As illustrated in the original inflation method, the rubber column 6 is pre-stressed to block the air passage. The gas is then charged into the spring by using the pressure from the air source against the elastic force of the rubber column. When the pressure gauge reaches a specific value, the inflation process stops, completing the operation. However, this method has a significant drawback: the gauge pressure does not equal the internal pressure of the spring. The difference between the two is the pressure difference caused by the elastic force $P$ of the rubber column 6. Due to the non-uniform material of the rubber column and manufacturing inconsistencies, such as height errors in the cavity, the pressure required to open the rubber column varies, resulting in different values of $P$ for each gas spring. The formula PN = PB - $P$ applies here. If PN is set to 315MPa and $P$ is set to 0.11MPa, then the gauge pressure PB would be 316MPa. However, if $P$ exceeds the set value, PN will fall below the desired level, leading to insufficient spring elasticity and premature failure of the gas spring.
The original inflation method involved an air pipe (11), an air source (11), an inflatable seal (31), an air inlet (41), a gas spring housing (51), a rubber column (61), a snap ring (71), an air chamber (81), and a telescopic rod. The new inflation method introduces improvements to enhance the process, as shown in the updated structure.
In the improved method, a head 5 is pre-positioned in the airway, and a hydraulically driven striker 2 is placed above it. When the air source is activated, gas flows into the spring chamber through the gap between the head 5 and the air passage. At this point, the pressure in the air chamber equals the internal pressure of the spring (PB = PN). Once the desired pressure is reached, the striker 2 strikes the head 5, causing plastic deformation that blocks the air passage and completes the sealing. This method’s accuracy depends heavily on the precision of the pressure gauge.
For the external port sealing, the air passage outer port is sealed using electric welding. The shell material is 1Cr18Ni9Ti, with an electrode type A102 and a diameter less than 215mm. The process involves manual arc welding. However, due to the small size of the outer port (less than 214mm), alignment is difficult, and defects like porosity and slag inclusion often occur. These issues can lead to the complete scrapping of the spring if not properly addressed. The heat from welding may also char the rubber column, making it unusable. To solve this, the external port is sealed using a more controlled method. As shown, the electrode 4 is clamped in a chuck 3, which rotates via a motor 2. The gas spring 6 is connected to the welder's ground, and the motor's upper end is connected to the welder through a brush. During operation, the electrode 4 is lowered, and the welding time is controlled by a timing device to regulate the weld size. The speed of the electrode is adjusted by a speed control motor, typically around 400r/min. When the arc is initiated, the rotating contact between the electrode and the workpiece mimics the scratching action in manual arc welding, but due to the forced rotation, there is no adhesion. This ensures better control and reduces waste. The rotation of the electrode helps stir the molten pool, improving its composition and reducing defects. It also aids in removing harmful gases and slag, resulting in a higher-quality weld and a smoother surface finish. This method significantly improves the appearance quality of the welds on the gas spring's air passage outside the welding head.
Conclusion: After over two years of practical application, the improved gas encapsulation process has proven to be highly effective. The initial encapsulation process had a success rate of only 80%, while the new process achieves a 95% success rate. Previously, the external sealing process could seal about 89 ports per electrode, which was inefficient and labor-intensive. The new process allows for the sealing of 1,618 ports per electrode, making the operation much easier. Additionally, the appearance quality of the sealed airways now matches that of imported gas springs from the UK. Due to the uniform internal pressure achieved by the new process, the service life of the gas spring has increased by 6%. Furthermore, the sealing method for the gas spring's air passage offers valuable insights and applications for other welding production processes.
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