一、山东电缆桥架原材料

1、 Raw materials 

高精度基材选择

High precision substrate selection

冷轧钢板：厚度公差±0.05mm（GB/T 708-2025标准），优先选用SPCC碳钢（屈服强度≥280MPa）。

Cold rolled steel plate: thickness tolerance ± 0.05mm (GB/T 708-2025 standard), SPCC carbon steel (yield strength ≥ 280MPa) is preferred.

智能分选：激光光谱仪检测材质成分（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.

预处理线

Environmental protection pretreatment line

脱脂除油：碱性电解液（PH 12-13）配合超声波清洗，油污残留量＜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：盐酸浓度18-20%（废酸回收率≥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.

助镀处理：氯化锌铵溶液，形成均匀预镀层。

Assisted plating treatment: Zinc ammonium chloride solution is used to form a uniform pre plating layer.

二、山东电缆桥架智能化成型加工

2、 Intelligent Forming Processing

激光切割下料

Laser cutting material cutting

光纤激光切割机（功率6kW）实现±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%.

山东临工集团引入AI排料系统，节省材料成本15%。

Shandong Lingong Group has introduced an AI material scheduling system, saving 15% of material costs.

辊压成型工艺

Roll forming process

伺服电机驱动多道次辊压（速度15m/min），侧板高度误差≤0.5mm。

Servo motor drives multi pass roller pressing (speed 15m/min), with side plate height error ≤ 0.5mm.

青岛四方车辆厂案例：采用柔性模具技术，5分钟切换不同规格（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.

机器人焊接

robot welding

六轴焊接机器人（重复精度±0.02mm），焊缝熔深≥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.

实时红外监测焊缝质量（气孔率≤3%），不良品自动分拣。

Real time infrared monitoring of weld quality (porosity ≤ 3%), automatic sorting of defective products.

三、山东电缆桥架热浸镀锌核心工艺

3、 Core process of hot-dip galvanizing

高温浸镀流程

High temperature immersion plating process

锌液控制：温度445-455℃，铝含量0.005-0.02%（抑制锌渣生成）。

Zinc liquid control: temperature 445-455 ℃, aluminum content 0.005-0.02% (inhibits zinc slag formation).

双锌锅工艺：预镀锌层（40-60μm）+ 主镀锌层（70-90μm），总厚度≥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).

技术

Energy saving and environmental protection technology

余热回收系统：锌锅烟气热量用于板材预热，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%.

锌灰分离装置：锌渣产生量＜1.5kg/t（传统工艺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、山东电缆桥架后处理与质量检测

4、 Post processing and quality inspection

表面优化

Surface Optimization

离心甩锌：2000r/min高速旋转，锌层均匀度偏差≤±8μm。

Centrifugal zinc throwing: high-speed rotation at 2000r/min, with a zinc layer uniformity deviation of ≤± 8 μ m.

钝化处理：三价铬钝化液，耐盐雾时间≥2000h。

Passivation treatment: trivalent chromium passivation solution, salt spray resistance time ≥ 2000h.

智能质检系统

Intelligent Quality Inspection System

X射线测厚仪：每10秒扫描一个截面，生成3D锌层分布图。

X-ray thickness gauge: Scan a section every 10 seconds to generate a 3D zinc layer distribution map.

盐雾试验：循环腐蚀测试（35℃×5%NaCl喷雾+50℃烘干），168小时无红锈。

Salt spray test: cyclic corrosion test (35 ℃ × 5% NaCl spray+50 ℃ drying), 168 hours without red rust.

附着力测试：划格法（间距2mm）锌层剥落面积＜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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