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(yōu)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(zhì)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(yù)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(yù)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(xiàn)±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(tǒng)，節(jié)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(qū)動多道次輥壓（速度15m/min），側(cè)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(shù)，5分鐘切換不同規(guī)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(fù)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(jiān)測焊縫質(zhì)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(yù)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(shù)

Energy saving and environmental protection technology

余熱回收系統(tǒng)：鋅鍋煙氣熱量用于板材預(yù)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(chǎn)生量＜1.5kg/t（傳統(tǒng)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(zhì)量檢測

4、 Post processing and quality inspection

表面優(yōu)化

Surface Optimization

離心甩鋅：2000r/min高速旋轉(zhuǎn)，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(zhì)檢系統(tǒng)

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(huán)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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