1、DNS SHIP DESIGN & RESEARCH INSTITUTE 舵机环氧树脂垫浇注工艺规程DNS507-400-16025 GY 共 6 页 第 2 页舵机环氧树脂垫浇注工艺规程The S/G epoxy resin chock pouring technology procedure1.参考资料：Reference drawings 舵机安装图： DNS507-232-16001Installation of steering gear 环氧树脂资料Epoxy resin specification2.浇注用材料和工具Material and tools for pouring1)
2、 内、外挡板用扁钢 尺寸：22000mm3mm 材料：Q235-A内挡板的高度=垫厚-10mm；外挡板的高度=垫厚+40mm（扁钢的具体高度由车间工艺人员根据实际垫的厚度给出） 。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、干净的抹布、砂布、钢锯条、巴氏硬度计、电加热器（供气温低时使用） 、手提搅拌器。The following tools should
3、 be prepared: ruler, knife, scissors, acetone, rag, heater ect.3.浇注前的准备工作：The preparation work before pouring1) 舵机安装前，按附图 1所示，将浇注环氧树脂垫块用的内挡板点焊于舵机座面板上（在焊接内挡板时，一定要注意内挡板的定位尺寸）参考附图 1和舵机安装图。内挡板选用厚 3mm、高度等于对应部位上舵机垫的厚度减去 10mm的扁钢。扁钢的长度应保证其两端至少长出最外端的垫块 25mm。垫块的厚度由车间工艺人员给出。具体的每侧DNS SHIP DESIGN & RESEARCH INST
4、ITUTE 舵机环氧树脂垫浇注工艺规程DNS507-400-16025 GY 共 6 页 第 3 页扁钢的长度尺寸和焊接位置以及海绵条的设置位置由环氧树脂的厂家服务商现场指导。Before installing the steering gear, spot welding the inner steel bar 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
5、 foam stripes will be determined by service engineer.2) 舵机的止推装置的焊接以及其他主要的焊接工作应该完成。The welding work of stopper should be completely.3) 必须将舵机基座垫块区域内的所有的油污、锈斑、油漆、鳞皮等杂物清除，并且涂上一层保养油。Removing grease, mill scale and rust, smearing the protection oil in pouring chock area.4) 舵机吊装到位。Lifting the steering gear
6、 in its position.5) 使用临时顶丝将舵机顶起，设置临时顶丝时，应考虑到浇注口的位置，方便于设置外挡板。根据“舵机安装工艺规程 DNS507-400-16024GY”进行舵机的找正工作。Adjusting the steering gear by using jacking screw according to the requirement in Steering Gear Installation Technology Procedure DNS 507-400-16024GY.6) 清除舵机垫块区域内的所有杂物和保养油，并用丙酮清洗与垫块接触的上下表面，必须保证所有油污全
7、部被清洗干净。Removing all the protection oil, and flushing the up and down surface contacted with chock by acetone.7) 根据服务商的指导，按各垫的尺寸制作环氧树脂垫浇注模框。DNS SHIP DESIGN & RESEARCH INSTITUTE 舵机环氧树脂垫浇注工艺规程DNS507-400-16025 GY 共 6 页 第 4 页Making the epoxy resin chock mould based on the chocks size.8) 环氧树脂垫浇注时应注意，环氧树脂垫
8、的最小厚度尺寸不能小于25mm。The height of the chock should not be less than 25mm.4.混合与浇注Mixing and pouring1) 在混合与浇注时，舵机室应禁止打磨、切割、电焊等有可能污染环境的作业。When mixing and pouring, the work of grinding, cutting and welding should be prohibited. 2) 根据对固化剂加入量的要求，将固化剂加入到环氧树脂桶中，使用搅拌器以约 200转/分钟的速度对环氧树脂进行搅拌 2-3分钟，使其与固化剂混合均匀。搅拌时应注
9、意不要让叶片露出液面，以防气泡带入。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 bottom of the epoxy can, you have to stir the epoxy resin until it
10、 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) 在浇注环氧树脂的同时，应同时浇注两块样块。The test samples are to be cast using the same epoxy resin at same time.4) 每个垫块浇注完毕后，应检查有无模框未被充满和环氧树脂泄露等DNS SHIP DESIGN & RESEARCH
11、 INSTITUTE 舵机环氧树脂垫浇注工艺规程DNS507-400-16025 GY 共 6 页 第 5 页现象，如有应立即采取补救措施，在所有环氧树脂固化前，必须有专人不间断地进行检查，以防止上述现象发生。Until resin hardens, ensure any air heating does not cause local hotspots which may promote excessive exothermic reaction during initial setting process.5) 环氧树脂的完全的固化时间为 24-48小时，固化的时间取决于当时的环境温度。如
12、果由于气温过低（低于 13） ，采用碘钨灯或者别的更有效的加热设备对垫块区域进行加热以确保环氧树脂垫的完全固化。固化时间： 13-18 大约 48小时19-21 大约 24小时21以上 大约 18小时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 e
13、quipment will be use to heat the chock area, to ensure the epoxy resin chock cure totally.Cure time of epoxy resin chock13-18 approx. 48hours19-21 approx. 24hoursabove 21 approx. 18hours6) 用巴氏硬度计检测垫块的硬度，要求巴氏硬度达到 35以上。Before tightening the holding down bolts, it is absolutely necessary to make a hard
14、ness test according to Barcol. Minimum Barcol hardness must be 35, this means that the DNS SHIP DESIGN & RESEARCH INSTITUTE 舵机环氧树脂垫浇注工艺规程DNS507-400-16025 GY 共 6 页 第 6 页epoxy resin chocks are fully cured.7) 移走碘钨灯或者其它的加热设备，待垫块冷却到环境温度后，可以开始紧固地脚螺栓。In case that electrical heaters or other heater were use
15、d for post curing, that before tightening the holding down bolts, chocks and engine are cooled down to ambient temperature.8) 按照服务商的要求拆除前挡板、海绵条、胶管等附件。Remove steel bar and damming foam stripes as required by service engineer.160*320*45135*25*16-M顶丝*40-5孔 油缸中心线 *船舶中心线 *M48螺栓 内挡板DNS SHIP DESIGN & RESEARCH INSTITUTE 舵机环氧树脂垫浇注工艺规程DNS507-400-16025 GY 共 6 页 第 7 页附图 1 舵机环氧树脂垫尺寸示意图Figure 1:the sketch for resin chock of S/G
