试验及误差：粘接时共同设备和活塞组装问题

曾经被告知过，当你没有得到你所期待的东西时，你得到了什么？如何真实，特别是当设备或简单的监督时都有LED建筑商来浪费宝贵的生产汇编时间追逐问题。这是通过经验，但我们学会了我们能够充满信心所做的事情。一旦我们确定了特定原因，就会获得令人满意的经验使我们更加明智，在下次发生的情况下，需要更少的时间来解决，并且通过技术论坛可以帮助他人，如TCRA和其他人所托管的技术论坛transmission重建者。

While the list is exponentially larger than what we have room for here, we'll explore three very common equipment and piston assembly issues, methodologies of resolution and if there are any tools that can help your shop return to production speed sooner:

1. Confirming Contact Pressure
2. Temperature Correlations
3. Root-causing the Impact of Machining-Related Issues on Bond Strength

在锁止和控制滑动期间，在表面制备期间，在表面制备期间锁定活塞的均匀接触压力取决于多个工具和彼此平行对准的曲面。从夹具平坦度和顶部到底夹的平行关系开始，确认两者的最简单方法是在启动时在室温下进行加热元件进行的简单焊接试验。

1. 1.标记焊料段，以防碎片掉落或后续播放（Figure 1A)。
2. Identify locations (12, 2, 4, 6, 8, and 10 o'clock); 6 o'clock in the bond station should be closest to you with the door open; 12 o'clock, of course, will be farthest from you (Figure 1B)。
3. Clamp the fixtures under pressure for 30 seconds (图1 c)。
4. 在所有六个件上的平板外端和内端的开放式固定装置，测量和记录压缩厚度，并识别他们来的位置。您可能希望在夹具本身上放置一个标记以供参考（图1 d)。

Figure 1A	Figure 1B	图1 c	图1 d

1. These fixtures yielded the following measurements near the outer and inner edges:

• 2 O'clock: 0.089" Outer, 0.089" Inner
• 4点：0.088“外，0.088”内部
• 6点：0.094“外，0.092”内部
• 8点：0.099“外，0.098”内部
• 10 O'clock: 0.097" Outer, 0.099" Inner
• 12 O'clock: 0.096" Outer, 0.095" Inner

Measurements indicate that the fixtures are parallel within 0.011", and the O.D. to I.D. flatness indicates fixtures are flat from inner to outer edges. From these measurements, we have verified that the current fixture arrangement and orientation will provide less contact pressure between the 8 o'clock and 12 o'clock positions. As a result, the clear decision is to re-machine both surfaces flat and repeat the solder test. Maximum variation should not exceed 0.007" around the fixture.

You also can use carbon transfer paper across the face of the fixture to identify any low/high points as a starting point for locating solder. Again, make sure heating elements are cold and fixtures/components are at room temperature.

Figure 2

Contact paper is more reliable and costs a little more; it also is a good tool to aid in identifying contact loading between the back of the piston being bonded and the fixture, as well as the relationship of the front of piston to the fixture (with and without material). Contact paper is available in multiple ranges depending on pressures being used. (For reference, I've used Pressurex, with pressure range 70 to 350 psi, from Sensor Products, LLC, Sensor Products, Inc., 300 Madison Ave., Madison, NJ 07940, 973-884-1755.)

债券站只有其维护历史反映，它将通过比较良好的准确性来做你编程的事情;但是，它只提供从能够控制的内容提供反馈。一个完美的例子是温度相关性。假设操作员为机器设定为450°F，用于上部和下固定装置。我们可以说热电偶到站设置关系将产生类似的数据。让我们在钢铁夹上螺栓。现在，测量最靠近支撑活塞或夹紧粘合侧的摩擦材料的夹具的温度。可能会惊讶地发现夹具的温度平均为20°至50°Flowerthan the bond station temperature controller. Combine this with a cover having a lot of mass, and actual bond interface temperature is now much lower than you are expecting.

温度确认

图3： Station Setting (450°F)	图4： Temperature Near the Heating Element (445°F)

Touch probes are reasonably accurate, and they'll plug into most DVOMs with temperature option. Lasers tend to be much less accurate and can be influenced by reflectivity of the fixture.

图5： Temperature Near Piston Interface w/Probe (413°F)	图6： Temperature Near Piston Interface w/Laser (328°F)

As long as you know the difference between actual fixture temperatures and setting temperature, you can create an offset by raising control setting temperature until actual fixture temperature matches desired temperature.

EXAMPLE:假设夹具在425°F稳定，控制器设置为450°F。通过将控制器温度调节至475°F，将夹具温度接近所需温度。这并不总是一个比例关系，而是关闭。结果，温度设置和相关性可以成为日常维护周期的一部分。

Taking it a step further, data loggers are available for less than $200 which plug directly into a laptop. The two-wire J-type thermocouple can be placed directly at the bondline between the adhesive and bond surface to document time/temperature curves.(不te: Either wiping adhesive completely off the test ring with MEK or placing tape over the adhesive in the area the thermocouple will be located will make it easier to remove once the cycle has finished)。数据记录器附带的软件将绘制您的T / T曲线，您可以将数据导出到Excel文档以进行多种设置的绘制结果，确认设置的可重复性，并查看对活塞/覆盖配置的温度影响。

The plot inFigure 7表示这是典型的2分钟键循环，钢芯/活塞温度在室温下达到350°F，在32秒内达到400°F的最佳固化温度，并且在固化区中的剩余时间和剩余的时间峰值循环温度为448°F。(Information gained from OE converter products supports the idea that a high-temperature fixture surface will not inhibit material integrity. For example, cottons normally found in what we know as Tan on-off lockup linings won’t burn off until 662°F.)

Figure 7

不用说,the bigger the mass, the longer it will take to heat up and stabilize. Another key consideration is whether the component being bonded to is aluminum or steel. If it is aluminum, you can bet it will pull a lot of heat from the fixtures. In other words, fixture temps may be at 475°F before the cycle, but they may drop to 400° F or 425°F during the cycle, and it will then take longer for fixture temps to recover before bonding the next part.

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Root Causing Bond Strength Issues

Here are a few questions to ask yourself if you are experiencing irregular bond issues:

它发生在整个部分中吗？如果是，请使用以下指南进行故障排除：

• 检查洗涤解决方案
• 石油和冲洗污染哪里how is the cleaning solution circulated?
• How often is it changed?
• Check pH level at start and after multiple washes

Is the issue occurring in one only section of each part?

• Do not move fixture
• Solder test
• 确认活塞平整度
• Are parts hanging on a rack after being stripped, prepped or after wash?
• Index part in the bond station. If they were hanging on a rack, identify the 6 o'clock position on the rack, place at 6 o'clock in bond station and mark accordingly for reference
• If bond issue occurs at 6 o'clock, make sure it is repeatable
• Since it can be either the fixture or a result of the cleaning process, index a minimum of three more parts, but rotate the next trial parts so that 6 o’clock on the hanging piston is at 3 o’clock in the bond station.

This will identify whether the issue lies in the part or station tooling.

Figure 8	Figure 9

Is the problem occurring on just the O.D. or just the I.D.?

• Since friction materials used in our industry are typically coated front to back rather than from O.D. to I.D. or I.D. to O.D., blaming the adhesive for a bad O.D. or bad I.D. bond does not address the real problem (Figure 8)

例1

Is the piston intentionally tapered inward from O.D. to I.D.? Since some pistons like theGM 258mmare formed with a taper having an O.D. to I.D. difference of up to 0.012" (0.30 mm), it is critical to confirm the tooling matches the contour of the part (Figure 9)。

例2.

典型的情况是粘合表面被加工平坦的粘合表面并且假设是底侧是平行的，当实际上，它是两侧具有相同锥度的形成部分（Figure 10)。如果两个上下工具是平的,result will be a good I.D. bond and a poor O.D. bond. The I.D. is resting on the lower fixture, and as the top fixture presses down against the material, the I.D. receives full contact, BUT because of a cantilever action/deflection on the O.D., and because the actual piston is thinner here, it is not fully supported and is only receiving temperature and light contact pressure (Figure 11)。Correction:制作专门适合部分轮廓的工具（Figure 12)。

Figure 10	Figure 11	Figure 12

间歇性债券问题，在哪里有交替的良好和坏的债券部分每x度数次数？

• It is important to support all 360° of the piston for cutting and prepping, especially with thin materials like the 258mm piston
• 当债券所关注的时间以均匀间隔的间隔发生时，您可能会在切割车床上正确支持的地区找到良好的粘合

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当我们面临问题时，这里有几次关闭提示：

• Stop and create a Design of Experiments (D.O.E.) to use as a guideline on methodology of how you will identify the root cause. A D.O.E. is a systematic approach to problem solving that applies principles and techniques at the data collection stage so as to ensure a definitive conclusion
• Establish a starting point by identifying variables that affect the outcome
• 确定每个试验中会更改哪些变量并记录影响
• Only change one variable at a time (even though the time it takes might be painful)
• Measure and record all results, even if they impact the test negatively, so that late in the day you don't find yourself repeating something you have already tried

The next time you think you have a problem, ask yourself who it affects, whether you can fix it and how it compares to the problems of the less fortunate. Turns out, our converter assembly problems are justinconveniences which lead us to gain experience when we don’t get what we were expecting。

Chris Horbach is a Raybestos®product development engineer and technical advisor who writes on issues of interest to torque converter rebuilders. Raybestos®支持转矩转换器ReBuilbob游戏怎么下载ders Association。了解有关小组的更多信息www.tcraonline.com。Sonnax感谢Raybestos.® for allowing us to share this information with rebuilders.