Bo day dien ket noi hai bo phan cung: mot dau noi o moi dau. Giua chung, cap uon cong va chiu tai co hoc tu rung dong, chu ky nhiet va thao tac bang tay. Giai phong luc cang quan ly vung chuyen tiep giua phan cung va phan mem. Khong co no, moi luc keo, xoan hay uon deu tap trung truc tiep len moi han va dau bam crimp.
Mo hinh hong hoc co the du doan: day bi keo tut khoi dau noi khi lap dat, soi dan dut trong vo dau noi sau nhieu thang rung dong, ket noi khong on dinh do moi dau dan tai diem uon cong dot ngot. Nhung hong hoc nay gay ra nhieu bao hanh hon bat ky nguyen nhan nao khac trong cac cum cap thieu giai phong luc cang phu hop.
Lua chon phuong phap dung doi hoi can nhac moi truong co hoc, san luong va yeu cau bao tri. Huong dan nay bao gom moi phuong phap voi du du lieu de xac dinh thong so giai phong luc cang mot cach tu tin.
Tai sao giai phong luc cang quan trong trong thiet ke bo day dien
Giai phong luc cang chuyen tai co hoc ra xa cac diem ket noi dien. Khi ai do keo cap, luc phai duoc vo cap va co cau giai phong hap thu, khong phai boi ong crimp, moi han hay pad PCB ben trong dau noi.
Vat ly rat don gian: viec uon cap tap trung ung suat tai diem co su thay doi do cong lon nhat. Khong co giai phong, diem do chinh xac la noi cap di ra khoi dau noi - mat xich yeu nhat cua cum lap rap.
Giai phong luc cang them tu $0,10 den $5,00 cho moi cum lap rap tuy theo phuong phap. So voi chi mot lan hong tai hien truong, loi tuc dau tu la ro rang.
"Chung toi thay cung mot loi trong mot phan ba yeu cau bao gia: ban ve chi dinh dau noi va tiet dien day nhung khong de cap gi den giai phong luc cang. Ky su gia dinh nha san xuat se xu ly. Nha san xuat chon day rut re nhat. Sau thang sau chung toi nhan duoc cuoc goi ve hong hoc tai hien truong."
Hommer Zhao
Giam doc Ky thuat, WellPCB Wire Harness Production
Bon phuong phap giai phong luc cang chinh
Moi phuong phap co su danh doi khac nhau giua muc do bao ve, chi phi, bao kin moi truong va kha nang bao tri.
Giai phong bang duc khuon tren
Phun nhua nhiet deo hoac elastomer truc tiep len moi noi cap-dau noi.
Khang luc keo cao nhat (50-200+ pound tuy thiet ke).
Bao kin chong am va bui (co the dat IP67/IP68).
Chi phi khuon: $2.000-$8.000 moi long khuon.
Khong the sua tai hien truong (thay the doi hoi cat cap).
Kep va vo dau noi
Kep kim loai hoac nhua giu co hoc vo cap.
Khong co chi phi khuon; linh kien tieu chuan san co.
Sua duoc tai hien truong (thao kep de thay dau noi).
Dai kich thuoc rong cho cap tu 3 mm den 50 mm+.
Bao kin han che neu khong co gioang bo sung.
Vong dem cao su va ong lot
Ong boc cao su hoac nhua co duong lot hinh non ben trong.
Chi phi thap nhat moi don vi ($0,05-$0,50).
Lap dat kieu ep; khong can dung cu.
Khang luc keo thap (thong thuong 3-15 pound).
Cao su bi suy giam khi tiep xuc tia UV va ozone.
Ong bao ve mem va ong co nhiet
Ong bao ve elastomer dinh hinh san hoac ong co nhiet thanh kep.
Chuyen tiep do cung dan tot (thiet ke phan doan).
Chi phi trung binh ($0,50-$5,00 moi don vi).
Phien ban co nhiet bao kin chong am (IP65-IP67).
Luc keo gioi han boi ma sat giua vo cap va ong bao ve (10-40 pound).
Vat lieu giai phong luc cang: Tinh chat va danh doi
Lua chon vat lieu quyet dinh dai nhiet do, khang hoa chat, tuoi tho moi va chi phi. Vat lieu khong phu hop se hong ngay ca khi thiet ke co hoc dung.
| Vat lieu | Dai nhiet do | Do cung Shore | Khang hoa chat | Ly tuong cho | Chi phi |
|---|---|---|---|---|---|
| PVC | -20 den +80°C | 60A-90A | Trung binh | Tieu dung, cong nghiep chung | $ |
| TPE | -40 den +120°C | 35A-95A | Tot | O to, cong nghiep | $$ |
| TPU | -40 den +100°C | 70A-95A | Xuat sac (dau) | O to, robot | $$ |
| Silicone | -60 den +200°C | 20A-80A | Tot (autoclave) | Y te, hang khong | $$$ |
| Nylon PA6/PA66 | -40 den +120°C | Cung (75D+) | Tot | Kep, vo | $ |
| Thep khong gi | -200 den +800°C | Cung (kim loai) | Xuat sac | Hang khong, quan su | $$$$ |
"Day rut siet chat phia sau dau noi khong phai la giai phong luc cang. No tap trung luc tren mot duong 2 milimet ngang qua vo cap. Sau vai tram chu ky uon, canh day rut cat vo cap va bat dau mai mon cac soi dan."
Hommer Zhao
Giam doc Ky thuat, WellPCB Wire Harness Production
Thong so thiet ke quan trong
Ban kinh uon toi thieu: 5 lan duong kinh ngoai cap cho lap dat tinh, 10 lan cho ung dung dong co chuyen dong lien tuc.
Ty le chuyen tiep do cung: giai phong ly tuong giam do cung dan dan tren khoang cach 3-5 lan duong kinh cap. Thay doi toi da 3:1 tai bat ky diem nao ngan tap trung ung suat.
Luc keo: IPC-620 quy dinh gia tri toi thieu theo tiet dien (0,9 kg cho AWG 28, 9,1 kg cho AWG 14). Cac OEM o to thuong yeu cau gap 1,5-2 lan gia tri toi thieu IPC.
Lua chon theo nganh cong nghiep
O to: duc khuon tren TPE cho cac ket noi bao kin, kep nylon co lot cao su cho tuyen cap, vo sau cho dau noi cao ap EV.
Thiet bi y te: duc khuon tren silicone cho cap ket noi benh nhan, TPE cap y te cho cap thiet bi, ong bao ve bao kin cho cum lap rap dung mot lan.
Tu dong hoa cong nghiep va robot: ong bao ve TPU phan doan cho khop robot (10 trieu+ chu ky uon), kep thep khong gi cho dau vao panel trong moi truong rua nuoc.
Hang khong vu tru va quan su: vo sau kim loai co bao ve EMI cho bo day boc giap, ong bao ve silicone phan doan cho tuyen khong boc giap.
Yeu cau giai phong luc cang theo tieu chuan IPC-620
IPC/WHMA-A-620 la tieu chuan chat luong chinh cho cum cap va bo day dien. No xac dinh ba cap san pham voi yeu cau giai phong luc cang tang dan.
| Yeu cau | Cap 1 (Chung) | Cap 2 (Dich vu) | Cap 3 (Do tin cay cao) |
|---|---|---|---|
| Can giai phong | Khi duoc chi dinh | Tat ca diem ket noi | Tat ca diem + tuyen cap |
| Kiem soat ban kinh uon | Kiem tra bang mat | Theo ban ve | Do va ghi chep |
| Thu luc keo | Khong yeu cau | San pham dau tien | San pham dau tien + dinh ky |
| Kiem tra | Lay mau | Lay mau theo AQL | Kiem tra 100% |
| Giai phong du phong | Khong yeu cau | Khong yeu cau | Yeu cau cho mach quan trong |
Nam loi giai phong luc cang gay hong hoc tai hien truong
1. Dung day rut lam giai phong chinh: tao diem ap luc nhon lam mon vo cap.
2. Bo qua chuyen tiep do cung: ong co nhiet tieu chuan tao phan cung di chuyen diem hong.
3. Vat lieu khong tuong thich: PVC tren TPU tao lien ket yeu bi tach khi thay doi nhiet do.
4. Chi dinh luc keo khong co phuong phap thu: 50 pound doc truc khac voi 50 pound o goc 45 do.
5. Khong dua giai phong vao ban ve: khong co dac ta, nha san xuat chon phuong an re nhat.