The improvement of fuel tank product quality is one of the main goals of the quality improvement of China National Heavy Duty Truck Rubber & Plastics Manufacturing Department. In 2011, China National Heavy Duty Truck Rubber & Plastics Manufacturing Department ranked the “Overall Quality Improvement of Fuel Tanks†as the Pioneer project.
From the small items of stamping workshop product transportation canvas protection to brush protection and other key processes to welding, inspection, and other key processes, all personnel unified thoughts and united, and adopted six measures to ensure that the quality of heavy gasoline tanks was comprehensively improved.
The oil leakage of the outer ring weld seam of the fuel tank is improved. In view of the instability of the welding quality of fuel tanks, the seat tank product processing department carefully analyzed the status quo, led the production backbone to carry out technical research, process improvement, through the use of precision machine to control the length of the fuel tank cylinder plate, using CNC rolling machine to ensure the accurate molding of the cylinder Therefore, the welding quality of the outer ring has been significantly improved. At the same time, refine the standard operation of the outer ring welding: before the welding, first half a circle is reversed to adjust the fit clearance between the fuel tank end cap and the cylinder body; adjust the fit gap between the end cap and the barrel body and then perform the outer ring welding; welding process is forbidden Then adjust the gap, prohibit the shutdown during the welding process to maintain the continuity of the welding. The leakage rate of the outer ring of the fuel tank produced after July 20, 2011 has dropped significantly.
Internal baffle welding improves. In view of oil leakage in the fuel tank, the processing department and the quality and technology departments analyzed the after-sales failure modes, compared the most advanced internal partitions and barrel connection methods in the world, and used cards and locks instead of welding technology to effectively solve the welding problem. After the weld is easy to leak the oil and the inner partition off the problem. No oil leakage occurred at the fuel tank bulkhead after the card lock process was applied. After the processing section was subjected to a destructive pressure drop test on the internal lock of the lock, the firmness of the internal lock of the lock was sufficient to meet the technical requirements of the fuel tank.
Strengthens the tightness of the wire. In order to further improve the welding wire exposed in the air, easy to oxidation, moisture, affecting the performance of the wire, easy to form welding cracks or pores, leading to leakage and other unfavorable factors. Based on the addition of wire seal barrels and desiccants, the processing department is responsible for the production workshop. After work, the welding wire is removed from the welding machine every day, and the welding wire sealing barrel and desiccant are placed to ensure that the welding wire is not affected by the weather and other environments. After this method is adopted, the arc is stable during welding, spatter is significantly reduced, the shape of the welding wave is uniform, the appearance quality of the weld is significantly improved, and pores, slag inclusions, and cracks are significantly reduced.
Airtightness testing means improved. The detection of the tightness of the fuel tank has been limited by factors such as personnel, tooling, weather, and light, so the phenomenon of missed welds often occurs. The processing department first adjusted the division of labor, put the fuel tank final inspection personnel under the management of the technical quality room, defined responsibilities, and played a role in mutual supervision. When the passing rate of one inspection was lower than 98%, the workshop was evaluated according to the number of products, and To publish the statistical results at the on-site training station and publicize the team with the highest oil leakage rate;
Secondly, every time a zero-kilometer tank leaks, it must look for the tank's circulation card, evaluate the final inspection personnel, conduct ideological education and post-retraining, and adjust to achieve a zero-oil leakage rate of 100%.
The third is to supplement the final test tube bile leak tester at the final inspection, adopt the method of filling the tank with compressed air and maintaining the pressure, and immerse the oil tank in water to observe the way of leakage, effectively improving the quality of the airtightness test of the fuel tank. Good operation improves the effectiveness of airtight detection.
Tank vibration test. Adding the oil tank vibration endurance test device is like adding a protective lock to the reliability of the fuel tank. The oil tank vibration tester is designed to have the effect of forming the torque on the tank and make the oil tank perform vibration test under the twisted state. With 24-hour continuous vibration test capability. The tank mounting arm can be moved laterally to perform vibration tests on all models of tanks.
Avoid bumping the fuel tank. The manufacturing department has increased its management efforts, formulated related assessment opinions, adopted effective measures, and worked hard to solve problems. On the one hand, to strengthen employees' sense of responsibility, quality awareness, earnestly understand the "second entrepreneurial" related spirit, unify thinking, love and respect for work, truly improve the quality as the current "second pioneering" the primary task; the other hand, take the line Effective methods and methods to change the quality of the status quo: fuel tank workshop is responsible for the rectification of protective facilities in the production process, rectify the production site, cleaning and sanitation without debris; manufacturing department to strengthen product protection during the delivery process, design and production of special transport tooling for the fuel tank The delivery and transportation of the fuel tanks ensure good protection of the fuel tanks during handling and loading and unloading, and prevent bumping and scratching of the products. Through a period of operation, the collision phenomenon of fuel tank bumps has been significantly improved.
Through a number of improvements, the number of after-sales of heavy gas tanks in 2011 decreased by 61.2% compared with the same period in 2010 from January to September, and the number of claims for fuel tanks produced in the same period of 2010 decreased by 93.3% from May to September 2011.
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