NGHIEN 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 Wn, Nguyen Thi Ngpc Huyen TrUdng Dai hpe Bich khoa Ha Npi TOM TAT TrHC cam dgng cd dot 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 dieu kien ma sdt trUdt, boi trdn bdng dau dongcd Deddm bdo ldm viec on dinh thdi gian ddi, 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 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 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, TAPCHf CO KHf VIETNAM V S6 l+2(Thang 1+2 nam201?) | NGHIEN CUfU - TRAO D | GIOI THIEU cong nghiep hd trP Viet Nam He thong phan phoi dpng cP dot bao gdm cie supap va mpt he cP dieu khien chung ddng md dung thdi diem Viec thay the thii bing hdn hpp mdi dUpc dieu khien bang true cam True cam cd cac vau cam day cac supap len va xuong de ddng va md cac van Bien dang cam quyet dinh thdi diem ddng, md cae supap, vay nd phii dupe tinh toan eho d i m b i o dupe cac pha phdi cua dpng cP theo nhu thiet ke L A CHON PHUONG PHAP DANH BONG TRUC CAM XE MAY True cam dpng co xe may cd cau tao gdm cam: Cam nap va cam xa (cam thai) Cae cam 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 tri kha nang dieu khien ehinh xic supap nap va x i q u i trinh Iam viec lau dai eua dpng eo Htnh - True cam xe mdy Chi tiet true cam Iam viee dieu kien ma sat trUpt, ed boi tron Do vay, de han ehe mon, dam bao Iam viec dn dinh thdi gian dai, eac nha sin xuat dpng cP xe miy dat yeu cau nham be mat cam ca Rz3,2|im De dat dupc nham 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 sin lUpng xe miy thdi gian gan day, viec nghien cdu thiet ke che tao miy danh bdng true earn, mpt may chuyen dflng gia cdng tinh ed tinh dac thu, la ddng gdp tieh efle viee tham gia vio chuoi gii tri toin eau TAP CHf CO KHf VIET NAM • True cam xe may vdi die 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 moi true cam can danh bdng bi" mat cam, n i m each tfl -^ 10mm theo phflpng dpc true Do kich thUdc die 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 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 robot 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, 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 dam bao eho day danh bong Iuon tiep xue vdi be mat gia cong, trinh va dap gifla cP cau ty diy va true cam P aL DQy danh b6ng Bi mOt cam Htnh - PhUdngphdp ddnh bong true cam bdng ddy ddnh bong s 1+2 (Thing 1+2 nam 2013) NGHIEN CUfU-TRAO D 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 li toe dp eat - AL: chieu dai tua diy Sau 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 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 dinh bdng cd dp hat 10 -H 6; ap Iflc ty 0,5 -H kG/cm^; lim nguoi bang dung dich xdda ([2]) THIET KE CHE TAO M A Y DANH BONG TRUC CAM XE MAY 3.1 Phuang an bd tri true cam De ning eao ning suat, yeu eau dat la may danh bong true cam gia cdng ddng thdi chi tiet 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 cd flu diem hon phflong an b6 tri hai true cam ga song song li d i bo tri he thong gi day dinh bdng va Iflc ty on dinh 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 dpng may danh bdng true cam nhu trin hinh Trong dd: - Chuyen dpng quay true cam dUpc din dpng tfl dpng eO dien dieu khien vo cap bing bien tan thong qua bp truyen dai rang cd ti sd truyen bing Toe truyen gin vdi ranh then trin true cam (ranh then true cam da co tfl nguyin cong trUde) - Qui trinh kep chat dUpc thflc hien nhd xi lanh nen - Viee gifl CO dinh eae cudn day danh bdng qua trinh gia cong dUpc thUe hien bing xi lanh nen - Ngoai sfl dung xy lanh nen khic de nang va cum dan bUdng day danh bdng qui trinh gia cdng vi thao sin pham ^% p^ y/KTi/ Hinh • PhUdng dn bo tri hai true cam gd thdng hdng ;;i r::g^d^ 3.2 Thiet lap so dong may danh bong true cam Yeu cau dat doi vdi may dinh bdng true cam la: - Cd ning thay doi dUpc bp thong sd cdng ngh? 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 TAP CHf C O KHf V I £ T Hinh -Sd dgng mdy ddnh bong true cam NAM So 1+2 (Thing 1+2 nim 2013) NGHIEN CUfU-TRAO 061 - H i thong thu day danh bong sfl dung cap b i n h rang rpng ban Z= 30 Chieu dai thu diy 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 danh bdng tinh xac true cam Tfl yeu cau dat ra, tren co sd so 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 2): Ga dong thdi chi tiet true cam, dinh vi bang mui tam, truyen dpng thong qua toe truyen gin vdi ranh then tren true cam Viic kep chit thflc hien bang xi lanh nen Cum ga diy danh bdng (hinh - 4): Ga cnpn day d i n h bdng t r i n true cd dia bao ngoii Cac cuon d i y n i y Iuon dflcfc gifl cd dinh bdi xi lanh nen qua trinh gia cong xi lanh ehi nha kep thUe h i i n tua day danh bdng - Cum d i n hUdng day d i n h bdng (hinh - 3): Co n h i i m vu dUa d i y d i n h bdng tiep xuc vdi be mat cam gia cong va nang l i n gia cong xong, lay chi tiet khoi true ehinh Viec nang dflpc thUc hien thong qua hai xi lanh nen Tren cum dan hfldng day danh bong bo tri ede chfla doi trpng de thay doi lflc ty len be mat cam gia cong - Cum tua day d i n h bdng (hinh - 1): Cd chfle nang tua diy danh bong den vung day mdi sau mdi chu ky gia cong xic 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 - 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 hinh cam flng Yeu cau cua be thong dieu khii'n: Hai che dp van hanh: che dp dieu khii'n TAP CHf CO KHf VIET NAM 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, ning 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 ehinh -* can d i n h bdng xuong vung gia cong S6 1+2 (Thing 1+2 nam 2013) NGHIEN C f l u - TRAO OOl -* sau thdi gian gia eong d i dinh, can dinh bong nang lin KET LUAN -* tit dpng ca ham dung dieh Iam ngupi -»true ehinh dflng May danh bdng true cam quay -• xi lanh nha kep chi tiet 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 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 Dflng may cd vat vao vung gia cong dang d i n h bdng - Nang suat: 2.800 chi tiet/ ea - Dp n h i m ehi tiet true cam gia cdng tren may: Rz < 3,2pm - Sd ehi tiet gia cong I lan ga: 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 nen Hinh 6-Sdd6 khoi hi thong dieu khien mdy ddnh bong true cam ãôBa [ - ' \tmmn\ '•T-mlr-%- wmrzi :::^S= nga [ISTO] '• | i ^ "••• i( Miy dinh bdng true cam xe may ehe tao nhfl trin Kha nang dieu khien: Dieu khien tfl dpng bang PLC: lfla chpn che dp gia cdng dieu khii'n tay hoac tfl dpng Bao code loi tren bing hien thi vi dflng miy 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 chu ky tua day danh bdng, chieu dai tua day dinh bdng binh? - 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 dip 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 dieu ehinh thong so eong nghi, hieu qui de tang nang suat gia cong, may hoan toan cd kha^^^ Oa Hinh - Mdy ddnh bong true cam BK.CMPM.2012 TAPCHf C O KHf VIETNAM V S6 1+2 (Thing 1+2 nam2013) NGHIEN cflu - TRAO DOI nang d i p flng tot yeu eau gia cong tinh nao ma khong bi rang bupc bdi thong so eong xic true cam xe miy, eung cap cho eac h i n g sin nghe dinh sin xuat dpng CO xe may nflde, thay the thiet bi - Thiet ke bp ga day danh bdng linh hoat ngoai nhap de cd the dii'u chmh gia cong dflpc nhieu loai true cam vdi eac kich thflde khac Hudng phit 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 tich cflc t r i n may danh bong de cd the Idem tra trUc tiep dp nham 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 - Md rpng cho viee tinh toan thiet ke gia cong ehi tiet true cam 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, 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 TAP CHf CO KHf VIET NAM V S6 1+2 (Thang 1+2 nam 2013) ... theo nhu thiet ke L A CHON PHUONG PHAP DANH BONG TRUC CAM XE MAY True cam dpng co xe may cd cau tao gdm cam: Cam nap va cam xa (cam thai) Cae cam dUpe che tao lien true Do nham be mat, dp cflng... the thii bing hdn hpp mdi dUpc dieu khien bang true cam True cam cd cac vau cam day cac supap len va xuong de ddng va md cac van Bien dang cam quyet dinh thdi diem ddng, md cae supap, vay nd... chong mai mon cao, giup true cam tri kha nang dieu khien ehinh xic supap nap va x i q u i trinh Iam viec lau dai eua dpng eo Htnh - True cam xe mdy Chi tiet true cam Iam viee dieu kien ma sat