NGHieNCCfU-TRflO DO!
mmm m THIET RE CHE TAO THIET BI
m XUAT 6m BTCT RICH THI/CIC loi^
TREN Ctf s d CORfG NGHE MIET RUNG VA EP THIIY l l f c
I • TS 0 6 VAN VU, ThS LE HONG SOU, KS N G U Y I N DANH T I I N
Vi^n Miy vk Dyng cu cfing nghiap - B6 C6ng tlni/ong
Bai bao gidl thieu nguySn ly hoat dong, mpt so'd^c dli'm chinh trong thie't •<§', chi'tao may rung ep hifdng kfnh dung cho san xua't 8'ng be tong co't thep (BTCT) kich thirdc Idn:
xay diTng ca'u hinh t^ng the; tinh toan cac cum truyS'n dpng va dieu khien; thie't kg'chg' tao khung may cung nhif cac cum chdc nang thie't ye'u kem theo nhif de' rung, dau ep, hg thd'ng dig'u khi^n,,. Nhiing kg't qua chay thuf ban dS'u cho thg'y, may dap iing cac yeu cau dat ra vg' ndng sua't, cha't lirong s i n pham cung nhii cac chi tigu ky thuat khac.
Tif khoa: may rung ep hiiSng kinh, ong BTCT, truyen tgng thuy luc.
Qnsr.KQCW PKSlkSL'l DI':SIC,NINC, AND MANIIFAC
DADIM. P D K S S rOD i'DODUC'INC
In the paper, some main aspects of study, tiesign, manufacture of the radial press are presented: the operating principles; building of the general configuration of the machine;
establishing the power transmission system and control system; designing the ; machine main frame and all other important
functional modules, components, sections such as vibration compactor, press head, control system... Some preliminary testing results are introduced.
Key wards: radial press, relntorced concrete pipe, liydraulic power transmission.
Datvan de
Trong thdi gian qua, Vien IVlay va Dung cu cong nghiep (Bo Cong thuang) dUdc giao thuc hien de tai oSp nha nadc:
"Nghien ciiu thiet l<e, che tao thiet b\ san xuat ong be tong loi thep kich thudc Idn, tren cd sd c5ng nghe miet rung va ep thijy luc", ma so KC.03.11/11-f 5, thudc ChUdng trinh KH&CN cap nha nudc "Nghidn cUu utng dung va phat trien cdng nghe cd khi va tU dpng hoa" (ma so KC.03/11 -f 5). DSy la mgt thiet bj thupc nhdm cac may san xuat cau kidn xay dung cd Idn, da va dang dUdc phat tnen thed hudng tu dpng hda vdi yeu c^u chat IUdng s^n pham ngay cang cao, nham dap Ung nhu cau ngay cang da dang va khat khe trong xay dung ha tSng do thj, cdng trinh giao thong...
Xua't phat tu yeu cau ky thuat cCia thiet bi, nhom nghien eflu da tap trung triln khai khio sat, nghien cUu hang lo?t thiet bj mlu cua cac hang che tao may hang dau tren thS gidi nhu Hess Group, IVIenegdtti... tfl do xay dung dUdc cS'u hinh thiet bi va tien hanh thidt ke che tao thanh cdng may ep ong BTCT hudng kinh tu dong, vdi cac thong so ky thuat chinh:
- Quy each san phim: ong BTCT chieu dai 2.500 mm, dudng kinh 600-1.200 mm, ket c l u cac diu ong theo TCXDVN 372-2006 [1] danh chd ong BTCT thoat nudc.
• Chat IUdng sSn pham (sai lech kich thudc, hinh dang, chat IUdng be mat treng va ngoai dng, kha nang chju t4i, do thim nudc.) dap Ung TCXDVN 372-2006 [1].
52
TapchKHOAHOC „ . , CONGNCHEVIETNlftf s° 10 nam 2014NGHieNCLrtJ-TRflO 001
- Nang suat he thd'ng: 17-22 dng/gid.
Npi dung nghien cihi
Chgn ti/a cong ngh$ va thiet bj
De thUc hien c h l tao dng BTCT theo cac nguyen ly milt, rung va ep phdi hdp, cd nhilu cdng nghe va thiet bj hien dai khac nhau nha- cdng nghd rung ban; cdng nghe rung Idi co djnh ddng thdi tren toan bd chieu dai dng, ep miet djnh hinh dau dng (goi tat la cdng nghe rung milt Idi cd dinh); cdng nghd rung Idi di ddng dpc theo chieu dai dng, ep milt dinh hinh dau dng {goi tat la cdng nghe rung miet Idi di ddng); cdng nghe ep hudng l<inh di ddng doc theo chilu dai dng, rung ban l<lt hdp ep miet dmh hinh dau dng (gpi tat la cdng nghe rung ep hadng i<inh). Trong cac cdng nghe neu tren, cdng nghe rung ep hifdng i<inh la mpt cdng nghe mdi daoc phat triln, cd nhilu au diem ndi b^t: cdng suat ngudn ep gi^m, l<lt cau l<hudn ddn gi^n, chat latjng s^n pham tang, nang suit sSn pham tang nhd chu trinh slin xuat rijt ngan, thich hop nhit cho cd d'ng dadng l<inh trung binh... (bang 1). Day chi'nh la cdng nghe va thilt bj dapc nhdm nghien cdu laa chpn de phat tnen, tren co sd may mau cua hang Schlosser-Pfeiffer, CHLB DJc.
cd cac canh ggt (10), con lan ep (3) va dng la nhin (4).
Diu ep vda tjnh tiln, visa quay trdn trong idng khudn_.
Do chuyen dpng quay trdn cua dau ep nen hon hdp bd tdng vda bi ep bdi lac quan tinh ly tSm cija canh gat (10), viia bj ep do con lan (3). De dam bao dd chat cua be tdng tren toan bd than dng, phai duy tri khdng ddi lac ep, cung tijic la duy tri ap suat P^p cua cac con lan ep (3) lan can gia trj P^p trong sud't qua trinh tao hinh tlian dng.
STT
1 2 3
Bing t so sanh cic chi ti§u theo tiinh tuang [1,
Cdng ngh^
Rung ban Rgng miet Rung 6phui}tig kinh
Chl tl§u ky t h u ^ E}$ c h | t
K = 0,93 K = 0,95 K = 0,9e
E>$ Cling (Sl 60 60-100 150-200
CiMng dp nin (MPa) 41,6 44,e 49,9
BQ chong Ihfm BIO BIO B1D
2, 3, 4]
Ch( (leu kinh \i C h l p h i n i n g li/^ng (KWh) 11,40
9,03 8,04
Nguyen ly lam vi$c cua miy rung 6p hucing kinh dng BTCT
Khudn dng (2) dUdc dat thang dflng va dong true vdi true dSn dong (9), (3au quay ep (3+4). True (9) dupc d p va duy tri mdmen, tdc do quay can thiet theo yeu clu cdng nghd tU ngudn dan ddng (8). T?i vi tri lam vide ban diu, diu quay ep d vj tri dudi cung cija khudn.
Hdn hdp bd tdng dUdc may nap (f) rot vao long khudn (2). Ktiuon (2) dfldc dat thing dflng tren ban rung (5).
Diu tien, phdi hdp vdi chuyen ddng quay tgi cho cija dau quay ep, ban rung hoat dong vdi t i n so' va cfldrig dd thich hdp d l lam chat hdn hdp va tad hinh chd phan lde cfla dau ong. Khi phln loe cua dau dng da dUdc lam chat tdi mdt ap suit P^ cln thief cho trudc, ban rurig dUng hoat dpng va dau quay ep (3+4) dUdc nSng dan len phia trdn ben trong khudn (2). Td'c dp quay cfla diu quay ep cung tang len va gifl d mgt gia tri on djnh nhd nguon din dpng (8), qua dd thflc hien viec ep hudng kinh t?o hinh phln than d'ng. Cum dau quay ep gom
Hinh 1: sa do nguyen 1^ may rung ep tiudng kinti dng BTCT Tuy nhien, trong qua trinh van hanh, IUdng be tdng cap vao khudn cd the bj thay doi (do nhflng nhilu dong dp am, mat dp, td'c dp may nap..), tfl dd din tdi bien dpng Pgp va qua do tdi dd nen chat be tdng. Co mpt so' phUdng phap dung de dieu chinh P,, nhu dilu khien toe dp nap cua may nap iieu (f), dieu khien tdc do quay true ep (9)..., trdng do cdng nghe hay duoc sil dung la dieu chinh td'c dd nang V cfla diu quay ep sao cho phij hop vdi su bien ddng ciJa P,^ thong qua cd cau nang ha (6), dong thdi giO khdng doi van tdc quay co cfla diu quay ep va td'c dp cap be tdng tfl may nap.
Ketqua
Cdng suit din ddng tn/c ip
Tinh toan ly thuylt dupc rut ra tU sd dd hinh 2:
S . t „ n . m . 0 t 4 e 6 „ a ™ » "
NGHIGNCQU-TRRO DOI
N.. = F^.V, = [k^^ + sin(a/2)l.p .Z.a.r.!.V, (1) Trong dd, F^, la tong hop li/c c^n dat len mdi con lan theo phaong V, (bao gdm F, va It/c ma sat F^J; k^^
la he sd ma sat lan giQa thep va hdn hdp be tdng (-0,1 vdi tiie tdng cd dp syt khdng qua 1-1-2 cm); p^^la ap suat lam chat dng; a la gdc ep; r la ban kinh con lan ep; Z ia sd con lan ep; I la chieu cao con ian ep; tdc dd quay true ep to = V/(R,- r); V, la tdc dp dai cua con lan; tdc dp n&ng dau quay ep u,, = I Z.(o/2nm [5]; sd lan ep tren mdi diem m^ (lay td 40-60).
Tinh theo cdng thdc kinh nghiem [5]: Np^, = 2K.R.k^ (2) Trong dd, k^ la cdng suat tren ddn vj chieu dai, lay bang 15 kW/m vdi dng cd cot thep, 17 kW/m vdi dng khdng cot thep; R la ban kinh ngoai dng BTCT.
Hinh 2: sO dd md ti cac Ihdng so qua trinh quay ep cua dau ep Tii cac dieu kien cy t h i cija bai toan, xac djnh dapc cdng suat ep Idn nha't bang 75 kW, taong ufng vdi dcii ap suat ep 160-^170 bar, td'c dd quay true ep 90 vdng/
phut, dadng kinh d'ng max 1.200 mm, tdc do nang true ep ~ 2,1 cm/s.
H$ thong truyen dQng dau quay ep Xuat phat tCr yeu cau truyen ddng quay dau quay ep; cdng suat Idn (tdi hang tram kW), d^i thay dd'i cdng sua't va td'c dp rdng (ty sd gia tn max/min tdi 300%), vj tri dat cd cau truyen ddng tren dau true ed cao do Idn de giy dao dpng Idn neu cd khdi lapng Idn..., nen d l tai chpn phadng an thi^c hien din dpng dau quay ep bSng si^ dung ddng cd thuy lac cd bd dieu chinh tdc dp thay vi dung dpng cd dien truyln ddng qua hop giam td'c ed khi va dilu khien td'c dp thdng qua bien tan.
Mac du phadng an sau ed the l<inh te hdn khi dau ta, nhang vdi phadng an da chon, ngadi dung se cd ldi vi chi phi nang lddng giam, nang suat he thdng tang, he
thdng van hanh on djnh hdn.
De tai da xay dang he truyln dpng thuy lyc mach kin trdn cd sd bd ddi bdm thuy lac piston hadng true thay doi lUu ladng kieu 90L075 (variable displacement axial piston pump) va dpng cd thuy lac piston hadng true true udn thay doi Idu lapng kilu 51 Dl 60 (variable displacement bent axis piston motor) cija hang Sauer- Danfoss, cCing cac phan tD thijy lac, dien phy trd cho dilu khien lau ladng va trang thai, giam sat qua trinh nha van ty le, cam biln ap suat, cam biln tdc dp ddng cd, cac van dien XiS, van an toan... Toan bd qua trinh dieu khien ta ddng mach ddng lac dapc tich hdp trdn hd thdng dieu khiln cija toan may vdi nen t&ng la bp dieu khien lap trinh S7-300 cua Siemens [6].
H# thd'ng dieu khien toe do nang diu ep De tai chpn phaong phap dilu khiln tde dp nang dau ep de duy tri ap suat nen on dinh trong qua trinh tao thanh dng BTCT. Cd sd trade tien eua phadng phap nay la quan h§ tuyIn tinh thuan giOa ap suat diu nen tao tren d'ng P va ap suat thuy lac P,, cua ddng cd thuy lac quay dau nen: P^^ = K.P,,. Nha v&y, viec duy tri P^ bang P cho trade daoc quy v l dieu chinh Pii bam theo gia trj dat P . He sd l< dapc tinh toan, xae djnh va kilm tra qua thac nghidm eho tCfng he thdng, dac trang cho cau tgo dau quay ep, kieu loai va eau tao dpng cd thijy lae. Cd sd thd hai la dac tinh cd cija he thdng, vdi md'i quan he ty le nghjch giOa td'c do nang dau quay ep M^^ vdi ap s_uat ep P^ . Vdi nhQng ly do taong ta nha khi chpn he din ddng dau quay ep, de tai cung chpn phadng an thuy lac cho dan ddng n§ng hg dau quay ep. Do vay, cd t h i thay the dai ladng can dieu khien la tdc dp nang -u,, bang lau ladng dau Q^„
cap cho xi lanh nang. Td dd, bai toan dilu khien quy ve dieu khien lau laong dau Q^^ nham duy tri ap suit thijy li^c ddng cd din ddng dau quay ep P,, theo gia tri yeu cau P^^,,. D l thac hien nhiem vu nay, cac tae gia da xay dang mpt mach dieu khien vdng kin tieu ehuan kieu P (dieu khien ty le) bao gom van ty le Rexroth 4WRBA cap dau eho xi ianh nang, cam bien ap suat Hydac HAD-4744 trdn ddng ed quay dau ep, md dun dilu khien ty le tich hpp tren S7-300 cCia toan may vdi tin hieu vao la P,,, tin hieu ra 1,^ cho dilu khien dd md van ty le tren [6, 7],
Tinh toan thiet ki de rung dinh hinh dau ong BTCT
De xac djnh cdng suit rung cijng nha sa phan bd ngudn gay rung nham dam b^o dd chat ddng deu trdn toan chu vi dau dng trong thdi gian cdng nghe xae dinh, nhdm nghien cdu da xac djnh dddc nguon rung gdm bdn dau rung lech tam RZ165K vdi cdng suit
c- Tap chl KHOA HOC ^ . , „ . „ „ , ,
^* CdNCNGHEVIETNJiM ' ° ^ ° " ' " ' ° ^ '
N G H I 6 N CLfu-TRRODOI
0,96 kW, lac ly tam 1.650 kP moi dau phan bd deu tren mat dadi tam de rung dadng kinh 1.650 mm.
Chpn vat U^u va cong ngh$ chit^o cac cijm may chfnh
Tryc din ddng dau quay ep bang thep cacbon trung binh hpp kim thap Crom-Niken 40CrNi, tdi cai thien dat dd cdng 230 HB, dam bao dp ben, dd dai tdng hpp eao nhat cho dang true dai, Idn va chju lac udn xoan phdc tap, he sd mdi cao.
Dau lan ep bang thep cac bon thip hpp kim thap Crom-IVIangan 18CrMn chuyen dung tham cacbon va tdi ram thip cho hieu qua chju mai mdn b l mat eao, ddng thdi vln cd dp dai va dap cua idi dam bao trong dilu kien hoat ddng cua diu ep.
Khung chinh cua may vdi nhiem vy dd va djnh vj eae chi tilt cau thanh cilia may nen dadc thiet k l cdng vOng, dam biio cae cum thiet bj chinh d l rung, phan phd'i lieu va diu quay ep hoat dpng on dmh va chinh xac trong cae ehuyen ddng tao hinh, ddng thdi khung dapc chia thanh eae modun d l thuan tien cho qua trinh van chuyen, lap dat sau nay. De dat dp ehinh xac c h l tao cac phan tD khung dapc to hdp bang cdng nghe han MAG, cac be mat din hadng va dinh vj dapc thac hien tren may doa va phay giadng chuyen dung ed Idn.
He thd'ng dieu khien may
He thd'ng dieu khiln may dapc thilt ke, xay dang va tich hdp tren ed sd bd dieu khiln sd lap trinh modun ddng S7-300 cua Siemens [6]. Bd xD ly trung tam la CPU315-2 PN/DP cau hinh m?nh (bd nhd 384 kB, tdc dp xD ly 0,05 ms/1.000 lenh, kit ndi mang cdng nghiep PROFINET, cau hinh da tang tdi 32 modun chdc nang cac loai, hd trd dieu khie'n thdi gian thae RT/IRT.,,), kit hdp man hien thj - thao tac MP377 12" kilu graphic, cam Dng, dadc cau hinh va lap trinh tieh hdp tren phan mem STEP7 v.5.5 cho S7/C7/M7 va WinCC flexible ES (2008 - SP2 Advanced) cho lap trinh giao dien ngadi - may HMI eua Siemens. Cac thiet bj do ladng, cae cam biln, ed eau chap hanh dadc kit ndi va quan ly tren mgng edng nghiep dae dyng ASI eua Siemens.
Phan mIm thu th§p, dilu khiln, giam sat va xD ly td ddng toan bd cac cum thilt bj cua may da dadc de tai soan thao, lap trinh, chay thi!f va hieu ch?nh tren eae phan mIm md phong chuyen dyng cija Siemens trade khi kiem tra va daa vao van hanh chinh thdc tren may thac.
May daoc lap dat chay thD vdi san pham cd kich thadc D1.200 X 2.500, tren cd sd chay thD tai xadng thuc nghiem, nhdm d l tai da cd dadc nhQng kit qua
ban dau nha sau: tim dapc cac thdng sd cdng nghe cDa may nha mdi quan he giQa dp nen chat cija be tdng va td'c dp chuyin ddng len xudng cua dau quay ep cung nha lau lUOng cap vat lieu tD phiu chDa xudng ldng khudn. Tren cd sd cac thdng so cdng nghe cd dapc, da td'i au hda phan mem dilu khiln he thdng, hdp iy hda quy trinh che tao, ISp dat va van hanh thilt bi.
Ket luan
Bade dau, may rung dp hadng kinh dng BTCT cd Idn da dapc cae nha khoa hpc thudc Vien May va Dung cu cdng nghidp thilt k l c h l tao va chay thD dgt cac ch? tidu d l ra, vdi eae thdng sd ky thuat tadng dadng vdi cac may cung logi cDa nUdc ngoai. V l chi tieu kinh te, sd bd tinh toan cho thiy, nlu dadc san xuat loat nhd, cd the giam gia thanh may so vdi nhap ngoai it nhat 30%. Dieu nay cho thay tinh kha thi cua viec san xult hang logt cae thilt bj s^n xuat dng BTCT kich thadc Idn tilp theo khi cd nhu clu cua thi tradng.
Tren co sd dd, nhdm nghien cDu de xuat can nghidn cdu thiet ke cae mlu may cd nho hdn va Idn hdn de hdan thien thiet k l gam may rung ep hadng kinh, vdi nhilu laa chpn ve kit cau, chung logi va gia thanh cho khach hang, dap Dng nhu cau da dgng cua thj tradng;
nghien cDu hoan thien edng nghe che tao, lap rap va thD nghiem d l sdm ed t h i tiln hanh sSn xuat loat nhd va trung binh cho ea gam may. phue vy rdng rai eho cac nganh xay dang va giao thdng ^
Tai lieu tham Khao
[1] Tieu chuan xay di/ng Viet Narrr TCXDVN 3722006 "Ong BTCT thoat nudc" - 2006,
[2] Cac tieu chuan quoc gia va tieu chuIn nganh cOa Viet Nam v6 be long, vat lieu cho s5n xuat be tong: TCVN 3107-1993, TCVN 3116- 1993.
[3] Tai lieu noi bg, cac bai bao da cong bo cua mot so nha may trong nudc da va dang i)ng dung cac cong nghe s i n xuSt ong be tong loi thep nhu Nha may be tong Amaccao, Nha may b§ tong due s i n Hung V J d n g -
[4] Giao trinh Vat lieu xay diing - Tri/cJng Dai hpc X§y difng mien Trung, 2004,
[5]Tran Thieu Xuan. Tran Van Tuan, Nguyin Thi Thanh Mai, Nguyen Kiem Anh: May san xuat vat lieu va can ki^n xay diing - Nha xuat ban Xay di/ng, Ha Noi, 2000
[6] Tai lieu ky thuat cua cac hang Hess Group, Menegotti, Sauer- Dafoss, Siemens, MathWorks
[7] Tran XuSn Tuy: He tha'ng dieu k h i l n t i ; dftng thCiy luc - Nha xuat ban Khoa hoc va Ky thuat, Ha Noi, 2002
S o 1 0 n a m 2 0 1 4 TgpchEHOAHOC CONGNGHtVIETNJW
