帶你了解山東電纜橋架的詳細信息
一、山東電纜橋架原材料
1、 Raw materials
高精度基材選擇
High precision substrate selection
冷軋鋼板：厚度公差±0.05mm（GB/T 708-2025標準），優先選用SPCC碳鋼（屈服強度≥280MPa）。
Cold rolled steel plate: thickness tolerance ± 0.05mm (GB/T 708-2025 standard), SPCC carbon steel (yield strength ≥ 280MPa) is preferred.
智能分選：激光光譜儀檢測材質成分（C含量≤0.12%，Mn含量0.3-0.6%），剔除不合格板材。
Intelligent sorting: The laser spectrometer detects the material composition (C content ≤ 0.12%, Mn content 0.3-0.6%) and removes unqualified boards.
預處理線
Environmental protection pretreatment line
脫脂除油：堿性電解液（PH 12-13）配合超聲波清洗，油污殘留量＜5mg/m?。
Degreasing and degreasing: alkaline electrolyte (pH 12-13) combined with ultrasonic cleaning, resulting in a residual oil content of less than 5mg/m?.
酸洗活化：鹽酸濃度18-20%（廢酸回收率≥95%），表面粗糙度Ra≤6.3μm。
Acid washing activation: hydrochloric acid concentration of 18-20% (waste acid recovery rate ≥ 95%), surface roughness Ra ≤ 6.3 μ m.
助鍍處理：氯化鋅銨溶液，形成均勻預鍍層。
Assisted plating treatment: Zinc ammonium chloride solution is used to form a uniform pre plating layer.
二、山東電纜橋架智能化成型加工
2、 Intelligent Forming Processing
激光切割下料
Laser cutting material cutting
光纖激光切割機（功率6kW）實現±0.1mm精度，板材利用率提升92%。
The fiber laser cutting machine (power 6kW) achieves a precision of ± 0.1mm and increases the utilization rate of the sheet to 92%.
山東臨工集團引入AI排料系統，節省材料成本15%。
Shandong Lingong Group has introduced an AI material scheduling system, saving 15% of material costs.
輥壓成型工藝
Roll forming process
伺服電機驅動多道次輥壓（速度15m/min），側板高度誤差≤0.5mm。
Servo motor drives multi pass roller pressing (speed 15m/min), with side plate height error ≤ 0.5mm.
青島四方車輛廠案例：采用柔性模具技術，5分鐘切換不同規格（200×100mm600×200mm）。
Case study of Qingdao Sifang Vehicle Factory: Adopting flexible mold technology, switching between different specifications (200 × 100mm to 600 × 200mm) in 5 minutes.
機器人焊接
robot welding
六軸焊接機器人（重復精度±0.02mm），焊縫熔深≥1.2倍板厚。
Six axis welding robot (with a repeatability accuracy of ± 0.02mm), with a weld penetration depth of ≥ 1.2 times the plate thickness.
實時紅外監測焊縫質量（氣孔率≤3%），不良品自動分揀。
Real time infrared monitoring of weld quality (porosity ≤ 3%), automatic sorting of defective products.
三、山東電纜橋架熱浸鍍鋅核心工藝
3、 Core process of hot-dip galvanizing
高溫浸鍍流程
High temperature immersion plating process
鋅液控制：溫度445-455℃，鋁含量0.005-0.02%（抑制鋅渣生成）。
Zinc liquid control: temperature 445-455 ℃, aluminum content 0.005-0.02% (inhibits zinc slag formation).
雙鋅鍋工藝：預鍍鋅層（40-60μm）+ 主鍍鋅層（70-90μm），總厚度≥100μm（GB/T 13912-2025 Class 4）。
Double zinc pot process: pre galvanized layer (40-60 μ m)+main galvanized layer (70-90 μ m), with a total thickness of ≥ 100 μ m (GB/T 13912-2025 Class 4).
技術
Energy saving and environmental protection technology
余熱回收系統：鋅鍋煙氣熱量用于板材預熱，能耗降低30%。
Waste heat recovery system: The heat from the zinc pot flue gas is used for preheating the sheet, reducing energy consumption by 30%.
鋅灰分離裝置：鋅渣產生量＜1.5kg/t（傳統工藝3-5kg/t）。
Zinc ash separation device: The amount of zinc slag produced is less than 1.5kg/t (traditional process 3-5 kg/t).
四、山東電纜橋架后處理與質量檢測
4、 Post processing and quality inspection
表面優化
Surface Optimization
離心甩鋅：2000r/min高速旋轉，鋅層均勻度偏差≤±8μm。
Centrifugal zinc throwing: high-speed rotation at 2000r/min, with a zinc layer uniformity deviation of ≤± 8 μ m.
鈍化處理：三價鉻鈍化液，耐鹽霧時間≥2000h。
Passivation treatment: trivalent chromium passivation solution, salt spray resistance time ≥ 2000h.
智能質檢系統
Intelligent Quality Inspection System
X射線測厚儀：每10秒掃描一個截面，生成3D鋅層分布圖。
X-ray thickness gauge: Scan a section every 10 seconds to generate a 3D zinc layer distribution map.
鹽霧試驗：循環腐蝕測試（35℃×5%NaCl噴霧+50℃烘干），168小時無紅銹。
Salt spray test: cyclic corrosion test (35 ℃ × 5% NaCl spray+50 ℃ drying), 168 hours without red rust.
附著力測試：劃格法（間距2mm）鋅層剝落面積＜5%。
Adhesion test: The peeling area of the zinc layer using the grid method (with a spacing of 2mm) is less than 5%.
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