Do nham be mat, dp cflng la cac thdng so quan trpng de dam bao tinh chong mai mon cao, giup true cam duy tri kha nang dieu khien ehinh xic supap nap va x i trong q u i trinh Iam viec lau
Trang 1NGHIEN CUfU-TRAO D O I
NGHIEN Ciru, THIET KE VA CHE TAO MAY OANH BONG TRUC CAM XE MAY
RESEARCH, DESIGN AND MANUFACTURING MOTORCYCLE CAMSHAFT
POLISHING MACHINE
Pham Van Hiing, Phan W n , Nguyen Thi Ngpc Huyen
TrUdng Dai hpe Bich khoa Ha Npi
TOM TAT
TrHC cam dgng cd dot trong co tdc dung dieu khien dong md supap ngp vd supap xd True cam dgng cd xe mdy gom cam ngp vd cam xd, thudng dUdc che tgo lien true vd ddn dgng bang xich True cam ldm viec trong dieu kien ma sdt trUdt, boi trdn bdng dau dongcd Deddm bdo ldm viec on dinh trong thdi gian ddi, do nhdm be mat true cam yeu cdu dgt cd Rz3,2fim Do nhdm ndy dgt dUdc thong qua nguyen cong ddnh bong Nhom tdc gid dd nghien cdu thie't ke che tgo mdy ddnh bong true cam xe mdy vdi muc tieu ddm bdo ndng cao ndng sudt gia cong vd dieu khien tu dgng bdng PLC
Cdc tdc gid da di tdphdn tich dgc diem true cam, lUa chon phUdng phdp ddnh bong vd phUdng
dn bd trigd dgt true cam, xdy dUng sd do dgng vd tinh todn thiet ke, che tgo hodn chinh mdy ddnh bong true cam chuyen ditng Sdnphdm dukhd ndng ddp dng yeu cdu chdt lUdng de co the cung cdp thiet bi cho cdc cong ty sdn xudt dgng cd xe mdy trong n Udc, thay the thiet bi ngogi nhgp
ABSTRACT
Cam-shaft is a machinery which controls combustion engine Cam-shaft in combustion engine
of moto-bike has innet cam and exhaust cam This cam-shaft works in sliding friction condition and od lubricated In order to enhance lifetime of camshaft, surface of camshaft need to be well polishing
In this paper author promote a design of motobike cam-shaft polishing machine in order to increase productivity
of manufacturing process This machine is automatic controlled by PLC
To design a camshaft polishing machine, technical characteristics of camshaft then decided camshaft polishing method, camshaft mounting method then design kinetic diagram of camshaft polishing machine and design camshaft polishing machine The design of camshaft polishing machine has been verified by a real camshaft polishing machine, this machine satifted all requirements from industrial companies and it
is able to replace the imported machines,
Trang 2NGHIEN CUfU - TRAO D 6 |
1 GIOI THIEU
He thong phan phoi khi trong dpng cP
dot trong bao gdm cie supap va mpt he cP khi
dieu khien chung ddng md dung thdi diem Viec
thay the khi thii bing hdn hpp khi mdi dUpc dieu
khien bang true cam True cam cd cac vau cam
day cac supap len va xuong de ddng va m d cac
van Bien dang cam quyet dinh thdi diem ddng,
md cae supap, do vay nd phii dupe tinh toan sao
eho d i m b i o dupe cac pha phdi khi cua dpng cP
theo nhu thiet ke
True cam dpng co xe may cd cau tao gdm
2 cam: Cam nap va cam xa (cam thai) Cae cam
nay dUpe che tao lien true Do nham be mat, dp
cflng la cac thdng so quan trpng de dam bao tinh
chong mai mon cao, giup true cam duy tri kha
nang dieu khien ehinh xic supap nap va x i trong
q u i trinh Iam viec lau dai eua dpng eo
Htnh 1 - True cam xe mdy
Chi tiet true cam Iam viee trong dieu kien
ma sat trUpt, ed boi tron Do vay, de han ehe mon,
dam bao Iam viec dn dinh trong thdi gian dai, eac
nha sin xuat dpng cP xe m i y dat ra yeu cau nham
be mat cam ca Rz3,2|im De dat dupc do nham
nay thi sau nguyen cong mai, true cam se phai qua
nguyen eong cuoi eung la danh bdng
Trong dieu kien cie hang sin xuat xe may
tai Viet Nam nhU Honda, Yamaha, Piaggio lien
tue md rpng nba may va s i n lUpng xe m i y thdi
gian gan day, viec nghien cdu thiet ke che tao m i y
danh bdng true earn, mpt may chuyen dflng gia
cdng tinh ed tinh dac thu, la ddng gdp tieh efle
trong viee tham gia vio chuoi gii tri t o i n eau
trong cong nghiep hd trP Viet Nam
2 L 0 A CHON PHUONG PHAP DANH BONG TRUC CAM XE MAY
True cam xe may vdi d i e diem bien dang earn khong ddi xflng, be mat l i m viec hep, be mat can d i n h bong khong phai Ii toan bp ehi tiet Ngoii ra moi true cam can danh bdng 2 bi" mat cam, n i m each nhau tfl 3 -^ 10mm theo phflpng dpc true Do kich thUdc d i e thu cua be mat gia cdng, ta lfla chpn phUPng p h i p danh bdng bang day danh bdng eo gan hat mai (bang mii) Day eung la phUPng p h i p d i n h bong pho bien de gia eong true khuyu hoae eic chl tiet cd bien dang khdng ddi xflng
Vdi phUPng phap d i n h bdng dung day
d i n h bong cd gan hat mai, thiet hi sfl dung ed the
la m i y d i n h bong CNC, thiet bi d i n h bong cd ro-bot hd trp hoac sfl dung may d i n h bdng true cam ehuyen dung De ban che dp phflc tap cua thiet bi,
d day tac gii Ifla ehpn thiet ke che tao may dinh bdng chuyen dung
Khac vdi eae trUdng hpp danh bdng van nang dung day dang bing tron quay vdi tdc dp eao, do tinh chat khong doi xflng eua be mat cam nen d day lflc ehpn phUPng i n d i n dpng true cam quay vdi toe dp thap, diy d i n h bdng khong dieh ehuyen m i cd cP cau mem ti day danh bdng len be mat earn gia cong Dieu nay dam bao eho day danh bong Iuon tiep xue vdi be mat gia cong,
t r i n h va dap gifla cP cau ty d i y va true cam
P
aL DQy danh b6ng
Bi mOt c a m
Htnh 2 - PhUdngphdp ddnh bong true cam bdng ddy ddnh bong
TAP CHf CO KHf VIET NAM • s 6 1+2 (Thing 1+2 nam 2013)
Trang 3NGHIEN CUfU-TRAO D 6 I
Cac thong so cong ngh$ dflpc the hiin nhfl
tren hinh 2, bao gom:
- P: Lflc ty day danh bdng len be mat cam,
thfldng sfl dung lUc ty mem
- n: toe dp quay true cam, day eung chinh l i
toe dp eat
- AL: chieu dai tua diy Sau khi gia cong
mpt so Iflpng chi tiet nhat dinh, hat mai tren day
dinh bdng bi bong ra, khong d i m bao kha nang
dinh bdng Khi do can tua diy mpt khoang AL de
dich chuyen sang vi tri diy mdi Chuyen dpng tua
day la chuyen dpng gian doan
Vdi vat lieu true cam xe miy bang gang cau,
sfl dung day d i n h bdng cd dp hat 10 -H 6; ap Iflc ty
0,5 -H 2 kG/cm^; lim nguoi bang dung dich xdda
([2])
3 THIET KE CHE TAO M A Y DANH BONG
TRUC CAM XE MAY
3.1 Phuang an bd tri true cam
nghiem va xiy dflng ehe dp cong nghe phfl hpp doi vdi mdi loai true cam de cd the dat dp nham yeu cau
- Tfl dpng kep chit chi tiet, g i dat trin mui tim v i truyen dpng true cam qua tdc truyin
- Tfl dpng tua diy danh bdng sang vi tri day mdi sau mpt chu trinh gia cdng nhat dinh (khi Idp hat mai trin day danh bdng da bi bong di dang ke, khong cdn dam bao kha nang gia eong) Tfl yeu eau dat ra, tac gia xay dflng so do dpng may danh bdng true cam nhu trin hinh 4 Trong dd:
- Chuyen dpng quay true cam dUpc d i n dpng tfl dpng eO dien dieu khien vo cap bing bien tan thong qua bp truyen dai rang cd ti sd truyen bing 1 Toe truyen gin vdi ranh then trin true cam (ranh then true cam da co tfl nguyin cong trUde)
- Q u i trinh kep chat dUpc thflc hien nhd 2
xi lanh khi nen
De ning eao ning suat, yeu eau dat ra la
may danh bong true cam gia cdng ddng thdi 2 chi
tiet trong mpt lin ga Phuong an thiet ke dflpc lfla
ehpn Ii bo tri hai true cam g i thang hang (hinh 3)
Phflpng i n nay cd flu diem hon phflong an b6 tri
hai true cam ga song song l i d i bo tri he thong gi
day dinh bdng va Iflc ty on dinh
^%
.p^
- Viee gifl CO dinh eae cudn day danh bdng
trong qua trinh gia cong dUpc thUe hien bing 2 xi lanh khi nen
- Ngoai ra sfl dung 2 xy lanh khi nen khic
de nang va ha cum dan bUdng day danh bdng trong qui trinh gia cdng vi thao sin pham
y/KTi/
Hinh 3 • PhUdng dn bo tri hai true cam gd thdng hdng
3.2 Thiet lap so do dong may danh bong true cam
Yeu cau dat ra doi vdi may dinh bdng true
cam la:
- Cd khi ning thay doi dUpc bp thong sd
cdng ngh? trong danh bdng, gom: i p Iflc ty eua diy
dinh bdng len be mat cam, tdc dp quay true cam vi
thdi gian gia cong Dieu nay, d i m bao cho viec thfl
1 ;;i r : : g ^ d < i M ! f r ] E : ^ , l i > ^
Hinh 4 -Sd do dgng mdy ddnh bong true cam
Trang 4NGHIEN CUfU-TRAO 061
- H i thong thu day danh bong sfl dung 2
cap b i n h rang rpng ban Z= 30 Chieu dai thu d i y
dupe dinh lUpng thong qua dieu khii'n gdc quay
cua dpng eP bfldc tua day
3.2 Thiet ke, che tao m i y d a n h bdng t i n h xac
t r u e cam
Tfl yeu cau dat ra, tren co sd so do dpng
cua may, tien tdi thiet ke va che tao may danh
bdng true cam De d i dang lap dit, h i i u ehinh,
b i o dudng v i sfla chfla, may dflpc thiet ke theo
tflng cum ket cau rieng biet, bao gom:
Cum ga kep va truyen dpng (hinh 5
-2): Ga dong thdi 2 chi tiet true cam, dinh vi bang
mui tam, truyen dpng thong qua toe truyen g i n
vdi ranh then tren true cam Viic kep chit thflc
hien bang 2 xi lanh khi nen
Cum ga d i y danh bdng (hinh 5 - 4):
Ga 4 cnpn day d i n h bdng t r i n 4 true cd dia bao ngoii Cac cuon d i y n i y Iuon dflcfc gifl cd dinh bdi 2 xi lanh khi nen trong qua trinh gia cong 2
xi lanh ehi nha kep khi thUe h i i n tua day danh bdng
- Cum d i n hUdng day d i n h bdng (hinh
5 - 3): Co n h i i m vu dUa d i y d i n h bdng tiep xuc vdi be mat cam khi gia cong va nang l i n khi gia cong xong, lay chi tiet ra khoi true ehinh Viec nang ha dflpc thUc hien thong qua hai xi lanh khi nen Tren cum dan hfldng day danh bong bo tri ede chfla doi trpng de thay doi lflc ty len be mat cam khi gia cong
- Cum tua day d i n h bdng (hinh 5 - 1):
Cd chfle nang tua d i y danh bong den vung day mdi sau mdi chu ky gia cong x i c dinh Thflc hiin
thong qua viic dii'u khien gdc quay dpng ca
bude dan dpng eho banh rang rpng b i n kep day danh bone
Hinh 5 - Mdy ddnh bong true cam
1) Cum lua ddy, 2)Cumgd kepva truyen ddng true cam,
3) Cum ddn hiidng ddy ddnh bong, 4)Cumgd ddy ddnh bong:
5) Mill! hmh dieu khien cdm ilng, 6) Khung mdy
- He thong dieu khiin; sfl dung bp dieu
khien PLC S7 - 200 Q u i trinh dieu khii'n dflpc
thflc hien thong qua m i n hinh cam flng
tay (cho phep dieu khien dpc lip cac qua trinh: quay true ehinh, bom dung dieh lam ngupi, kep phoi, kep gifl cuon day d i n h bdng, n i n g ha cum dan hfldng diy danh bdng) v i ehe dp tfl ddng (tU dpng gia cong theo chu trinh: bPm dung dich lim ngupi -* xi lanh kep phoi boat dpng -» quay true Hai che dp van hanh: che dp dieu khii'n ehinh -* ha can d i n h bdng xuong vung gia cong Yeu cau cua be thong dieu khii'n:
Trang 5NGHIEN C f l u - TRAO OOl
-* sau thdi gian gia eong d i dinh, can d i n h bong nang l i n 4 KET LUAN
-* t i t dpng ca ham dung dieh Iam ngupi -»true ehinh dflng
quay - • xi lanh nha kep chi tiet May danh bdng true cam
BK.CMPM.2012, dflpc thiit ke che tao
- Cho phep cai d i t cie thong so: toe dp quay true hoan chinh vdi cac tinh nang co ban sau: chinh, so Iflpng ehi tiit gia eong trong mot ehu trinh tua - ©ong co diiu khien vo cap bang bien day, thdi gian gia eong, chieu dai tua day tin, eong suat 0,37kW, tdc dp 1370v/ph
- Cac b i o loi he thong hien thi bang tieng Viet v i
am thanh Dflng may khi cd vat vao vung gia cong khi dang
d i n h bdng
Hinh 6-Sdd6 khoi hi thong dieu khien mdy ddnh bong true cam
•«Ba [ 3
-wmrzi
nga [ISTO]
' \tmmn\
'•T-mlr-%-:::^S=
1 '• | ^ 1 "••• i (
b i n h ?
Miy d i n h bdng true cam xe may ehe tao nhfl trin
O a
Hinh 8 - Mdy ddnh bong true cam BK.CMPM.2012
- Nang suat: 2.800 chi tiet/ 3 ea
- Dp n h i m ehi tiet true cam gia cdng tren may: Rz < 3,2pm
- Sd ehi tiet gia cong trong I lan ga: 2 true cam
- Tua diy tU dpng
Phuang thflc gi phoi va h i thong kep: Ga phoi bing tay, he thdng kep tu dpng bang khi nen
Kha nang dieu khien: Dieu khien tfl dpng bang PLC: lfla chpn 2 che
dp gia cdng dieu khii'n tay hoac tfl dpng Bao code loi tren bing hien thi vi dflng miy khi cd vat la vao vung gia cdng Kha ning dieu ehinh: Dieu chinh thdi gian gia cdng, lflc kep, tde
dp quay true ehinh, lUe ty eua day danh bdng lin be mat cam, lflu lUpng dung dich Iam ngupi, thdi gian hoac sd lan gia cong trong 1 chu ky tua day danh bdng, chieu dai tua day d i n h bdng
- Kich thflde toin miy: 1440 x
700 X 1660mm
Qua trinh ehay thfl eho thay may danh bdng true cam BK.CMPM.2012 hoan toan d i p flng dupe yiu cau cua chat lupng b i mit true cam xe miy Vdi tinh nang tfl dpng dflpc tich hpp va kha ning linh hoat trong dieu ehinh thong
so eong nghi, hieu q u i de tang nang suat gia cong, may hoan toan cd kha^^^
Trang 6NGHIEN cflu - TRAO DOI
nang d i p flng tot yeu eau trong gia cong tinh
xic true cam xe miy, eung cap cho eac h i n g s i n
xuat dpng CO xe may trong nflde, thay the thiet bi
ngoai nhap
Hudng p h i t trien;
- Xay dflng phUPng an thiet ke che tao
may d i n h bong true cam cap phoi tfl dpng
- Tieh hpp thiet bi do tich cflc t r i n may
danh bong de cd the do Idem tra trUc tiep dp
nham trong khi gia eong, rut ngan thdi gian thd
nghiim xiy dflng ehe dp gia eong va tang dp
chinh xac gia cong eho bat ky chi tiet true earn
nao ma khong bi rang bupc bdi thong so eong nghe dinh sin
- Thiet ke bp ga day danh bdng linh hoat
de cd the dii'u chmh gia cong dflpc nhieu loai true cam vdi eac kich thflde khac nhau
- Md rpng cho viee tinh toan thiet ke gia cong ehi tiet true cam 6 to, true khuyu eung bang phflpng phap danh bong sfl dung dai gan hat mii •
Ngiy nhan bai: 26/12/2012 Ngay phan biin: 20/01/2013 Ngfldi phan bien: PGS, TS Tang Huy,
Trfldng Cao dang nghe Bach khoa
Tai lieu tham khao:
[1] PhamDap, Nguyen Dac Loc, Pham The TrUdng, Nguyen Tien Ludng (1974) Tinh toan thiet ke may cat ldm loai NXB DH&THCN
[2] GS.TS Tran Van Dich (2004) Gia cong tinh be mat chi tiet may NXB Khoa hoc Ky thuat
[3] S Jahanmir (1986) Examination of wear mechanisms in automotive camshafts Wear - An International Journal on the Science and Technology of Friction, Lubrication and Wear, Volume 108, Issue 3, 1 April 1986, Pages 235-254
[4] Gunther Spur (1999) Honing and Superfinishing - Handbook of Ceramic Grinding & Polishing [5] Glen Carlson (5/1/2002) Advancements in Automated Polishing, Buffing and Deburring, PFOnline (Products Finishing Magagine)
[6] George J Anselment (January 2002) Belt polishing Metal Finishing, Volume 100, Supplement 1, Pages 71-81
[7] Mohamed El Mansori; Patrick Ghidossi; Stephane Deblaise (2 April 2007) An energy analysis of belt polishing process and its applications to time cycle and tracking effects Machining Science and Technology, Volume 11 [8] M Bigerelle, A Gautier, B Hagege, J Favergeon, B Bounkhan (19 November 2009) Roughness characteristic length scales of belt finished surface Journal of Materials Processing Technology, Volume 209, Issue 20, Pages 6103-6116
[9] Yue Feng Leng, Nina Zhang (2010) Experiment Research on Abrasive Belt Vibration Grinding Terminal Surface of Work Piece Advanced Materials Research, Volumes 154 - 155, page 1240-1243