New Energy Pneumatic Air Smart Lock Motor Cup Head Hexagon Socket Head Cap Half

Release time：2020-01-16 18:44 Browse：

1. Material Science & Alloy Composition

• High-Tensile Alloy Steel:

• Grade 10.9 equivalent (ASTM A325) with chemical composition: C 0.38–0.45%, Si ≤0.35%, Mn 0.6–1.0%, Cr 0.9–1.2%, ensuring tensile strength ≥1,000 MPa and yield strength ≥800 MPa.

• Quenched and tempered at 830–860°C, followed by tempering at 450–550°C to achieve balanced hardness (33–38 HRC) and fatigue resistance.

• Surface Engineering:

• Zinc-nickel plating (Zn-Ni, 8–12μm) with trivalent chromium passivation (RoHS-compliant), providing 1,500+ hours of salt spray resistance (ASTM B117) and anti-corrosion for marine-grade new energy installations.

2. Precision Mechanical Design

• Cup Head Geometry (ISO 4762):

• Head diameter: 1.5×d (e.g., M10 = 16mm), height: 0.7×d (7mm), with chamfered edges to prevent burrs in automated assembly.

• Internal hex socket depth: 0.6×d (e.g., M12 = 7.2mm), compatible with DIN 913 hex keys for 30% higher torque transmission than Phillips heads.

• Half-Threaded Shank Engineering:

• Shear load optimization (EN 1993-1-8 tested: 28% higher shear capacity than full-threaded).

• Reduced thread galling in deep holes (thread engagement ≤6×d recommended).

• Thread length = 2×d + 10mm (e.g., M12×150mm has 34mm thread), leaving a 116mm solid shank for:

3. Ultra-Long Length Manufacturing

• Cold Forging Process:

• Multi-stage upsetting for lengths up to 500mm (M16), maintaining grain flow alignment to enhance fatigue life by 40% (vs. machined rods).

• Thread rolling (non-cutting) for M5–M16, creating work-hardened threads with 30% higher tensile strength than cut threads.

• Straightness Control:

• Post-forging heat treatment (stress relieving at 300–350°C) ensures straightness ≤0.1mm/100mm, critical for deep insertion in motor shafts (e.g., EV rotor alignments).

4. Pneumatic System Optimization

• Anti-Vibration Features:

• Serrated under-head (24 teeth/inch) to prevent rotational slip under pneumatic pulses (tested at 10 bar pressure cycling, 500 cycles/min for 1,000 hours).

• Optional nylon insert (M8+) for self-locking in high-frequency pneumatic actuators (vibration resistance up to 20G, 10–2,000Hz).

• Lubrication Systems:

• Micro-porous zinc-nickel plating impregnated with molybdenum disulfide (MoS₂) for dry lubrication, reducing friction coefficient to 0.08 (vs. 0.15 for standard plating).

5. New Energy Application Scenarios

• EV Powertrain Integration:

• Securing permanent magnet rotors in 800V drive systems (temperature resistance -40°C to +150°C), with anti-magnetic coating options (permeability μ ≤1.05).

• Pneumatic brake booster mounting, requiring 100% thread engagement in aluminum alloy housings (with anti-galvanic washers).

• Renewable Energy Infrastructures:

• Wind turbine pitch system bolts (M20×500mm), tested for 10⁸ cycles under 100kN tensile load (IEC 61400-1).

• Solar tracker actuators: black Zn-Ni plating for anti-glare (reflectivity <5%) in photovoltaic arrays.

6. Advanced Testing Protocols

• Dynamic Load Testing:

• Fatigue testing on M12×300mm bolts: 500,000 cycles at 60% yield strength (10Hz frequency) per ISO 15330.

• Hydrogen embrittlement prevention: bake-out at 190°C for 24 hours post-plating (ASTM F519).

• Electrical Conductivity:

• For grounding applications, Zn-Ni plating ensures surface resistance <100mΩ (IEC 60529), critical in battery management systems.

7. Customization & Industry Compliance

• Specialized Coatings:

• Dacromet 500 (5–8μm) for offshore wind farms (2,000+ hours salt spray), or PTFE (2μm) for cleanroom environments (ISO Class 5).

• Color-coded passivation (yellow/blue) for torque differentiation in multi-bolt assemblies.

• Regulatory Certifications:

• EN 14399-4 (structural bolting), ISO 16130 (electric vehicle fasteners), and UL 2596 (battery energy storage systems).

8. Smart Manufacturing Integration

• IoT Traceability:

• QR code laser-engraving (ISO 15426-2) with batch data (material lot, heat number, test results) for Industry 4.0 inventory systems.

• Anti-static packaging (ESD bags, 10⁴–10⁶Ω surface resistance) for semiconductor-grade motor assemblies.

9. Installation Engineering Guide

• Torque-Tension Calibration:

• Dry torque: 22–25 Nm (preload 18–20kN);

• With MoS₂: 18–20 Nm (preload 16–18kN) per VDI 2230.

• M10×150mm:

• Tool Recommendations:

• Pneumatic torque wrenches (±3% accuracy) with angle monitoring for critical joints (e.g., motor stator mounting).

10. Sustainability & End-of-Life

• Circular Economy Features:

• 95% recyclable content (steel & plating), with disassembly design (non-permanent coatings for easy separation).

• Water-based plating baths (reduced COD by 70% vs. solvent systems) compliant with ISO 14001.

11. Technical Comparisons

• vs. Traditional Bolts:

• Half-thread design reduces weight by 15% in long lengths (e.g., M12×300mm: 0.45kg vs. 0.53kg full-threaded).

• vs. Titanium Alloys:

• 60% lower cost with comparable corrosion resistance in non-seawater environments.

12. Environmental Operation Limits

• Temperature: -50°C to +250°C (PTFE coating up to +260°C).

• Chemical Resistance:

• Resistant to 30% sulfuric acid (20°C, 1000h) and automotive fluids (ASTM D471).