冷焊Weldquality焊接品质课件.ppt

1、AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 1integrated touch screen incl. PC, Printer(整合的觸摸式螢幕 包括電腦, 列印機)230 V, 16 AComplete set of quick change inserts (20 90 mm)(整組的快速更換治具 (20 90 mm)bar-coded identification of welding personal (焊接之後自動產生條碼識別)Shipping box (出貨盒) Dimension range(尺度範圍)

2、:20 - 110 mm (“ - 4“) Materials (材料): PVDF, PP, PP-natural (本色), ECTFE, PFA optional (選項) IR-heating element, Planer (紅外線加熱元件,刨刀)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 2 IR- and butt welding(紅外線對焊熔接機) Dimension range(尺寸範圍):75 - 250 mm (2“ - 10“) Materials(材料): PVDF, PP, PP-natur

3、al(本色) IR-heating element, Planer, Clamping jaw( 紅外線加熱元件,刨刀, 夾具) 11.4” Touch Panel incl. PC, Printer (11.4”觸摸式螢幕包括電腦, 列印機) 230 V, 20/25 A Complete set of quick change inserts (75 225 mm) (整組的快速更換治具(75 225 mm) PCMCIA Access and memory card (PCMCIA卡和記憶卡)Shipping box (出貨盒20)AGRU - Kunststofftechnik Gmb

4、H AGRU - Technology in Plastics 3 compact construction (結構輕巧) low weight (重量輕) automatic move-in and move-out of the heating element (加熱元件自動定位) integrated process data software for easy administration of all recorded welding data (整合的處理資料軟體，輕鬆管理全部的焊接數據記錄) site and workshop equipment (設備適合工地和工廠工程施工)A

5、GRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 4 menu navigation in different languages: (目錄操作提供下列的語 ) - German (德文)- English (英文)- French (法文)- Korean (韓文)- Swedish (瑞典文)- Spanish (西班牙文)- Italian (意大利文)- Japanese (日文)- Simplified Chinese (簡體中文)- Traditional Chinese (繁體中文)AGRU - Kunststo

6、fftechnik GmbH AGRU - Technology in Plastics 5 variable adjustable planing distance (變數調整刨平距離) easy adjustable measurements of isometrics (焊珠量測容易調整) easy correction of cut pipe length (管材長度容易修正)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 6Welding (的焊接) of PVDF, PP, PP-n, E-CTFE and P

7、FA (opt.) all parameter included (包括全部的參數)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 7 easy handling and control of the welding process ( 焊接程序容易處理控制 ) fully traceability of welding data (焊接數據可以完全追蹤 ) label print out (標籤可以列印出 )AGRU - Kunststofftechnik GmbH AGRU - Technology in Plasti

8、cs 8 Fully automated welding process (完全自動化的焊接程序) Minimized influence of the operators (不良的人為操作減至最低) 100 % reliability of the welding quality (100 % 可靠的焊接品質) Perfect weld bead shape (完美的焊珠形狀 ) (high mechanical weld strength, reduced bead and small tolerance of the bead size around the whole weld bea

9、d circumference. (高機械焊接強度, 減少整個焊接周圍的焊珠尺寸公差) Welding process is in accordance the DVS-guidelines (焊接程序符合 DVS-標準) Shortest weld times (pre-heating cooling) 最短的焊接時間 (預熱 冷卻) Single phase power source, control of power supply (單相電源, 電源供應器控制)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 9Uni

10、que design of the clamping equipment (usable for different components of fittings with short legs heating element butt fusion fittings) 夾具設備的獨特設計 (方便快速更換不同的接頭組件 加熱元件對接焊熔合接頭) No special or separate elongated fittings necessary!不需要特別的或分開的加長接頭!AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics

11、 10Elongated support clamps:Elongated support clamps:( (加長的支橕夾具加長的支橕夾具:) :) - better support for pipes (支橕管線更佳) - large diaphragm valves OD 110 are weldable (可焊接外徑110mm隔膜閥) AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 11New kind of closing mechanism:(新式的閉合機構) Ensures uniform and repea

12、table clamping pressure (確保夾具壓力的一致性和重覆性) Clamps are movable (可移動式夾具) Vertical and horizontal offset (垂直和水平偏置)Magnetic fixation of the clamping inserts:(夾持治具的磁鐵定位:) Reduced exchange time (減少換刀時間) Reduced particle contamination (減少粒塵污染) Universal clamping equipment (萬用夾具設備)AGRU - Kunststofftechnik Gmb

13、H AGRU - Technology in Plastics 12Offset AdjustmentOffset Adjustment 偏置調整偏置調整 Vertical offset 垂直偏置Horizontal offset(水平偏置)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 13PC controlled welding process電腦控制焊接程序電腦控制焊接程序AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 14Traceabili

14、ty with joint number (up to 99999 joints)可追蹤接合點數目 (最多 99999接合點)2000 weldings can be stored in the welding equipment(可以儲存2000 筆焊接數據)The welding reports can be displayed on the screen.(焊接報告可顯示在螢幕上焊接報告可顯示在螢幕上)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 15PC or NotebookOrganised by Data-

15、work program(電腦或筆記型電腦以 數據-工作程式組織)Welding data transfer(焊接數據轉換)Welding record printout20(焊接記錄列印出)Direct printout(直接列印出)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 16Vergleich der PP SchweizeitenSchweizeit (Anwrm- und Khlzeit)Comparison PVDF welding timesPVDF (焊接時間之比較焊接時間之比較)Welding ti

16、mes (preheating and cooling time)焊接時間焊接時間 ( 預熱和冷卻時間預熱和冷卻時間 )AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 17AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 18AGRU provides combined welding training, welding certification and maintenance courses In-house at the AGRU Training

17、 Centre in Bad Hall/Austria At customers place On site at the customers project place Evaluate welding joints and issues welding training certificatesFREE OF CHARGE!Additional on request:AGRU provides SUPERVISING on site with special educated and certified welding personnelAGRU - Kunststofftechnik G

18、mbH AGRU - Technology in Plastics 19 Basic in Material(材料基礎) Tool set-up (工具設定) Mechanical (機械) Weld Procedure (焊接程序) Quality Control (品質管理) Tool Maintenance (工具維護) Operation Considerations (操作考量) Accessories (if available) (附屬元件 (如果有) Name, Signature and Date of Welder and Trainer (焊接者和訓練者姓名, 簽名和日期

19、) Operation of Welding Machine, Trouble Shooting and Weld coupon (焊接機的操作, 故障排除, 焊接測試樣板)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 20Identity card (Identity card (識別卡識別卡) ) is used for the operator (給操作人員配帶 ) (Issued by AGRU after a welding training)( AGRU 在焊接訓練之後會發行此卡)Info of the op

20、erator is automatically stored with the welding data Welder can only operate the equipment.操作人員的資訊和焊接數據自動地儲存在一起,焊接者只能夠操作此設備Select Card (Select Card (管理卡管理卡 ) )is used from the QA/QC Person andforeman (是由品質管制人員和領班使用)- Download/delete welding data (下載/刪除焊接數據)- Change time/date (更換時間/日期)- produce param

21、eter for special materials (產生特殊材料的參數)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 211. Set-up of the SP welding machineSP (機種的設定)2.Guidelines for Maintenance/Service (維修/服務的指導)3.Guidelines for Welding Personnel (焊接人員的指導)4.Guidelines for Evaluation of Welding Joints (焊接點的評估之指導)5.Guide

22、line for Documentation (文件製作的指導)QA/QC Guidelines during Installation (安裝時期的品管指導)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 22AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 23 HS Heating element butt welding method (加熱元件對焊熔接方法 ) acc. DVS 2207 - part 11 (依據DVS 2207 - part

23、 11 )IR Infrared welding method (紅外線焊接方法) (non contact heating element butt welding) (非接觸式加熱元件 對焊熔接) acc. DVS 2207 part 6 (依據 DVS 2207 part 6)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 24Preparation of the welding area Preheating Joining and Cooling (焊接區域的準備 ) ( 預熱 ) (接合和冷卻)AGRU - K

24、unststofftechnik GmbH AGRU - Technology in Plastics 25AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 26AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 27PVDF 110 x 5,3Way controlled, way 1,1 mm / actual measured pressure inthe joining area way控制控制, way 1,1 mm / 在接合區域實際量測的壓力在

25、接合區域實際量測的壓力Time sec時間 秒Pressure N壓力? NRequired pressure 122 N!(需要壓力需要壓力 122 N!)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 28Uniformity of the Weld BeadUniformity of the Weld Bead( (焊珠的均勻度焊珠的均勻度) )Weld Bead SizeWeld Bead Size( (焊珠大小焊珠大小) )Contamination in Weld AreaContamination in We

26、ld Area( (焊接區域的污染焊接區域的污染) )Colouration in Weld AreaColouration in Weld Area ( (焊接區域的色澤焊接區域的色澤) )Weld StrengthWeld Strength( ( 焊接強度焊接強度) )Influence of Weld Quality (焊接品質的影響)Offset Alignment Offset Alignment ( (偏置偏置 對準對準) )Heating Time Heating Time ( (加熱時間加熱時間) )Built-up Pressure Built-up Pressure ( (

27、施加壓力施加壓力) )Weld Force Weld Force ( (焊接力道焊接力道) )Heating Element Adjustment Heating Element Adjustment ( (加熱元件調整加熱元件調整) )Air Current Air Current ( (氣流氣流) )Drag Force Drag Force ( (牽引力量牽引力量) )Ambient Area Ambient Area ( (周圍區域周圍區域) )Weld Preparation Weld Preparation ( (焊接預備焊接預備) )AGRU - Kunststofftechni

28、k GmbH AGRU - Technology in Plastics 29Comparison of the bead layout (HS / IR-d焊珠佈置的比較)IR-d-welding- (焊接)Butt welding (對焊熔接)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 30Typical IR WeldTypical IR Weld( (典型紅外線焊接典型紅外線焊接) )AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 31Di

29、al gauge(針盤量規)Weight (重量)Testmedium (測試媒體) Test specimen (待測試料)Heat isolated Bath (熱隔離槽)Chronometer (時計)Pump180 psi180 psiAcc. DVS 2203 Part 4AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 32Performed tests acc. DVS 2203-4/ (EN 12814-2/8): Welding machine: SP 110SP 110 pressure controll

30、ed (IR-d)pressure controlled (IR-d)Specimens(試料):Pipe Pipe SolefSolef 1010 / Pipe 1010 / Pipe SolefSolef 1010, OD 63 SDR21 1010, OD 63 SDR21Pipe Pipe SolefSolef 1010 / Fitting 1010 / Fitting SolefSolef 1009, OD 63 SDR21 1009, OD 63 SDR21Pipe Pipe SolefSolef 1010 / Fitting 1010 / Fitting SolefSolef 1

31、008, OD 160 1008, OD 160 SDR33SDR33 The specimens have been produced under standard conditions (20C, short cooling times) with standard parameters. (此試料在標準狀況下以標準參數製造(20C, 短冷卻時間) AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 33Welding machine: IR 63 way controlled (IR-w)IR 63 way contro

32、lled (IR-w)Specimens(試料):Pipe Pipe KynarKynar / Pipe / Pipe KynarKynar, OD 63 SDR21, OD 63 SDR21To determine the notch sensitivity 2NCT tests have been performed on the basic material. (為了決定刻痕敏感度 2NCT 試驗實施在基本的材料上.) The tests were performed by Hessel Ingenieurtechnik (2000 2002*) by order of AGRU. (本

33、試驗被Hessel Ingenieurtechnik依照AGRU的指令而實施 (2000 2002*) .AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 34Results of the Long Term Behaviour acc. DVS of IR (force) welded PVDF S-Type welding samples: (長時間表現性能結果是依據紅外線(力量)焊接的PVDF S- 型式焊接樣本的DVS:)Test performed by Test performed by Hessel Ingen

34、ieurtechnik Hessel Ingenieurtechnik GmbH/Germany 2002 T = 95 GmbH/Germany 2002 T = 95 C CSpecimen identification G: basic material S: welding Test pressure N/mm Time to fail in hours Geom., average in hours Standard- deriation in hours Remarks G1.1 1274,9 G1.2 1253,9 G1.3 2466,3 G1.4 1239,8 G1.5 166

35、0,6 G1.6 12,5 1620,2 1536,4 723,4 Brittle fracture share 30 % S2a/1 171,1 S2a/3 515,1 S2a/4 644,3 S2b/1 987,7 S2b/5 380,8 S2b/8 12,5 216,4 408,1 421,8 Breakings from the bead notch; Brittle fracture share 30 % S2a/10 19162 8,8 19162 - Test are still running (05.11.2002) AGRU - Kunststofftechnik GmbH

36、 AGRU - Technology in Plastics 35Specimen identification G: basic material S: welding Test pressure N/mm Time to fail in hours Geom., average in hours Standard- deriation in hours Remarks G4.1 211,4 G4.2 397,5 G4.3 157,1 G4.4 140,1 G4.5 239,7 G4.6 12.5 237,5 217,3 97,0 Brittle fracture share 30 % S2

37、a/10 19100 8.8 19100 - Test are still running (05.11.2002) Results of the Long Term Behaviour acc. DVS of IR (distance) welded PVDF-E (competitor) samples: (長時間表現性能結果是依據紅外線 (距離) 焊接的 PVDF E(競爭者)-樣本的 DVS :)Test performed by Hessel Ingenieurtechnik GmbH/Germany 2002 T = 95 CAGRU - Kunststofftechnik Gmb

38、H AGRU - Technology in Plastics 36Sample IR-d welding PVDF S-Type (AGRU)IR-w welding PVDF E-Type(other supplier)Service life differenceBasic material1536,4 Std.217,3 Std.+ 607 %IR welding sample408,1 Std. fs 0,957,6 Std.fs 0,88+ 610 %AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 37AGRU

39、Supplier B PP-PureStandardPP-cdpStandardPipePPR b-PPH /PPRb-PPHb-PPHFittingPPRPPRb-PPH /PPRb-PPH /PPRValveb-PPHb-PPHb-PPHb-PPH PP-H (Homopolymer) (同元聚合物) PP-R (Random-Copolymer) (隨機-共聚物)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 38Welding machine: SP 110 pressure controlled (IR-d)(焊

40、接機) SP 250 pressure controlled (IR-d)Specimen: (試料)Pipe / Pipe PPR OD 110 x 10 SDR11Pipe / Pipe PPH OD 110 x 10 SDR11Welding machine: Butt welding machine (HS)(焊接機: 對焊熔接機對焊熔接機 (HS)Specimen: (試料)Pipe / Pipe PPR OD 110 x 10 SDR11Pipe / Pipe PPH OD 110 x 10 SDR11AGRU - Kunststofftechnik GmbH AGRU - Tec

41、hnology in Plastics 39Comparison of the bead layout HS / IR-d (焊接佈置的比較)HS-welding(HS-焊接)IR-d-welding(IR-d-焊接)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 40Tests were performed by Hessel Ingenieurtechnik GmbH 2002/2003Comparison Material PP-H / PP-R: (比較材料)80C / 2% liquid wetting agen

42、t Nm5 (4 N/mm2)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 41Tests were performed by Hessel Ingenieurtechnik GmbH 2002/2003Comparison service lifes HS-welded pipes: (HS-焊接管的使用壽命比較)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 42Tests were performed by Hessel Ingenieurte

43、chnik GmbH 2002/2003Comparison service lives IR-d-welded pipes:(IR-d-焊接管的使用壽命比較)AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 43Break on an infrared welded sample out of PP-H(PP-H斷裂的紅外線焊接樣本斷裂的紅外線焊接樣本)Broken IR-welding sample out of PP-R (PP-R 斷裂的紅外線焊接樣本斷裂的紅外線焊接樣本)PP-HPP-RAGRU - Kunstst

44、offtechnik GmbH AGRU - Technology in Plastics 44AGRU - Kunststofftechnik GmbH AGRU - Technology in Plastics 45Automated IR Automated IR FusionSystemFusionSystem Benefits Benefits ( (自動的紅外線熔接系統的利益自動的紅外線熔接系統的利益) )Weld IntegrityFunctionalityWeld ReliabilityTraceabilityAutomationSize RangeWeld timesEase of Use(自動的紅外線熔接自動的紅外線熔接系統的利系統的利)(自動的紅外線熔接自動的紅外線熔接)(自動的紅外線熔接自動的紅外線熔接)