Design scheme of welding process quality optimizat

Design scheme of welding process quality optimization model of torque converter

as a backbone enterprise of independent research and development in China's automotive industry, it has always adhered to complete independent intellectual property rights for automotive research and development. However, many core technologies of automatic transmission have been in the hands of foreign companies. In particular, the welding technology of the key component torque converter has always been a difficult problem to overcome. The traditional plasma welding process will bring a lot of sputter accumulation inside the torque converter, and then gradually move to the other end along the length of the test mold with a transverse sawing action, which will affect the hydraulic transmission of the internal fluid, thus reducing the efficiency and accuracy of torque converter. In order to solve this problem, we need to make the performance of products and processes insensitive to interference without increasing costs, and make the performance close to the target value. The quality characteristics of this process are analyzed by using quality function deployment technology. On the basis of determining five key process parameters, the welding process is optimized by using robust parameter design technology, and a design scheme meeting the optimization model is proposed

project overview

as a backbone enterprise of independent research and development in China's automobile industry, it has always adhered to complete independent intellectual property rights for automobile research and development. However, many core technologies of automatic transmission have been in the hands of foreign companies. In particular, the welding technology of the key component torque converter has always been a difficult problem to overcome. The traditional plasma welding process will bring a lot of sputter accumulation in the torque converter, which will affect the hydraulic transmission of internal fluid, thus reducing the efficiency and accuracy of torque converter

in order to solve this problem, we need to make the performance of products and processes insensitive to interference and make the performance close to the target value without increasing the cost. The quality characteristics of this process are analyzed by using the quality function deployment technology. On the basis of determining five key process parameters, the welding process is optimized by using the robust parameter design technology, and a design scheme meeting the optimization model is proposed. Next, we will introduce the functional characteristics of the static torsion experimental machine:

project challenge

(1) determination and level selection of key welding factors. Finding the key factors that affect the deposition of sputters in the welding process is the prerequisite for modeling, experiment and optimization analysis. At the same time, setting a reasonable level of the determined parameters has a great impact on the representativeness of the final experimental data

(2) determine the interactive relationship between various factors. Due to the interaction between plasma velocity and current, current and welding time, the interaction must be taken as one of the factors of experimental analysis to design the scheme

(3) determination and verification of priority schemes. Through the analysis of test data, we can determine the best optimization scheme, which must be able to quantify and evaluate the value of the improved scheme through the loss function

horizontal design of welding process parameters

experimental scheme design

solution

establish an analytical view of house of quality for many factors that affect welding quality, such as plasma flow rate, nozzle distance, current, welding time, torch angle, etc., and determine the key factors through the evaluation of weight, correlation and importance. Through preliminary experiments on key factors, the experimental scheme of two levels of each factor is determined to be as economical and reasonable as possible

taking the interaction of a, C and C, D as the 6th and 7th factors, the solution participated in the experimental scheme design together, and the significance of the interaction effect was analyzed

for multiple groups of test data, the company has an experimental machine technology center, which uses signal-to-noise ratio (SN) to evaluate the impact of factor level combination on fluctuation. Determine the significance of each factor and optimize the operating conditions. By establishing the quality loss function of welding diameter, the gain before and after improvement is calculated. Thus, the effectiveness of the improvement scheme is further clarified

factor SN ratio trend analysis

optimal design scheme and significance analysis

optimized data governance

user value

through the analysis of the plasma welding process of torque converter with the quality design software ality, the key factors affecting the welding quality are found, and through the analysis of experimental data, the optimal scheme to improve the process quality without increasing the cost is found. If the annual output is 100000 pieces, the annual benefit will reach nearly 2 million yuan. Therefore, the system not only improves the quality, but also reduces the production cost, which lays a solid foundation for improving the market competitiveness of products

user evaluation

through the analysis of process parameters on the quality design platform of Alice, the most reasonable experimental scheme is quickly given. Through modeling and experimental data analysis, the influence degree of each parameter level on performance is determined, and the best parameter combination is given, which greatly improves the quality level of welding process