tp on kinh t vinashin cng ty cng nghip tu thy nam triu

bo co tng kt ti theo ngh nh th

nghin cu thit k ch to my p chn tn thy lc 1200t dng trong ng tu thy c ln

ch nhim ti: kS nguyn vn canh

5985
23/8/2006

Hi phng 2006

Phiu ng k v giao np kt qu nghin cu KHCN

1- Tn ti: Nghin cu, thit k, ch to my p chn tn 1.200T dng
trong ng tu thu c ln.

2- M s: ti NCKH theo N119. 3- Cp ti: Nh nc 4- C quan ch tr ti: Cng ty cng nghip tu thy Nam Triu. a ch: X Tam Hng - Huyn Thu Nguyn - Hi Phng. in thoi: 031.775533 5- C quan cp trn trc tip. 6- B, a phng ch qun: B Khoa hc v cng ngh. a ch: S 39-Trn Hng o H Ni 7- Tng kinh ph: 7.941 triu ng Trong : T Ngn sch Nh nc: 1.000.0000 ng 8- Thi gian thc hin: 30 thng, t thng 6/2003 n thng 12/2005. 9- Ch nhim ti: K.S Nguyn Vn Canh a ch lin h: Tam Hng Thu Nguyn Hi Phng in thoi: 031.775533-124 10- Danh sch c nhn tham gia nghin cu H v tn - Bi Minh iu - V Vn Qun - Bi nh Hin - Nguyn c Dc - o Vn Ngon - Nguyn Th Dung - Nguyn Xun Thng - Phm Trng Tam 11- Bo mt thng tin: Ph bin hn ch 12- Tm tt kt qu nghin cu * V gii php khoa hc cng ngh Trong ti a ra phng php tnh ton thit k my c lc p ln 1.200T v p c mi to trn bn p. a ra c cc quy trnh cng ngh ch to cc b phn ca my p thu lc (c bit l h thng thu lc) trn c s s dng cc thit b tin tin. Hc hm, hc v K s my- Cng ty CNTT Nam Triu K s my- Cng ty CNTT Nam Triu K s in - Cng ty CNTT Nam Triu K s v - Cng ty CNTT Nam Triu K s - Cng ty CNTT Nam Triu K s - Cng ty C kh Quang Trung K s - Cng ty C kh Quang Trung K s - Vin KHCN tu thu Fax: 031.875135 Fax: 031.875135

* V phng php nghin cu Nghin cu cc ti liu v cc my p thu lc hin i trn th gii, nghin cu thc trng cng ngh ca mt s Nh my ng tu v ca ring Cng ty CNTT Nam Triu a ra m hnh my p chn tn thu lc 1.200T ph hp. - i ng k s tip cn vi cng ngh tin tin, hin i p dng vo sn xut. Khng nh chng ta hon ton c th thit k, ch to my p thu lc vi kch thc, cng sut ln hn na vi ciing ngh tin tin, hin i hn. - Cc dng sn phm to ra + Sn phm ca ti l my p chn tn thu lc 1.200T t c cc ch tiu k thut: + Kch thc my: Di x rng x cao : 13 x 3.8 x 4.6 (m) + Tc p: 12m/pht + Tng cng sut: 60 kw + Cc dng chy ci p: 4 b + Di chuyn u p: Mi to trn bn p. + iu khin bin tn, mn hnh tinh th lng. + S quy trnh cng ngh k thut to ra: 15 quy trnh Hi phng, ngy Ch nhim ti thng nm 2006 Th trng C quan ch tr ti

Nguyn Vn Canh

Bi tm tt
Thc hin pht trin n, Tng Cng ty cng nghip tu thu Vit Nam vi hn 60 n v thnh vin trong c 25 n v thnh vin trc tip ng mi v sa cha tu thu v ang ng thnh cng cc con tu c trng ti kh ln, bc u khng nh c uy tn v v tr trong lnh vc tu thu khu vc th gii nh: tu hng 15000 tn, ni 14000 tn, tu du 13500 tn v ang trin khai ng tu tr slan LASH 10900 tn, tu tr hng 53000 tn xut khu sang vng quc Anh. Mun ng c nhng loi tu ln ny m bo k thut, m thut v tin th cc nh my ng tu phi trang b cho mnh cc thit b my mc trong cc loi my un, lc tn, p chn tn thu lc c ln l khng th thiu c. Do cng ty Cng Nghip tu thu Nam Triu, mnh dn ch to my p chn tn c ln phc v qu trnh ng tu v sa cha tu. Vi quan im my p chn tn phi p c cc loi tn c chiu dy t 5070mm (kch thc ln ), do bn my phi c kch thc ln. u p phi di chuyn c ti cc v tr khc trn bn p v ti cc v tr ny my p u phi p c. Chnh v iu thc y i ng k s ca Cng ty CNTT Nam Triu bt tay vo cng vic nghin cu v ch to loi my p chn tn c ln phc v ng tu. Vic ch to thnh cng my p 1200T u tin Vit Nam, ngoi vic p ng ng cc con tu c trng ti c ln. N cn gp phn nng cao trnh nhn thc v kh nng nghin cu ca i ng k s, trong vic nghin cu ch to cc thit b. ng thi lin kt gia cc ngnh cng nghip C, in , Thu lc, chnh v iu ny mang li hiu qu tit kim ngoi t cho t nc.

Mc lc
STT 1 2 Bi tm tt Li m u Chng I: Nghin cu phn tch sn phm, ti liu nc ngoi chn m hnh ph hp vi iu kin vit nam. 1.1. Nghin cu tng quan v my p chn tn 1200T. 3 1.2. Nghin cu cu to ca my p 1200T. 1.3. Nghin cu phn tch tnh nng ca my p chn tn 1200T. 1.4. Nghin cu phn tch nguyn vt liu ch to my p 1200T. 1.5. La chn m hnh thch hp nht. Chng II: iu tra nh gi hin trng cng ngh thit b ca mt s nh my trong nc phn tch kh nng cng ngh ch to. 4 2.1. iu tra nh gi hin trng cng ngh ca mt s nh my. 2.2. nh gi nng lc cng ngh ca ring cng ty. 2.3. Nghin cu quy trnh sn xut ca cng ty. Chng III: Nghin cu thit k my p chn tn 1200T 3.1 Chn cng thc v phng thc tnh ton thit k my 3.2 Nghin cu s tng th ca my. 3.3 Xc nh iu kin ca my. 3.4. nh gi hiu qu ca my vi cng ngh ng, sa cha tu v gia cng c kh 3.5.Tnh ton thng s k thut ca my.

mc

Trang
1

3.6. Nghin cu, tnh ton la chn xylanh, bm 5 thu lc ph hp vi my p chn tn 1200T. 3.7 Thit k v v cc bn v ch to kt cu bn p 1200T. 3.8 Thit k v v cc bn v ch to kt cu khung dm p 1200T. 3.9 Thit k cm truyn ng c kh. Cm di chuyn ngang Cm di chuyn dc 3.10. Phn tch la chn h thng iu khin. 3.11. Thit k v cc v bn v ch to chy, ci p. Chng IV: Xy dng quy trnh cng ngh ch to lp rp, kim tra bo dng. 4.1. Quy trnh cng ngh gia cng bn p ca my. 6 my. 4.3. Quy trnh cng ngh gia cng cc chi tit v cum di chuyn ngang dc ca my. 4.4. Quy trnh cng ngh gia cng cc dng chy ci p ca my ( thit k ch to 04 dng) 4.5. Quy trnh lp rp tng th ca myp chn tn 1200T. 4.6. Quy trnh kim tra 4.7. Quy trnh th cc chi tit v ton my. 4.8. Quy trnh vn hnh v bo dng my. Li cm n 4.2. Quy trnh cng ngh gia cng thn dm ca

Li m u
My p chn tn 1200T l loi cng c rt quan trng phc v trong lnh vc ng mi, sa cha tu thu v lnh vc gia cng kt cu c kh. My p 1200T c kh nng gia cng c cc chi tit dng L, dng U, dng na cu, cc dng cong nhiu chiu. Tu theo cng ngh ca sn phm yu cu. Trong thi k hin nay v nhng nm tip theo ngnh cng nghip tu thu c c bit quan tm pht trin vi quy m ln v tc pht trin nhanh theo kp khu vc v th gii. V vy ng c nhng con tu c trng ti ln v gia cng cc kt cu c dy ln, chi tit c phc tp nht phi c my p chn tn loi ln mi p ng c. Trn th gii c rt nhiu hng sn xut my p thu lc l SICMI ( ITALIA), WARTSILA (Phn Lan )cc hng ny ch to my p chn tn thu lc ni ting vi cht lng tt, c s dng rt nhiu trong ngnh cng nhip ng tu v cc ngnh c kh khc. Nhng thng tin v l thuyt tnh ton th hn ch v c gi thnh rt cao v phi nhp ngoi trn b Tng quan nn kinh t Vit Nam pht trin nhng nm va qua cho chng ta thy vic u t c s h tng, y nhanh s pht trin cc ngnh cng nghip C kh v cc ngnh cng nghip khc l tt yu. Vic pht trin ngnh c kh ch to sn xut ra nhng thit b my mc phc v cho cc ngnh cng nghip nht l c kh ng tu khng th thiu c. Ring v ngnh ng tu Vit Nam ang c chnh ph quan tm nh hng u t thnh ngnh trng im, c bit l quyt nh s 1420/QTTg ca Th tng chnh ph ngy 2/1/2001 v vic ph duyt n pht trin Tng cng ty cng nghip tu thu Vit Nam giai on 2001 2010, trong mc tiu quy hoch ca ngnh nu r xy dng v pht trin ngnh Cng nghip tu thu Vit Nam p ng c nhu cu pht trin kinh t x hi
4

t nc, cng c an ninh quc phng ng thi p ng c yu cu i mi c cu i tu quc gia v c sn phm tu thu xut khu ra nc ngoi. Phn u n nm 2010 a Vit Nam tr thnh quc gia c nn cng nghip tu thu pht trin vo loi trung bnh tin tin trong khu vc. Thc hin pht trin n, Tng Cng ty cng nghip tu thu Vit Nam vi hn 60 n v thnh vin trong c 25 n v thnh vin trc tip ng mi v sa cha tu thu v ang ng thnh cng cc con tu c trng ti kh ln, bc u khng nh c uy tn v v tr trong lnh vc tu thu khu vc v th gii nh: tu hng 15000 tn, ni 14000 tn, tu du 13500 tn v ang trin khai ng tu tr slan LASH 10900 tn, tu tr hng 53000 tn xut khu sang vng quc Anh. Mun ng c nhng loi tu ln ny m bo k thut, m thut v tin th cc nh my ng tu phi trang b cho mnh cc thit b my mc trong cc loi my un, lc tn, p chn tn thu lc c ln l khng th thiu c.

Chng I : Nghin cu phn tch sn phm, ti liu nc ngoi chn m hnh ph hp vi iu kin vit nam. 1.1 Nghin cu tng quan v my p chn tn thu lc Nn kinh t Vit Nam vt qua giai on kh khn, tc tng trng ngy cng cao, cht lng, hiu qu, sc cnh tranh ca mt s lnh vc v sn phm c chuyn bin ln. Ba nm lin tc tng trng kinh t nm sau cao hn nm trc, c th nm 2001 tng 6,9%, nm 2002 tng 7,04%, nm 2003 tng 7,24%, nm 2004 tng 7,5%. Danh mc cc sn phm c kh nng cnh tranh trn th trng ngy cng c m rng, mt s sn phm thng hiu Vit Nam t tiu chun quc t. Trong c cu nn kinh t t trng nng nghip , t trng cng nghip tip tc tng. Cc ngnh kinh t chuyn dch theo hng tip cn cng ngh tin tin, hin i. Vi tc chuyn giao cng ngh ca mt s ngnh c bc tin r rt. Trong nhng nm va qua, nh nc , ang v chun b xy dng c chn lc mt s c s quan trng v cng nghip c bn nh nng lng, ch to c kh, cn thp, xi mng, nht l cng nghip c kh mi nm tng bnh qun 17,7%. to tin cho s pht trin mnh hn giai on tip theo, nh nc ban hnh nhiu c ch chnh sch tho g nhng vng mc, khi ng ngun lc trong nhn dn, u t v pht trin sn xut kinh doanh. Nhng nm ti y, chng ta ang tin trnh hi nhp nn kinh t khu vc v th gii. Quan h kinh t quc t tip tc c cng c v m rng. Tng quan nn kinh t Vit Nam pht trin trong nhng nm qua cho chng ta thy vic u t c s h tng, y nhanh s pht trin ca cc ngnh cng nghip, c kh v cc ngnh cng nghip khc l tt yu. Vic pht trin ngnh c kh ch to sn xut ra nhng thit b my mc phc v cho cc ngnh cng nghip nht l c kh ng tu khng th thiu c. Ring v ngnh ng tu Vit Nam ang c chnh ph quan tm, nh hng, u t thnh ngnh kinh t trng im, c bit l quyt nh s
6

1420/QTTg ca th tng chnh ph ngy 2/1/2001 v vic ph duyt n pht trin cng ty CNTT Vit Nam giao on 2001 2010, trong mc tiu quy hoch ca ngnh nu r Xy dng v pht trin ngnh cng nghp tu thu Vit Nam p ng c nhu cu pht trin kinh t x hi, t nc, cng c an ninh quc phng ng thi p ng c yu cu i mi c cu i tu quc gia v c sn phm tu thu xut khu ra nc ngoi. Phn u nm 2010 a Vit Nam tr thnh quc gia c nn cng nghip tu thu pht trin vo loi trung bnh tin tin trong khu vc . Thc hin pht trin n. tng cng ty CNTT Vit Nam vi hn 60 n v thnh vin, trong c 25 n v thnh vin trc tip ng mi v sa cha tu thu v ang ng thnh cng cc con tu c trng ti kh ln, bc u khng nh c uy tn v v tr trong lnh vc cng nghip tu thu khu vc v th gii nh: Tu hng 15000T, ni 14000T, tu du 13500T v ang trin khai ng tu ch Slan LASH trng ti 10.900T, tu ch hng 53.000T xut khu sang vng quc Anh. Mun ng c nhng loi tu ln ny m bo k thut, m thut v tin th buc cc nh my ng tu phi trang b cho mnh cc thit b my mc trong c loi my un lc tn, p chn tn thu lc c ln l khng th thiu c. Theo s liu iu tra v d bo th trng v nhu cu ng mi tu thu giai on 2007 2010 nh sau: S lng TT 1 2 Tn sn phm Tu hng kh di 3000T Tu hng t 3000T n v Chic nt 20012005 165 40 20062010 250 95

15.000T 3 4 Tu Tu hng cont, t 20.000 nt 11 27 40 100

50.000T L8G, tanker nt

7

2000m3 5 6 7 Tu 100.000T Dch v du kh 400.000T Cc tu cng trnh, salan, tu nh c, tu khch... nt nt nt 4 10 790 10 35 1300

Ngnh cng nghip tu thu cng pht trin s y nhanh s pht trin ca cc ngnh cng nghip khc trong c ngnh c kh ch to thit b, hn na ch trng ca ng v chnh ph Vit Nam l tng cng ni a ho cc sn phm. Qua cc t tham quan mt s ni trn th gii nh Trung Quc, Ba Lan, c, , Php... Chng ti nhn thy cc nh my c kh nht l cc nh my ng tu mun thnh cng th phi c my p chn tn thu lc. Sn phm ng tu cng ln yu cu tn phi dy th loi my p chn tn thu lc c ln mi p ng c cng vic. Trong nc ta c cc nh my ng tu v ang s dng my p chn tn thu lc ca nc ngoi sn xut nhng cha c loi my no vt qu 500T. Cc nh my c kh trong nc cng cha sn xut cc loi my p chn tn thu lc ln. Trn th gii mt s quc gia sn xut my p chn tn thu lc chng ta c th lit k nh sau: 1/ Cng ho Phn Lan c hng WARTSILA 2/ Cng ho ITALIA c hng SICMI, FACCIN.. 3/ Ty Ban Nha c hng rarael casanva.,s.a. 4/ Trung Quc c mt s hng trong c hng - hefei metal forming machine tool - natong hengli heavy industry machinery co.ltd v mt s quc gia khc nh Nht Bn, Anh ... Nhng v gi thnh u t mt my p chn tn thu lc t 1000 1200T t 1triu n 1,5 triu USD.
8

T nhu cu bc xc v loi my p chn tn thu lc ny Cng ty cng nghip tu thu Nam Triu mnh dn u t nghin cu t nhng ti liu ca cc hng nu trn, t cc loi my p chn tn thu lc c cng sut nh ang dng ti Vit Nam thit k ch to ra mt my mi c cng sut 1200T phc v cho vic ng tu thu c ln nht l lot tu s xut khu sang vng quc Anh. 1.2 Nghin cu cu to my p chn tn
1.2.1.Cu to ca bn p.

phng i

Bn p dng chi tit cn p, thn dm di chuyn dc v chu lc p ca h thng chnh v vy bn p phi c yu cu c cng vng cao. Tu theo yu cu ca mc s dng m bn p c kch thc ln hay nh. Nhn chung cc loi bn p ca my p chn tn thu lc c kt cu t t hp cc loi thp tm c chiu dy ph thuc vo lc p cn s dng vo c lin kt bng hn. di y l mt v d v cu to bn p ca mt s my p chn t thu lc. 1.2.2.Cu to thn dm bn p. Thn dm p dng xi lanh thu lc, mang xy lanh thu lc di chuyn dc theo bn p hoc di chuyn ngang bn p ng thi thn dm chu lc tc dng ca xy lanh thu lc khi chn p . V vy yu cu thn dm p phi c cng vng cao tu theo yu cu s dng lc p ln hay nh m kt cu thn dm p phi thit k ph hp. Ton b thn dm p c kt cu t t hp
9

cc loi thp tm c chiu dy khc nhau v c lin kt bng hn v bng lp ghp bi cc bu lng chu lc cao. Hnh v sau gii thiu 1 loi thn dm p ca my p chn tn thy lc.

1.2.3. Cu to h thng di chuyn xi lanh p v di chuyn thn dm p. Trn th gii dng nhiu loi h thng di chuyn xylanh p ngang bn p v h thng di chuyn dc bn p: B phn di chuyn hon ton s dng h thng piston-xy lanh thu lc nh my PMM do hng SICMI (Italia) ch to, nh hnh v.

B phn di chuyn bng e cu- vt me c chuyn ng bng m t in. B phn di chuyn dng bnh xe (con ln) trn ray hoc trn b mt tm phng c thit din nh ph hp bnh xe di chuyn truyn ng thng dng
10

Mt thng qua hp gim tc hoc bin tn, nh hng SERTOM (Italia).

1.2.4. H thng thu lc dng trong my p chn tn thu lc bao gm cc b phn : Kt du thu lc Xylanh thu lc, bm thu lc, van thu lc- in t Cc ng h o H thng ng thu lc do hng SICMI (Italia) ch to cho my PMM nh hnh sau:

11

 to c lc p cho piston c lp chn p tc dng ln vt cn p th xylanh thy lc vi p xut cao c cung cp bi bm thu lc tng ng. Du thu lc c dn t bm qua h thng val thu lc cp du ln nh piston trong bung p y piston xung v du trong khoang di theo ng val, ng v thng cha (kt ). nng piston ln c th dng xy lanh ph ko hc dng ng du o chiu cp vo khoang di y piston i ln. h thng val, ng thu lc phi ph hp lu lng v p lc ca tng loi my p chn tn thu lc. H thng thu lc my p 1200 tn

12

fa700/630-900st
A2
27 25 scv-10t-b1 250l/p 21 RV-03G-H 200L/P 250bar 19 20 500l/p a T 18 400bar 17 14 26 16 12 M1 30KW 1450v/p 1
tank 1000l

ds-06G-3C6 b 350l/p 0-250bar 24 23 sv-10t-b4

cv- 10t 22

cv-06t 100l/p 11
P1

18KW 1450v/p 10 Ls-3 3 2 M2

A1
9 8 150t -161 165l/p P2
P3

max.300kg/cm2 48l/phy-08
MF-10

7 set 156

210L/P

MF-12 265LP 5

210kg/ 4

1.2.5. Cu to h thng in: H thng in ca my p chn tn thu lc bao gm. H ng lc Mch iu khin Cc m t in.

13

W W W AT1 AT2 K1 AT3 AT4

AT1

K2 RLN

K3

RLN CD2

L1

L2

L3 11 12 10 9 7 out1 out2 out3 out4 Bin tn 11 12 10 9 7 out4 out5 out6 out7

Bin tn

ng c bm thu lc

w CD1

C Bm thu lc chnh Kw C Bm thu lc ph Kw C di chuyn dc 2x1.5Kw C di chuyn ngang 2x0.75Kw

ng c di chuyn dc

ng c i chuyn ngang

hp iu khin

Mn hnh hin th v nhp to

e2

Panen gn trn vch my

Ngun

High speed couter

Dout

Din

e1

van tl

bm 1

K1

K2

Bin tn

Bin tn
ls1 ls2 ls4

bm 2

ls3

1.2.6. H thng khun p. Tu theo yu cu ca cng ty s dng , tu theo tng loi cng vic, hnh dng chi tit cn un p m c cc loi khun p ph hp. Cu to ca cc loi khun p ny thng l thp c hoc kt cu thp tm c lin kt bng hn vv...
14

Sau y gii thiu mt s cc loi khun p hay s dng.

90

60

1.3 Nghin cu tnh nng ca my p thu lc 1.3.1/ Tnh nng mt s loi my p thu lc ca nc ngoi Nhiu nc trn th gii thit k, ch to my p chn tn thu lc phc v cho ngnh ng tu v mt s ngnh cng nghip khc. Tu theo tnh nng tc dng v nhu cu s dng thit k, ch to ra cc loi my p khc nhau. - My p rn: Tnh nng ca my gia cng rn t do v dp th tch trong cc khun. - My p dp nng: Dp trn my p thu lc nhm to ra cc phi rn thp v d phi bnh xe tu ho, my hi nc. - My p ng Thanh: Cc thanh ng, cc dy v cc profin t kim loi mu, hp kim mu ca chng c c gia cng bng phng php p trn my p thu lc. - My p p chy cc hnh ni ca khun. - My p gia cng cht do.

15

- My p chn p ngui thp: Loi my ny c xilanh, piston thu lc di chuyn p theo chiu thng ng (Z). Loi my p chn tn thu lc ny c 3 phng n thit k ch to. + Loi th nht: Loi my c thn, dm (cn) di ng theo chiu trc X, Xilanh p di ng trn xa ngang v chuyn ng ca piston trong xilanh theo phng thng ng( Z). Bn p c nh v phi thp tm c c nh trn bn p. Phng n ny u p c di chuyn ti mi im trn bn p. + Loi th hai: Loi my c thn dm c nh, xilanh di chuyn trn x ngang, piston (u p) chuyn ng theo phng thng ng (Z). Bn p v phi c di chuyn theo chiu trc X. + Loi th ba: Loi my c bn p, thn dm (cn) c nh. Piston v xi lanh di chuyn theo phng thng ng (Z ) p thp tm. Mun p c cc im theo yu cu th thp tm phi di chuyn sau mi ln p nh Palng hoc cn cu. 1.3.2/ Nghin cu c im, tnh nng my p ca hai hng sn xut nc ITALIA chng ti a ra mt s tnh nng nh sau: 1.3.2.1 My ca hng SERTOM

16

* Min lm vic: - Chiu rng: - Chu di: * c tnh hnh hc. - Chiu rng ti a ca my: - Chiu cao ti a ca my: - Chiu cao bn p: - Chiu cao t bn p n x ngang: - Khong cnh ca xilanh v bn p: - Khong cch ngang gia hai thn: - Chiu rng bn p: - Hnh trnh dch chuyn bn p: - Hnh trnh u p: - Hnh trnh dch chuyn dc ca thn dm: - Chiu di bn p: - Chiu rng p ti a: - Khi lng ca my: * c tnh k thut. - p sut ti a h thng thu lc: - Lc p ti a: - Cng sut ng c in rt xi lanh: - Cng sut ng c in chnh: - in p/ tn s: - Tc dch chuyn nhanh Piston p: - Tc p: - Tc li ca Piston - Tc d dch chuyn ngang u p: - Tc dch chuyn cn (Thn dm):
17

3.000 mm 10.000 mm 5850 mm 5200 mm 1190 mm 1600 mm 800 mm 3350 mm 2800 mm 2000 mm 600 mm 8000 mm 10.000 mm 2650 mm 112 tn

310 bar 1200 tn 5,5 kw 55 kw 380v/50Hz 9 22 mm/sec 4 mm/sec. 22 45 mm/s 1,2 4,2 mm/s. 1,2 4,2 mm/s.

- Thng du thu lc: 1.3.2.2 My ca hng SICMI

1200 lt.

1.3.2.3/ Tnh nng my p thu lc 1200 tn m cng ty CNTT Nam Triu la chn thit k v ch to c m hnh v tnh nng sau: Do nhu cu ca cng vic ng tu ln l phi p c loi tn dy ti 70 mm cc v tr mi tu, ui tu v hng tu nn lc p ca my phi ti 1200 tn v phi p c mi v tr trn bn p. Mun p c mi v tr trn bn p th my phi c c cu di chuyn dc ca thn my v c cu di chuyn ngang ca xi lanh p.
18

Kt hp 2 chuyn ng ny chng ta x p ng yu cu p mi im trn bn p. ng tu ln kh tn thng c chiu di 12m, chiu rng 2,5m v vy bn my phi c kch thc di 13m, rng 3,8m, thn my cao 4,6m mi p ng c yu cu gia cng. Bn my l tn tm t hp c lin kt bng hn kch thc 13m x3,8m. Thn my dng cng tro c cu to l tn tm lin kt bng hn c chiu cao 4,6m. C cu di chuyn: Vi c cu di chuyn ca mt s my p chn tn thu lc nh th vic dng c cu thu lc hoc vt me + cu l ph hp v gi thnh va phi. y My p 1200 tn c kch thc v trng lng ln nu dng c cu di chuyn l thu lc th phi nhp ngoi rt t, hn na nu dng c cu di chuyn l trc vt me + cu kh ch to, kh lp rp m bo di chuyn ton b thn my trn hnh trnh 13 mt, vic gia cng cc cng phc tp chnh v vy y ta chn phng n c cu di chuyn l hp gim tc truyn ng bng cc bnh xe c dng bnh xe ng ray va r tin, r ch to, lp rp v m bo c tnh nng hot ng ca my. Phn thu lc: m bo lc p cho my y ta chn phn p bng thu lc gm cc chi tit: Xi lanh thu lc vi lc p 1200 tn, h thng ng thu lc chu p lc > 350 bar, cc van in t, mt in ph hp, bm thu lc, in p 380V 50Hz ba pha. H thng in: Vi quan im thit k my p ng c tnh hin i kt hp vi iu kin Vit Nam, chng ti chn h thng iu khin lp trnh PLC.

19

Thng s k thut ca my p chn tn 1200 tn - Lc p ti a: - Kch thc bn p: - Tc p: - Dung tch xi lanh: - Tc di chuyn dc bn p: - Tc di chuyn ngang xi lanh - M t bm chnh: - Kiu bm Piston: - Mt di chuyn bn p: - Mt di chuyn xi lanh: - H thng iu khin lp trnh PLC - Hnh trnh xi lanh: - Tc chy khng ti: 900 mm 1m/p (45 1200 tn 3800 x 1000 x 13000 2mm/s 570L/700x1500 10 m/ph 3 m/ph 48Kw 1450v/p 380V-50Hz 150L/p-300 bar 1,5Kw - 1450v/p 380V-50Hz 0,75Kw - 1450v/p 380V-50Hz

20

1.4: Nghin cu, phn tch nguyn vt liu ch to my p chn tn 1200 Tn My p chn tn 1200 tn l my c khi lng rt ln, vi nhiu b phn nh : bn p, bn p, xe con di chuyn bn p, kt cu khung di chuyn bn p, cm bnh xe di chuyn xi lanh Chnh v vy vic chn vt liu ph hp vi kt cu v p ng c kh nng lm vic ca my chng ta s i phn tch c th thnh phn ho hc v c tnh ca tng loi vt liu. * Thp 65: L thp cacbon c cht lng tt vi hm lng cacbon v Mn cao c tnh n hi v bn cao nn c dng ch yu lm l xo, nhp... Chng c ti v ram trung bnh c t chc trooxtit vi b >800Mpa. Thp c dng lm cc chi tit n hi nh nhp phng, nhp vng, l xo rut g, m vnh v cc chi tit n hi khc. trng thi thng ho thp c dng lm trc cn, trc dn hng ca my cng c v cc chi tit ln khc. Thnh phn ho hc v c tnh ca thp nh sau: Thnh phn ho hc, % C Si Mn P S Cr Ni C tnh (Kg/mm2) b c 75

0,620,70 0,170,37 0,91,2 >0,04 >0,04 >0,25 >0,25 44 * Thp 20X, 40X:

y l thp hp kim c thm ti cao thng dng ch to cc chi tit ln, hnh dng phc tp chu mi mn. u im ca thp hp kim thm cacbon l: + C bn cao do thm ti ln, u vit ny cng r khi chi tit cng ln + Tnh chng mi mn cao duy tr c nhit hn 2000C + t bin dng, nt khi ti do c lm ngui trong du nn lm c cc chi tit c hnh dng phc tp:

21

Thnh phn ho hc ca thp hp kim thm ccbon l: Mc thp 20X 40X Thnh phn ho hc, % C 0,20 Mn Cr P S C tnh (Kg/mm2) b 65 80 c 80 100 HB 179 217

0,70 0,90

0,035 0,035 -

0,360,44 -

0,81,1 -

* Thp CT3, CT5 y l nhm thp cacbon cht lng thng v r tin nht. Trong chng cho php cha mt lng kh ln cc tp cht c hi cng nh kh ho tan v cc tp cht phi kim loi. Thp cacbon cht lng thng c dng ch to cc kt cu thp khc nhau cng nh cc chi tit my chu ti nh. Chng thch hp cho cc trng hp khi kh nng lm vic ca chi tit v kt cu cn c xc nh bng tnh cng vng. i vi chng, kch thc hnh hc phi th hin nh th no m bo bn cho trc. Vy vic la chn thp khng ch v c tnh m cn c tnh cng ngh, trc ht l tnh Hn v kh nng gia cng bng bin dng ngui. Thp CT3, CT5 c dng rng di trong ch to my dng lm cc chi tit nh thanh truyn, trc chnh, tay bin Thnh phn ho hc c tnh ca thp cacbon cht lng thng: Thnh phn ho hc, % Mc thp CT3 CT3 C 0,140,22 0,280,37 Mn 0,400,65 0,500,80 Si 0,150,17 0,050,17 C tnh (Kg/mm2) b 3849 4660 c 2224 2729

* Thp C45,C70 y l nhm thp ho tt c thnh phn cacbon trung bnh dng ch to cc chi tit my chu ti trng tnh v ti trng va p tng i cao m b mt c th b mi mn nh trc, bnh rng, cht
22

 t c c tnh tng hp cao nht thp phi qua nhit luyn ( ti + ram cao). Thnh phn ho hc ca thp ho tt: Mc thp C45 C70 %C 0,45 0,70 %Mn 0,70 0,70 %P 0,004 0.,004 %S 0,004 0,004

* C 15-32 Gang l loi vt liu c dng kh ph bin ch to my v xy dng c bn. Nhn chung gang c c tnh tng hp km hn thp song c nhiu c im qu cn tn dng trit ; l nhit chy thp hn, d nu luyn, tnh c tt v r gia cng ct Thnh phn ho hc v c tnh ca gang xm: %C %Si %Mn %S %P bk(MPa) bn(MPa) Hb <500 150 3,03,7 1,22,5 0,251,00 <0,12 0,051,00 <150 T cc phn tch trn ta chn c vt liu cho my p chn tn 1200 tn nh sau:

23

thng bo
Bn gc ti liu ny khng c cc trang t 24 dn 28 mong bn c thng cm xin cm n

1.5 La chn m hnh thch hp nht 1.5.1 Nghin cu tng quan v my p thu lc. Trn th gii c nhiu hng sn xut my p, un thu lc V d: - Cng ho Phn Lan c hng: WARTSILA - Cng ho ITALIA c hng SICMI, FACCIN, SERTOM.. - Ty Ban Nha c hng RARAEL CASANVA, S.A - Trung Quc c nhiu hng trong phi k n + HEFEI METAL FORMING MACHINE TOOL + NATONG HENGLI HEAVY INDUSTRY MACHINERY Co.LTD Cc nc c, Anh, Nht cng c rt nhiu hng sn xut nhng gi thnh nhp trn gi mt my p chn tn thu lc 1000 1200 tn khong 1 1,2 triu USD. Trong nc cha c mt c s no chuyn sn xut my p chn tn thu lc nht l cc dng my ln. Cc cng ty ng, sa cha tu trn th gii hu ht u c t 1 n 2 my p chn tn thu lc, cn trong nc nhiu nh my, cng ty ng v sa cha tu c my p chn tn thu lc nh Bch ng, Ph Rng, Nam Triu xong cc my ny lc p con nh, cha c my no > 500 tn. p c nhng chi tit c chiu dy, kch thc ln phc v lp ghp, ng nhng con tu ln nhng vng mi tu, hng tu c cong theo nhiu chiu, hoc p nhng tm m cho b thit b hoc cc cnh ca tu th vic c mt my p thu lc c lc p ln l khng th thiu. 1.5.2 Nghin cu tnh nng ca my p thu lc. 5.2.1. Trn th gii c nhiu nc thit k ch to my p chn tn thu lc phc v cho ngnh ng tu v mt s ngnh cng nghip khc. Tu theo nhu cu s dng m ch to cc my c tnh nng tc dng ph hp.

29

- My p Rn: Tnh nng ca my gia cng rn t do v dp th tch trong khun. - My p dp nng: Dp trn my p thu lc nhm to ra cc phi rn thp, v d nh phi bnh xe tu ho, my hi nc. - My p ng thanh: Cc thanh ng, cc dy c p trn my p thu lc. Ngoi ra cn c cc my p chy cc hnh ni ca khun. - My p gia cng cht do. - My p sn thp tm (thnh cc khung cc tm ) - My p un un thp hnh I, U, thp m vv. c bit dng my p chn p thp ngui l my p chn tn thu lc: loi my ny c xilanh, piston thu lc di chuyn p theo chiu thng ng (Z) v c 3 phng n thit k ch to. 1.5.2.2. Tnh nng ca mt s my p thu lc. 1.5.2.3. My p thu lc ca hng WARTSILA (cng ho Phn Lan) y l phng n thit k ch to th nht: bn my v thn dm p c nh, xilanh di chuyn ngang (Vit me - cu) Piston p di chuyn theo chiu thng ng (Z) p. Phi p phi di chuyn bng palng hoc cu. 1.5.2.4. My p ca hng SERTOM * y l phng n thit k th 2 - Bn my c nh - Thn dm di chuyn dc nh bnh xe t. - Xilanh di chuyn ngang nh piston xilanh di chuyn - u p di chuyn ln xung theo chiu thng ng (Z). * Min lm vic: - Chiu rng: - Chu di: * c tnh hnh hc.
30

3.000 mm 10.000 mm

- Chiu rng ti a ca my: - Chiu cao ti a ca my: - Chiu cao bn p: - Chiu cao t bn p n x ngang: - Khong cnh ca xilanh v bn p: - Khong cch ngang gia hai thn: - Chiu rng bn p: - Hnh trnh dch chuyn bn p: - Hnh trnh u p: - Chiu di bn p: - Chiu rng p ti a: - Khi lng ca my: * c tnh k thut. - p sut ti a h thng thu lc: - Lc p ti a: - Cng sut ng c in rt xi lanh: - Cng sut ng c in chnh: - in p/ tn s: - Tc dch chuyn nhanh Piston p: - Tc p: - Tc li ca Piston - Tc d dch chuyn ngang u p: - Tc dch chuyn cn (Thn dm): - Thng du thu lc:

5850 mm 5200 mm 1190 mm 1600 mm 800 mm 3350 mm 2800 mm 2000 mm 600 mm 10.000 mm 2650 mm 112 tn

- Hnh trnh dch chuyn dc ca thn dm: 8000 mm

310 bar 1200 tn 5,5 kw 55 kw 380v/50Hz 9 22 mm/sec 4 mm/sec. 22 45 mm/s 1,2 4,2 mm/s. 1,2 4,2 mm/s. 1200 lt.

1.5.2.5.My p ca hng SICMI (PMM 400ME) My ny cng thit k ch to theo phng php th ba l Bn p c nh
31

Thn dm p di chuyn dc bn nh lc piston xylanh di chuyn u p : di chuyn ngang nh piston, xylanh thu lc Xy lanh- piston p di chuyn theo chiu ln xung(Z) Tnh nng k thut + Chiu di k thut + Chiu rng + Chiu cao + Hnh trnh p + Hnh trnh di chuyn dc + Hnh trnh di chuyn ngang + Chiu cao bn p + Lc p Max 4m 4m 2,6m 500mm 2,9m 1,8m 0,7mn 400T

1.5.3 Nghin cu cu to ca my p thu lc Qu trnh nghin cu nhiu loi my p thu lc ca mt s hng trn th gii, chng ti thy my p thu lc c cu to gm cc b phn sau: 1.5.3.1 Bn p . Bn p thng kt cu bi cc loi tn tm t hp lin kt bng hn Bn p chu lc p tc dng ln b mt tu theo lc p yu cu m kt cu thp tm c dy mng khc nhau 1.5.3.2 Thn dm p. Thn dm p mang thn dm p trn x ngang thn dm p c cu to bi t hp cc loi tn lin kt bng hn v cc bulng chu lc. Tu theo yu cu lc p m cc loi tn ny c chiu dy mng khc nhau, kt cu t hp cng khc nhau 1.5.3.3.H thng thu lc Bao gm xylanh thu lc, cc ng ng thu lc, cc val in t, cc ng h, bm thu lc + mt, bu lc du, vv Tu theo nhu cu s dng m cng sut ca bm v p sut trong h thng cng khc nhau ph hp vi lc p.
32

Nguyn l hot ng ca h thng : Bm qua cc val n cc ng ng thu lc xylanh- piston v kt. 1.5.4 H thng in H thng in ca cc hng qua nghin cu chng ti thy c ba dng Dng iu khin c nt bm, cc khi ng t cc loi rle bo v (dng bn dn ) n cc m t( dng ny hin nay t ch to) Dng iu khin k thut s, lp trnh PLC: gm cc nt iu khin, cc khi ng t, cc bin tn, mn hnh Dng iu khin CNC: Lp trnh sn v lm theo dy truyn, khi lng chi tit cn p thng xuyn, mt hng t thay i. 1.5.5 H thng di chuyn H thng di chuyn dc : c hng dng piston- xylanh di chuyn thn dm dc theo bn C hng dng bnh rng thanh rng, c hng dng bnh xe v mt lai thng qua hp s v iu khin bi bin tn. C hng dng trc vt me- cu Dng h thng xylanh - piston Dng h thng bnh rng thanh rng hoc bnh xe hp s Dng trc vt - cu 1.5.6 H thng khun p. Gm cc loi khun vung 900, 600 trn , cu.. tu theo yu cu s dng 1.5.7 Nguyn vt liu ch to my p chn tn thu lc. Sau khi nghin cu phn tch mt s my mu chng ti thng k c cc thnh phn vt liu ch to my p chn tn thu lc bao gm. 1.5.7.1 Thp ch to bn p l loi thp t hp dng thp tm c thnh phn ho hc nh sau.

33

Thnh phn ho hc C 0,280,37 Si 0,050,17 Mn 0,50,8

C tnh ( kg/cm2) b 4660 c 2729

Cn c vo thnh phn trn so snh vi bng thnh phn ho hc ca cc nguyn t thy rng y thp ny c thnh phn tng t CT3 ta chn CT3 ch to bn p 1. Thp ch to thn dm my ( mu phn tch tng t rt ra kt lun chn thp) 2 Thp ch to bnh rng di chuyn 40X 3 Thp ch to bnh xe di chuyn C45 4 Thp ch to trc bnh xe 20X 5 Thp ch to trc bnh rng 40X 6 Chn m hnh my p chn tn thu lc 1200T (hnh v )

34

T nhng phn tch trn, chng ti a ra m hnh my p chn tn thu lc 1200T m cng ty CNTT Nam triu thit k v ch to nh sau. 7. Bn p l tn tm t hp c kch thc 13m x 3mx1m 8. Thn dm l tn tm t hp cao 4,6m x lin kt 2 thn x ngang bng cc bu lng chiu lc M 30. 9. H thng thu lc : bm ( 2 bm nhanh , chm ) val ng xy lanh 10. H thng in in iu khin thng qua mn hnh cm ng v h thng PLC, hoc t xaqua cc bin tn. 11. H thng di chuyn ngang + dc. in c ng c inu c iu khin bi cc bin tn, lai qua hp s n bnh xe di chuyn a u p n mi v tr trn bn p.

35

Chng II: iu tra nh gi hin trng cng ngh thit b ca mt s nh my trong nc phn tch kh nng cng ngh ch to.

2.1 iu tra nh gi cng ngh ca mt s nh my Trong nc c rt nhiu nh my, cng ty lm nhim v gia cng c kh, kt cu thp. Phn gia cng kt cu thp ca My p chn tn thu lc chim 90% tng khi lng ca my. Chnh v vy vic iu tra nh gi hin trng cng ngh ca cc nh my l rt cn thit nhm xem xt kh nng p ng phn gia cng kt cu My p thu lc c kh thi hay khng. Theo iu tra nh gi ca chng ti mt s nh my vi nhng thit b v kh nng cng ngh nh: * Nh my ng tu H Long (Qung Ninh): Vi h thng lm sch thp tm bng phun ct, c cc my ct dng xy Gas iu khin CNC, my ct Plasma c kh nng ct tn dy ti 150mm. Hng chc my hn t ng v hn trm my hn bn t ng, my hn 1 chiu. nh my ny c xng c kh gm cc loi my gia cng ct gt kim loi nh my Tin, my Phay, my Bo, my Mi. Ngoi ra nh my cn c cc thit b o lng chnh xc, cc thit b kim tra mi hn bng siu m hoc chp X-Ray. * Cng ty ng tu Ph Rng: Cng ty ny trc y c Cng ho Phn Lan trang b h thng nh xng gia cng c kh gm cc my Tin, my Phay, my Mi, l Nhit luyn. Nhng nm gn y Cng ty c trang b h thng lm sch thp tm bng phun ct, cc my ct nhit xy-Gas iu khin CNC, hng trm my hn t ng, bn t ng v my hn 1 chiu, thit b kim tra o lng kh nng kim tra cc bc cng ngh gia cng kt cu thp. * Cng ty ng tu Bch ng: y l mt trong nhng Cng ty c truyn thng ng tu. Cng ty ny c phn xng ng lc vi cc loi
36

my Tin, Phay, Bo, Mi, c xng c v ti luyn chi tit. Cng ty c trang b 02 my ct nhit xy Gas iu khin CNC, 01 my Plasma iu khin CNC. Cc loi my Hn ca Cng ty Bch ng gm 50 my Hn t ng, 150 my Hn bn t ng v hng trm my Hn 1 chiu. Cng ty ny c nhiu kinh nghim trong lnh gia cng kt cu thp v ch to thnh cng cu chn 120 tn phc v cho ng tu. Kh nng thit b o kim tra kt cu kt cu thp m bo nh my o khuyt tt bng siu m, chp X-Ray * Cng ty ng tu Bn Kin: y l c s ng tu c truyn thng xong quy m ca Cng ty nh hn so vi cc Cng ty trn nhng thit b ca Cng ty cng c trang b y nh h thng lm sch kim loi bng phun ct, my ct nhit xy-Gas, my ct Plasma iu khin CNC v hng trm my Hn t ng v bn t ng, my hn 1 chiu, xng gia cng c kh cc my gia cng ct gt c kh nng ch to c cc chi tit ca h thng di chuyn my p thu lc. * Mt s nh my c kh nh: Nh my c kh H Ni, nh my c kh ch to Hi Phng, Nh my c kh Duyn Hi, X nghip c kh Quang Trung(Ninh Binh) u c cc thit b gia cng ct gt, c xng c v ti luyn chi tit.. Vic gia cng ch to h thng di chuyn ca xi lanh thu lc 1200 tn khng c g kh khn. c bit x nghip c kh Quang Trung, y c cc thit b ct nhit xy-Gas, Plasma iu khin CNC, c cc my hn t ng v bn t ng. Ngoi ra x nghip cn c 01 my Phay ging vi bng di 37 mt , chiu cao my 6,5 mt, c kh nng gia cng tinh c chi tit bn p v thn dm my p thu lc 1200 tn. Cc nh my ng tu nu trn u c kh nng ch to bn p, thn dm ca my p chn tn thu lc 1200 tn, nhng gia cng mt s b mt c chnh xc cao, bng cao th cc nh my phi lm bng phng php th cng nh vic gia cng b mt t ca bn p, mt t ca x ngang xilanh thu lc v b mt t ca thn dm vi bn p.
37

* nh gi v kh nng cng ngh lp rp. Cc cng ty trn l nhng cng ty c nhiu nm kinh nghim trong lnh vc lp rp my mc thit b tu thu. Yu cu v chnh xc lp rp my tu thu rt cao. Cc cng ty ny u c i ng k s, cng nhn lnh ngh, vic thc hin lp rp cn chnh cho my p chn tn thu lc hon ton c kh nng thc hin c. Tm li, vi kh nng cng ngh ca cc cng ty nu trn, nu c thit k cng ngh v quy trnh ch to my p chn tn hon chnh th vic ch to lp rp mt my p chn tn lc 1200 tn nh ti nghin cu ca Cng ty cng nghip tu thu Nam Triu l hon ton thc hin c. 2.2: nh gi nng lc cng ngh ca ring cng ty CNTT nam triu. Cng ty CNTT Nam Triu c nh hng pht trin ca Chnh Ph v ca Tng cng ty CNTT Vit Nam vi cc nhim v chnh sau: - ng mi tu thu c trng ti n 100.000 tn. - Sa cha cc loi tu bin. - Gia cng cc sn phm c kh. - Dch v vn ti bin. - Sn xut, kinh doanh vt liu hn. y chng ti mun gii thiu su hn v lnh vc cng ngh ca Cng ty. T nm 2001 n nay Cng ty Cng Nghip Tu Thu Nam Triu quy hoch v xy dng mi hu ht c s vt cht, ci to li ton b c s c cn gi li. Cho n thi im ny cc nh xng mi ca cng ty bt u i vo hot ng trong c cc nh xng nh: Nh xng gia cng ch to tn v, phn xng gia cng C Kh, phn xng My, Phn xng ng, Phn xng , Phn xng in v phn xng Lm Sch Tn, Cng ty CNVL Hn.

38

Ton b cc phn xng ny u c mt phn cng ngh tham gia ch to my p thu lc 1200 tn. C th nh sau: 2.2.1/Phn xng lm sch tn. Vi din tch nh xng 26x61,19m2 - c trang b dy truyn lm sch tn c th lm sch c tn vi kch thc: +Thp tm: *Rng 1000-2500 mm *Dy 3-40 mm *Di1500 mm +Thp hnh: *Rng 1000 mm * cao 500 mm *Di 15000 mm -Ph ti cho php ln nht ng trc ln 1,5T/m -Tc chuyn vn vt liu 0,5- 4 m (iu tc v cp): +Khi s l thp tm : V=1,5 -3 m/min +Khi s l thp hnh: V=1,5 m/min -ng cp cht lng tr g SISO 55900-1967A-BSA2. - dy mng sn phun 15-25m. -Lng tiu hao ng lc: +Lng kh nn: 200m3/h +Tng cng sut thit b 607Kw -Kch thc ngoi hnh (LxWxH)=60000x12000x7500 mm - Trang b cu trc trong nh xng. Q = 5 T, L = 24,32 m, H = 14m

39

Phn xng lm nhim v a tn vo phun ht kim loi lm sch b mt tn, phun sn chng g ton b tn trc khi a vo gia cng ch to kt cu. 2.2.2/Phn xng v - Trong c 2 phn xng V 1 v V 2, mi phn xng c mt bng l (81x210) m2 - c trang b hng trm my hn 1 chiu ca Php, Nht, hng chc my hn t ng v bn t ng Trang b 4 cu trc 10 tn, 2 cu trc 20 tn, 2 cu trc 30 tn. Mt xe gong 15 tn. * 02 my ct tn CNC s dng gas - xy ca Php Chiu rng ct hu ch : 2500mm Chiu di ct hu ch : 6200 mm S m ct xy gas : 2 m B iu khin NC : 01 b * 02 my ct Plasma ca Php. S m xy gas : 03 m S m ct Plassma : 01 m Chiu di ct hu ch : 14 m Chiu rng ct hu ch : 6 m * 01 my ct nhit ph bng 12 m Chiu rng ct hu ch : 4500 mm Chiu di ct hu ch : 12 m S m ct oxy gas: 12 m ng c iu chnh bng b bin tn. * My vt mp tm tn. Kh nng vt mp bng phay 0-450 -Chiu di thp tm phay mp 6-50mm -Chiu su vt mp ca mt ln gia cng 12mm
40

-Tc ngang ca u phay 0,3-0,5 m/min -Tc di chuyn ca u phay 5 m/min -Tc ct u phay 125-800 m/min -p sut h thng thu lc 3,5Mpa -Cng sut ng c phay. -Cng sut ng c chy dc. -Cng sut ng c bm du. * My sn tn. -L=1000mm -R=42Kg/mm2 * My un thp m iu khin CNC( ITALIA) -Hnh trnh ngang un ra 180mm -Hnh trnh ngang un vo 280mm -Khong cch tm cc tay un 1500-1550mm -Kch thc ln nht ca thp gc(bng x cnh) 600x250mm -Kch thc nh nht ca thp gc (bng x cnh)100x65mm -Thp T un ln nht (bng x cnh) 600x260mm -Thanh phng ln nht (bn rng x chiu dy)600x40mm -Bn rng ln nht ca bng thp hnh 600mm -Chiu cao ln nht ca cnh thp hnh 250mm -Bn rng nh nht ca bng thp hnh 100mm -Kch thc max ca thp m khi un i 550mm -Kch thc nh nht ca thp m 120mm -B iu khin CNC vi cng chuyn d liu RS232 * My un a nng (ITALIA). -Kh nng un thp m bn rng 120-340mm(1 chi tit) -Bn knh un nh nht 1500mm -Kh nng un thp ch T 340mm

41

-Bn knh un nh nht 1500mm -Lc un ngang theo hai hng * My ct CNC. -Chiu di hnh trnh 13m -Chiu ngang hnh trnh 5m -My c 4 m ct : +1 m ct plasma +3 m ct xy Phn xng ny tham gia vo cng vic ct ton b cc chi tit ca bn p, ca thn v dm p lp trnh sn sau a sang phn nn phng gia cng bn p, thn dm ca my p thu lc 1200 tn. 2.2.3/ Phn xng gia cng c kh. Mt bng phn xng 26,6x73,2 m2. c trang b cc my gia cng c kh hin i nh ; * My tin iu khin CNC Khong cch gia hai mi chng tm 1500mm rng ca bng my 450mm ng knh tin ln nht qua bng my 770 mm ng knh tin qua bn xe dao 500 mm ng knh vt gia cng ln nht xuyn qua l trc chnh 100 mm Hnh trnh dc max theo theo trc Z ca bn xe dao 1350 mm Hnh trnh ngang max theo trc X ca bn xe dao 450 mm Di tc tin dao dc 4000mm/min Tc di chuyn nhanh bn dao dc 7000 mm/min Tc di chuyn nhanh bn dao ngang 5000 mm/min ng c trc chnh: ng c di chuyn bn xe dao dc theo trc Z: SEM AC 8,4 Nm * My Phay CNC
42

- Hnh trnh lm vic : +Dch chuyn dc theo trc X: 800-1000mm + Dch chuyn ngang theo trc Y:500-600mm + Dch chuyn ng theo trc Z: 600mm -B k CNC vi giao din ho m phng gia cng ,mn hnh mu phn gii cao.C kh nng va gia cng va lp trnh cho cc chng trnh khc. -Kh nng lp trnh theo chu trnh :Khoan,taro,khot,phay rnh -Kh nng ni suy tuyn tnh,ni suy ng cong ,ni suy ng xon v ni suy khng gian 3 chiu. * 02 My tin bng di -Chiu di ln nht Lmax=12000mm -ng knh vt tin trn bng my 1000mm -Khi lng ti a ca vt tin trn my 10T * My tin ng -ng knh vt tin l 2800mm -Khi lng ti a ca vt tin trn my l 16 tn * My tin vn nng. -ng knh mm cp 3 chu 400mm -Chiu di chi tit (khong cch 2 mi tm)3000mm -Tc quay 8-1600v/min -Gia cng c cc loi ren mt ,anh, modul * My doa ng. -ng knh doa 30-400mm -Chuyn dch u doa ln nht 970mm -Tc quay trc 60-600vng/min -Dch chuyn dc bn ln nht 1950mm -Dch chuyn ngang bn ln nht 175mm

43

-Chiu di phay ln nht 1775mm -ng knh li phay 410mm -Tc dao 0-200mm/min -Tng cng sut ng c : * My ca vng. - 00 : Ct vt trn 330 mm - 00 : Ct vt hnh ch nht 305x400 mm - 450 : Ct vt trn 330 mm - 450 : Ct vt hnh ch nht 305x305 mm - 600 : Ct vt trn 250 mm - 600 : Ct vt hnh ch nht 250x250 mm - Tc ct :25,45,70,100 m/pht - Kch thc li ca 4115x27x0,9mm - ng c truyn ng li ca: - ng c bm du thu lc: - ng c bm lm mt: * My cn ren thu lc. -Di ren vi ng knh ln nht 70mm, ng knh nh nht l 5mm -Bc ren t 0,25-2mm -Di tc 20-80 vng/pht -p sut cn ln nht 10T -Cng sut ng c chnh: -Cng sut ng c bm thu lc: -Cng sut ng c bm lm mt: * My tin rng ng. -Hai mm cp bn chu -ng knh mm cp 800mm -ng knh l trc chnh 350mm
44

-Chiu di chi tit chng tm 3000mm -Gia cng c cc loi ren:Mt,modul,anh bao gm c hnh cn -ng knh tin ln nht qua bn trt 550mm -ng knh tin ln nht qua ch hm u bng my:1000mm * My phay ng. - B mt lm vic ca bn 400x1600mm - S lng rnh kp 05 - Dch chuyn chiu ngang ca bn my 1000-1200mm -Dch chuyn chiu vo chiu ra ca bn dao ch thp t 300-400mm -Dch chuyn chiu ng ca bn my 400-500mm -ng knh ti a ca u dao 300-350mm * My mi dao c vn nng. -B mt lm vic ca bn 400x1600mm -S lng rnh kp 05 - Dch chuyn chiu ngang ca bn my 1000-1200mm -Dch chuyn chiu vo chiu ra ca bn dao ch thp t 300-400mm -Dch chuyn chiu ng ca bn my 400-500mm -ng knh ti a ca u dao 300-350mm * My mi trn vn nng. -ng knh vt mi ln nht 280mm -Chiu di chi tit ln nht 1500 mm * My xc. -Hnh trnh ca u dao 1000mm -Chiu cao ti a ca b mt ch to 900mm -Khong cch t mt phng ngoi n kp dao n tr my l 1000mm -Khong cch t bn n mp bn di ca thit b hng u xc 500-1000mm -ng knh ca mt lm vic 1200mm

45

-Dch chyn ca bn theo hng dc 1200mm -Dch chuyn ca bn theo chiu ngang 800mm -Gc quay ti a ca bn my 3600 * My bo ngang * My khoan cn - Hnh trnh khoan ca trc dao 400mm - Hnh trnh dch chuyn ngang ca u khoan max 1200 mm - Hnh trnh di chuyn theo chiu ng ca u khoan 750 mm - ng knh khoan: + Vi thp: max 50mm + Vi gang: max 65mm * c trang b cu trc trong nh Q = 10T, L = 24,32 m, H = 14m Phn xng c th gia cng ton b cc trc, bnh xe ln v cc chi tit ca hp gim tc ca cc cm di chuyn thn my. 2.2.4/ Phn xng my. Mt bng phn xng 24x72m2. c trang b my hn 1 chiu, my hn xoay chiu, * My doa ngang di ng -ng knh l gia cng : +T 127 - 300mm +T 300 - 660mm -Chiu di l cn gia cng: +L gia cng lin tc 7000mm +L gia cng khng lin tc 8000mm * T hp gia cng c kh Phm vi hot ng Trc X (tr ngang) Trc Y ( rnh trt trc chiu thng ng)
46

13000 mm 2100 mm

Trc Z ( trc chiu ngang) Dn ng - n dao dng s n dao Trc X Trc Y Trc Z Trc X Trc Y Trc Z 2 -20000 mm/pht 2 - 24000 mm/pht 2 -24000 mm/pht 20000 mm/pht 24000 mm/pht 24000 mm/pht

1600 mm

Dch chuyn ngang nhanh

trc vi u phay t ng Thanh kp u phay khu vc xoay 360 x 1 Grad Cng sut co li ca hnh rng ca xp x 125 kN Khu vc xoay u phay khu vc t ng 180 x 1 Grad Cng sut co li ca hnh rng ca xp x 100 kN chnh xc lp li Thit b kp dao Cng sut kp dao cn ca trc Vi nt hm Cnh tay r bt t ng i g dao cho ng knh ti a ca dao Chiu di ti a ca dao Trng lng ti a ca dao Mmen ti ti a ca dao cn
47

+/-0,002 mm thu c ~ 25 kN DIN 69871 50 DIN 69872 - B28 48 dao 125 mm 400 mm 25 kg 40 Nm SK 50 DIN 69871

ng knh ti a ca dao vi cc trm khuyt xung quanh 250 mm

Thi gian thay dao V tr thay dao

10 giy ngang
Bn xoay - CNC

B mt kp 6 rnh hnh T im giao nhau ca rnh dn hng Khong cch rnh hnh T Tc ti a ng lng nghing ti a, c kp Bng cn trn Ti trng ti a ca bn Trng lng bn My hn 6 kim Kch tho chn vt, kch 60T, kch 100T Cu trc trong nh 20T

1600 mm DIN 650 22 H12 mm 22H7 x su 10 mm 250 mm 4 vng/pht 60000 Nm 3000 Nm 10000 kg xp x 6500 kg

ng lng tip tuyn ti a trong v tr c kp, ghi ch s 26000Nm

Phn xng c trang b y cc dng c cm tay, cc dng c o c chnh xc cao. Phn xng my tham gia lp rp my, lp t my vo v tr s dng. 2.2.5/ Phn xng in. Din tch mt bng 26x61,19 m2 c trang b 5 my nn kh t 1200 2500 m3/gi 1 my hn 1 chiu Cu trc trong nh 5T. Phn xng c trang b y cc dng c cm tay, thit b o, kim tra in m bo nng lc sa cha v lp t cc thit b in ca my cng c cng nh cc loi tu c trng ti ln

48

Phn xng in tham gia lp rp mt phn h thng in cho my p 1200 tn 2.2.6/ Phn xng . Din tch mt bng 26,62x61,19 Trang b 3000T km theo ton b cc my mc thit b h thng kh nn, h thng in c th sa cha c tu c ti trng n 6500 tn tu 20.000T trang b ton b cc my mc thit b h thng kh nn, h thng in c th ng mi tu c trng ti n 30000 tn tu 70.000T trang b cc my mc thit b h thng kh nn, h thng in c th ng mi tu c ti trng 75000 tn Ngoi ra phn xng cn c trang b my phun sn, dng c lm sch kim loi. Phn xng ny lm nhim v cui cng l sn, trang tr li ton b my. Trong d n giai on 1 nng cao nng lc sn xut ca cng ty Cng nghip tu thu Nam Triu n ht nm 2005, chng ti u t thm nhiu trang thit b hin i c kh nng gia cng ton b phn c kh ca my p thu lc c ln 1200T v ln hn.

49

2.3 Nghin cu xy dng quy trnh sn xut ca cng ty Ton b qu trnh sn xut my p thu lc loi 1200 tn c tun theo quy trnh kim tra di y.
Nguyn vt liu c la chn Kim tra

Lm sch b mt, phun sn

Kim tra

Gia cng c kh

Kim tra

Ct phi theo kch thc yu cu

Nhit luyn Kim tra Mi

Kim tra

Kim tra

Nn thng

Kim tra Lp rp tng cm Kim tra

Gia cng tinh a v b g t

Kim tra

G lp tn bn p Hn bn p

Kim tra

G lp thn my ` Hn thn my Gia cng tinh

Kim tra

Kim tra

Kim tra

Kim tra Lp rp tng th Tng kim tra

50

-Vn hnh th - iu chnh

Kim tra thng s

-Vn hnh - p th - iu chnh

Kim tra kt qu

Chng III: Nghin cu thit k my p chn tn 1200T

51

3.1 Chn cng thc v phng php tnh ton thit k my

T nhu cu s dng ca Cng ty CNTT Nam Triu ng mi cc loi tu ln phi c my p chn tn thu lc vi lc p ln 1200 tn p ng p nhng loi tn dy v cong theo nhiu chiu. Trn c s kt cu, tnh nng my p thu lc ca hng SICMI (ITALIA), bng cc ti liu k thut v my p thc t ang s dng vi cng sut nh (400 tn) tnh ton thit k ch to my p chn tn thu lc 1200 tn ph hp vi iu kin Vit Nam. Da trn nguyn l tnh ton thit k h s tng ng ca cc tc gi Nga, tham kho cc ti liu v thit k chi tit my, sc bn vt liu, sch tnh ton my trc, sch my ba v my p thu lc (Nh xut bn Gio Dc 2004) ng thi da trn c s da trn c s nguyn l tnh ton thit k h s tng ng ca gio s tin s Phm Vn Lang phng php thit k nh sau: 1. Tnh ton thit k khung dm p, kim nghim theo iu kin bn v lc p 1200 tn 2. Tnh ton thit k h thng thu lc chn xi lanh, bm thu lc v cc van iu khin theo lc p v tc p ban u. - Lc p 1200 tn - Tc p 4 mm/s - p sut h thng thu lc 300 bar 3. Tnh ton thit k h thng truyn ng chy dc bn my v hnh trnh chy ngang ca xi lanh p theo thit k C kh- in. 4. Tnh ton thit k truyn ng in. 5. Thit k ch to h thng khun p T quan im tnh ton h s tng ng ca my mu a ra kt cu my ph hp, nn y vic chn cc cng thc tnh ton nhm kim nghim li sc bn theo thng s gi nh chn trc v cc cng thc tnh

52

ton chn cc chi tit tng ng m bo sn c trn th trng trong nc v nc ngoi. Ton b cc cng thc tnh ton v phng php tnh ton c th hin phn tnh ton thit k cc thng s ca my p chn tn thu lc 1200 tn dng trong ng tu thu c ln. 3.2. Nghin cu s tng th ca my My p chn tn thu lc 1200 tn c nhng b phn ch yu sau:

1- Kt cu thp bn p 2- Xi lanh thu lc. 3- Kt cu khung bn p 4- ng c di chuyn xi lanh. 5- ng c di chuyn bn p. 6- Ray di chuyn bn p. 7- Ray di chuyn xi lanh. 8- Dy cp in.
53

9- H thng ng ng thu lc. 10- Mt bm chnh. 11- T iu khin. 12- ng du thu lc cao su * Bn my: Ch to t tn tm t hp c chiu dy 40, 50, 80 lin kt bng phng php hn bn t ng.

1- Thnh ng bn p. 2- Xng ngang. 3- Xng dc bn p. 4- Ray di chuyn b p. 5- Tm thnh ng c hnh trnh. 6- Tm bt u c hnh trnh. * Thn dm: c ch to t tn tm t hp 20, 30, 50 lin kt bng hn, X ngang l t tn tm t hp 80, 60, 40 lin kt bng hn, lp ghp vi thn my bng lp ghp bu lng nh v.

54

1- Tm p ngoi 2- Tm thnh ng 3- Tm p pha trong 4- Thnh xi lanh * H thng di chuyn xi lanh, di chuyn thn dm gm. - Khung: ch to bng thp tm t hp - Cm di chuyn bn p: Gm ng c v cc bnh rng n khp

- Cc bnh rng: Ch to t thp 40X

55

- Trc truyn ng: Ch to bng thp 20X, C70. - Cc bnh xe di chuyn xi lanh va di chuyn bn p: c ch to t thp C45 v C70.

* H thng thu lc: Xi lanh Piston thu lc, cc Van thu lc, Bm thu lc c nhp t Nht bn

56

S thu lc ca my p chn tn 1200 tn nh sau:

fa700/630-900st
A2
27 250l/p 25 scv-10 bg-06-h-32 20 500l/p a dshg-06-0c3e b 350l/p 16 17 14 cv-06t 100l/p 12 30KW 1450v/p M1
MF-10 P1

0-250bar 24 cv- 10t

A1
23 sv-10t-b4 11 18KW 1450v/p M2 MF-12 265LP 5 9 8 150t -161 165l/p P2
P3

Ls-3 10 pv-63 50l/p-350bar hy-09 3 210L/P 2

7 set 156

210kg/ 4

Tank 1000l

Hnh 3 S h thng thu lc

57

01- Thng du 02- B lc ng ht ca bm. 03- Kho thu lc. 04- ng c iu khin. 05- Khp ni. 06- Bm thu lc 07- Van mt chiu 08- B lc ng x ca bm 09- Van tit lu. 10- ng h p sut 11- Van an ton 12- Van 13- ng c iu khin 14- Bm thu lc. Cc thng s k thut Lc p ln nht: p sut Max ca h thng: Tc xung nhanh: Tc p: Tc ln nhanh: Lu lng bm: p sut Max ca bm: Cng sut ng c: * H thng in iu khin: S iu khin: 1200 tn 300Kg/cm2 18 mm/s 2 m/s 30 mm/s 46 l/ph 300 kg/cm2 48 KW

58

H thng iu khin PLC c nhp t Nht. S iu khin PLC nh sau:

59

Bng cc thit b iu khin ca my p chn tn 1200 tn. STT Tn thit b 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 V t iu khin V t in tng tng 150A 3 pha tng 100A 3 pha Khi ng t 100A B iu khin PLC Mn hnh iu khin Bin tn 3,7Kw/380V Bin tn 2,2 kw/380V Bin 380V/220V/2KVA R le nhit 100 180A B thc o Cng tc hnh trnh R le trung gian ng h o dng ng h o in p Bin dng 100/5 Bo v mt pha, o pha n bo Cng tc chuyn mch Nt n iu khin Tay iu khin Dy in iu khin Dy in cp ngun Ray in cp ngun p Xut x c c Nht Nht Nht Nht Nht Nht Nht Vit Nam Nht Nht Nht c i loan i loan i loan i loan Hn Quc Hn Quc Hn Quc Hn Quc Hn Quc Hn Quc i Loan
60

n v Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic Chic mt mt mt

SL 02 01 01 01 01 01 01 01 01 01 01 02 07 08 01 01 01 01 08 02 06 01 20 50 13

26 27

B ly in 120A B ko cng

i Loan i Loan

B B

01 01

* H thng khun: c ch to t thp CT# v tn tm t hp gm 04 b - Khun p 900. + Chy p 900 + Ci p 900

Kh un p 600: + Chy p 600

+ Ci p 600 -

61

Khun p cu: + Chy p cu

+ Ci p cu

62

- Khun p trn + Chy p trn + Ci

p trn 3.3 Xc nh iu kin lm vic ca my My p chn tn thu lc 1200 tn lm vic vi cc thng s k thut nh sau:
63

3.3.1. Thng s hnh hc: - Chiu di 13 m - Chiu rng 3,8 m - Chiu cao 4,6 m - Khong cch t bn my n xi lanh thu lc 1000 mm - Khong cch gia 2 thn dm 2,8 m - Khong dch chuyn theo chiu dc 12,8m - Khong dch chuyn theo chiu ngang ca u p - Chiu cao ca bn p 0,8m - Tng trng lng my: 3.3.2. Thng s k thut. - Lc p: - Tc p: - Hnh trnh p: - Tc di chuyn theo chiu dc: - Tc di chuyn ngang ca u p: - Cng sut mt bm: - Lu lng bm thu lc: - p sut ti a ca h thng thu lc: - Thng du: - Chiu dy ti a ca chi tit: 1200 tn 2 mm/s 900 mm 10 m/pht. 3 m/pht. 48 Kw. 100 l/pht. 300 bar. 1000 lt. 80mm. 175 tn.

3.4 nh gi hiu qu ca my p chn tn 1200T vi cng ngh ng, sa cha tu v gia cng c kh Ngy nay cng nn cng nghip nc ta ang trong gia on pht trin v hin i ho, vi 5 mi nhn pht trin l cng nghip nh, nng nghip, in t, cng ngh sinh hc v cng nghip nng. Cng vi s h tr ca chnh ph, nn cng nghip nng nc ta bt u khi sc trong phi ni n cng nghip luyn kim, ch to my, ng tu, trong hng lot cc
64

nh my ng tu ra i. Cng vi cc nh my c truyn thng lu i nh Bch ng, H Long, Sng Cm, Cng ty Cng Nghip Tu Thu Nam Triu cng u t v m rng sn xut ng mi cc con tu c trng ti ln, lm c iu ny. Nh my phi trang b thm mt lot cc my cng c c ln nh my lc ba trc, my un thp m, my p chn tn, Trong khi nn kinh t cn hn hp. Loi my p chn tn mua t nc ngoi rt tn km , trong khi iu in trong nc c th ch to c. Do cng ty cng nghip ch to loi my p chn tn 1200T. Loi my ny s dng chn tn lm mi qu l ca con tu, cc m m trong cc hm hng cc vch sng vi chiu di t 800 n 30000mm, cc tr ca cc con cu trn cc con tu chn lm cc mang sng ng ni ca cc ng ng dn du v dn nc balat. Ngoi ra my cn lm thm cng vic un tn v dui tn theo cc bin dng nh hnh cc on mi v ua ca mt con tu, lm cc khun ca hm hng, cc cnh ca thng hi, hay thng gia cc khoang vi nhau. Ngoi ra my cn p cc chm cu lm cc bnh p lc cho h thng nn kh ca cng ty, Lm cc nh chp ca cc my bn ht kim loi. My p chn tn 1200T dng trong ngnh ng tu l khng th thiu c, v khi lng cng vic m my p chn tn tham gia vo ng mt con tu khong 35%. 3.5 Tnh ton thng s k thut ca my 3.5.1 Kt cu khung di chuyn Khung di chuyn bn p c kch thc bao ngoi c chn s b nh hnh v:

65

5230

My p chn tn 1200 tn lc tc dng ln nht tp trung ti thanh dm v khung. Ti v tr ny mt ct nguy him nht, ch i tnh ton sc bn cho khung dm. Do khung c tnh cht i xng nn ta c th tnh kim tra cho mt pha vi 60% tng ti trng. Ti trng tc dng ln khung bao gm: . Ti trng tp trung P c gi tr ln nht khi my lm vic vi lc p ln nht: P = 1200 000x60%KG = 720 000KG . Ti trng phn b do trng lng bn thn ca bn p v mt pha: - Ti trng phn b do trng lng bn thn thanh ngang gy ra: q1= 1,32 KG/mm - Ti trng phn b do trng lng bn thn ca ct : q2 = 1,38 Kg/mm. Lc ny thanh ngang ca khung chu mt phn lc ng bng lc p xung.

5016

66

S tnh ca khung nh sau:

3820

q2=1,382KG/mm

q2=1,382KG/mm

p=720 000KG

Biu m men ca khung c hnh dng sau:

mmax = 685132,2kgm

Chn thp lm khung l thp CT3 c gii hn chy: c= 2400 2800 KG/cm2 H s an ton i vi loi vt liu ny: n = 1,5 3 . Ly n = 3 Vy: [] = c/n = 800 933,3 KG/cm2
67

4680

Ta kim tra tit din ngang ca khung theo tit din nh hnh v

1400 80 140 1120 80 60 400 50

1100

300

300 60

Mt ct ngang ca tit din c kt cu thp t hp, gm nhiu thanh c tit din khc nhau ghp vi nhau to nn. Do , ta kim tra bn theo cng thc: = M x .y
Jx

Trong : - Mx = Mmax = 685 132,2 KGm - y: Khong cch t im u n trng tm mt ct: y = 0,75m. - Jx: Mmen qun tnh tng din tch vi trc qun tnh chnh trung tm Jx= 0,12 m4 Thay s vo cng thc ta c: = 685132,2x0,75/0,12 = 4282076,25 KG/m2 = 428,2 KG/cm2 < [] Vy tit din chon tho mn iu kin bn. Ti trng tc dng ln ct thnh xilanh: Ti trng ln nht tc dng ln thnh ng l khi xilanh p di chuyn v ht hnh trnh theo phng Oy(S nh hnh v).

140

68

5229
3824 3824

Theo s ny th: * Ti trng P1 do lc p P gy ra. P1 =

3824 .120000000 5229

= 87750000 N

* Ti trng phn b do trng lng bn thn ca khung di chuyn xilanh p: - Ti trng phn b do trng lng bn thn ca thanh ngang gy ra: P2 = 62400 N - Ti trng phn b do trng lng bn thn cuar ct : q2 = 1,38 kg/mm. Nh vy ti trng tc dng ln ct l: Pc = P1 + P2 = 87812400 N. Chn thp lm ct l thp CT3 c gii hn chy: c = 2400 2800kg/cm2 H s an ton vi loi vt liu ny: n = 1,5 3. Ly n = 3. Vy [] = c/n = 800 933,3 kg/cm2. Kim tra bn ca ct theo cng thc: = Trong : N = Pc = 87812400 N Lc tc dng ln ct . F = 152000 mm2 Tit din ct .
69
N F 87812400 152000

= 577 N/mm2

Nh vy kt cu ct ta chn tho mn yu cu Ti trng tc dng ln ngm khung xilanh p:

PN

Pc

Ta c lc tc dng ln ngm l: PN = PC = 87812400 N. Lc ny s gy ra mt mmen un Mx i vi gc ngm, nu kt cu khng tt s gy ra s ph hu ti gc ny. Ta kim tra bn ca tit din: Mt ct ngang ca ngm c tit din l kt cu thp t hp gm nhiu thanh ghp li to nn. Do ta kim tra bn theo cng thc: Trong : - Mx = 120xPN = 10537488000 N/mm2. y: Khong cch t im u n trng tm mt ct y = 0,55m. JX: Mmen qun tnh tng din tch vi trc qun tnh chnh trung tm JX = 0,11m4. Thay s vo ta c: =
MX .y JX
10537488000 x55 11000000

MX .y JX

= 768,7 N/mm.

Nh vy kt cu ct ta chn tho mn yu cu.

70

3.5.2 Kt cu bn p.

Kt cu bn p c thit k nh hnh v trong : cc xng trong dy 40mm l thp CT3 v c cch 400mm th c mt xng theo c chiu dc v chiu ngang, xng mp ngoi dy 80mm l thp CT3 chng c lin kt vi nhau bng mi ghp hn, que hn s dng l loi Kobeco ca Nht.

Bn p ca my p chn tn khi lm vic s chu mt lc p l 1200 tn. Tuy nhin lc p ny khng tp trung ti mt im m s gin u trn mt tm tn b p theo din tch ca mt lm vic ca Piston. Din tch b mt lm vic ca Piston l D = 600 mm. Do khi lm vic ti bt k v tr no trn b mt ca bn p u c 04 thanh chu p v mi thanh p s chu mt lc p l P4 = 300 Tn. Tnh bn ca xng ngang bn p. Theo s nh hnh v th ti trng tc dng ln xng bn p bao gm. * Ti trng tp trung P4 c gi tr ln nht khi my lm vic vi lc p ln nht: P4 = 3000000 N q = 3,1 N/mm. * Ti trng phn b do trng lng bn thn ca xng bn p:

71

3800
P4

750

Chn thp lm khung l thp CT3 c gii hn chy: c = 24002800 KG/cm2 H s an ton i vi loi vt liu ny: n = 1,53. Ly n = 3. Vy [] = c/n = 800 933,3 kg/cm2. Ta kim tra tit din ngang ca khung theo tit din nh hnh v: Mt ct ngang ca tit din c kt cu thp t hp, gm nhiu thanh c tit din khc nhau ghp vi nhau to nn. Do ta kim tra theo cng thc: = Trong : - Mx =
P.l ql 2 + 4 8

MX .y JX

= 2855959500 N/mm2.

- y: Khong cch t im u n trng tm mt ct y = 0,35m. - JX: Mmen qun tnh tng din tch vi trc qun tnh chnh trung tm JX = 0,14m4. Thay s vo cng thc trn ta c: = 713,8 N/m2 < [] Vy tit din chn tho mn iu kin bn. 3.6 Nghin cu, tnh ton la chn xylanh thu lc, bm thu lc, ng c in ph hp vi my p 1200T My p chn tn 1200 tn c thit k v ch to phc v ch yu cho cc nh my ng tu. My c cu to b c nh, khung p v xi lanh
72

1000

p c lp di ng. Ti trng v t trng my p ln nn h thng thu lc c chn cho my p l h thng m, lun lun khng c p sut ngun, do vy trnh c qu ti cho ng c in v trnh cho h thng khng b rung git, phn ng m van du c lm vic gin tip. Bm van v ng c in dng trong h thng l ca cc hng ni ting ca Nht Bn. Du thu lc dng loi thng thng th trng Vit Nam, tuy vy nht nhit cao nht ca h thng khng c thp hn 10cSt ( 1,90E). nht ca du thu lc nhit mi trng thp nht cng khng c vt qu 300cSt ( 400E). i vi cc h thng thu lc c p sut maximum > 250 Kg/cm2 nn dng du trong gii hn 30-110 cSt (5-150E) l tt nht. ng thu lc dng cc loi ng c b mt nhn, un ng nng, bn knh un ng khng nn nh trnh tn tht cng sut ca h thng. Tt nht bn knh un ng R>4d (d- l ng knh ngoi ca ng dn). Lp rp bm vo ng c cn trnh lch tm v gy gc ng tm ca cc thit b. gii quuyt vn ny, c th lm nhiu kt cu, song trn thc t ch nn dng hai kiu kt cu l: khp mm v trc cc ng t la dn hng. 3.6.1. Tnh chn xilanh thu lc. T lc p theo yu cu 1200T, ta i tnh ton la chn xilanh ph hp vi yu cu k thut. p dng cng thc: Trong : p - p sut ln nht ca bm kg/cm2. P - p lc yu cu 1200T = 1200.000 kg. F Din tch b mt tc dng ca p sut du thu lc (Din tch ng knh trong xilanh). p=
F

73

 m bo p sut tc dng hiu qu, cc chi tit khc nh ng, van v mt s ph kin thu lc thng dng, d mua c sn trn th trng. Chng ta chn p sut t 300 320 bar. S b chn p sut p = 300 bar = 300 x 1,0130 kg/cm2. Thay s vo cng thc ta tnh c. F=
P p 1200.000 303,9

= 3950 cm2.

Tnh ng knh lm viic ca piston ( ng knh trong).

D
Piston Xilanh

p dng cng thc: D=2

3950 3,14

F=

D 2
4

D=2

= 2 x 35,46 = 70,9 cm.

D = 709 mm. T kt qu tnh ton nh trn ta chn c loi piston xilanh ph hp vi yu cu l. Xilanh thu lc ca Nht c cc tiu chun sau. - ng knh trong xilanh: D = 700mm. - Chiu di tng th: 1500 mm.
74

- p sut lc > 350 bar. - van 0,005 - cn 0,005 - bng 8 3.6.2. Tnh chn bm v cng sut ng c in. m bo cho my lm vic m vi mt lc p rt ln (1200 tn) ta chn phng n dng bm thu lc. Bm thu lc c chia lm hai loi: Bm bnh rng v bm piston. Bm bnh rng c c im l nh gn, lm vic tin cy, c th lm vic vi s vng quay ln tng ng vi s vng quay ca ng c in. V vy ch tiu kinh t ca loi ng c ny cao. Tuy nhin, so vi loi bm piston th kh nng to p sut ca loi my ny thp hn. Khong lm vic thng dng nht ca loi bm ny l 20-210 at. Lu lng ca loi my ny c th t n 600 l/ph. Bm piston lm vic theo nguyn l l s thay i th tch lm vic c to nn bi chuyn ng tnh tin ca piston trong xi lanh. Nguyn l ht, y ca bm piston n gin. Bm piston c kh nng to c p sut rt cao, cng ngh c kh thu lc ngy nay cho php ch to nhng bm lm vic vi p sut 1000 at v cao hn na. T nhng c im ca tng loi bm nu trn, ph hp vi iu kin lm vic ca my p chn tn cn thit k ta ch loi bm piston m bo t c lc p nh yu cu. tng nng sut lm vic ca my chn tn th ta dng hai h thng bm thu lc: - Mt h thng bm p lc ln to p lc cho xi lanh trong qu trng chn. Mt l h thng bm lu lng ln di chuyn hnh trnh xi lanh khng ti, tit kim thi gian, tng nng sut.

75

Q1 + Q2

Xilanh

Piston

1200T

Q2 V2 Q1 + Q2

Q1 V1 Q1 + Q2

Vt p

* Bm p lc cao (Bm ny cung cp p lc tng n p lc max p vi lc 1200 tn) T s cung cp p lc cho xi lanh ta tnh c bm p lc cao nh sau: Khi piston lp chy p tip xc vi chi tit cn p, lc tc dng bt u tng v p sut s tng do bm cp ta chn. Tc p l 120mm/ph nh vy lu lng Q1 ca bm c tnh Q1 = F.V1 F Din tch nh piston. ng knh D = 700 mm = 7dm. Din tch chu p lc F =
.D 2
4

= 0,785 x 49 = 38,465 dm2

Gi s tn tht ct p khng c Lu lng d r bng khng ta c. Lu lng : Q1 = F.V1 = 38,465 x 1,2 = 46,152 l/pht. p sut bm cn phi to ra cung cp p lc cho xilanh thu lc la p1
76

p1 =

P F

1200.000 3846,5

= 312 kg/cm2. NB1 = p1xQ1

Cng sut ca bm:

Thay s vo ta c NB1 = 312 x 46,152 = 14,399. Cng sut ng c in lai bm Nc1 =

N B1 612. E

Trong : E = 0,85 1 h s ca ng c in 612 h s tnh ton chuyn i Nc1 =

14.399 0,85 x612

= 27,68 kw

Tng ng tra bng chn ta chn c bm v ng c in lai bm ca Nht c cc thng s sau: - Cng sut ng c in 30 Kw 380V 50 Hz, n= 1450 v/ph. Bm thu lc p lc cao. C Pmax = 320 kg/cm2 Q = 46 l/ph. * Bm cp nhanh: (lu lng cao, p sut thp) cung cp cho xilanh khi hnh trnh xung cha c ti, nhm gim thi gian tng nng sut trong khong di chuyn xung h. Lc ny hai bm u cung cp du thu lc cho xilanh m bo tc di chuyn xung khng ti ca xilanh l 500mm/ph. Nh vy lu lng bm cn cung cp l: Q=FxV
Q = 38,465 x 5 = 192,325 l/ph

m bo cho xilanh di chuyn vi tc khng ti V= 500mm/ph th lu lng bm cp nhanh Q2 phi cp Q2 = Q Q1 = 192,325 46,152 = 146,173 l /ph.

77

Q1 + Q2

Xilanh

Piston

1200T

Q2 V2 Q1 + Q2

Q1 V1 Q1 + Q2

Vt p

Tnh cng sut mt in: Nc2 = Trong p2 = Nc2 =

p2 .Q2 612. E

250.000 x 4 xD 2

= 64,994 kg/cm2 = 17,248 kw

64,994 x146,173 612 x0,9

Chn ng c Nht c cng sut 18kw c cc thng s sau: N = 18 kw 380V-50Hz, n= 1450 v/ph 3.6.3. Tnh ng dn du. Theo tnh cht ca ng trn, mt trong nhn, dng chy u, c gii hn tc 3 6m/s th dng chy trong ng s khng b chy ri. i vi my p 1200 tn ta chn v= 4m/s. . ng knh trong ng dn c tnh nh sau: d = k.
78
Q v

Trong :

Q- Lu lng tng cc bm (l/pht). v Tc dng chy trong ng dn (m/s). k H s tnh ton tra bng theo cc thng s ca Q,v.

Trong trng hp ny k = 4,6077 Do : d = 4,6077 32mm. 3.6.4. Mt s yu cu k thut khc. Cc yu cu i vi mt lm vic ca xi lanh nh sau: - van 0,005 - cn 0,005 - bng 812 3.7 Thit k v v cc bn v ch to bn my p. 3.8 Thit k v v cc bn v ch to kt cu xng dm my p. 3.9 Thit k cm truyn ng c kh . Cm di chuyn ngang. Cm di chuyn dc . 3.10 Phn tch la chn h thng iu khin. 3.10.1 My p chn tn 1200T c tnh ton thit k theo cng ngh chn tn phc v trong cng tc ng tu. Qu trnh iu khin my p c t ng ho theo cng ngh CNC cho php cng nhn vn hnh xc nh chnh xc to im cn gia cng trn hai trc to ( X,Y). My p c thit k hot ng hai ch iu khin bng tay v iu khin t ng : Ch iu khin bng tay gip cho ngi vn hnh cn chnh chi tit gia cng, nh gi tnh trng hot ng ca thit b trc khi tin hnh gia cng hng lot. Ch iu khin t ng my p lm vic theo chng trnh c lp trnh theo cng ngh PLC.
79
Q v

= 31,95 mm

Ta chn ng dn l loi ng trn, mt trong nhn, c ng knh d =

Cc ng c di chuyn dc bn p, ng c di chuyn ngang xy lanh c iu khin theo nguyn l thay i tn s ( INVERTER ) iu ny gip cho my hot ng nh nhng , vic kt ni vi h thng my tnh ht sc thun li. Thng qua mn hnh giao din vi chc nng ho phong ph ngi vn hnh d dng gim st vic gia cng , cng nh thit lp mt qu trnh lm vic mi. My c thit k cho php thc hin nhiu im cn gia cng theo th t lp trnh cho trc vi chnh xc < 5mm . T in iu khin c thit k, lp t theo ng quy trnh, quy phm ca ngnh in, ngi vn hnh d dng theo tc. trong t in iu khin chia thnh cc modul cung cp, ng lc, iu khin, cho php h thng lm vic n nh v lu di. Cc ng c c bo v chng ngn mch, qu ti . ngun iu khin ch in p thp 24V. H thng iu khin Gm c cc thit b iu khin hot ng ca my c lp t trong t iu khin v cc thit b trn my, ngun cung cp cho cc thit b ny c ly t mch ng lc qua bin p cch ly ( 380/220). Mn hnh iu khin hin th cc to di chuyn ca pitng v t to cho pitng di chuyn . Cc rle trung gian trong t, iu khin cho cc thit b mch ng lc bn ngoi VD : Bm thu lc, cc van thuy lc . iu khin cho hai c cu di chuyn ca pitng l hai b bin tn iu khin cho bn ng c khng ng b r to lng xc, c u im l khi ng m, hm dng chnh xc, thay i tc d dng ( v cp ), tit kim in nng. Bo v qu dng, qu ti, ngn mch cho ng c. Cng tc chuyn mch, nt n : Chuyn ch lm vic ca my. Bn ngoi t iu khin cn c lp t cc thit b nh hai b pht xung encoder thit b ny c lp t vo h c cu di chuyn v t vo thnh
80

my, khi c cu di chuyn hot ng encoder s quay v a tn hiu v PLC iu khin, hin th to ra ngoi mn hnh. Trn thn my cn c cc hnh v hnh trnh ( cc senxo v tr, khng ch cc hnh trnh chuyn ng , c cu di chuyn v chuyn ng ca piston) h thng val bo v qu p xut. B tay bm c iu khin c iu khin t xa mi v tr to iu kkin thun li cho ngi vn hnh. 3.10.2. Mch ng lc Ngun in cung cp c ly t nh my a vo t in tng v n ray in ca my, sau qua tay ly in v n t ng lc Dy cp in cp ngun v ray in, chi in c tnh chn ph hp vi cng sut ca my. Trong t ng lc lp t cc p tomt: ng ct v bo v cho my. Khi ng t, r le nhit ng ct bo v cho cc bm thuy lc Bin p 380v/220v cp ngun cho h thng iu khin Cc r le trung gian ng h o dng, ng h o p, bin dng , n bo, cu ch,,, 3.10.3 iu khin hot ng ca cc c cu thu lc. Hot ng ca c cu thu lc gm c ba hnh trnh chuyn ng v mt hnh trnh ngh. Hnh trnh piston xung, khng ti ( chuyn ng nhanh S1-LS23). B iu khin cp in cho: ng c M6 ( ng c bm lu lng ln) val in t SOL-D, Val thu lc SLO-F c m a p lc du n xy lanh my p. ng hi du xylanh c a v thng du 1000L. Thc hin qu trnh xung nhanh . Hnh trnh p ( LS2 b- LS3) b iu khinh cp in cho: ng c M5 ( ng c tng p )

81

Val in t SOL-B, Val thu lc SOL-E c m, p lc du c a n xylanh thc hin qu trnh chn. Khi chn n mt p lc nht nh th val p sut a tn hiu v b iu khin dng qu trnh chn Hnh trnh Piston i ln ( LS3-LS1) b iu khin cp in cho val in t SOL-A v SOL-C val thu lc 12 m a lu lng du n xy lanh a piston dch chuyn ln nhanh vi tc 150mm/s 3.10.4. H thng in a. Cc loi dy in l loi gm nhiu si kim loi c bc cch in ca nht T in iu khin: v t ic ch to c kh nng chng n mn v khng g vi ch bo v IP55, Bin tn l ca Anh cn cc thit b khc l ca hng SIMN ca c. T ch c m bng kho c bit hoc bng vime dn ng. Cc thit b c thit k c th bo dng mt cch t nht. Thit b c b tr trong t c th trnh c cc tai nn do tip xc vi t in b. Cc ng c in Tt c cc ng c in dng tcho my p chn tn l loi ng c rtlng xc, ca nht bn vi ch lm vic nng, coa h thng qu mt tn nhit v h thng sbo v IP55 c. Cc thit b iu khin ng c in Cc c cu, thit b phc v khi ng, thay i tc , m bo chiu quay ca cc ng c in c b tr lp t mt cch thun tin, nhe nhng khi thao tc, d dng khi s cha. H thng in iu khin ng c trn My p chn tn ny l bin tn ca anh, vi phng php thay i tc bng bin tn m bo ng c kh ng m, c kh nng iu chnh tc trn v cp ( Khng git cc) hn ch ch c dng khi ng , c n nh cao, to ra c m men khi ng ln, cho php dng c ng c lng xc nng cao c tui th ng

82

c, n nh tt, y l h thng iu khin lm vic ti vit nam s dng d dng, iu khin chnh xc, h s n ton cao. Tt c h thng in c b tr y cc thit b kho tri khi o chiu, ngt in khi qu in p, khng t khi ng sau khi mt in. d. Cc kh c in lp t trn my p chn tn tt c cc kh c in, thit b in hu nh: cu dao, cu ch, p to mt, cng tc t, r le, thit b in bn dn ca nht bn. c y cc thng s k thut ca nh ch to v ph hp vi iu kin ca nh ches to v ph hp vi tiu chun Vit nam v tiu chun Quc t. Cc kh c in bn chc chn v chu c s rung ng ca thit b lm vic tin cy, sa cha, thay th c tnh lp ln cao. Cc kh c in duy tr c tnh nng lm vic trng iu kin lm mt t nhin, vng nhit i bin Cc kh c, thit b in m bo chc chn, khng c hin tng lng, t b ch lm vic hoc t ng khi ng. 3.11 Thit k v v cc bn v ch to chy ci p

83

Chng IV: Xy dng quy trnh cng ngh ch to lp rp, kim tra bo dng.

4.1 Quy trnh gia cng ch to bn p My p chn tn 1200T 4.1.1. Mc ch yu cu. - Son tho ra mt phng n ti u mang tnh trnh t v h thng phc c cho cng tc gia cng bn p v thn my p thu lc trong qu trnh sn xut. - Chuyn mn ho sn xut nhm nng cao nng sut lao ng, rt ngn chu k sn xut, h gi thnh sn phm. - Tiu chun ho cc chi tit In hnh nhm nng cao cht lng sn phm, gim cc chi ph khng cn thit m bo cc yu cu k thut ra. - Tho mn cc yu cu ca khch hng. 4.1.2. Phm vi ng dng. Gia cng ch to bn p v thn ca my p chn tn 1200 tn. Trong cc nh my c cc trang thit b yu cu. 4.1.3. Cc nh ngha. Cng ngh: L tp hp cc thng s c trng ca qu trng sn xut nht nh. - Nguyn cng: l phn cng vic sn xut mt ni do mt cng nhn hay mt nhm cng nhn tin hnh trn mt i tng lao ng nht nh. - Chi tit: l mt phn kt cu khng th phn chia. - Cm chi tit: l mt b phn ca my hoc kt cu thn my c to thnh t hai hoc nhiu chi tit ring bit c lp ghp vi nhau bng cc loi mi ghp. 4.1.2 Quy trnh cng ngh ch to 1/ T mc ch yu cu trn, cn c vo thit k tng th v thit k chi tit, chng ta a ra lu ca quy trnh cng ngh ch to bn p ca my p thu lc 1200 tn nh sau:

84

Phn loi tn theo bn v yu cu Nn phng

Lm sch tn

Phun sn bo v

Gia cng chi tit

L phng s l sau khi ct bng nhit a v bn g

Gia cng

G lp cm chi tit

G lp ton b bn p

Hn nh cc chi tit

Hn ton b bn p

Sn ln cui

Vn chuyn v v tr lp rp

85

4.2. Quy trnh gia cng ch to bn p 4.2.1/ Din gii lu Theo thit k bn p c hai loi tn ch yu cu to nn bn p l tn 80 ca hai bn tm thnh v tn 40 ca cc xng ngang v xng dc. Phn loi tn nhm cung cp s lng, chng loi cho cng on tip theo iu chnh my cho ph hp.Vn chuyn tn bng xe v cn cu. - Nn phng. Nn phng n gin loi tr ch li lm trn b mt thp tm do vic ngui khng ng u trong qu trnh sn xut thp, cn thp hay do vn chuyn bc xp. Loi tr ng sut d cn li trong vt liu v loi tr mt phn xt st bm trn b mt thp bung ra sau thi gian nm ngoi tri. Vic nn phng thp tm c tin hnh t nhng my cn chuyn dng c kt cu nhiu trc, cc tm thp c a vo un i un li nhiu ln. S ln cn mt tm thp ph thuc vo chiu dy v thi gian vt liu ngoi tri. - Lm sch b mt thp tm. Lm sch b mt thp nhm loi tr xit st, du m v cc tp cht bn khc bm trn b mt nguyn vt liu. Tu thuc vo cu trc ca lp xit st v cc cht bn khc nhau trn b mt vt liu m chn cc phng php nh sch. + Phng php c hc: c hai phng php lm sch c hc l phng php th cng (dng ba g r, bn chi thp, da co) lm sch v dng c gii (phun ct kh, phun ht mi). + Phng php ho hc: Dng cc cht ho hc ty + Phng php nhit: S dng ngn la xy-axtylen hoc xy-gas t nng b mt vt liu. y ta dng phng php c gii l phun ht mi. Sau khi phun xong, kim tra t tiu chun sch SA2.5 mi chuyn sang bc cng ngh tip theo.

86

- Phun sn bo v (Sn lt chng r): Sau khi dng ht mi lm sch b mt phi phun mt lp sn chng r ngay v thp rt r b xy ho tr li trong mi trng t nhin. Cht liu sn lt phi m bo mt s yu cu sau: + Sn phi phun (x v kh nhanh) + Sau khi kh phi to thnh mt lp bo v ngoi chc chn khng b dn nt. + Khng gy kh khn cho qu trnh cng ngh tip theo nh ct hi, hn + Phi tng i bn vng trong sut thi gian ch to v chu c cc va p c hc trong khi vn chuyn, xp ng hoc trong cc cng on sn sut. + Khng c gy nh hng xu n lp sn tip theo. Kim tra t yu cu chuyn sang bc tip theo. Tiu chun kim tra: dy lp phun ph t 15 25m 4.2.2. Gia cng chi tit Phi phn nhm cc chi tit trc khi gia cng - Nhm cc chi tit thnh ng bn p. - Nhm cc chi tit xng ngang - Nhm cc chi tit thnh ng c hnh trnh. - Nhm cc chi tit bt u c hnh trnh. Sau khi phn nhm cc chi tit n bc ly du trn cc nguyn liu hoc vo s liu cho cc my ct nhit CNC. y chng ta dng phng php ct my CNC t a thit k ch to chi tit ca bn p S lng cc chi tit gia cng ct bng my ct CNC ph thuc vo s lng chi tit ca bn p c thit k. Ton b cc chi tit xng dc c vt mp 2 bn, gc vt mp >= 450 Ni s dng ct trn my CNC thng dng Gas v xy xy: C th s dng trm iu ch dn vo bng cung cp cho my, cng c th dng cc chai ng sn.
87

Gas: Dn t trm vo bng h thng ng, van hoc dng chai ng sn. Cc nhm chi tit ct xong yu cu kim tra kch thc theo thit k t mi cho chuyn bc tip theo. + Phn loi nhng chi tit cong vnh sau khi ct nhit a sang cng on l phng nhng chi tit t chuyn v bn g. 4.2.3. L phng sau khi ct nhit a qua my cn nhiu trc nh phn nn phng thp. Sau khi kim tra t a v bn g. Bn g ca bn p c gia cng trc c chiu di > 13m, chiu rng > 4m, cao 0,2 0,3 m. Yu cu ca bn g lm bng thp cng vng, trn b mt c lt mt lp tn 10. B mt c cn k m bo phng. B mt bn g c kim tra my o ton c in t. Trc khi g lp cc chi tit bn p chng ta phi ch to dng g m bo khong cch gia cc tm khi g lp. Khi kim tra cng tc chun b y s chuyn n bc tip theo g lp cc chi tit ca bn p. 4.2.4. Gia cng tinh thnh ng. Tin hnh gia cng tinh hai tm thnh ng bn p. a ln my t hp gia cng c kh phay phng cnh trn v di t 5. song song ca hai cnh <0,1 4.2.5. G lp cm chi tit. Ly du trn bn g v tr ca cc chi tit cn g lp nh thnh ng bn p, v tr cc xng ngang, xng dc, kim tra kch thc theo cc chiu: chiu ngang, chiu dc v hai ng cho ca du khi m bo chng ta bt u g. Dng cn cu hoc Palng a cc tm xng ngang, xng dc vo v tr ly du, kim tra song song gia cc chi tit, vung gc vi mt bn g v vung gc gia cc chi tit, hn nh chc chn gia xng ngang
88

v xng dc vi nhau v hn nh vi bn g. Kim tra hai thnh bn ca bn p bng knh ngm, t yu cu tip tc cho cu cc tm thnh 2 bn bn p vo lp ghp. Kim tra li song song ca 2 thnh ng vi bn g xong cho hn ng chc chn vi cc xng ngang v hn nh vi bn g. Dng c kim tra dng my o ton c in t, Niv in t, thc ke vung gc. Hn nh li ton b cc mi ghp, kim tra li ln cui t yu cu cho chuyn sang bc tip theo. 4.2.6. Hn cc chi tit. Ta tin hnh hn tng cm chi tit sau khi kim tra t yu cu mi chuyn sang hn ton b bn p 4.2.7 Hn ton b bn p: Thc hin theo ng quy trnh ca cng ngh hn. in y lng kim loi ti cc mi hn rt ln chnh v vy yu cu hn nhiu lp, thc hin lm nhiu ln trnh nhit qu ln vo mi hn gy bin dng. Hn phi i xng mi hn. Thc hin hn mt lp u tin ti v tr gia xong chuyn ra hai u bn p. Khi hn xong mt lp ton b bn p phi kim tra siu m. Mi hn khng t yu cu phi mi ht mi hn, hn li t yu cu mi chuyn hn lp th hai. Th t ln lt n khi chiu cao mi hn. Thit b s dng khi hn: C th dng my bn t ng, my hn 1 chiu hn. y chng ta dng my hn bn t ng dng kh bo v mi hn l CO2, ng knh dy hn l 1.2mm v 1.6mm hn bn p. Thit b kim tra mi hn: C th dng my siu m hoc my chp XRay mi hn. 4.2.8. Sn ln cui. Ch chi sch nhng ng hn, nhng v tr sn chy trong qu trnh hn, v sinh sch s, thi gi kh, cho tin hnh sn chng g sau ln lt sn lp sn mu.
89

Cng vic sn thc hin theo quy trnh cng ngh sn thp. Kim tra ton b bn p ln cui, vn chuyn v v tr tp kt tin hnh bc cng ngh tip theo. Thit b dng vn chuyn l xe v cn cu. 4.3.Quy trnh cng ngh ch to thn - dm my p 1200T 4.3.1. Cn c vo thit k chi tit, thit k thn- dm my p, quy trnh cng ngh ch to thn dm my p thu lc 1200T c th hin qua lu sau: Phn loi vt liu Nn phng Lm sch b mt Phun sn lt chng r Gia cng chi tit Lm phng s l sau ct nhit Phn loi chi tit G lp chi tit thn my Hn cc chi tit
90

Gia cng tinh

G nh v thn my v dm Khoan, doa cc l lp ghp Sn hon thin

Vn chuyn v v tr lp 4.3.2/ Din gii lu . Theo thit k thn dm gm cc loi tn ch yu: 80, 50, 40, 20 - Phn loi vt liu: To nn hp thn v dm ca my p. - Nn phng: Nn phng n gin loi tr cc l li lm trn b mt thp tm do vic ngui khng ng u trong qu trnh sn xut thp, cn thp, hay do vn chuyn bc xp. Loi tr ng sut d cn li trong vt liu v loi tr mt phn xit st bm trn b mt thp bung ra sau thi gian nm ngoi tri. Vic nn phng thp tm c tin hnh t nhng my cn chuyn dng c kt cu nhiu trc, cc tm thp c a vo un i un li nhiu ln. S ln cn mt tm thp tu thuc vo chiu dy v thi gian vt liu ngoi tri. - Lm sch b mt: Lm sch b mt thp tm nhm loi tr xit st, du m v cc tp cht bn khc bm trn b mt nguyn liu. Tu thuc vo cu trc ca lp xit st v cc cht bn khc nhau trn b mt vt liu m chn cc phng php nh sch. + Phng php c hoc: Phng php th cng ( ba g r, bn chi thp, di, co).
91

Phng php c gii ( Phun ct kh, phun ht mi). + Phng php ho hoc: Dng cc cht ho hc ty. + Phng php nhit: S dng ngn la xi- axetilen hoc xi-gas t nng b mt vt liu. y chng ta dng phng php c gii: Phun ht mi. Sau khi phun xong, kim tra t mi cho chuyn bc cng ngh tip theo. - Phun sn lt chng r: Sau khi ht mi lm sch b mt phi phun sn chng r ngay v thp rt r b xi ho tr li trong mi trng t nhin. Cht liu sn lt phi m bo mt s yu cu sau: + Sn phi phun (X v kh nhanh). + Sau khi kh phi to thnh mt lp bo v chc chn khng dn nt chn chim. + Khng gy kh khn cho cc qu trnh cng ngh tip theo nh ct hi, hn + Phi tng i bn vng trong sut thi gian ch to v chu c cc va p c hc trong khi vn chuyn, xp ng hoc trong cc cng on sn xut. + Khng c gy nh hng xu n cc lp sn tip theo. - Gia cng chi tit: Vt liu ch to cc chi tit thn my, dm my (thnh xilanh) c phn loi thnh cc loi vt liu c chiu dy theo tng nhm chi tit. Thn my c cc loi tn t hp dy 50mm (tm p pha trong), tn dy 30mm (tm p pha ngoi), tm thnh ng dy 30mm, tm chng lt tn dy 20mm. * Dm (thnh xilanh) c ch to t tn dy 80mm. * Dm chng lt gi xilanh c ch to t tn dy 50mm.

92

Cc chi tit ny c ct theo bn v chi tit bi my ct nhit CNC * xy c dng t my sn xut xy cha vo cc bnh cha, dn vo my bng cc ng ng dn hoc dng xy ng chai sn. * Kh gas cng c dn vo my bng cc bn cha hoc chai ng sn. Cc chi tit gia cng xong u c kim tra v chuyn bc cng ngh. - L phng chi tit : (nh quy trnh gia cng bn p) - Phn loi chi tit: Thn my p c thi cng bi 3 phn on l 2 tr bn kt cu hp v 2 dm (thanh xilanh) l cc tm phng. Chnh v vy n cng on ny phi phn loi cc chi tit v chuyn n bc tip theo. * Thn hp (tr) c vn chuyn n bn g chi tit. * Dm (thnh xilanh) c vn chuyn n my gia cng tinh. Thit b vn chuyn : xe ti, cn cu. - G lp chi tit thn my: Bn g c gia cng sn sng bng kt cu thp, yu cu chc chn, phng. Kim tra bn g bng my o ton c in t. * Cc chi tit u c vt mp, mi nhn, gc vt mp t 450 * Gia cng cc dng chnh xc phc v g lp. * G thn hp theo th t sau: t nm tm p pha ngoi xung bn g, nh vi bn g. Ly dng dng 2 tm thnh ng. Kim tra song song ca 2 tm t gi tr dung sai 3mm. Kim tra vung gc ca 2 thnh ng vi tm p, t dung sai cho php 2mm. nh g chc chn cc tm vi nhau. * G tip tm p pha trong vi 3 tm g. Kim tra song song v vung gc cho php dung sai 2mm * Hn nh chc chn gia cc tm.
93

Dng g gng chc chn li, th nh v hp thn trc khi chuyn bc hn. Dng c kim tra: * ke vung gc. * Dng kim tra. * My ton c in t. - Hn cc chi tit thn my. V tn c chiu dy ln, mi hn ln nn lng nhit v cng ln khi hn mt ln t chiu cao mi hn. trnh bin dng do nhit, chng ta hn t t, tng lp, hn cch on, hn i xng cc mi hn. Sau khi hn xong lp th nht, tin hnh cng tc kim tra kch thc: nu c hin tng bin dng thi phi s l bng hn chng bin dng. Kim tra cht lng mi hn bng phng php siu m loi b khuyt tt. Hn xong mt lp pha di ta cu lt hn cc ng hn gia tm p trong v hai tm thnh ng. Cc bc cng tin hnh tng t nh thc hin vi tm p pha ngoi. Cc bc tip theo ln lt cu lt hn n khi chiu cao mi hn. Kh ng sut d bng nhit xong kim tra cht lng mi hn bng siu m hoc chp X-Ray. - Gia cng tinh thn dm: + Dm: a dm ln bn g ca my phay ging, gia cng tinh cc b mt bao quanh ca dm. Yu cu chnh xc: khng song song cnh t vai xilanh thu lc so vi cnh A 0,05mm. Khi gia cng xong dm my, thn my ta t ln bn lp ghp. Ly song song v vung gc ca dm v 2 thn m bo 0,1mm.

94

Ly du tm cc l bulng. Dng my khot khot cc l 30 xong doa ln 30,5. Dng c kim tra: - Thc cp. - Dng kim. - My o khong cch bng Laze. - My o ton c in t. * Sau khi kim tra m bo k thut theo bn v ch to cho chuyn bc cng ngh. - Sn hon thin: Ch chi v sinh ton b mi hn, nhng ch sn chy, dng kh thi sch ri sn 2 nc sn mu. * Kim tra t yu cu cho chuyn bc cng ngh. - Vn chuyn v v tr tp kt lp ghp. 4.3 Quy trnh cng ngh gia cng cc chi tit v cm di chuyn dc ngang ca my

4.4 Quy trnh cng ngh gia cng cc dng chy ci p ca my 4.4.1- Quy trnh cng ngh ch to ci p chm cu. Chn phi l phi c, c kch thc nh hnh v.

95

y l ci p c dng chm cu, b mt cn c chnh xc l phn chm cu. Cc b mt khc khng lm nh hng n chnh xc v cht lng sn phm nn khng cn gia cng. Ta ch gia cng phn chm cu. G chi tit ln my tin ng 1L532. Chi tit gia cng c hnh dng phc tp nn ta dng phng php chp hnh. Gia cng dng theo kch thc c bn ca chm cu. Gia cng b mt A ca ci t kch thc 200mm. Gia cng chm cu theo dng t kch thc R440 Sau khi gia cng xong tin hnh kim tra, dng c kim tra dng thc cp kim tra 680, dng kim tra chm cu. 4.4.2- Quy trnh gia cng chy p chm cu. Chn phi l phi c c kch thc nh hnh v
96

Chi tit chy v tr cn gia cng l chm cu v mt bch vi l bt vo xilanh. y l chi tit c kch thc v khi lng ln nn ta dng my tin ng 1L532. Gia cng dng theo kch thc c bn ca chm cu. Bc 1: gia cng mt B ca bch t kch thc 580, tin mt u A ca bch t kch thc 70. Tin mt C t kch thc 360 su 15. Bc 2: Gia cng u chy theo dng t kch thc R296. Kch thc chiu cao ca chy 600mm. Kim tra: Tin hnh kim tra ng knh ca bch lp vi xilanh p, kim tra bn knh u chy. Dng c kim tra: dng thc cp, thc dy, dng kim.
97

4.4.3- Quy trnh gia cng ci p 900. Chn phi l phi c, vt liu lm ci p dng thp c C70. Chy p 900 dng p cc chi tit c gc vung v vy b mt cn gia cng t chnh xc l mt trong ca ci. Kch thc ca ci p nh hnh v.

gia cng c b mt trong ca ci ta dng my phay. G chi tit ln my phay, phay mt A ca ci t kch thc 235mm, phay mt E,F t kch thc 1500mm. Sau nh nghing u phay 450 phay mt B, phay mt C nh nghing u phay 900 theo chiu ngc li, cui cng phay mt D. Cc mt khc khng cn chnh xc, khng nh hng n cht lng ca sn phm nn khng gia cng. Kim tra: Tin hnh kim tra chiu cao ca ci, chiu di, gc nghing 900. Dng c kim tra: thc cp, thc dy, dng c o gc. Kim tra cc kch thc t theo yu cu bn v tin hnh sn mt lp sn chng g, tip theo sn mt lp sn mu en.. Yu cu: Ci p phi chu c lc p ln, cnh vt gc 900. 4.4.4- Quy trnh gia cng chy p 900. Chn phi ca chy p l phi c, vt liu lm chy thp C70. Chy p 900 c kch thc nh hnh v.

98

 gia cng chy p ta dng my tin ng v my phay. Bc1: G chy ln my tin ng tin mt A t kch thc 508, tin mt B t kch thc 520mm. Bc 2: G t ln my phay, phay 2 u C,D t kch thc 1500mm. nh nghing u phay phay 2 mt E v F, vt u chy p sao cho t R20. Kim tra: Tin hnh kim tra chiu cao chy, chiu di, gc vt u chy, bn knh R. Dng c kim tra: Thc cp, thc dy, dng c o gc. Khi kim tra cc kch thc t yu cu ta sn mt lp sn chng g sau sn mt lp sn en. Yu cu: Cnh vt ca u chy phi t 900, bn knh u chy R=20, vt liu lm chy phi chu c lc p ln. 4.4.5- Quy trnh cng ngh gia cng ci p 600. Chn phi l phi c, vt liu lm ci p dng thp c C70. Chy p 600 dng p cc chi tit c gc nhn 600 v vy b mt cn gia cng t chnh xc l mt trong ca ci. Kch thc ca ci p nh hnh v.

99

 gia cng c b mt trong ca ci ta dng my phay. G chi tit ln my phay, phay mt A ca ci t kch thc 235mm, phay B,C t kch thc 1500mm. Sau nh nghing u phay 300 phay mt D, phay mt E nh nghing u phay 600 theo chiu ngc li, cui cng phay mt F. Cc mt khc khng cn chnh xc, khng nh hng n cht lng ca sn phm nn khng gia cng. Kim tra: Tin hnh kim tra chiu cao ca ci, chiu di, gc nghing 600. Dng c kim tra: thc cp, thc dy, dng c o gc. Kim tra cc kch thc t theo yu cu bn v tin hnh sn mt lp sn chng g, tip theo sn mt lp sn mu en.. Yu cu: Ci p phi chu c lc p ln, cnh vt gc 600. 4.4.6- Quy trnh cng ngh gia cng chy p 600. Chn phi ca chy p l phi c, vt liu lm chy thp C70. Chy p 900 c kch thc nh hnh v.

100

 gia cng chy p ta dng my tin ng v my phay. Bc1: G chy ln my tin ng tin mt A t kch thc 508, tin mt B t kch thc 520mm. Bc 2: G t ln my phay, phay 2 u C,D t kch thc 1500mm. nh nghing u phay phay 2 mt E v F, vt u chy p sao cho t R30. Cc mt khc khng cn chnh xc, khng nh hng n cht lng ca sn phm nn khng gia cng. Kim tra: Tin hnh kim tra chiu cao chy, chiu di, gc vt u chy, bn knh R. Dng c kim tra: Thc cp, thc dy, dng c o gc. Khi kim tra cc kch thc t yu cu ta sn mt lp sn chng g sau sn mt lp sn en. Yu cu: Cnh vt ca u chy phi t 600, bn knh u chy R=30, vt liu lm chy phi chu c lc p ln. 4.4.7 Quy trnh cng ngh gia cng chy p trn Chn phi ca thn chy phi c, du chy l thp thanh 210. Chy c kch thc nh hnh v

101

G chi tit ln my tin ng 1L532, gia cng b mt A t kch thc 70mm, Gia cng b mt B t kch thc 580. gia cng b mt C l mt cong phc tp, ta g chi tit ln t hp gia cng c kh dng dao cu phay b mt C t kch thc R200. Phay mt u D,E t kch thc 1000mm. u chy l thp thanh 210, g ln my tin bng di 982, tin b mt tr ngoi t kch thc 200. Hn u chy v thn chy, yu cu mi hn phi chc, p khng bi r kh. Kim tra: Kim tra kch thc chiu di t 1000mm, chiu cao ca chy p 600mm, kim tra mt bch lp vi xilanh ca my t kch thc 580. Dng c kim tra: thc dy, thc cp. 4.4.8. Quy trnh cng ngh gia cng ci p trn Chn phi cho ci p trn l phi c. Kch thc ca ci nh hnh v.

102

G chi tit ln my t hp gia cng c kh. Phay mt A t kch thc 250mm. Phay hai mt u A,B t kch thc 1000mm. Dng dao phay cu phay mt C m bo kch thc R150. Kim tra: Kim tra kch thc chiu dai, chiu cao ca ci, kim tra bn knh ca cung trn t R150. Dng c kim tra: thc dy, thc cp, dng. 4.5. Quy trnh lp rp tng th my p chn tn 1200 T My p chn tn 1200T c chia lm hai phn chi tit chnh nh sau: - Phn bn my ( bn chn ) hay b my - Phn dm my hay tr p Trong qu trnh lp rp chng ta phi s dng cc thit b c bit c kh nng nng ln nht, khng phi nh hn ton b trng lng ca my (Tng trng lng ca my nng 175T, trong phn bn my nng 120T phn dm my nng 40T). Trc khi tin hnh lp rp my cc phn chi tit chnh v ph ca my phi c tin hnh cu t xng ch to ln cc xe chuyn dng ch n v tr cn lp rp 4.5.1/ V tr lp rp my hay mng my. Mt iu n gin nhng cn thit l sp xp v tr t my p lun lun phi ch n an ton khng ch l nhng ln thao tc m cn c vi nhng my xung quanh trn cng mt ni lm vic. Do trc khi t my cn phi kim tra ton b v tr cn t. Lu : My khng t trc tip trn nn nh m phi t trn nn trung gian (s dng tn = 3040 kch thc 500 x 13000 mm, lm nn trung gian t hai tm song song nhau dc theo hai cnh mp bn my), phi kim tra nn my c kh nng chu c trng lng ca my v cc ph tng chi tit km theo my hn na chng ta phi xt n h s ma st thch hp trnh ln hn h s ma st trt ca my
103

Trc khi t bn my vo v tr ta phi xc nh chu vi ca my nh hnh v sau:

4.5.2/ Qu trnh lp rp tng th c tin hnh nh sau: 4.5.2.1/ Tin hnh t bn my vo trc: Dng cp mc vo 4 v tr trn bn my nh hnh v sau:

104

Hnh : H1 ( Bn v cu bn my vo v tr) Sau khi mc xong cp chng ta tin hnh di chuyn cu bn my t t vo ng v tr t bn my, tip theo h bn my xung t t, tho cp ra v thc hin cng on tip theo.

105

Hnh : H2 (Bn v cu dm my p chn tn 1200T) 4.5.2.2/ Qu trnh lp rp phn dm my Trc khi tin hnh cu dm t trn bn my chng ta phi tin hnh di chuyn xilanh p ( sao cho bn xilanh p t vo im trng tm ca my) trnh nguy him trong qu trnh cu. Khi a xilanh p v im trng tm, chng ta tin hnh xit cht cc mang trn, di ca xilanh p ( v xilanh p di chuyn bng bn bnh xe hai bnh ch ng v hai bnh b ng, bnh ch ng c lp vo cc ng c in c hp gim tc v lin phanh), khng cho xilanh p di chuyn theo chiu ngang, nu mun an ton chng ta c th dng cp mm buc cht xilanh p gh cht vo hai vai ca dm. Pittng p phi a v v tr cao nht ( hay im cht trn ) cng s dng cp mm buc gi cht khng cho pittng c th di chuyn c theo chiu ln xung sau chng ta tin hnh mc cp vo hai vai ca dm dng cu cu
106

dm nn ( lu khi cu dm ln phi kim tra xem hai bn thnh dm c song song vi mt nn khng, nu khng chng ta phi chnh cho tht chun sau mi c tin hnh a dm vo bn my ). Qu trnh mc cu dm nh hnh v H 2. Dng cu a dm vo cch bn my 100mm cn chnh sao cho hai bn thnh dm cch mp bn u nhau l 4mm v y l khong cch gia thnh dm v mp bn, h thp dm xung cch mt nn 800mm, tin hnh a dm vo bn my sao cho dm vo chnh gia ca bn my. Chng ta dng cn vt k tm di hai thnh ca dm, cn chnh sao cho hai bn thnh ca dm song song vi mp bn khe h gia thnh di ca dm vi mp bn l rt nh 2mm, nn sau khi k cn thn chng ta dng 2 kch thu lc 100T kch hai bn thnh dm ln cn chnh khe h sao cho t yu cu. Sau khi cn chnh chun dm chng ta tin hnh lp rp c cu di chuyn ca dm. C cu c cu to bng bn cm bnh xe di chuyn trong c hai cm l bnh xe ch ng cn hai cm l bnh xe b ng , mi bn lp mt cm ch ng, chng ta tin hnh lp bnh xe b ng trc (y l bnh xe chnh dng di chuyn dm trn bn my nn i hi chng ta phi lp chnh xc nu khng trong qu trnh hot ng trc nng dm x b cong v lm cho bnh xe ny chch ra khi ray rt nguy him cho ngi vn hnh my) sau lp hp s ca c cu di chuyn ( bao gm trc v bnh rng trung gian, qu trnh lp cng nh lp bnh xe b ng chng ta lp trc trc sau mi lp bnh rng ) bnh xe ch ng c lp vo tip theo lp ng c in. Sau khi hon tt cng vic lp cm di chuyn ca xilanh p chng ta c th b cp mc vo thnh ca dm lc ny c th dng kch thu lc cn chnh. Cn chnh hon thin chng ta tin hnh lp rp h thng thu lc v h thng in ca my. Sau khi lp rp hon thin chng ta phi tho ri cc bulng cht cht xilanh p li v cn chnh li khe mang ca bn chn ( lu

107

trong qu trnh cn chnh khe h ca mang phi t theo yu cu c k thut ). 4.5.3/ Lp rp h thng thu lc: H thng thu lc ca my nh s nh s sau: Sau khi cu dm t vo bn v cn chnh hon chnh ,b cp ra chng ta bt u tin hnh lp rp phn thu lc. Phn thu lc bn trong dm trong qu trnh ch to c lp rp sn nn rt thun tin cho vic rp phn thu lc v sau. thun tin trong qu trnh lp rp phn thu lc chng ta s dng cu trc 5T h tr trong sut qu trnh lp rp. u tin chng ta phi lp h thng ng ni gia hai dm vo cc mt bch nm ch sn, sau dng cl xit cht vo, tip n lp h thng x sau khi thay duv h thng bm du chnh. Lp bu lc du vo hai bn thnh dm sau , lp bm thu lc, tip n lp ng c lai bm thu lc, vo cc mt bch ch sn sau cng dng cl xit cht vo tip n chng ta lp b phn lc kh v cc ng tyo vo cc val thu lc, xy lanh v cc ng h p xut. Trong qu trnh lp chng ta lp rp theo s h thng thu lc sau ( Hnh H3).

108

fa700/630-900st
A2
27 250l/p 25 scv-10 bg-06-h-32 20 500l/p a dshg-06-0c3e b 350l/p 16 17 14 cv-06t 100l/p 12 30KW 1450v/p M1
MF-10 P1

0-250bar 24 cv- 10t

A1
23 sv-10t-b4 11 18KW 1450v/p M2 MF-12 265LP 5 9 8 150t -161 165l/p P2
P3

Ls-3 10 pv-63 50l/p-350bar hy-09 3 210L/P 2

7 set 156

210kg/ 4

Tank 1000l

Hnh 3 S h thng thu lc

Hnh H 3 : S h thng thu lc Bng thng s k kut ca h thng thu lc STT 1 2 3 4 5 6 7 8 9 Tn gi Np du thot kh Thc o du v nhit du B lc du ng ht B lc du ng ht Val an ton t iu khin Bm p thu lc Khp ni ng c in 11Kw 1450v/p Bm cao p
109

n v HV=68 LS- 05 MF-04 MF-04 RV 02 T ANV112

S lng 01 01 01 01 01 01 01 01 01

Ghi Ch

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

Khp ni ng c in 20Kw 1450v/p Val mt chiu Val an ton iu khin t xa Kho ng h ng h o p xut 400Bar Panen thu lc Val an ton bm cao p Val phn phi in t chnh Val iu khin x nhanh Val an ton bm chy nhanh Val 1 chiu bm chy nhanh ng h p xut 150 Bar Val chng ri B lm mt du Xy lanh thu lc

ANV149 CV 06T RV9I ST-02 MV2004 RV DS CGC SG SV CV19T SCV 10 OR FA25

01 01 01 01 02 01 01 01 01 01 01 01 01 01 01 01

4.5.4/ Lp rp h thng in H thng in ca my c lp rp theo s mch ng lc v s mch iu khin. Trnh t lp rp mch ng lc theo bn v sau Hnh H4. cn mch iu khin c lp rp theo cc bn v Hnh H5, H6

110

Hnh H4 : S mch ng lc

H nh H5 : S mch iu khin r le

111

Hnh H6 : S mch iu khin Mch iu khin c chng ta lp rp sn trong t iu khin t trc. Nn trong qu trnh lp rp chng ta ch cn lp rp phn ng lc ca my. S mch ng lc ca my nh sau: Chng ta dng cp 3C x50 +1x30 PVC cp ngun cho my t bng in n thanh ray trt pha di bn my v t thanh ray trt ln t iu khin tip theo chng ta lp phn in cp ngun cho cc ng c bm , c cu di chuyn dm v bn chn. 4.5.5/ Lp b chy ci ca my p 1200T Sau khi lp hon thit my chng ta tin hnh lp rp b chy ci v th my Trong qu trnh lp rp chng ta tin hnh nh sau: dng cu cu b chy ci t v tr bo qun nn bn my, t ci xung bn my trc sau t chy nn, dng cn k cn thn sau h du p ca xy lanh xung, lp chy vo khp ni trung gian sau dng cale trong xit cht cc bu lng vo khp ni trung gian. Cc cng vic hon thnh, yu cu v sinh ton b mychun b my sn sng thc hin bc tip theo- th my 4.6 Quy trnh kim tra 4.6.1/ Kim tra thit b. Da vo yu cu k thut ca bn v thit k m la chn thit b kim tra cho ph hp vi tng chi tit, cm chi tit v kim tra thng th nh: thc l, thc cp, PanmeNu chi tit gia cng, lp t t cc yu cu th mi c chuyn bc cng ngh. 4.6.2/ Kim tra lm sch b mt, phun sn.
112

Lm sch b mt thp nhm loi tr xit st v cc tp cht bn khc trn b mt vt liu. Tu thuc vo cu trc ca lp xit st v cc cht bn khc nhau trn b mt vt liu m chn cc phng php nh sch. y ta dng phng php c gii l phun ht mi. Tiu chun sch: SA2,5 Tiu chun kim tra dy lp phun ph: 15 25m. 4.6.3/ Kim tra ct phi. Sai s cho php: 2mm Sau khi ct phi cc chi tit phi c mi sch ba via 4.6.4/ mp m b mt. mp m b mt tn sau khi s l cong vnh 6mm/m 4.6.5/ Kim tra g, hn bn p v thn dm. khng song song gia cc xng dc v xng ngang 3mm. khng vung gc gia cc xng dc v xng ngang 2mm. Cc xng u phi c vt mp, mi sch ba via trc khi hn. Cc mi hn khng c r kh, chy chn. Chiu cao mi hn gia tm thnh, xng ngang, xng dc = 5mm. Cc mi hn ni tn ca tm y v ca thnh ng u phi c siu m 100%. mp m b mt bn p sau khi hn tn mt y 5mm/m. khng song song gia 2 thnh ng bn p 2mm/m. Dng c kim tra: Thit b kim tra mi hn: C th dng my siu m v my chp X- Ray mi hn, my o khong cch in t, my o ton c in t, Niv in t, thc ke vung gc. 4.6.5/ Kim tra gia cng tinh bn p.

113

b mt cn gia cng tinh

Kim tra b mt gia cng tinh: mt trn v di 2 thnh ng bn p. bng t 5 khng song song ca 2 cnh 0,1mm. * Kim tra bng, song song ca 2 mt Dng c kim tra: Mu kim tra bng. Niv in t. My ton c in t. My o khong cch laze. 4.6.6/ Kim tra gia cng tinh thn- dm.

114

A A A

Tm thnh trt xilanh Nhng b mt A cn gia cng tinh. khng song song ca cnh t vai xi lanh thu lc so vi cnh 0,1mm. khng song song ca cnh y vai lp dm ngang 0,1mm. khng song song ca b mt t so vi cnh y 0,1mm. Dng c kim tra: Niv in t chnh xc 0,001 ng h so chnh xc 0,001 4.6.7/ Kim tra gia cng c kh. Kim tra gia cng v lp rp c cu di chuyn khung dm v di chuyn xilanh theo yu cu k thut ca bn v. Dng c kim tra: Thc cp, Panme, thc l, ng h so. 4.6.8/ Kim tra lp rp tng thnh. Khe h lp rp phn c cu di chuyn v thn my t 2mm. vung gc gia tm thnh ng v ray di chuyn bn p 0,1mm. khng song song gia tm thnh xilanh v mt phng 2 ray 0,1mm. Kim tra lp t h thng thu lc. Kim tra p sut ti cc ng h theo thit k, kim tra rc ni v mi hn ng khng b r r du. 4.6.9/ Vn hnh th. - Chy th khng ti: Kim tra hnh trnh ln xung ca piston thu lc, cc c cu di chuyn theo vn tc thit k a ra. + Di chuyn ngang u p: 3m/pht.
115

+ Di chuyn dc thn dm:10m/pht. + Di chuyn xung ca Piston: 120mm/pht. - Chy th c ti. + Th p tn c chiu dy n 80mm: Pmax=1200T; p sut = 300 bar 4.7 Quy trnh vn hnh th v o c cc thng s k thut ca my Sau khi tin hnh lp rp hon chnh, chng ta tin hnh du thu lc cho my v tin hnh chy th my. ng ptmt cp ngun cho my, kim tra h thng thu lc, kim tra c cu di chuyn ca dm my, kim tra c cu di chuyn ca bn chn, kim tra c cu di chuyn ca xylanh p. Cc qu trnh kim tra phi t yu cu. Bc 1 tin hnh th cc c cu nh c cu di chuyn dc c cu di chuyn xy lanh, c cu p, o cc thng s k thut ca tng b phn. - Cho c cu di chuyn dc theo bn my hai, ba ln bng cc nt bm t bng iu khin, tip theo th vn hnh c cu di chuyn bng b iu khin t xa xem c cu di chuyn c hot ng bnh thng khng, nu c cu di chuyn khng di chuyn u, phi kim tra li dng ray v c cu di chuyn xem n nh cha. Tip theo cho c cu di chuyn ngang hot ng, cng lm tng t nh c cu di chuyn dc. Th hot ng ca xylanh cho u p xy lanh ln xung, kim tra xem du thu lc c d h thng val, cc ng ng dn du v xylanh khng. Nu tt c cc hot ng tt chng ta chuyn sang bc th hai. Bc 2 o cc thng s k thut ca my ch khng ti. - Tc di chuyn dc 10m/p - Tc di chuyn ngang 3m/p - Tc ln ca piston 30mm/s - Tc xung ca piston 18mm/s - Cng dng in ng c bm thu lc chnh 70A Bc 3 o cc thng s k thut ch c ti

116

Tin hnh th p chi tit o cc thng s k thut ca my chn tn =30, =50, =80, kch thc 1000 x 3000mm. Lc p tn 30 t 300T. p xut 110 Bar Lc p tn 50 t 700T. p xut185 Bar Lc p tn 80 t 1200T. p xut 300 Bar Cng dng in ng c bm thu lc chnh 90A 4.8 Quy trnh vn hnh v bo dng my 4.8.1 Gii thiu chung v my: My p 1200T thuc my cng c c ln, vi h thng iu khin t ng dng PLC v mn hnh cm ng h tr sut trong qu trnh vn hnh. Nn ngi vn hnh c th d dng vn hnh my theo ba ch , vn hnh bng tay, vn hnh t ng v vn hnh t xa. Cc thng s c bn ca my: Chiu di bn my: 13 m Chiu rng bn my : 4,8m Chiu cao 5m Tc di chuyn khung dm ca my l 5m /1pht Tc di chuyn bn p : 0,3m /1pht Tc i ln ca xy lanh: 0,2m /1pht Tc xung nhanh 18mm/giy Tc ln nhanh 30mm/ giy Cng sut ng c p 30Kw Cng sut ng c p 18Kw Lc p ti a 1200T p xut Max h thng 300kg/cm2 Th tch du 1000 lt 4.8.2 Nhng quy nh khi s dng my p 1200T

117

Trc khi vn hnh my, th vn hnh phi kim tra xung quanh my, xem c vn g cn tr n ng di chuyn ca dm my khng. Sau th vn hnh ng p tomt cp ngun cho my, tra cha kho vo kho trn t in ca my vn sang v tr ON (1), ngoi ra trn t in ca my cn c nt dng khn cp (mu ). Nt dng khn cp c tc dng dng mi hot ng ca my, ti bt k thi im no khi my ang hot ng. Trn bng iu khin n sng bo hiu my sn sng hot ng, th vn hnh bm nt c n mu xanh (k hiu nt chy) bm du. Trc khi a my vo hot ng, th vn hnh kim tra li mt ln na h thng ng h o p xut, xem cc ng h cn hot ng tt khng. Sau mi thc hin cc cng vic tip theo. 4.8.3 Quy trnh vn hnh my: Thng thng trc khi ht gi hay ngng hot ng ca my, th vn hnh cng h bn p (hay chy) ln trn mt tm g k trn bn p (hay ci ). Nn trc khi p th vn hnh bao gii cng di chuyn bn p ln trn bng cch n vo nt mu xanh c n (nt ln), sau b tm g ra v chun bi cc cng vic cn lm. di chuyn bn p i ln hoc trong lc chn tn chng ta c ba cch iu khin. 4.8.3.1 Quy trnh vn hnh trn bng iu khin. Bng iu khin nh hnh v sau( H1):

118

H1: Bng iu khin trn my Trc tin chuyn sang ch iu khin bng tay, bng cch n vo nt mu xanh c n , n sng (nt bng tay, t ng). Nu khng n vo nt ny my s lm vic ch t ng, tu theo cng vic v tnh cht ca cng vic m ta cho my hot ng ch chy nhanh hay chy chm bng cch n vo nt nhanh hay chm ( nu nt nhanh chn trn hnh v c n l my hot ng ch chy chm, cn khng n my hot ng ch chy nhanh). Trong qu trnh hot ng mun dng my th vn hnh ch cn n nt dng (nt n mu xanh c n) my lp tc dng li, mun di chuyn dm chng ta ch cn n nt Y+ ( y cng l nt n c n) hoc nt Y- , nt Y+ di chuyn v pha sau ca my, cn nt Y- di chuyn v pha trc ca my, mun di chuyn bn chn th vn hnh ch cn n nt X+ ( y cng l nt n c n) hoc nt X- , nt X+ di chuyn v pha bn tri ca my, cn nt X- di chuyn v pha bn phi ca my. Khi mun p hoc chn th vn hnh ch cn n nt ln hoc xung.

119

4.8.3.2 Quy trnh vn hnh bng b iu khin t xa B iu khin t xa nh hnh v sau ( H2): s dng b iu khin t xa, th vn hnh phi chuyn ch ca my v ch bng tay trn bng iu khin . Trc khi s dng b iu khin t xa th vn hnh phi tra cha kho ( Key) vo b iu khin (Cha kho l mt thanh nam chm vnh cu). Khi cha kho c tra n nt Start khi ng b iu khin t xa, cn nu mun dng ta ch cn n nt dng (Stop). Mun di chuyn bn chn ngi vn hnh ch cn n nt East hoc West, Nt East s di chuyn my sang bn phi ca my,
H2 B iu khin t xa

cn nt West s di chuyn my sang bn tri ca my. Mun di chuyn u p ngi vn hnh ch cn n nt Up hoc Down, Nt Up s di chuyn u p i ln pha trn ca my, cn nt Down s di u p i xung pha di ca my. Mun di chuyn dm my ngi vn hnh ch cn n nt South hoc Nonth, Nt South s di chuyn my v pha trc ca my, cn nt Nouth s di chuyn my v pha sau ca my. Lu : Khi th vn hnh cha tra cha kho vo b iu khin t xa n tn hiu s cho tn hiu mu khi n mt nt bt k, ngc li khi cha kho c tra tn hiu pht ra t n tn hiu khi n nt n bt k l mu xanh. 4.8.3.3 Quy trnh vn hnh bng cch lp tnh trn mn hnh cm ng. Mun lp trnh trn mn hnh cm ng trc tin ngi vn hnh phi n vo nt Menu trn mn hnh cm ng (nh hnh v trn H1). Trn mn hnh cm ng s th hin mn hnh la chn hnh (H3):

120

Nu ngi vn hnh n nt mn hnh t to (trn hnh H3) trn mn hnh s xut hin mn hnh t to nh sau( H4):

Hnh 3 : Mn hnh chn ch Hnh 4 Mn hnh t to Khi iu khin bng cch lp trnh trn mn hnh cm ng chng ta ch c lp trnh ti a l 6 bc, mun t bao nhiu bc tho vn hnh ch cn vo ct bc t s bc (nu ngi vn hnh mun t s bc l bn ngi vn hnh ch cn n + bn ln Trn ct bc s xut hin s 4 nu mun gim chng ta ch cn n nt -, mi mt ln n l mt ln s bc gim i. V d ta mun chn( p) bc th hai vi to l 820 x 1500. Mn hnh to s c t nh sau ( H5).

121

H5: Mn hnh thng s, khi t thng s trn mn hnh cm ng Trc khi nhp thng s ca cc bc th vn hnh phi xo cc thng s ca cc bc t t trc i bng cch n vo nt xo. Sau n nt nhp bt u nhp thng s ca cc bc nh trn, nu mun xem thng s ca bc no ngi vn hnh ch cn chn bc , sau n vo nt xem thng s ca cc bc s hin ra cc ct t trc X v t trc Y. Sau khi t thng s xong th thot ra khi mn hnh dt to bng cch n vo nt thot trn mn hnh cm ng tr v mn hnh (H1). Trc khi cho my chy t ng ngi vn hnh phi kim tra li mt ln na cc thng s xem chnh xc cha sau n nt chy t ng trn bng iu khin my s chy t ng ti cc v tr chn v thc hin cng vic. Nu trong qu trnh lm mun dng hoc b mt bc no , ngi vn hnh s n nt dng trn bng iu khin, sau vo mn hnh to

122

v xo bc i. Tt cc cc bc v thng s ca cc bc cng nh thng s thc ca my s hin ln trn mn hnh H1, hoc nh mn hnh sau: H6 : Mn hnh khi ch my chy Trong qu trnh lp trnh nu chng ta n vo nt mn hnh h thng s xut hin mn hnh sau:(H7)

H7 Mn hnh h thng Trong trang mn hnh ny dng t cc thng s di chuyn ca dm v ca bn chn. Thng thng t c nh khng cn thay i thng s na. Lu : Trong qu trnh chn tn hay p th vn hnh lun lun phi kim tra p xut ca my nu p xut vt qu mc quy nh th phi dng my ngay. Trc khi cho my chy ch t ng chng ta phi chuyn my v ch t ng trn bng iu khin. 4.8.4 Quy nh thay chy ci v gi phi trong qu trnh chn tn Khi thay chy ci th vn hnh phi iu khin ti v tr nh sau h chy ci vo v tr n ton, cn k cn thn tho ri cc bu lng ra khi khp ni sau di chuyn my sang v tr ca b chy ci mi v lp b
123

chy ci ny vo khi ni , tip theo tin hnh chy th v p th. Sau dng cu cu b chy ci c vo v tr bo qun. Khi cu phi th vn hnh lun lun phi lu phi khng va p vo my c bit mn hnh iu khin v pittng thu lc, s lm hng my. trc khi p hoc chn tn phi kim tra xem an ton cha sau mi p trong qu trnh p th vn hnh khng c ng gn phi, hoc dng cu cu phi 4.8.5/ Bo dng my Tt c cc thao tc bo dng hoc lm sch my u phi tt ht cc cng tc iu khin Cng vic bo dng c bit ( nh sa cha) phi c thc hin bi ngi c o to c chuyn mn. Cng vic bo dng phi c xem xt mt cch c th cc chi tit my, iu quan trng l phi kim tra mc du, c im ca loi du c dng ( v c th thay du mi nu cn ) v thay cc b lc trong h thng thu lc Di y chng ti a ra bng xc nh thi gian bo dng my Phn thu lc Kim tra Gi 50 100 300 500 1000 1500 Kim tra Kim tra Thay Kim tra Kim tra Thay Thay Thay Thay Kim tra b lc du Kim tra Thay Kim tra du Thay du Thay b lc du Thay b lc kh Kim tra cc van thu lc

124

2000

Thay

Thay

Thay

Kim tra

Lu : Cn ghi li cc cng vic bo dng s gip ta nh tt c cc cng vic c thc hin trn my p. c bit l i vi h thng thu lc khi thay th cc b lc du, chng ta phi tho du t van tho ra cc phi d phng sau tho tip ng c bm du, ng c iu p v tho bm ra khi ng c sau tho b lc du v thay th. Sau lp li theo cc trnh t ngc li mi tho ra. 4.8.6 V sinh my. Phi tin hnh v sinh my hng tun nn tin hnh v sinh my thng xuyn loi tr bi bn t bn ngoi bay vo, chng c th lm cn tr cc phn chi tit chuyn ng ca my. Cn thn khi lau chi bi v cc rc bn trn nh ca my v chng c th lm tc b lc kh trn v bn u vo nhng chi tit trong s thu lc. Lu : Tt c cc cng vic bo dng v v sinh my khi tin hnh u phi tt ht cc cng tc iu khin Vic lau chi rc t xy lanh p c th lm xc c b mt xy lanh v vng m xylanh. Trong qu trnh v sinh my, s dng cht khng gy hi, khng nhim v ng vi cc quy nh v an ton.

125

Biu BCTT-TKCT2001-2005

Bo co tm tt kt qu thc hin ti, d n

(Km theo cng vn s 914/BKHCN-KHTC ngy 19/4/2006 ca B Khoa hc v cng ngh).
1- Tn D n: "Nghin cu thit k, ch to my p chn tn 1.200T dng trong ng tu thu c ln". M s: ti NCKH theo N119 2- C quan ch tr thc hin: Cng ty Cng nghip tu thu Nam Triu. 3- Ch nhim d n: K.S Nguyn Vn Canh. 4- Thi gian thc hin: 30 thng, t thng 6/2003 n thng 12/2005. Theo hp ng s: 5- Tng kinh ph thc hin d n: 7.941 triu ng Trong : - T Ngn sch s nghip khoa hc: 1.000 triu ng. - T ngun khc: 6.941 triu ng (S liu chi tit c th hin trong Biu 3A-TKCT2001-2005 Biu 4B-TKCT2001-2005). 6- Kt qu thc hin d n (nu cc kt qu ni bt c ngha khoa hc v trin khai p dng tt). * V gii php khoa hc cng ngh Trong ti a ra phng php tnh ton thit k my c lc p ln 1.200T v p c mi to trn bn p. a ra c cc quy trnh cng ngh ch to cc b phn ca my p thu lc (c bit l h thng thu lc) trn c s s dng cc thit b tin tin. * V phng php nghin cu Nghin cu cc ti liu v cc my p thu lc hin i trn th gii, nghin cu thc trng cng ngh ca mt s Nh my ng tu v ca ring Cng ty CNTT Nam Triu a ra m hnh my p chn tn thu lc 1.200T ph hp. 6.1- Gi tr khoa hc (tnh mi, tnh sng to, trnh khoa hc cng ngh t c so vi khu vc v th gii). - i ng k s tip cn vi cng ngh tin tin, hin i p dng vo sn xut. Khng nh chng ta hon ton c th thit k, ch to my p thu lc vi kch thc, cng sut ln hn na vi ciing ngh tin tin, hin i hn. 6.2- Cc dng sn phm to ra (nu cc dng sn phm, cc ch tiu cht lng ch yu ca d n).

TT 1 1.1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11

Tn kt qu to ra S sn phm KHCN to ra (mu, sn phm, vt liu, thit b, ging cy - con,...) My p chn tn thu lc 1.200T S quy trnh cng ngh k thut to ra Bo co tng kt khoa hc cng ngh ti Nghin cu xy dng quy trnh sn xut ca Cng ty CNTT Nam Triu Nghin cu phn tch tnh nng ca my p chn tn thu lc 1.200T Nghin cu tng quan v my p chn tn 1.200T Nghin cu cu to ca my p chn tn 1.200T Nghin cu phn tch nguyn vt liu ch to my p chn tn 1.200T Nghin cu s tng th ca my p chn tn 1.200T Chn cng thc v phng php tnh ton thit k my Tnh ton thng s k thut ca my p chn tn 1.200T Thit k v v cc bn v ch to kt cu bn p my p chn tn 1.200T Thit k v v cc bn v ch to kt cu khung dm my p chn tn 1.200T

n v tnh

S lng

Ghi ch

My

01

Bn Bn Bn Bn Bn Bn Bn Bn Bn Bn Bn Bn Bn Bn Bn

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2.12 Quy trnh gia cng ch to bn p 2.13 Quy trnh cng ngh ch to thn dm 2.14 Quy trnh kim tra 2.15 Quy trnh lp rp tng th S kin ngh khoa hc c s dng trong xy dng cc ch trng, chnh sch, c ch, gii php ca ng v Nh nc Trung ng v a phng

Bi

4 5 6 7 8

S cng trnh khoa hc cng b nc ngoi S cng trnh khoa hc cng b trong nc S u sch c xut bn S gio trnh c bin son mi S cn b o to, nng cao trnh - S cn b c o to tin s, thc s - S cn b c o to qua HTQT t 3 thng tr ln

Cng trnh Cng trnh Quyn Quyn

0 0 0 0

Ngi Ngi Ngi

0 0 2

S lt ngi c c i trao i, hp tc quc t v KHCN

6.4- Hiu qu kinh t x hi (nu c th cc gi tr c th tnh bng tin). * Hiu qu t chuyn giao cng ngh cho sn xut. - S liu thng s k thut: nu c y chnh xc, kt qu a dng tin cy. - Cc bn v thit k: y cc bn v thit k t bn v tng th n bn v chi tit ch to. Phn tch y kh nng cng ngh trong nc ch to sn phm. - Cc qui trnh cng ngh: a ra c s qui hoch t chc sn xut my p chn tn 1.200 tn. a ra c s khi th hin t chc sn xut v mi quan h gia cc b phn. Cc qui trnh cng ngh cht lng cao, tin tin hin i. - To ra c s lin kt gia cc ngnh c kh ch to, c, luyn kim, in.Thc y ngnh c kh ch to trong nc pht trin, nng cao tay ngh cho cn b k thut. * Hiu qu sn xut kinh doanh, kinh t x hi. My p chn tn 1.200 tn c ch to ra l mt sn phm quan trng cho x hi, nng cao nng sut lao ng gim gi thnh sn phm, tit kim ngoi t cho t nc, ci thin iu kin lm vic cho ngi lao ng.

Hi phng, ngy 29 thng 5 nm 2006. Ch nhim d n Th trng C quan

Nguyn Vn Canh