r MGI-lliiN Ci/U - i/NO PUNO
Nghien cim cong nghe han tu dong
phuc vu han vo tau va thiet bi hoa dau
Datvan de
Phat tiien manh cdng nghiep ddng va su^ chiia tau thuy, che tao ddng co odng suat Idn cho tau bien hoat ddng xa bd la rrot trong nhuhg trpng tam ciia Chtidng trinh phat trien cdng nghiep dtidc de ra trong phPPng hu'dng nhiem vu muc tieu chu yeu ciia ke hoach phat tnen kinh te - xa hdi cua nu'dc ta giai doan 2001-2005 va cho den nam 2020.
Viec nang cao chat lu'Ong, hieu qua sir dung trong khai thae tinh nang va phat huy cdng suat dpi tau, ddi bdi mdt su dam bao chat che cac yeu a u ky thuat cung nhu' viec kiem dinh, giam djnh ky luQng cac nguyen cdng trong che tao ddng mdi va sira chiia vd tau.
Cdng nghe lap rap va ban hoan thien tiong che tao tau tiiuy vi tiie ma ngay cang dtidc chii y nghien ciru ap dung rdng rai cung vdi su' phat tnen ciia cac ttianh qua ky thuat trong nhi/ng nam gan day
Cac phu'dng tien cdng nghe phuc vLi eho viec co gidi boa va t i i ddng hoa trong ttiiet ke, che tao tau thuy da va dang du'dc ap dtjng hieu qua va chat lu'Ong d cac nu'dc cdng nghiep tien tien. Cdng nghe ban t i / ddng du'di Idp trO dung va ban t i / ddng tiong mdi tir/dng khi C02 bang day han bdt t i / bao ve, ban dien xi, ban dien khi... da gdp phan cai thien dieu kien lao ddng cua cdng nhan nganh ddng tau mdt each dang ke, cung nhu' dam bao yeu
cau ky thuat.
Vi vay, d Viet Nam, muc tieu nghien ciru, uTig dung cdng nghe t i / ddng boa cdng nghe ban trong cong nghiep ddng tau, trien khai uTig dung vao san xuat bieu qua co mdt vai trd quan trpng, nham ddi mdi cdng iighe cua nganh cd khi che tao trong cdng nghiep ddng tau cua dat nPdc.
Qua trinh nghien Cdu
1. Thiet ke do ga han:
Trong cdng nghiep che tao ket cau ban, cac thiet bi va dd ga ban tii ddng thdng thPPng dPPc phan loai tiieo cac tieu chi sau: Theo each dich chuyen tu'dng ddi ddi vdi mdi han; Phan loai theo dang dien ciic ban; Ddi vdi dang day han ndng chay dd ga du'dc phan loai theo 3 loai chinh; Od ga va thiet bi dPpc phan loai theo phu'Png phap bao
TS.HOANG VAN CHAU KS. LUC VAN THU'QNG KS. NGUYEN OINH SAO
ve vung ban; Phan loai dd ga thiet bi theo phuong phap tao dang mdi han.
Tren cP sd nhiem vu va muc tieu cua de tai la thiet ke' che tao t d dd ga han vd tau va thiet b; hda dau cd dieu khien chUPng trinh sd, cung nbd sau kill da phan tich dani i gia a i ttie v'e cac cdng nghe han phd bien ap dung trong san xuat, de tai lua chon che tao dd ga han h/ ddng dich chuyen theo xich de phu hpp vdi cac bien dang khdng gian khae nhau cua nhi'eu chung loai tau va thiet bi hda dau cd ki'ch ttiddc khae nhau.
Cdng nghe ban du'Oc Itja chon la cdng nghe ban day Id dac (hoac day Id bdt) tiong mdi hu'dng khi bao ve (hoac t l / bao ve) vdi di/dng ki'nh day han tu' 0,8 - 1,6 mm, dam bao cho kha nang ap dung phii hop vdi hau bet chieu day thep (8 - 30 mm) ciia cac loai vd tau va
PHAI OAM BAO AN TOAN LAO OONG VI NGUOI LAO OQNG LA VON Q U Y N H A T / Khoa hoc & Cong nghe |3'2009] ( E J E C E ! ! ! ? 4 3
I:N Cl/U - l/NG OUNG Tk
thiet bi hda dau thdng dung.
2. Nghien culi tich hdp dau do cam bien Laser va thiet lap phan miem dieu khien: (xem hinh minh hoa)
'He tiidng dau do bang cam bien laser gom: Oiu dd Laser-camera MINI-i/90 (1), tii dieu khien Ez-TRAC-IT (2) ke't ndi vdi may ti'nh bang cdng RS232/422 (3), giao tiep bang phan mem WinUser Tat ca cac phan tii nay ket hPp lai de di'eu khien co cau chap hanh thep yeu cau d'e ra (cd cau chap hanh gem 2 cum chuyen dpng thep hai phu'Png Y va Z) (4).
O'au dd Laser - camera MINI - i/90 vtfti nguyen ly heat ddng la cam bien quang hpc, su" dung chum tia laser de chieu sang: Ngu'dn sang la laser diede 50mW; khoang each 50mm, chieu sau quan sat 90mm; pham vi eiia tam nhin mat phang g'an la 43mm, xa la 71mm; chi'eu sau dp phan giai trung binh la 0,15mm; cac diem mau cho mdi Profile la 239 hoac 478;
tdc dd 30/CO Profile cho mdi giay; tdc dd di/ lieu 14340 diem cho mdl giay.
Til di'eu khien Ez-TRAC-IT la mdt ddn vi xii ly nhanh tin hieu dang hinh anh thu dtidc tu' si/dich chuyen he true tpa dp va dti lieu 3D ciia Laser-Camera. Nd ludn ludn dieu khien cac qua trinh vdi dieu kien gia tang kha nang nhan biet bang d'au de 3D va cd kha nang thich nghi dieu khien thdng tin phan hei. Vdi Mpdul di'eu khien chuyen ddng tdc dp cao va Sl/ t l / ddng hoa lam ddn gian boa cac thiet bi chuyen ddng ciia d'au dd theo ddi dtidng han trong cac irng dung han hd quang.
'00 ga dau han.
Od ga dau ban thi/c chat la xe ban tren dd gan dien cPc ban, dLidc di'eu khien theo mdt yeu cau nhat dinh do yeu cau ve cdng nghe da dat ra. Nd dam bao cac nhiem vu sau:
Dam bao dPPc tdc dp ban nhu' mong mud'n; theo sat du'Oc hinh dang, cung nhti vi tri md'i han ma he thdng giam sat da chi dan.
Trong HTDl, do EZ-TRAC-U da bao dam giam sat dtidc diing vi tri mdl han theo 2 phu'Png Y va Z, vi vay ma dd ga dau han chi can phd'i hpp de dieu khien d'au han theo phtidng X cho ddng bd va phii hpp vdi cdng nghe ban da dtidc dat ra.
0am bao sti chuyen ddng ciia true X la mdt ddng cd mdt chieu kich tid ddc lap, thay ddi tdc dp vd cap bang dien ap mdt chi'eu (0 ~ 40VDC). Do bd chinh lull cd di'eu khien bang thyns-
tor cung cap, thay doi dien ap ra tii 0 ~ 40 VDC bang ti'n hieu ap di'eu khien ti/dng ti/ (0 ~ 5 VDC) ti le vdi dien ap ra. Lua chpn cau hinh thiet bi PLC: PLC ngoai nhiem VIJ ket ndi, dieu khien cac thiet bi tren cdn phai ItiU tri/ va ti'nh toan dtidc cac che dp cdng nghe dat tn/dc. Oe' bae dam ket ndi cac ttiiet bi tren va dap uhg dtidc cdng nghe theo yeu cau, PLC dtitjc chpn a n phai od kha nang md rdng cao. Bd nhd, tdc dp phai dii de lull git/ va ti'nh toan; dieu khien che phii hop.
Tu' cac thiet bi va yeu cau tren, PLC dtidc chpn la loai:
Siemens S7-200 CPU 224XP 14DI/10DO Relay va 2 /\nalog Input/1 Analog Output; 1 module md rdng EM232 vdi 2 cdng analog ra; 1 cap PC/PPI de ket ndi may tihh vdi PLC S7-200; dung Itidng bd nhd: 5KB dii' lieu va 8KB chtidng tiinh;
tdc dp 1024 phep tinh nhi phan/mm giay
3. Thiet lap Quy trinh cong nghe han:
^ ^ ^ ^ • i Sa do ket noi thiet bj cua he thdng Wm^
May tinh •; • Bo vi xif ly dung PLC . 1 Dieu khien xa
1 1
1Til dieu khien
d^u d6 1
Til dieu khien do gel hcin
1 .._.J.._J__._
Oau do Laser Do ga han
[
1
Thiet bi han
1
D^u du'a dSy
Quy trinh van hanh thiet bi: sau khi da dua he thdng cac tiiiet bi nhti: xe ban, dau dua day, dau de vao vi tri chuan bi han, tien hanh cac cdng viec sau:
- Chua'n bi cac thdng sd cdng nghe han tren may tihh nhti: tdc dp cap day, tdc dp han, dien ap han, dtidng kihh day han, phan doan han; nhap dti lieu vao chtidng trinh phin mem va tai den bd vi xu' ly; kiem ti^ cac thiet bi ve mat an toan (dien, day, khi bao ve,...), tat ca cac tiiiet bi tien dam bao dieu kien boat ddng thi ddng dien cho cac thiet bi d che dd san sang boat ddng; bam nut Start tren bang dieu khien xa, tat ca cac thiet bi hoat ddng theo trinh tii da dtidc lap tn/dc bang chtidng trinh di'eu khien sd; bam Stop ta't ca cac thiet bi se dirtig lai theo ti'inh tii da dtidc lap tn/dc bang chtidng trinh di'eu khien sd; lap lai cdng viec nhti d che dp lua chpn cho cac dtidng ban tiep theo.
Trong che dp nay, cac thdng sd v'e cdng nghe ban tti ddng dtidc thi/c hien ttiep cac btidc bdi cac dir lieu ti'png phan mem va dtidc ti'nh toan trong bd vi xti ly PLC. Qua tiinh han dien ra mdt each tti ddng. Khi thtic hien xong tat ca cac cdng doan dtidc lap trinh trtidc, may tii ddng duhg lai sau khi ban diien (Jay vet Idm cudi diTdng ban.
(^ trinh han: 01 cung vdi he ttidng thiet bi va do ga la cac quy trinh cdng nghe han diing day Idi dac va day Idi bcit frpng khi bap ve C02, trong dd la tap hop cac bu'dc cdng nghe
4 4 tK');n:i-t:iHjKhna hoc & Cong nghe [3/2009] X PHAI DAIVI BAO AN TOAN LAO DONG Vl NGUOI LAO OONG LA VON QUY NHA'T
r NGMlfEN Cl/U - l/NG IDUNG
QJ the va cae chi dan van hanh thiet bi.
Phan tich ket Qua nghien cihi
- Bang thi/c nghiem da tien hanh xac dinh cac che dp cdng nghe ban chu yeu khi han t i / ddng vdi day ban Idi bdt trong khi bao ve nhu' dien ap ban, ddng ban va tdc dp ban phu hdp vdi gdc nghieng cua be mat chi tiet trong khdng gian lam od sd de xay duTig co sd dti lieu cho t d vi xti ly va phan mem dieu khien do ga ban khi ban cac ket cau cua vd tau thuy.
- Tren ccf sd ban ve thiet ke vd tau, sau khi ti'nh toan cho tuhg mdi ban cii the can cii vao gdc nghieng cua mdl ban trong khdng gian so vdi phtidng nSm ngang, vdi phan mem va bd vi xti ly da dtipc che tao, od the lap trinh du'Oc chuyen ddng cua dd ga ban va t i / ddng thay ddi cac thdng sd cdng nghe han trong qua trinh ttidng uhg vdi ti/ng doan chuyen ddng cua quy dao han, dam bao chat lu'Ong mdl ban.
- Sti dung dd ga ban ket hPp vdi dau dd cam bien Laser da dam bao chinh xac chuyen ddng cua dau han ttieo mep vat cho tnidc cua phdi.
Khoang didi chuyen cua bd tii/pt theo hai phu'dng Y va Z du de thay ddi vi tn' dau ban trong khdng gian bjy theo dd chinh xac lap ghep trong thuc te cua qua trinh thi cdng.
- Phan mem du'dc thiet lap da ket ndi d'dng bd vdi dd ga va bd vi xti ly, dam bao hoat ddng oJa ca he thdng vdi
bd ngu'dn han, cho phep dieu chinh cac thdng sd cua che dd ban d cac vi tn' khae nhau phu hop vdi yeu cau thi/c te san xuat.
Ket luan
- Lan dau tien De tai da tiien khai ap dung cdng nghe dd dUdng ban h/
ddng bang d'au dd cam bien vdi camera laser de dinh vi chinh xac vi tri ban, tao dieu kien nang cao chat lu'Png cdng nghe cho han t i / dong cac mdi ndi trong khdng gian.
- De tai cd ti'nh toan thiet ke va che tao dd ga ban trong khdng gian dam bao yeu cau ve phdi hop chuyen ddng phuc vu chp viec dich chuyen tiiep quy
dap khdng gian. Ket cau dd ga gon nhe, dam bao du'Oc tinh o3 ddng va phu hop chp dac diem ban vd tau ttiuy va thiet bi hoa dau.
- Bd vi xti ly du'dc ttiiet ke va lap rap trong nu'dc. Phan mem ket ndi ddng t d vdi dd ga va bd vi xti ly di'eu khien sd dam bao cho cac chuyen ddng cua dd ga tiieo quy dao d n thiet, ddng thdi dieu khien che dp cdng nghe han phuc vu cho viec nghien ciru thiet lap oSng nghe han h/ ddng cac mdi ndi trong khdng gian.
- Oa thi/c hien viec tiep thu mdt each cd chpn loc cdng nghe tien tien cua nu'dc ngoai (ciia cac nPdc G7 nhu Canada, Nhat Ban) de trien khai cac ndi dung va muc tieu nghien cirii de ra.
- Thdng qua nghien cuU thi/c nghiem, Oe tai da thiet lap dddc Quy trinh cdng nghe ban cua tiiiet bi han hi ddng cd dieu khien sd tiong khdng gian nhieu chieu vdi cac che do o5ng nghe ban chu yeu nhii dien ap ban, ddng ban va tdc dp ban phu hpp vdi gdc nghieng cua be mat chi tiet ttpng khdng gian cua vd tau.
- Quy trinh cdng nghe da du'dc uhg dung tai Nha may Odng tau Sdng Cam cho ban tau 4.000 tan va du'Oc danh gia dam bap cac yeu cau v'e chat lirpng mdi ban ddi vdi vd tau ttiuy. •
Tiilidu tham khao
1. Jean-Paul Boillot, Kolchi Uota, Etienne Berthlaume. Laser trackmg and inspection for high speed laser welding. Industrial Laser Solutions. 2004.
2. ]. Noruk, Improve Weld Quality in Automotive Laser Tailor-Welded Blanks. Forming &
Fabricating. August 2003.
3. J.P. Boillot, K. Uota, E. Berthlaume & J. Noruk. Tracking and Inspection for Laser Weld- ing. Ua Today. September/Octotier 2002.
•f, J.P. Boillot & J. Noruk. Benefits of vision In laser welding. Industrial Laser Solutions. No- vemtier 2001.
5. Jean-Paul Boillot, Jeffrey Noruk, Laurent Rimano. Current Applications & Trends In In- telligent Control of Joining Processes in the Automotive Industry. 2003.
6. Nelson J. Orozco, Paul A. Blomqulst, Robert B. Rudy, Steven R. Webtier Proceedings of the 23rd International Congress on Applications of Lasers & Electro-Optics 2004. Real-Time control of Laser-Hybrid welding using weld quality attributes.
7. R. Boekholt, ICWET, Sweden. Welding mechanisation and automation in shipbuilding worldwide: Production methods and trends based on yard capacity. 2003.
8. J. K. Paik, Pusan National University, Korea. Ships and Offshore Structures. 2002.
PHAI OAM BAO AN TOAN LAO OQNG Vi NGUOI LAO OQNG LA V 6 N QUY NHAT / K h o a hoc & Cong nghe (3/2009] ( 2 1 3 3 2 3 ? 4 5
