可以使用。5.2.2.4 不合格判定：电极端面小于6标准孔，或8标准孔内无法可以看到整个电极端面，判断该电极不可以使用。5.2.3 修磨方式5.2.3.1 手工在线锉刀修磨：在生产时，使用锉刀直接对安装在焊钳上的电极进行修磨端面的方法。特殊型式电极使用锉刀在线修磨。5.2.3.2 线外统一设备修磨：使用修磨标准

5、设备集中处理换下的电极的方法。5.2.3.3 为了保证修磨后电极质量（电极形状及端面直径），公司规定所有16mm、13mm手工用点焊电极使用线外统一修磨。对于与有角度焊钳接杆连接的电极，在安装后，还需要使用锉刀根据上下电极的实际接触面修正电极端面。5.2.3.4 机器人在线设备修磨：点焊机器人工作站使用修磨设备在线修磨电极。5.2.4 修磨频次5.2.4.1 对未开启焊接电流递增器的点焊电极的修磨周期,应根据工位的实际情况决定:原则上,应随时检查电极的端面,如果磨损超过标准就要进行修磨。5.2.4.2 未开启焊接电流递增器的点焊电极建议修磨频次：见附录二点焊电极修磨频次建议表（无递增版）。本表

6、格每年或逢新项目批产更新。5.2.4.3 对开启焊接电流递增器的点焊电极的修磨周期,应根据递增器的工艺设定，在递增器报警后进行修磨。5.2.4.4 点焊机器人工作站的修磨频次设定在机器人程序中，焊接点数符合要求后会自动在线修磨电极。5.2.4.5 突发情况：一旦发生爆电极情况，应立即修磨或更换电极。5.3 点焊电极的回用5.3.1 回用标准5.3.1.1 对于需要修磨的电极，首先要判定是否可以回用。5.3.1.2 点焊电极下半部分为了散热而开孔通水,在电极中间有修磨截止线（一个环形槽）用来标识最短电极长，考虑到电极在焊接时受热受压，电极端面到截止线应有剩余量，建议为2mm。5.3.1.3 16

7、mm电极：电极长度（从端面到底部）13mm时,必须报废，不可回用。5.3.1.4 13mm电极：电极长度（从端面到底部）15mm时,必须报废，不可回用。5.3.1.5 特殊型式电极：电极端面至截止线距离2mm时，必须报废，不可回用。5.3.2 电极回用检测工具5.3.2.1 检测工具：电极卡板（适用于16和13电极）。5.3.2.2 检测方式：将电极根据直径大小放入相应的卡板检测槽内，保证电极在槽内保持竖直状态。5.3.2.3 回用判定：如果电极长度高于检测槽，判断该电极可以回用。5.3.2.4 报废判定：如果电极长度小于等于检测槽，判断该电极必须报废。5.3.2.5 特殊型式电极使用游标卡尺

8、测量。5.3.3 电极状态隔离箱5.3.3.1 【旧电极】箱：存放使用过的，但未判断是否回用的电极。5.3.3.2 【待修磨】箱：存放已经被判定可回用的，但未修磨的电极。5.3.3.3 【回用】箱：存放已经修磨好的电极。5.3.3.4 【新电极】箱：存放外购进来未使用过的电极。5.3.3.5 【报废】箱：存放不能回用，确认报废的电极。5.4 点焊电极的更换5.4.1 更换对象5.4.1.1 手工点焊：应优先使用【回用】箱内的电极。5.4.1.2 机器人点焊：只能使用【新电极】箱内的电极。5.4.2 更换方式5.4.2.1 先关闭冷却循环水的2个阀门（进水阀+出水阀）。拿来专用盛水桶。5.4.2

9、.2 将电极对准盛水桶，使用专用工具（管子钳）夹住电极,向外旋转拆除电极。注意，应引导剩余冷却水注入盛水桶，避免场地、零件、夹具被喷溅到水。5.4.2.3 将拆下的旧电极放置在一边，换上领来的新电极，用1.5磅木锤轻击电极端面，使电极与接杆接口紧实。5.4.2.4 对于手工焊枪，应将焊机切换到调整档，连续闭合焊钳35次，彻底压实电极。用电极卡板检测上下电极的对中度，确认上下电极对中度符合要求。对带角度的电极需要使用锉刀修正接触端面。将换下的旧电极放入【旧电极】箱内。打开进出水阀门，将焊机切换回焊接档，继续生产。5.4.2.5 对于机器人焊枪，应先打开进出水阀门，再根据作业指导书指导步骤操作，程

10、序会提示校验对中度并自动完成压实电极步骤，然后机器人自动继续生产。焊接操作人员应将换下的旧电极放入【旧电极】箱内。5.4.3 如果发现上下电极对中度不符合要求，应立即向焊接机修报修。修理完成后，才可以生产。5.4.4 电极更换时，尽量上下电极一起更换。5.4.5 拆装电极时应保护好电极的锥度面,安装时应清除电极锥度孔中的油污,保持装配面的清洁。5.4.6 焊枪应保持清洁，避免油污、飞溅物沉积。6 记录 （无）7 附录附录一：点焊电极的修磨与更换流程图附录二：点焊电极修磨频次建议表（无递增版）发放数编制/修改审 核批 准批准日期实施日期2凌晶2011.2.22附录一 点焊电极的修磨与更换流程图负

11、责部门/岗位依据流程记录配合部门/岗位新电极箱生产装新电极更换？拆旧电极修磨回用箱报废箱回用？旧电极箱待修磨箱焊接班组焊接操作工夹具修理工夹具修理工焊接操作工焊接操作工焊接操作工焊接操作工点焊电极修磨频次建议表NOYESNOYES点焊电极的修磨与更换作业指导书6development of problem, insisted liberation thought, and times, set on new development concept of consciously confidence, do advocate innovation, and focused on coordina

12、tion, and advocate green, and thick plant open, and advance shared. For in economic development new normal Shang of awareness errors, deep awareness economic development new normal of objective inevitability, prevent one-sidedness, and simplistic, cannot to whether on himself favourable to judge new

13、 normal bad; cannot put new normal as a basket, what are to in loaded; cannot put new normal as haven, put work bad do, and didn't dry good of reasons are due Yu new normal, for not officer, and not development find excuses. Actively promote the supply side of structural reforms and implement th

14、e CPC Central Committee defined "five pillars of policy" and "five priorities", implementation of the Central Government, provincial party Committee and the major decisions and arrangements of the party support accelerated development of XX XX, a good grasp of Fujian construction

15、 of free trade zone area XX XX block major historical opportunity. (4) lead to overcome difficulty, dare to play. Dare not sword, before major problems before dare not afraid to come forward for difficulties, crises, mistakes afraid to take responsibility, before the evil struggle before asking Prob

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17、reform and development, and a doer. Insist on seekingprogramme, and XX city learning education implementation programme spirit and town party implementation programme requirements, according to distinguish level, and has targeted solution problem of requirements, ensure learning education made effec

18、tiveness, Promotion of all party members and consciously respect the party Constitution, abide by party rules, armed with XI series of important speech by General Secretary head, guide, and promote the work, be qualified party members and learning arrangements are hereby makes the following specific

19、 programmes. Learning requirements, on all party members to study the party Constitution and party rules and unify the XI series of important speech, General Secretary, speech learning series to deepen understanding of the Constitution Party rules, Constitution Party rules in the deep insight series

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22、oldings", mastering various types of disciplinary offence and punishment provisions. 2, and learning series speech to XI General Secretary series important speech reading (2016 version) and out poverty work to dream into really-XI comrade in XX work during advocate practice line "immediate

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