m TAI: NGHIEN CUtl THIET KE, CHE TAO DONG CO DI - fi - DEN 3 XI LANHCONG SUAT 30-45HP VA NGHIEN CUU CHE TAO PHU TUNG
D O N G CO DI-E-DEN CONG SUAT 400-600HP I.Mfisfi: KC.05.02
2. Chfl nhiem de tai: TS D6 Hoang Thjnh.
3. Co- qiian chli tri di fai: Tflng cong ty May dpng lire va May nong nghiep Viet Nam (VEAM).
4. Thoi gian thuc hien dc tai: thang 10-2001 dSn thang 04-2004.
5. Tiing kinh phi thuc hien a'e tai: 2.100 trieu dflng; trong dfl kinh phi tit nguon ngan sach nha nuflc: 1.000 trieu dong.
6. Muc ticu Clia de tiii KC.05.02
1. Dpng CO Di-c-den 3 xi lanh cong xuat 30-45 HP: Lfln dSu tien o Viet Nam lam nghien ciru Ihiet ki va che- tao dpng cpDi-e-den da nang.3 xi lanh. cao toe. hicu suiil cao, ket can hicn dai nhu phiin lon ciic dpng co 3 xi lanh ciia Nliiil Bim Vii I lan quoe dang siin xuat. Tir thidt k6 ch6 tao trong nuflc cac chi tiet chii yeu ciia dong CO nhu: than may, qui lat, true khuyu, true cam, pit tong. so mi xi lanh,...
\oi giii thanh (khi vao siiii xuk hang loat) ch! bfing 40-50% gia dpng co tuong duong nhap lir Nhat Dan, Han Quflc, la dieu kicn ban ddu da co tlie canh tranh dupe vfli dpng co cung Ioai nhap lir Trung Quoe ve gia ca.
2. Phu tiing dpng eo Di-e-den 400-600 HP; De tai KC05.02 chpn lam sim phiim nghien cuu ch6 tao la: Bp hoi (gflm 6 loai chi tilt: Pit tong, ehflt pit tong, sec mang, so mi xi lanh, sup pap, flng dSn sup pap) cua dpng co 0i-e-den 6 xi lanli YANMAR-6KAL-170 (Nhat Ban) cong xult 420HP/1200v/ph, co tua bo tilng iip.dp bCn sir dung cao (8000-lOOOOh). Hien nay o Vict Nam chua co co sfl niio siin xuiit dupc cac loai chi tiet efl yeu ciiu cao niiy.
7. Nhfing ket qua dill duoc trong thuc hicn dc tin KC.05.02
Ciic nlia miiy cliS tao dong co Di-c-dcn Irong nirflc liiu nay clii sim xuiil llieo lliiC'l ke Clia nuflc ngoai, eiie dpng co Di-e-dcn 1 xi lanh, toe dp Irung binh (den 2200viing/pliu0. hicu suiit thiip. tieu hao nhicn lieu cao (210~230g/HP.h). Rieng cong ly Di-e-dcn Song Cflng da co siin xuiit (theo thiet kc vii cflng nghe ciia MMZ Belarus) dpng.co 4 xi lanh D242 (60HP/ 2000 vflng/phiil) dimg cho miiy keo MTZ Lien Xo cu.
Iti loai dpng CO cfl hieu sutit thiip. ticu hao nhicn lieu cao (210g/I-IPh). khoi lupng Ifln (8,5 kg/IIP).
Ngiiy nay trinh dp thiet ke va che tao dong eo Di-e-deii tren tlie gioi dii CO iilurng bufle ticn xa lion nhieu. Viet Nam muon duy tri va phiit trien nganli clie lao niii;' dpng lire \'a phu timg thi phiii nhanli chflng ciii ticn dupe trinli dp ciia Siin pliiiin \a phiit Irien them Ciie siin phiim moi eo tinh nang cao, dii sirc eanh tranh eii ve chat luong liin giii cii.
Dae Irung eo biin ciia eae the he dpng co Di-c-den hicn dai hi cfl hieu sufit cao
\ii klii tliiti sach hon trirfle. Huong giiii quyet eac yeu eau nay pho biln hicn nay ciia Ciie hang san xuilt dpng ea trcn the gifli la di vao eai ticn qua trinh chay (phun nliien
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lieu ap suat cao, phun phan doan, phun nhien lieu cfl dieu khien dien tu,...), nang cao he so nap khi (bang tua-bo tang ap) va tang vflng quay ciia dong ca.
Dong CO no efl ap suat phun nhien lieu cao, vflng quay cap, dfli hfli cac ehi tiet Clia dpng ca co dp ben chju lire, chiu mon cao hon (vat heu mfli) va can duac che tao voi dp chinh xac cao hem, cac moi ghep va toa dp cac be mat lam viec chinh cua dpng CO no truflc day thuong chi fl dp chinh xac cap 2 (TCVN), nay yeu cau cap 1 va cap 0.
Nhiem vu dat ra cho de tai KC.05.02 la phai ehpn Iua va thirc hien dupc thiet ke ket cau san pham tien tien phii hpp va giai quyet dupc cac yeu cau cong nghe trong che tao nhitng chi tilt cbinh ctia dpng co, khai thac dupc kha nang ttang bj cong nghe da CO va moi dupc dau tu bo sung chieu sau cua cac nha may trong tong eong ty VEAM.
Nghien eiiu thiet ke,che tao cac san pham cua dl tai, cac thanh vien cila to thuc hien de tai KC.05.02 da bat dau tir viec nghien cilu tim hieu ve nhiJng thanh cong trong thiet ke ket cau dpng co Di-e-den va cac cum chinh ciia dpng co va ve cong nghe che tao cac chi tiet ehu yeu cila dpng ca Di-e-den tren the gifli. De tai KC.05.02 da khai thac tu lieu chu yeu qua cae nguon:
-I- Ky yeu (A.S.M.E.) cac nam 1997 ~ 2002 cua chi hpi Dpng ca dot ttong, thupc Hpi ky su cong nghe cua My (S.A.E).
-I- Gang cha va cong nghe che tao ttnc khuyu gang cSu "Ductile iron data" SOREL Metal (Canada).
-I- Tai lieu huong dan su dung dpng ca di-e-den 3 xi lanh cua cac hang san xuat Nhat Ban, Han quoe, Trung Quoc.
+ Khao sat true tiep tai cac nha san xuat dong ca di-e-den 3 va 4 xi lanh fl cac nuflc Nhat Ban, Han Quoe va Trung Quoc.
Sau thfli ky nghien ciiu khao sat (6 thang) de cfl dupc nhiing hieu biet ve dpng CO di-e-den hien dai va cac thanh tuu trong ehe tao dpng ea di-e-den 3 xi lanh cua nhieu bang san xuat dpng ca cd uy tin tren the gioi, to ^huc hien de tai da chpn mua 2 loai dpng ca Di-e-den 3 xi lanh co he nap khi tu nhien (khflng cfl tua-bo tang ap) lam mau tham khao:
l.Dpng CO YANMAR (Nhat-Ban) 3TNE88, cong suat 32HP/2600vong/phiit, sudt tieu hao nhien lieu 172g/HP.h khoi luong rieng 5kg/HP, dupe xep loai cfl trinh dp cao, chat lupng cao (gia ea cung rat cao);
2.D6ng ea XINCHANG (Trung Quflc) NB385B, cflng sudt 30HP/2600v/ph, sudt tieu hao nhien lieu 180g/HP.h, dupe xep loai cfl gia ban thap nhat.
Dpng CO Clia De tai thiet ke 3DN88,3xi-lanh D88mm, hanh trihh 100mm,c6ng-xuat 32HP/2600v/ph. sudttieu hao nhien lieu 175g/HP.h Thilt kl dpng ca 3DN88 cua De tai dupe thue hien tren may vi tinh vfli phan mem thiet ke ''Solid Work 3D" ; mfl hinh hoa tinh toan kiem nghiem dpng lue hpe va kiem nghiem ben vfli phan mem
"Working Model 4D" cOa M.S.C software.Corp.(U.S.A),va phan mem do nhflm de tai tu xii\' dyng cho bp truyen dpng chinh: khiiyu-biel-pit tong-banh da cua dpng ca 3DN88; phfli hpp vfli Bp mon dflng co dflt trong eua Dai hpe Bach Khoa Ha npi, sir
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dung phdn mim mo hinh hoa dpng co Di-e-den cua hang A.V.L (Austtia) dl kilm nghiem dflng bp cac thong sfl ca ban cua thiet kl dpng eo 3DN88.
Qua ttinh chpn mdu kit cdu va tinh toan xac djnh cac thong sfl co ban ciia thiet ke dpng CO nhu tren da tao dupe dp tin cay cao cho thilt kl ban ddu eua De tai KC.05.02 : kit qua eu thl la khi dua cac biin ve thilt kl vao san xudt thii nghiem, ngay Ian dau da dat dupe cae thong sfl thilt kl da xae lap eho dpng ca. Rieng ve cae thflng so cua buflng chay tren pit tong, ngay tir thilt kl ban ddu da lap 4 phuong an kh ac nhau de khao sat va lira chpn toi uu.
San phdm cila dl tai KC.05.02 v l bp hoi cua dpng co Di-e-den YANMAR.6RAL-170 (xi lanh D170mm, hanh trinh 205mm) dupe lam theo cac tieu chudn ky thuat va chdt lupng theo mdu hien vat va ea-ta-16 cua dpng co 6RAL-170 cila YANMAR Diesel.Co.Ltd. Khong cfl vdn dl gi lon ISm trong viec lap ban ve thiet ke. Cac khfl khan phiic tap la fl khau xac djnh vat lieu va tim dupe cong nghe che tao dat dupc yeu eau dfli hfli cua cac loai chi tiet nay.
D I tai da giai quylt thanh cong viee chl tao bp hoi cho dpng ca YANMAR.6RAL.
Mpt bphoi (6xilanh)YANMAR.6RAL.170 cua De tai KC.05.02 chl tao ra, da dupc Cue Dang kilm Viet Nam giam djnh, cho phep lip chay trong dpng ca may phat dien YANMAR.6RAL s6 may 4399FRK cua tau van tai biln VAN DON cua Cong ty Van tai biln va xudt nhap khdu Quang Ninh. Din thang 12/2004 dpng ca YANMAR.6RAL so 4399FRK da lam viec dupe 8250h (theo nhat ky chay tau cua tau Van Don), chuan bi vao ky bao duong tiep theo, trong khi cac chi tiet cua bp hoi do De- tai san xuat, lap trong dflng ca nay, chua cfl chi tilt nao phai thay the va van cfln dang tiep tuc hoat dpng dupc. Gia ban (du kien) 1 bfl phu tilng 6 xi lanh nay (do cflng ty Di-e-den Sflng Cflng san xuat) la 30 trieu VND so vfli 198 trieu VND hang nhap khau ciia YANMAR.
Ve cong nghe chl tao va vat lieu che tao dpng ca Di-e-den va cae chi tiet chu yeu eua dpng CO, De tai KC.05.02 cung da thu duoc nhiing thanh cong dang ke trong thuc hien:
+ Diic gang hpp kim thap trong khuon eat ty cirng, eac chi tiet cfl hinh dang phdc tap, yeu cau dp chinh xac cao: nhu than may, qui lat, cfl gop cua dpng co 3 xi lanh . -I- Due ehinh xac vii nhiet luyen true khuyu 3x1 lanh.gang cau mae gang 100.70.03 A.S.T.M.
+ Due chinh xac pit long dpng co cao toe, cfl dp bin nhiet cao. (Nhflm hop kim thuang diing lam pit tong cila Lien Xo cu AL.25 chua dat yeu cdu).
+ Gang diic sec mang, sa mi xi lanh cfl dp bin moi eao.
-I- Cflng nghe gia cong true khuy'u gang edu, 3 cfl khu>'u can bing dpng khong sai lech qua 60g.cm, dp ben mfli kiem nghiem fl 10 trieu chu ky lam viec cfl tai.
+ Sir dung cac may cflng cu CNC hoac NC va NC hoa dl gia cong cac bl mat va kich thufle ehinh xac ma cac may van nang thflng dung khong thl thye hien dupe.
De tai KC.05.02 da gop phan dao tao dupe 1 thae si v l dpng eo dflt trong va hinh thanh dupc, nhom ky su cfl kien thue nghien ciru thilt kl, chl tao dflng eo Di-e-den
nhieu xi lanh hien dai, chuan bj cho chuang ttinh san xuat dflng co Di-e-den 4 va 6 xi lanh cho 6 to cua Tong cong ty VEAM va ciia Viet Nam nhiing nam tfli.
De tai KC.05.02 hoan thanh da tao ra dupc bfl tai lieu thiet ke hoan ehinh cila dflng co Di-e-den 3 xi lanh 3DN88 va bp hoi (6 loai ehi tiet) cua dpng co YANMAR.6RAL.170. Khufln mau, ga lap de che tao cac chi tiet chinh ciia dpng ca 3DN88 va 6 loai phu tiing cua dpng co 6RAL.170 ; 5 dpng ea 3DN88 va 12 bp hai Clia dpng eo YANMAR.6RAL.170 da dupe che tao fl eac nha may thufle Tflng eflng ty VEAM: Cflng ty Di-e-den Sflng Cong, Cflng ty phu tiing nfl sfl 2, Cflng ty co khi Viet Nhat VJE, trong dfl 1 dflng ea va 6 bfl hoi da dupe chay khao nghiem giam djnh chat lupng va dp bin theo ehi tieu De tai da dang ky.
Dl tai KC.05.02 da dupc Hpi dflng nghiem thu cdp Nha nuoc (1177QD-BKHCN) nghiem thu ngay 12/7/2004, xep loai Xuat sac.
Dong CO Di- e-den 3 xi lanh, cong sudt 30 ~~ 45HP
