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In China, the production technology and production process of industrial electric detonators have long been lagging behind the mechanized production level in developed countries such as Europe and the United States. The majority of manufacturers ’industrial electric detonator ignition wire bridge wires are still welded by traditional manual soldering In the production process of electric detonators, the welding of the ignition element bridge wire is an important process in the production process of electric detonators. The welding quality directly affects the electrical performance of the electric detonator and the reliability of its ignition. The manual soldering process of the bridge wire has poor welding firmness, low tensile strength, large resistance dispersion, and corrosion of the bridge wire by the flux and chemicals, which is not easy to store for a long time (especially in the humid area in the south), low production efficiency, and high labor intensity , Defects such as poor operating environment conditions, which have been hindering the advancement of the modernization process of industrial electric detonator production in China. In view of this, our factory and the 213th Research Institute of China Ordnance Industry jointly developed a bridge suitable for China ’s industrial electric detonator elastic ignition element Wire welding energy storage type bridge wire automatic welding machine The welding machine was in October 1997 After the design, finalization and achievement appraisal work organized by the former Ministry of Coal, a detonator bridge wire welding production line composed of the welding machine was established in our factory at the end of 1998. Here is a brief introduction to the DCQH- 9718 multi-function energy storage type detonator bridge wire automatic welding machine (Hereinafter referred to as welding machine) performance and application situation, for peers.
2 Basic principles and main technical indicators The welding machine integrates electromechanical and gas. Using compressed air as the power source, the automatic control originates from the electric signal, and the mechanical transmission completes the actions of each station. Welding is performed by capacitive energy storage welding, that is, a pulse of concentrated energy is used to generate heat through the contact point of the workpiece to be welded under appropriate pressure to weld the metal, thereby forming a weld spot with a certain strength. The storage of pulse energy uses the power frequency alternating current to charge the capacitor after being rectified and stabilized. The charged energy is then converted into a low-voltage pulse welding current by the welding transformer discharge. Due to the steep current waveform, the heating is concentrated and there is no AC zero crossing The intermittent process is easy to control, so the welding quality is stable. 2.2 The main technical indicators are 10%, 50 input air pressure: 0.6MPet 0.8MPa working voltage range of the energy storage capacitor: 80V ~ adjustable range of the upper and lower limits of the test resistance (T 101000; solder joints bear Tensile force: 00.04mm nickel-chromium wire two-weld joint tensile strength is not less than 100g; working mode: pneumatic (jog or linkage optional); 3 functional characteristics and working process The welding machine is a set of cutting head, welding bridge wire 〠Resistance inspection, pinch blocking, identification of non-conforming products, a multi-functional detonator bridge wire welding special equipment. It is mainly composed of transmission, automatic control, sealing plug fixture, cutting, flattening, bending, wire feeding calibration, compression, burning The working process of wire energy storage welding, resistance inspection pinch, identification of unqualified products, automatic unplugging and other devices is as follows: manual installation of sealing plug-cutting, flattening + bending-wire feeding-calibration pressure Tight-firing wire-storage welding-resistance inspection-pinch block-unqualified product handling + automatic unplugging 4 Application and analysis 4.1 Application of welding machine in production and analysis After the welding machine has been designed and finalized, it was built in our factory A detonator bridge wire welding production line Since the trial operation of the production line in April 1999, there have been nearly 20 million rounds of welding products and nearly 20 million rounds of assembly products. The user has good results. The operation of the machine during the production trial in the past two years The quality of the welding products is inspected. The machine runs smoothly, in good condition, the positioning of each component is accurate, the precision is good, the welding of the bridge wire is good, the pass rate is high, and the efficiency is high. Although the machine has many functions and the structure is more complicated, the operation is simple. Some problems were also found and solved in the process. At first, the cutter design was easy to wear and hard to grind, and the wire was broken easily during the wire walking process; the resistance was unstable, after analysis and research, and part of the improved design, the cutter structure and material were improved , Overcoming the above defects, the effect is remarkable. The improved design of the wire feeding device structure and the addition of the broken wire parking alarm system have overcome the broken wire phenomenon. The results have been greatly improved; the optimized design of the welding head structure, the improvement of the welding line and the optimization of the welding head material have enabled the resistance instability caused by the welding insufficiency caused by the insufficient welding energy of the welding head to be overcome 4.2 Product quality and performance In order to better reflect the quality and performance of the welding products, the quality and performance of the welded products were investigated while the welding machine was being inspected. During the trial, 1000 pairs of machine welding bridge wires were randomly checked for bridge head resistance inspection. The value is 3.05n, the minimum value is 2 58n, the average value is 2.8in, and the distribution is basically normal. The breaking of the bridge wire was found in the static tensile test (the breaking resistance of the 0Q 04mm wire produced in Xi'an and Shanghai is Q98N and 1.18N, respectively) The energy storage solder joints are not disconnected. In order to facilitate inspection during production, combined with the standard, we tested 200g welding bridge wire with 100g static tensile force. The result is 100% qualified, which is higher than the current manual soldering bridge wire 60g static tensile qualification rate (95 %) Has greatly improved.
Table 1 shows the performance comparison of energy storage welding products and manual soldering products (all equipped with copper clad steel shell instantaneous detonators) of the welding machine. Table 1 Performance comparison of energy storage welding products and manual soldering products of the welding machine Bridgehead resistance 0 seconds / ms single firing current / A firing impulse / A2.ms series quasi-explosion 200 rounds (10 groups) all qualified safety current qualified vibration test qualified table 2 machine welding product storage performance full resistance D seconds / ms Lead plate perforation value / mm single firing current / A 0.36 series quasi-explosion qualified safety current qualified ratio. From Table 1, it can be seen that the performance of both products meets the requirements of GB8031-87 standard, and the difference is almost the same. 4.3 Welding machine welding product storage test For more comprehensive Understand the storage performance of machine-welded products. We conducted storage test on paper-wrapped products of copper-clad steel shell instantaneous detonators assembled with welding bridge wire igniting powder heads of welding machine designed and shaped after welding in October 1997. Natural storage indoors, heating in winter, temperature 8 ° C ~ 20 * C, storage time: October 20, 1997 to February 20, 2001, 40 months. Observe that there are rust spots on the shell of the tube. The performance is shown in Table 2. The results of Table 2 show that the performance of the machine energy storage welding product remains unchanged after long-term storage and meets the requirements of GB8031 ~ 87 standards. 5 Conclusion The change of the welding method of industrial electric detonator bridge wire, The electrical and explosive properties of the electric detonator are not changed, but the product quality and storage performance can be guaranteed. The successful development and use of the welding machine has improved the manufacturing process of the ignition element, improved the labor efficiency, improved the working environment, reduced the labor intensity, and economical. And significant social benefits
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