舵機(jī)環(huán)氧樹(shù)脂墊澆注工藝規(guī)程

1、舵機(jī)環(huán)氧樹(shù)脂墊澆注工藝規(guī)程The S/G epoxy resin chock pouring technology procedure1. 參考資料：Reference drawingsl 舵機(jī)安裝圖： DNS507-232-16001Installation of steering gearl 環(huán)氧樹(shù)脂資料 Epoxy resin specification2. 澆注用材料和工具M(jìn)aterial and tools for pouring1) 內(nèi)、外擋板用扁鋼 尺寸：22000mm×3mm 材料：Q235-A 內(nèi)擋板的高度=墊厚-10mm；外擋板的高度=墊厚+40mm（扁鋼的具體高

2、度由車間工藝人員根據(jù)實(shí)際墊的厚度給出）。 The inner and outer steel bar should be prepared for pouring the epoxy resin (the height of steel bar will be determined on spot).2) 尺、小刀、剪刀、丙酮、干凈的抹布、砂布、鋼鋸條、巴氏硬度計(jì)、電加熱器（供氣溫低時(shí)使用）、手提攪拌器。The following tools should be prepared: ruler, knife, scissors, acetone, rag, heater ect.3. 澆注前的

3、準(zhǔn)備工作：The preparation work before pouring1) 舵機(jī)安裝前，按附圖1所示，將澆注環(huán)氧樹(shù)脂墊塊用的內(nèi)擋板點(diǎn)焊于舵機(jī)座面板上（在焊接內(nèi)擋板時(shí)，一定要注意內(nèi)擋板的定位尺寸）參考附圖1和舵機(jī)安裝圖。內(nèi)擋板選用厚3mm、高度等于對(duì)應(yīng)部位上舵機(jī)墊的厚度減去10mm的扁鋼。扁鋼的長(zhǎng)度應(yīng)保證其兩端至少長(zhǎng)出最外端的墊塊25mm。墊塊的厚度由車間工藝人員給出。具體的每側(cè)扁鋼的長(zhǎng)度尺寸和焊接位置以及海綿條的設(shè)置位置由環(huán)氧樹(shù)脂的廠家服務(wù)商現(xiàn)場(chǎng)指導(dǎo)。Before installing the steering gear, spot welding the inner steel b

4、ar to the foundation of steering gear, the height of inner steel bar should be chock height 10mm. The position of each side steel bar and damming foam stripes will be determined by service engineer.2) 舵機(jī)的止推裝置的焊接以及其他主要的焊接工作應(yīng)該完成。The welding work of stopper should be completely.3) 必須將舵機(jī)基座墊塊區(qū)域內(nèi)的所有的油污、銹斑

5、、油漆、鱗皮等雜物清除，并且涂上一層保養(yǎng)油。Removing grease, mill scale and rust, smearing the protection oil in pouring chock area.4) 舵機(jī)吊裝到位。Lifting the steering gear in its position.5) 使用臨時(shí)頂絲將舵機(jī)頂起，設(shè)置臨時(shí)頂絲時(shí)，應(yīng)考慮到澆注口的位置，方便于設(shè)置外擋板。根據(jù)“舵機(jī)安裝工藝規(guī)程DNS507-400-16024GY”進(jìn)行舵機(jī)的找正工作。Adjusting the steering gear by using jacking screw acco

6、rding to the requirement in Steering Gear Installation Technology Procedure DNS 507-400-16024GY.6) 清除舵機(jī)墊塊區(qū)域內(nèi)的所有雜物和保養(yǎng)油，并用丙酮清洗與墊塊接觸的上下表面，必須保證所有油污全部被清洗干凈。Removing all the protection oil, and flushing the up and down surface contacted with chock by acetone.7) 根據(jù)服務(wù)商的指導(dǎo)，按各墊的尺寸制作環(huán)氧樹(shù)脂墊澆注?？颉aking the epoxy

7、resin chock mould based on the chocks size.8) 環(huán)氧樹(shù)脂墊澆注時(shí)應(yīng)注意，環(huán)氧樹(shù)脂墊的最小厚度尺寸不能小于25mm。The height of the chock should not be less than 25mm.4. 混合與澆注Mixing and pouring1) 在混合與澆注時(shí)，舵機(jī)室應(yīng)禁止打磨、切割、電焊等有可能污染環(huán)境的作業(yè)。When mixing and pouring, the work of grinding, cutting and welding should be prohibited. 2) 根據(jù)對(duì)固化劑加入量的要求，

8、將固化劑加入到環(huán)氧樹(shù)脂桶中，使用攪拌器以約200轉(zhuǎn)/分鐘的速度對(duì)環(huán)氧樹(shù)脂進(jìn)行攪拌2-3分鐘，使其與固化劑混合均勻。攪拌時(shí)應(yīng)注意不要讓葉片露出液面，以防氣泡帶入。Add hardener and power mix at speed 200rpm for 2-3 minutes to ensure homogenous mixture, for quantity of hardener and temperature guides should based on requirement of supplier. In case the filler has settled on the bott

9、om of the epoxy can, you have to stir the epoxy resin until it is free of streaks. Pour mixed resin without delay and with minimum free fall to avoid air entrapment. Don not scrap remaining resin out the can.3) 在澆注環(huán)氧樹(shù)脂的同時(shí)，應(yīng)同時(shí)澆注兩塊樣塊。The test samples are to be cast using the same epoxy resin at same t

10、ime.4) 每個(gè)墊塊澆注完畢后，應(yīng)檢查有無(wú)?？蛭幢怀錆M和環(huán)氧樹(shù)脂泄露等現(xiàn)象，如有應(yīng)立即采取補(bǔ)救措施，在所有環(huán)氧樹(shù)脂固化前，必須有專人不間斷地進(jìn)行檢查，以防止上述現(xiàn)象發(fā)生。Until resin hardens, ensure any air heating does not cause local hotspots which may promote excessive exothermic reaction during initial setting process.5) 環(huán)氧樹(shù)脂的完全的固化時(shí)間為24-48小時(shí)，固化的時(shí)間取決于當(dāng)時(shí)的環(huán)境溫度。如果由于氣溫過(guò)低（低于13），采用碘鎢燈或

11、者別的更有效的加熱設(shè)備對(duì)墊塊區(qū)域進(jìn)行加熱以確保環(huán)氧樹(shù)脂墊的完全固化。 固化時(shí)間： 13-18 大約48小時(shí) 19-21 大約24小時(shí) 21以上 大約18小時(shí) Normally the epoxy resin cures in 24-48 hours, the curing time will be determined by ambient temperature. If the ambient temperature is very low (below 13), the iodine tungsten lamp or other heating equipment will be use

12、to heat the chock area, to ensure the epoxy resin chock cure totally. Cure time of epoxy resin chock 13-18 approx. 48hours 19-21 approx. 24hours above 21 approx. 18hours6) 用巴氏硬度計(jì)檢測(cè)墊塊的硬度，要求巴氏硬度達(dá)到35以上。Before tightening the holding down bolts, it is absolutely necessary to make a hardness test according to Barcol. Minimum Barcol hardness must be 35, this means that the epoxy resin chocks are fully cured.7) 移走碘鎢燈或者其它的加熱設(shè)備，待墊塊冷卻到環(huán)境溫度后，可以開(kāi)始緊固地腳螺栓。In case that electrical heaters or other heater were used for post curing, that before tightening the holding down bolts, chocks and e