NGHIEN cuu-TRAODO! TWET KE Vl^ CHE TAO MQY BIEN DMIG THEP TOM DUn T R ^ NGUYEN LY COM IfNG DIBI TO (*) TS NGUYEN TRlTOfNG THINH TS NGUYEN NGOC PHU^CmC KS BUI TUAN ANH ThS TU^OnVG PHU^dfC THO T M TAT Qua trinh dot ndng cam ufng la mot qua trinh nung ndng thep than thien vdi mdi trifdng vi sU nung ndng dien dUa tren qua trinh bien dang khdng qua tiep xuc thdng qua tii trUdng sinh tam thep Hien cac thiet bj nung ndng bang cam ling difpc sCf dung kha rpng rai cac thiet bj gia dung cung nhU cac nganh cdng nghiep, nhUng van la cdng nghe kha mdi me tai Viet Nam, dac biet la nganh cdng nghiep nang nhU ddng tau Bai bao trinh bay tong quan ve qua trinh phat trien cua may nung ndng cam ling, cung nhir thiet ke phan ciing, md phdng va dieu khien qua trinh theo thdi gian thUc vdi dang may dieu khien chuong trinh so Muc tieu chinh la cung cap mot cai nhin sau hon vao ban chat ciia qua trinh nung cam ufng va diia cac khai niem co ban thiet ke cua may bien dang thep c^m ling Vdi yeu cau la thiet ke va che tao may cd kha nang lam viec on djnh, cd kha nang tich hop tU ddng, thdi gian dap ufng nhanh va qua trinh gia cdng la qua trinh khdng tiep xiic tao nen bien dang cac tam thep day sCr dung nganh ddng tau May bien dang thep Ceim ijfng di/pc cau tao bdi ket cau khung vdi bac tiJ la khdp tjnh tien Sau tien hanh che tao, cac ket quS thiic nghiem cho thay rang hieu qua cCia sii nung ndng cam ufng cd the sir dung hieu qua viec bien dang thep tam day cdng nghiep ddng tau ABSTRACT Induction heating is clean environmental heating process due to a non-contact heating-deformation process There is lots of the induction heating type that be used in the home appliance and industry but it is still new technology in Viet Nam, especially in shipbuilding industry This paper presents a comprehensive overview of the process of development of induction heating machine, as well as machinery hardware design, simulation and real-time process control.The main objective is to provide a deeper insight into the nature of the induction heating process and to summary the design of induction heating machine The goal of this project is to build a machine capable of stable, autonomous, fast and non-contact manufacturing for deformation the thick steel plate in shipyard Induction heating machine is characterized by gantry configuration with linear 3-DoF structure G i d l T H I E U Trong chien lupc phat trien cua Viet Nam tir den nam 2020, nganh ddng tau dupc coi la mot nhimg nganh quan trpng nhat cua cdng ^nghiep hang hai Cdng nghiep ddng tau dupc du k i k se la linh vuc ddng gdp vao ngan sach nha nude Idn diii hai sau nganh dau sau nam 2020 Qua trinh bien dang ^ , , Bp „ Mon , Co „ „ , ^Truong Z~7, U Ky I'-Tu 'tTTp VR (*) Dien tii, Dai Hoc ^ Su D Pham Thuat Ho thep ddng tau dupe xem nhu mot giai doan quan quyet dinh tdi nang suat va dp chinh xac Tren ^he gidi, hai loai nguon nhiet dupc su dung qua ^^^ ^ien dang thep tam: ddng nhiet dot hon hpp ^ oxyacetylenee va ddng nhiet tir hien tupng cam ^ ^ ^.^ ^ ^^^^^ ^^ ^^^ ^^^ ^^^^ ^ - ^ ^ ^^ ^^ ^ ^^^ ^^^ ^ ^ ^ ^ ^ ^ ^ ^ ^^^^ ^ ^ ^ ^ ^ ^ ^^^^ , A TU'^ U U-^ J U-* J »* cae tam thep day Thiet bi bien dang lunet su dung dau oxyacetylene •' •' _ cd uu diem linh hoat hon va it ton kem, Chi Minh nhung nd lai phu thudc vao kinh nghiem va cac ky nang ^ TAP CHi c a KHi VIET NAM • So 7-Thang nam 2011 NGHIEN cuu-TRAODOI cua ngudi cdng nhan de kiem soat su bien dang nham tao cac dudng cong pham vi cho phep De cd the kiem soat su bien dang mot each chinh xac qua trinh gia cdng, ddng nhiet tir nguon phai dupc kiem soat chat che Tuy nhien, rat khd de kiem soat ddng nhiet tir oxyacetylene vi nhiing dac tinh nhiet tir phan ling cua hon hpp Idii Trong dd, ddi vdi nhiing yeu cau ddi hdi sir chinh xac ve kich thudc than tau, qua trinh dot ndng bang oxyacetylene cd the hi ban che Phuong an dupc de xuat de thay the la sir dung nguon nhiet cua hien tupng cam img dien tir thay cho viec nung ndng bang ngpn lira dot So vdi qua trinh nung ndng bang nguon nhiet cua oxyacetylene, qua trinh cam ling dien tir ed nhiing uu diem nhu: cdng suat va su phan bo cua nguon nhiet cd the dupc kiem soat va tai tao mot each de dang Ben canh dd he thdng cam ling cd the dupc tich hpp vdi mot he thdng robot de tu ddng hda Qua trinh nung ndng bang cam ling khdng phai la mot cdng nghe mdi [1] Chi vai thj^ ky qua phuong phap da dupc ling dung rpng rai nung ndng dua tren qua trinh bien dang deo va cho thay ring day la mot phuong phaprathieu qua cho viec bien dang nhiet tdc dp cao cdng nghiep Nguyen ly cua qua trinh kha don gian: mot dien ^ xoay chieu dupc dat vao mot cudn day dan dien, mot ddng xoay chieu dupc sinh Sau dd ddng xoay chieu se gayramot tir tradng thay doi theo thdi gian va co cimg tan so vdi ddng xoay chieu gay nd Khi mot vat heu dan dien va mangtinhchat tir tinh dupc dat gan vdi tir tradng xoay chieu sinh cua cudn day, vat dan se xuat hien ddng dien xoay (Eddy current) cd tan so tuong duong tan so ciia tir tradng Cac ddng fien xoay dupc sinh tu D theo trd khang cua vat lieu va nang lupng cua no se hi mat di dudi dang nhiet va lam ndng vat lieu Hinh la Tren the gidi, bien dang thep bang tir tradng dupc So dd nguyen ly cua may nung cam ling sir dung rpng rai cac cdng nghe che tao may hien Dong AC vai tin so cao cuon day dai de tao hinh vat lieu d nhiet dp cao Hien d Viet Dinh luat Ampere Nam, qua trinh nung ndng cam ring thudng xuyen dupc Thay doi tu* trLPong tim th6p ap dung diic, tdi, ram, nau chay, ban Cac qua Djnh luat Faraday yf trinh ddi hdi su kiem soat chinh xac dp tham sau va Thay d6i dong dien tim th6p chat lupng be mat •• Djnh luat Ohm yf Qua trinh nung cam ling dupc biet den nhu mot qua Dong di#n xoay tam thep trinh tao nhiet tren chi tiet dan dien Trong qua trinh nung Hieu img Joule cam ling, sii dung thiet hi dieu khien tu ddng cudng >r' Hinh nhi^t tam thep dp ddng dien cua dau nung cam ling cimg vdi giai thuat tim dudng nhiet, nang suat ciia qua trinh bien dang thep tam se dupc cai thien dang ke Bai bao la cdng trinh Hinh 2: Cac buac tao ngu6n nhiet va cac dinh luat lien quan qua trinh dot nong cam ling tam thep nghien ciiu cdng nghe nung cam ling dau tien nganh ddng tau tai Viet Nam, ddng thdi cac nghien ciiu Nung cam ling la qua trinh gia cdng khdng tiep trade day tren the gidi da khdng dua bat ky phuong xiic, su dimg nguon dien tan so cao de lam ndng vat lieu phap thiet ke va che tao thiet hi nung cam ling dan dien [2] Vi Ididng tiep xiic, qua trinh lam ndng se khdng pha buy vat lieu dupc lam ndng Nd ciing rat hieu qua vi nhiet thuc su dupc tao ben chi tiet Dieu DOT NONG CAM UNO DIEN TlT cd the trai ngupc vdi cac phuong phap gia cong '}i B6 diiu iwrn' m nhiet khac, noi ma nhiet dupc tao tu ngpn lua hoac ' khien thiet bi dot ndng, sau dd dupc dat vao chi tiet 25 kW, Ddng dien cam img cd tan so giong nhu ddng dien 45 kHz Tarn thep cudn day va cd hudng trai ngupc vdi ddng cudn day Ddng dien cam ling tao dien trd nhi?t theo Dau cam dinh luat Joule tren chi tiet, va cd the dupc su dung de img uon cong cac tam thep Phuong phap tinh toan nhiet qua trinh nung ndng cam ling dupc the hien tai so Vung tir truang hinh [3], vdi cac van de va dinh luat cd lien quan duoc the hien Hinh 1: Qua trinh dot nong cam ling cong nghiep dong tau TAP C H i c a KHi VIET NAM V So - T h a n g nam 2011 NGHIEN cuu-TRAODOI Mot nguon dien tan so cao dupc su dung de dieu khien ddng xoay chieu kha Idn chay cudn day Cudn day dupc gpi la cudn day lam viec Su di chuyen cua ddng dien qua cudn day tao mot vimg tir tradng thay doi rat manh va nhanh ben cudn day lam viec Chi tiet can nung ndng dupc dat viing tir tradng xoay chieu [4] Cach s ^ xep cudn day lam viec va chi tiet cd the xem nhu mot may bien ap Cudn day lam viec giong nhu cudn so cap noi ma nang lupng dien dupc dua vao, va chi tiet giong nhu cudn thii cap vdng day va hi n g ^ mach Dieu gay ddng dien cue Idn chay chi tiet Day chinh la ddng dien xoay THIET KE HE THONG NUNG CAM LTNGTIT 3.1 Mpt soyiu cau vi thiit bi dung hi thdng nung cam ung tit: He thong nung cam ling dupc sir dung viec lam bien dang cac tam thep ddng tau sii dung hinh dang nhu Hinh Kha nang tao lap tir tradng cua bat ky cudn day nao cung thudc vao ampe-vdng cua cudn day, hinh dang hinh hoc, va mach dien ciia nd Su lua chpn nguon dien, tan sd va chieu dai cudn day nung cam ling tir ciing dupc nghien ciiu trade day dua Cac cdng thiic cua nung cam ling chu yeu dua tren vao loai kim loai dupc nung, dp ddng deu cua nhiet dp hai hien tupng vat ly noi tieng la hien tupng cam ling yeu cau, thdi gian nung Ngoai tan so la mot dien tir va hieu ling Joule nhu sau: nhiing thdng so cd tinh quyet dinh nhat phuong gia cdng Neu tan so qua thap, mpt sir triet tieu cua P=R^ (1) ddng dien xoay ben vat the hi nung se dien ra, dan Vdi la ddng dien di qua mot day dan cd dien trd den giam hieu suat cudn day Tuy nhien, tan so qua R, cdng suat tao nhiet tren vat dan P Them vao dd, ddng cao, hieu img be mat se Idia ro rang, ket qua la dien tan so cao dupc sir dung eac ling dung nung mpt su tap trang ddng dien mpt ldp be mat rat cam ling tuan theo mot hien tupng dupc gpi la hieu ling mdng so vdi be day cua bd phan hi nung ndng be mat Hieu ling lam ddng xoay chieu tap trung Vi ddng qua vdng cam ling cd hang tram den hang tai mot ldp mdng tren be mat cua chi tiet trayen ngan Ampe nen ton hao dien chiem tdi 25-30% cdng suat vao sau kim loai, dp Idn ciia cac vecto EvaH {2 hiiu ieh cua thiet hi Do vay can lam mat vdng cam img phan cua tradng dien tir) bi giam dan va tir dd nang Lam mat bang nude chay vdng cam ung rong tiet lupng tradng dien tir cung giam dan (theo dp sau trayen dien trdn, d van hay chir nhat cho phep mat dp ddng dien Z) Ngoai hieu ling be mat cdn lam tang dien trd hieu dat tdi 50-70 A/mm2 Day dan lam vdng cam ling ed the dimg cua kim loai doi vdi su di chuyen cua ddng dien rong vi ddng cao tan chi phan bo phia ngoai day Trong Idn Vi vay nd lam tang dang ke hieu qua nhiet gay bdi giai tan radio, thudng dimg ong day 0,l-0,5nim Trong ddng dien chi tiet Hieu ling be mat dupc dac trung bd phat thiet bi su dung tu dien nham lam ehiic nang bdi dp tham sau 5, dupc tir mat ngoai chi tiet, la dp day phan li ddng dien chieu hoac bii coscp Cac tu phai cua ldp ma 87% nguon dien dupc sinh Dp tham sau la cac tu chiu dien ap cao (tdi lOOOV) va chiu tan so cao cd the dupc suy tir phuong trinh Maxwell (tdi lOkHz) phu thudc vao thiet hi gia nhiet Dp tham sau, mot mat phu thupc vao cac dac tinh Trong thiet hi gia nhiet cao tan, eac contactor dupc cua vat lieu can lam ndng (n, p), mat khac, ciing chiu dimg la contactor cao tan cue chiu dien ap 1600 V va ardi hudng ciia tan so ddng dien Su phu thudc vao tan tan so tir 500-lOOOOHz Q moi cue cd tiep diem: tiep so giiip de dang kiem soat dp tham sau hon diem chinh (tiep diem lam viec) va tiep diem dap ho quang Tiep diem dap ho quang dat buong dap ho quang va cd ludi, cd cudn day phu de thoi tir tradng Moi cap tiep diem dupc noi song song Khi ddng mach, tiep diem dap hd quang ddng trade roi den tiep diem chinh Khi ngat mach thi ngupc lai, tiep diem (a) (b) (c) chinh md trade rdi den tiep diem dap hd quang Hinh 3: Hinh dang cac cuon day ca ban: (a) Vong dan, (b) Cuon day (c) cuon day phing Tir tham cua cac vat lieu sat tir phu thudc rat Idn vao phan cua vat lieu va cac yeu to ben ngoai (nhiet dp, cudng dp tir tradng, dp bao hda) Day dan cao tan thiet hi gia nhiet bang tan so thudng la cai phang, ong rong cd nude lam mat, cap dong true cao tan hay cap mpt rapt, nhieu rapt thdng thudng Dac trung cua day dan cao tan la cd cam Idiangc^ TAP CHI C a KHI VIET NAM V So - Thang nam 2011 NGHIEN cuu TRAO DOI dac biet Idn hieu ling be mat, ho cam va chiing phu thudc vao tan so [2] mang theo true Z va ket noi vdi trapt bi bluig cac trapt Ddng co trayen ddng qua hop giam toe va bo trayen banh rang - rang Dan hudng bang hai 3.2 Sa hoat dpng cua hi thong nung cam img trapt bi giiip tang kha nang chiu tai va tang dp chinh xac tie: qua trinh gia cdng Cung nhu tren true Y mang theo ket cau cua hai true X va Z b2ng cac tam va thimg dd Dpng CO trayen ddng thdng qua hop giam toe, bp tmyen banh rang - rang va hai cap banh lan Cac chi tiet cua may dupc gia cdng ISp rap theo mpt quy trinh nhat dinh de dam bao tinh ciing viing va chinh xac Cac true trayen dpng dupc bo tri mpt dpng co, rieng true Y dung hai dpng co cd cdng suat nhu de trayen ddng Dieu giiip tranh hien tupng rung lac cua may Ngoai hai ddng co cdn cimg nhan mpt tin hieu dieu khien va Hinh 4: Sa hoat dong cua he th6ng nung cam ling tu deu phan hdi ve may tinh nen khi mpt ben gap su co Dau nung cam ring tir bai bao boat ddng d thi ben cdn lai ciing dupc thdng bao dimg boat dpng tan so trang tan De tao dupc dien ap xoay chieu vdi dd dam bao su on dinh he thong Sau thiet ke he ca, tan so cao va dap ling dupc yeu cau ve dien ap, nguon cac chi tiet dupc tinh toan md phdng ling suat va chuyen dupc chpn sir dung la nguon xoay chieu pha 380VAC vi tai cac vi tri khac bang phan mem md phong Nguon pha dupc dua vao khoi chuyen doi AC-DC de Abaqus de thay dupc nhiing vi tri nguy hiem ciing nhu chuyen nguon xoay chieu AC nguon mpt chieu kha nang chiu tai cua ca he thong Tir dd lua chpn duoc DC Tir dd nguon mpt chieu thdng qua khoi DC thdng sd cac chi tiet phu hpp yeu cau to AC Inverter se dupc chuyen doi nguon xoay chieu AC cd tan so cao thdng qua mpt mach cau H sir ^-^ dung IGBT, cung cap nguon cao tan cdng suat cao cung cap cho cudn day cam ring boat ddng Tan so ddng xoay ^ chieu dupc tinh toan theo cdng thiic: / = JV-T" V_^ rp (3) Dau nung cam Lpng THIET KE CO KHI -•XR Phan md ta cae chi tiet ky thuat va cac tinh nang cua may nung cam ling Trade tien, cac chi tiet ky thuat cua cau tnic may dupc the hien hinh Hinh Mo hinh hoa hinh hoc may duoi dang robot Decard Budc ke tiep thiet ke co la tinh toan cac thdng so ddng lire hpc he thong bao gom: ma tran chuyen vi cua he, van toe va gia toe dau tir Hinh la md hinh hoa may tao nhiet b3ng tir tradng dudi md hinh robot Decani Ma tran chuyen vi: -1 T, = "T T X X T 0 Hinh 5: Mo hinh cua may cam ling ttr TAP C H i c a KHi VIET NAM V So - Thang nam 2011 /j+a l,+b -1 K - h ^ 0 'p' 'dPJdt 'I o" Van toe ciia dau tir: May dupc thiet ke theo nguyen ly chung cua may gia cdng dieu khien sd ba true True Z: mang thiet hi gia cdng (dau tir) Di chuyen len xudng b5ng true vit me bi Ddng CO trayen ddng thdng qua hop giam toe tu ham True X cd nhiem vu mang theo cac tam dong thdi 0 X X K p _ z_ = dP Idt = y 0 dPJdt_ y =J y z z NGHIEN cuu-TRAODOI Gia toe dau tir: 'p' 'dvjdt' X '\ a = py = dv^ldt = P dv Idt _ Z _ - 0" 0 X X y =J y z z z Til nhung ket qua tren, nhung gia tri ve vi tri, van toe ciing nhu gia toe cua he cd the de dang xac dinh May nung cam ling cd ket cau dua tren robot cd bac tu tinh tien vdi khdng gian lam viec 3,0 x 2,0 x 1,0 m' Khoi lupng cua he thong cam irng va dau tir khoang 30 kg Kich thudc vat ly cua nd dupc tinh toan dua tren dii lieu nhan trSc Hinh cho thay hinh anh ciia robot va bang la tdm t^t mot so thdng so quan dupc phan phdi deu d hai ben dau dam, noi dau cac true dupc lap Trong trudng hpp A, vdi "mdi ghep ban" nghia la vdi cac bien cdng (do dd loai bd tac dung cua sir tap trang ling suat) va tradng hpp B thi khdng cd chiing Cac trudng hpp C va D tuong ling vdi img suat xoan mem: Trong phan tich cua cac thep khung may, tai trpng tiep xue dupc ap dung, vdi gdc 10° tradng hpp A va 30° tradng hpp B, bdi vi chimg la gdc lam viec, bat dau va ket thiic moi trudng hpp Cac tradng hpp C va D dai dien cho ring suat xoan mem O day chung tdi cung xem xet tong trpng lupng may, nhan vdi he sd an toan Ddi vdi cac phan tich bien, chung tdi da chia bien tren va bien dudi Trong phan tich bien dudi, mpt nhiing phan gidi han nhat va khd nhat, tradng hpp A, chiing tdi ap dung kieu md phdng tai ling suat ngang Trong phan tich cau tnic may, viec ludng tat ca co cau da dupc thuc hien vdi su kiem tra bang phuong phap phan tir hiiu ban (FEM) Trade di vao phan tich, ciing HE THONG DIEU KHIEN can phai de cap rang tat ca cac cau tnic cua thiet ke eo Mdi quan he giiia cac phan dieu khien dupc dupc lam til thep Sau dd, qua trinh kiem tra nay, the hien hinh chiing tdi se trinh bay nhiing phan tich quan trpng sir hieu biet cua chiing tdi ve cau tnic cua robot [5] Chu'O'ng trinh gia May tinh cong CNC I Bo dieu khien AC SERVO DRIVER X T AC SERVO DRIVER Y1 I AC SERVO DRIVER Y AC SERVO DRIVER Z Hinh 8: He thong dieu khien tong quat Hinh 7: Mo hinh va may cam ling tu thuc te Trong phan tich dam (Trong tat ca nhung phan ma phuang phap tuong tu dupe sir dung), tai trpng tuong duong vdi tat ca trpng lupng may da dupc dat tai moi be mat tiep xiic vdi su chong dd cua cac true, md phdng nhiing gi tren thuc te nhiim giu lai tat ca lupng cua ket cau giai doan chiu tai don gian Tai dupc xem xet cd khoi lupng 45 kg va nhan vdi he so an toan la dupc 90 kg, tiic la khoang 900 Newton Cau tnic phan cimg ciia he thong dieu khien phan than may va vi tri cua cac thiet bi phan ciing dupe chi hinh Mpt CPU-3 OGHz chay tren nen Windows XP dupc su dung nhu la may tinh chinh Cac thiet hi khac, nhu bd dieu khien servo (bd dieu khien ddng co cua cae true Ididp) va cam bien ket ndi cac khu vuc dieu khien (CAN) tdi may tinh chinh Cac bd dieu khien servo va cac cam bien cd bd vi xir ly rieng Cac bd vi xir ly cho phep bd dieu khien servo dieu khien gdc dp va van tdc ciia ddng co vdi cac lenh chuyen tir PC, va bd vi xu ly cho phep cam bien xii ly tin hieu tuong tu va trao doi cac dii lieu thdng qua CAN May tinh chinh phuc vu nhu bd dieu khien chu Nd tinh toan cac thuat toan dieu khien hoi tiep sau nhan dupc cac dii lieu tir cam bien, tao quy dao cua cac khdp, va giri cac lenh dieu khien cua may de dieu khien ddng co servo c cua eac khdp thdng qua mang trayen thdng CAN TAP CHi c a KHi VIET NAM V So - Thang nam 2011 NGHIEN cuu TRAO DOI dang thep cd kha nang gia cdng trang binh 15 phiit/1 san pham Qua thuc nghiem thay r ^ nang suat lam viec cua may gap 5-10 lan so vdi ngudi cdng nhan dung md han Oxyaxetylen de lam bien dang tam thep Quy dao dau tir dupc tien doan theo cac quy tSc cua mang than kinh nhan tao, viec dau tir di chuyen theo dung quy dao da dupc % trinh vdi dp chinh xac cao (sai so