THIT K V CH TO H THNG IU KHIN

LP TRNH CHO MY DP CNC

DESIGN AND MANUFACTURE A CNC CONTROLLER

FOR STAMPING MACHINE

T Nguyn Minh c, Trn Mai Vn

Trng i hc S phm K thut TPHCM

TM TT

t tnh chuyn mn ha trong sn xut sn phm dp th phi tin hnh t ng ha cc khu trong sn xut t vic thit k c kh cho ti h thng in, in t, lp trnh, iu khin thng minh Do , cn thit phi c mt h thng dy chuyn t ng, chnh xc v lin lc. H thng dp t ng c kh nng iu khin hnh trnh dp, thay i thi gian v chu k dp linh hot kt hp vi h thng cp phi t ng ra i nhm p ng nhng yu cu trn. Trong phn nghin cu ny, mt h thng my dp t ng hon thin cng h thng cp phi t ng nhm phc v ging dy v qung b cng ngh n khch hng tim nng c thc hin. u tin, nguyn l hot ng c bn ca ton h thng c thit k. Tip theo, qu trnh m phng ng hc v kt ni ton h thng c thc hin. Ba module gm module truyn ng cho my dp, h thng cp phi t ng v h thng x cun c thi cng. Cui cng tan b h thng c lp rp v th nghim. Sn phm dp th cho kt qu chnh xc. Ton b h thng hot ng n nh v tin cy nh mong i.. Tuy nhin, h thng vn cn cng knh. Do cn c s ci tin trong vic thit k to ra kiu dng nh gn hn

T kha: CNC controller, stamping machine, automatic systemABSTRACT

Automation in manufacturing from designing machanisms to electrical system, programming must be done to increase the capacity of stamping system. Therefore, its necessary to get an automatic system which is accuracy and progressive. An automatic stamping system which can be programmed to change stroke, time and stamping cycle combining with an automatic feeding can fully response these requirements. In this research, an automatic stamping system with the automatic feeding were done. Firstly, operating procedure was designed. Then, dynamic and acquisition simulation were done. Three modules including driven module, feeding system and feeder were manufactured. Finally, fully system was assembled and experimented. The experimented products were calibrated and the accuracy was very great. This system operated stabilitily and highly trusted. However, the dimension of fully system is too large. So, an innovation in redesign the system need to be required.

Keywords: CNC controller, stamping machine, automatic system1. Tng quan1.1 H thng t ng trong cng nghip

Trong cng nghip yu cu v t ng ha ngy cng tng. T cc my cng tc cho n dy chuyn sn xut i hi lun cn h thng iu khin iu khin v vn hnh cho dy chuyn lm vic. im ni bt ca h thng iu khin l kh nng p ng cao vi iu kin lm vic, t c iu th phi c mt b no x l mi vic to nn mt trung tm x l (MCU). Trung tm iu khin y c th c to nn t nhng b vi x l, vi iu khin, hay PLC,

H thng iu khin cho my dp cng c th c t ng ha, v t chnh xc cao, kh nng p ng trong cng nghip tt l i hi phi c mt trung tm iu khin vi tc x l cao v chnh xc, v ta cng c th thc hin bng chng trnh nh kt hp nhng vi khi x l bng mch in t nh vi x l, vi iu khin, PLC,

1.2 Cc module ca h thng dp t ng

Mt h thng dp t ng bao gm:

1.2.1 Khun dp

- Chc nng: Nhn lc t my dp v trc tip bin dng kim loi trong lng khun to ra sn phm

Hnh 1: Khun dp

1.2.2 My dp

- Chc nng: Nng khun, to ra lc dp cung cp cho khun khun lm vic.

Hnh 2: My dp thy lc

1.2.3 My cp phi

- Chc nng: Np phi vo khun dp u n theo chu trnh dp ca my (phi cun hoc phi ri). C th hot ng bng kh nn hoc bng in.

Hnh 3: My cp phi t ng

1.2.4 My x cun i vi phi di lin tc

- Chc nng: Gi cun phi v x phi cho my cp phi va u n theo chu k.

Hnh 4: My x cun

2. Cc c cu phc v iu khin vn hnh

2.1 C cu iu khin hnh trnh dp

2.1.1 B o khong cch dng cm bin quang v thanh cn quang lp trn pen thy lc

Hnh 5: B o khong cch s dng cm bin quang

2.1.2 B truyn vt me ai c bi

Hnh 6: B truyn vt me ai c bi

- Thng s b truyn: Bc trc vt: 10mm/vng;

ng knh trc vt: 12mm;

Chiu di trc vt: 600mm.2.1.3 ng c bc

Hnh 7: ng c bc

2.1.4 Nguyn l lm vic ca c cu

- Khi c lnh t b phn iu khin, ng c bc s quay trc vt me iu chnh cao ca cm bin quang v tr cn thit. Trong qu trnh dp, khi thanh cn quang trn pen thy lc i qua rnh trn cm bin quang, cm bin quang s xut tn hiu v cho b phn iu khin bo ht hnh trnh dp.

2.2 C cu nh hng phi trn khun

Hnh 8: C cu nh hng phi trn khun

2.3 C cu ly sn phm

Hnh 9: C cu ly sn phm

Hnh 10: Qu trnh ly sn phm

Hnh 11: Thng cha sn phm ri ra

2.4 C cu kch x v kch dng x phi cun

2.4.1 C cu kch x phi cun

Hnh 12: C cu kch x phi cun

- Hot ng: Khi my cp phi ko cng phi, di phi s lm thanh gt bt ln, gii phng cng tc hnh trnh (b tc ng trng thi t do), gi tn hiu v mch in iu khin tin hnh quay trc tang nh phi.

2.4.2 C cu kch dng x phi cun

Hnh 13: C cu kch dng x phi cun

- Hot ng: Khi tang quay ng 1 vng, thanh cn quang lp trn trc tang s chn vo khe ca cm bin quang, gi tn hiu v mch in iu khin dng tang, tang s dng khi thanh cn quang va ra khi khe ca cm bin.

3. Cc mch in t v h thng in iu khin

3.1 Mch iu khin

S 1: S nguyn l mch iu khin my dp NC

Hnh 14: Mch iu khin my dp NC thc t

3.2 Mch Driver ng c bc

S 2: S nguyn l mch Driver ng c bc

Hnh 15: Mch Driver ng c bc thc t

3.3 Mch Driver van thy lc

S 3: S nguyn l mch Driver van thy lc

Hnh 16: Mch Driver van thy lc thc t

3.4 Mch giao tip My dp My cp phi

S 4: S nguyn l mch giao tip My dp My cp phi

Hnh 17: Mch giao tip My dp My cp phi thc t

3.5 Mch ngun xung cho Vi iu khin

Hnh 18: Mch ngun xung cho Vi iu khin

3.6 Mch ngun chnh lu 12V 24V

Hnh 19: Mch ngun chnh lu 12V 24V

3.7 H thng in iu khin trn my dp NC

3.7.1 Bng iu khin

S 5: S in bng iu khin My dp NC

Hnh 20: Bng iu khin My dp NC thc t

3.7.2 T iu khin

S 6: S in t iu khin

Hnh 21: T iu khin thc t

3.7.3 T cng sut

S 7: S t ng lc

Hnh 20: T ng lc thc t

3.7.4 in c cu chp hnh

S 8: S in c cu chp hnh My dp NC.4. Qu trnh hot ng ca h thng

4.1 Qu trnh hot ng ca my dp NC

4.1.1 Ch Manual (bng tay)

- Ch Manual cho php thc hin cc thao tc ng m khun, dp sn phm thng qua iu khin hon ton bng tay. C th s dng bn p gii phng c 2 hay nhm thun li cho g phi to, nng , tuy nhin cn ht sc cn thn.

- C 2 kha: Kha pen thy lc, kha bn p nhm m bo an ton.

4.1.2 Ch Auto (t ng)

- Ch Auto cho php ci t khong hnh trnh khun t v tr khun ng n im kt thc hnh trnh cng tc bng cch nhp khong cch thng qua bn phm.

- Sau khi ci t khong cch, my a ra 2 s la chn:

Thc hin dp tng chu k (1 cycle): ch cn nhp thi gian dng DT(s). Khi nhn nt DOWN hoc p bn p, my s tin hnh dp n v tr ci t, sau dng khong thi gian DT ri t ng m khun.

Thc hin dp nhiu chu k (N cycle): cn nhp thi gian dng DT(s), s chu k dp N(rounds) v thi gian gia 2 chu k k tip CT(s). ch ny cn lp rp h thng cp phi t ng, cm cp giao tip gia my dp v my cp phi, c my cp phi v my x cun ch t ng. Khi nhn nt START, my s tin hnh dp n v tr ci t, sau dng khong thi gian DT ri t ng m khun, my cp phi s ko phi vo 1 on nh trc sau my dp s ch thi gian CT ri tin hnh dp chu k tip theo. Thao tc lp i lp li N ln nhp.

4.2 Qu trnh hot ng ca my cp phi

4.2.1 Ch Manual (bng tay)

- Ch Manual trn my cp phi c dng ch yu trong qu trnh np phi mi. Sau khi np phi xong, chuyn my sang ch Auto chun b cho qu trnh dp t ng nhiu chu k.

4.2.2 Ch Auto (t ng)

- Trong ch t ng, tn hiu bt u 1 chu k ko phi c truyn bi My dp. Qua mch chun 2 tng, my s ko 1 on phi c chiu di t trc. Sau my cp phi s gi tn hiu hon thnh cp phi v cho my dp my tin hnh dp.4.3 Qu trnh hot ng ca my x cun.

4.3.1 Ch Manual (bng tay)

- Ch Manual trn my x cun c dng ch yu trong qu trnh np phi mi hoc thu li phi tha. Sau khi x l phi xong, chuyn my sang ch Auto chun b cho qu trnh dp t ng nhiu chu k.

4.3.2 Ch Auto (t ng)

- ch t ng, my hot ng c lp, ko giao tip vi cc my khc. Khi my cp phi ko cng phi, phi s lm thanh gt bt ln, tc ng vo cng tc hnh trnh S lm kch hot chu trnh x phi. Khi tang cun phi quay 1 vng, thanh cn quang lp trn trc tang s chn vo khe trn cm bin xut tn hiu dng ng c quay tang.

- Trong sut qu trnh x phi, my c th dng bt k lc no bng cch nhn nt STOP.

5. Th nghim v nh gi

5.1 Th nghim nh gi my dp NC

5.1.1 u im:

- Qu trnh th nghim thc hin trn cc hng mc sau:

+ Ch vn hnh bng tay, my hot ng n nh, kh nng p ng thao tc vn hnh ca ngi ng my tng i nhanh.

+ Ch t ng: kh nng tng tc tt, giao din thn thin vi ngi dng, hot ng chnh xc tng i cao, hu nh khng b nhiu; kh nng giao tip, phi hp vi cc thit b khc ca h thng t ng rt chc ch.

5.1.2 Nhc im

- Lc dp cn yu, cha lc p dng vi cc khun cn lc dp 10 tn tr ln.

- Khng gian g khun hn ch ch p ng c cc khun c kch thc nh.

- H iu khin cha chng chu c vi cc ngun gy nhiu khc nghit nh hn h quang, my EDM, v.v...

5.1.3 Hng khc phc:

- Nng cng sut ng c cng nh ng knh pen thy lc.

- Ci tin tng khng gian g t khun trn my.

- S dng cc thit b iu khin kh trnh c kh nng chng nhiu tt nh PLCs.

5.2 Th nghim nh gi my cp phi.

5.2.1 u im:

- C cu thay i chiu di on phi cp vo n gin, hot ng n nh, tin cy.

- C c cu nn thng phi trc khi cp vo khun.

- Truyn v nhn tn hiu vi my dp chnh xc, n nh.

5.2.2 Nhc im

- Tc cp phi cha cao.

- Ch p ng phi c b rng khng qu 70mm v b dy khng qu 2mm.

5.2.3 Hng khc phc:

- S dng xilanh kh nn c tc cao, chu p sut cao.

- Ci tin, m rng c cu nh hng tng b rng phi c th p ng.

5.3 Th nghim nh gi my x cun.

5.3.1 u im:

- Hot ng c lp, tin cy, chnh xc, n nh cao, khng nhiu, moment ln.

5.3.2 Nhc im

- Tc quay cn chm, cha iu khin c tc . Ch p ng phi c b rng khng qu 300mm v tng khi lng cun phi khng qu 200kg.

5.3.3 Hng khc phc:

- S dng ng c c tc ln hn

- Ci tin, thay i kt cu, tng ti trng trc tang.

5.4 Th nghim nh gi ton b h thng t ng

5.4.1 u im:

- Tng hp u im ca c 3 thnh phn ni chung.

- Hot ng linh hot, n nh, chnh xc.

- Khng cn cng nhn ng vn hnh sau khi thit lp xong cc thng s u vo.

- Tit kim thi gian, nng sut cao hn kiu cp phi truyn thng.

5.4.2 Nhc im

- Nng sut cha cao bng cc h thng cp phi vi cc li my dp bnh .

5.4.3 Hng khc phc:

- Ci tin tng tc dp, gim hnh trnh t do trn khun.

5.5 Kt qu t c

Hnh 22: Kt qu t c

6. Kt lun

Sau khi thit k v thi cng mch in iu khin, lp trnh iu khin ton b h thng my dp CNC cc kt qu c rt li nh sau:

Tnh ton thit k hon chnh cc thnh phn ca ton b h thng iu khin my dp CNC

Phn tch qu trnh xy ra khi thc hin thao tc dp. Thi cng ton b cc mch in iu khin

Lp trnh hon thin cc thao tc iu khin my dp.

Thc nghim nh gi v hon tt ton b h thng my dp CNC

TI LIU THAM KHO

[1]PGS.TS Trn Xun Ty, ThS Trn Minh Chnh, KS Trn Ngc Hi

Gio trnh h thng truyn ng thy kh,Trng HBK Nng, 2005

[2]inh B Tr, Nguyn Trng An, My p thy lc, Hc vin k thut qun s, 2005

[3]PGS.TS ng Thin Ngn, Trang b in- in t trong trong my cng nghip, Trng i hc s phm k thut TP.HCM, 2013

[4]Nguyn nh Ph, Vi iu khin PIC 16F887, Trng i hc s phm k thut TP.HCM, 2012

[5]B mn in cng nghip, Gio trnh thuyt b iu khin in, Trng i hc s phm k thut TP.HCM

[6]Gio trnh Ngn ng lp trnh C, Trng i hc s phm k thut TP.HCM

[7]H Vit Bnh Trn Th San, T ng ha qu trnh sn xut

Trng i hc s phm k thut TP.HCM

[8]John Moton, The PIC Microcontroller - Your Personal Introductory Course, 3rd Ed

[9]Milan Verle, Pic Micro controller programming in C

[10]Microchip, Pic Micro Mid-Range MCU Family Reference Manual

[11]Nigel Gardner, An introdution to programming The Microchip Pic in CCS-C

[12]C- Compiler Reference Manual

Thng tin lin h tc gi chnh (ngi chu trch nhim bi vit): T Nguyn Minh cH tn: T Nguyn Minh cn v: Khoa C kh my, trng i hc S phm K thut TPHCM

in thoi: 0908.477.232Email: minhduc@hcmute.edu.vnChuyn ngnh chnh: T ng ho