仿威圖機(jī)柜作為工業(yè)控制設(shè)備的核心載體，其標(biāo)準(zhǔn)化生產(chǎn)流程是保障產(chǎn)品質(zhì)量與交付效率的關(guān)鍵。從原材料選型到成品出庫(kù)，整個(gè)過程通過精細(xì)化分工與嚴(yán)格品控，實(shí)現(xiàn)規(guī)模化生產(chǎn)與定制化需求的平衡。

　　As the core carrier of industrial control equipment, the standardized production process of the imitation Weitu cabinet is the key to ensuring product quality and delivery efficiency. From raw material selection to finished product delivery, the entire process achieves a balance between large-scale production and customized needs through refined division of labor and strict quality control.

　　原材料選用與檢驗(yàn)

　　Raw material selection and inspection

　　生產(chǎn)始于冷軋鋼板的選用，材質(zhì)需符合GB/T 708-2019標(biāo)準(zhǔn)，厚度公差控制在±0.05mm以內(nèi)。鋼板入庫(kù)前需通過三道檢驗(yàn)：，光譜分析儀檢測(cè)元素成分，確保碳、錳含量符合耐腐蝕要求；第二，拉伸試驗(yàn)機(jī)測(cè)試抗拉強(qiáng)度與屈服強(qiáng)度，數(shù)據(jù)需達(dá)到345MPa以上；第三，鹽霧試驗(yàn)箱模擬48小時(shí)腐蝕環(huán)境，表面銹蝕面積不得超過0.5%。

　　Production begins with the selection of high-quality cold-rolled steel plates, which must comply with the GB/T 708-2019 standard and have a thickness tolerance controlled within ± 0.05mm. Before the steel plate is stored, it needs to undergo three inspections: firstly, the elemental composition is detected by a spectrometer to ensure that the carbon and manganese content meets the corrosion resistance requirements; Secondly, the tensile testing machine is used to test the tensile strength and yield strength, and the data must be above 345MPa; Thirdly, the salt spray test chamber simulates a 48 hour corrosive environment, and the surface rust area shall not exceed 0.5%.

　　數(shù)控加工與折彎成型

　　Numerical Control Machining and Bending Forming

　　采用全自動(dòng)數(shù)控沖床進(jìn)行板材切割，模具間隙精確0.1mm，孔位誤差控制在±0.02mm范圍內(nèi)。對(duì)于異形開孔，引入激光切割機(jī)實(shí)現(xiàn)動(dòng)態(tài)焦距補(bǔ)償，確保切割面垂直度≤1°。折彎工序由數(shù)控折彎?rùn)C(jī)完成，通過角度補(bǔ)償算法控制回彈變形，單次折彎角度誤差不超過0.5°，多道折彎累計(jì)誤差控制在1°以內(nèi)。

　　Using fully automatic CNC punching machines for sheet cutting, the mold clearance is precise to 0.1mm, and the hole position error is controlled within ± 0.02mm. For irregular openings, a laser cutting machine is introduced to achieve dynamic focal length compensation, ensuring that the perpendicularity of the cutting surface is ≤ 1 °. The bending process is completed by a CNC bending machine, and the rebound deformation is controlled by an angle compensation algorithm. The single bending angle error does not exceed 0.5 °, and the cumulative error of multiple bending is controlled within 1 °.

　　焊接與表面處理

　　Welding and surface treatment

　　焊接環(huán)節(jié)采用機(jī)器人自動(dòng)化焊接工作站，焊縫軌跡規(guī)劃基于三維模型離線編程，焊接速度穩(wěn)定在800mm/min，熔深控制在3-5mm區(qū)間。關(guān)鍵承重部位實(shí)施雙面焊接，破壞性試驗(yàn)顯示焊縫抗拉強(qiáng)度達(dá)母材85%以上。表面處理采用型前處理工藝，脫脂、表調(diào)、磷化三道工序后，磷化膜重達(dá)到2-3g/m2。靜電噴塑選用聚酯粉末涂料，膜厚控制在60-80μm，經(jīng)百格試驗(yàn)附著力達(dá)0級(jí)標(biāo)準(zhǔn)。

　　The welding process adopts a robot automated welding workstation, and the weld trajectory planning is based on offline programming of 3D models. The welding speed is stable at 800mm/min, and the penetration depth is controlled within the range of 3-5mm. Double sided welding is implemented in key load-bearing areas, and destructive tests show that the tensile strength of the weld seam reaches over 85% of the base metal. The surface treatment adopts an environmentally friendly pre-treatment process, which includes three steps of degreasing, surface adjustment, and phosphating. After that, the weight of the phosphating film reaches 2-3g/m2. Polyester powder coating is selected for electrostatic spraying, with a film thickness controlled at 60-80 μ m, and the adhesion strength reaches the 0 level standard after the hundred grid test.

　　裝配與調(diào)試

　　Assembly and Debugging

　　標(biāo)準(zhǔn)化裝配流程包含七個(gè)工位：進(jìn)行門板鉸鏈預(yù)裝配，通過扭矩扳手控制預(yù)緊力在12-15N·m；接著安裝承重導(dǎo)軌，水平度偏差≤0.2mm/m；然后進(jìn)行密封條貼合，采用進(jìn)口雙面膠帶確保IP55防護(hù)等級(jí)；隨后進(jìn)行模塊化安裝，強(qiáng)電/弱電區(qū)域分隔間距符合IEC 60529標(biāo)準(zhǔn)；再進(jìn)行線纜管理，使用尼龍?jiān)鷰Ч潭ǎ瑥澢霃讲恍∮诰€徑6倍；接著進(jìn)行接地連續(xù)性測(cè)試，電阻值≤0.1Ω；進(jìn)行功能調(diào)試，模擬滿載工況運(yùn)行24小時(shí)，溫控范圍需保持在-10℃60℃之間。

　　The standardized assembly process includes seven workstations: firstly, the door panel hinges are pre assembled, and the pre tightening force is controlled at 12-15N · m through a torque wrench; Next, install the load-bearing guide rail with a horizontal deviation of ≤ 0.2mm/m; Then, the sealing strip is attached and imported double-sided tape is used to ensure an IP55 protection level; Subsequently, modular installation will be carried out, and the separation distance between strong and weak electrical areas will comply with the IEC 60529 standard; Perform cable management again, fix with nylon zip ties, and the bending radius should not be less than 6 times the wire diameter; Next, conduct a grounding continuity test with a resistance value of ≤ 0.1 Ω; Finally, perform functional debugging and simulate full load operation for 24 hours. The temperature control range should be maintained between -10 ℃ and 60 ℃.

　　成品檢驗(yàn)與包裝

　　Finished product inspection and packaging

　　成品檢驗(yàn)包含23項(xiàng)檢測(cè)項(xiàng)目，包括：門板開啟耐久性試驗(yàn)達(dá)10000次無變形，鎖具防盜等級(jí)通過EN 1300 B級(jí)認(rèn)證，抗震性能滿足IEC 60068-2-27標(biāo)準(zhǔn)。包裝環(huán)節(jié)采用蜂窩紙板，內(nèi)部使用EPE緩沖材料，包裝箱跌落試驗(yàn)從1.2米高度自由落體后，機(jī)柜變形量不超過2mm。

　　The finished product inspection includes 23 testing items, with a focus on the durability test of the door panel reaching 10000 times without deformation, the anti-theft level of the lock passing the EN 1300 B-level certification, and the seismic performance meeting the IEC 60068-2-27 standard. Environmentally friendly honeycomb cardboard is used in the packaging process, with EPE cushioning material used internally. After the packaging box falls freely from a height of 1.2 meters, the deformation of the cabinet does not exceed 2mm.

　　通過上述標(biāo)準(zhǔn)化流程，仿威圖機(jī)柜實(shí)現(xiàn)日產(chǎn)能200臺(tái)套，直通率達(dá)98.7%，關(guān)鍵尺寸CPK值保持在1.67以上。該體系既保證了大批量生產(chǎn)效率，又能通過模塊化設(shè)計(jì)滿足200余種定制配置需求，為工業(yè)自動(dòng)化領(lǐng)域提供可靠的基礎(chǔ)設(shè)施保障。

　　Through the above standardized process, the imitation Weitu cabinet achieves a daily production capacity of 200 sets, with a pass through rate of 98.7%, and the critical dimension CPK value remains above 1.67. This system not only ensures mass production efficiency, but also meets over 200 customized configuration requirements through modular design, providing reliable infrastructure support for the industrial automation field.