NGHIEN Cflu TRAO OOl V THiiT Kg CHt TAO MAY D^M BAO TAY TU" DONG DESIGN AND DEVELOPMENT AUTOMATIC GLOVES COUNTING MACHINE Nguyen Ngpc Phiioing', Tran Thj Thiiy Nga' 'Trudfng Dai hpc Su pham Ky thuat TR Ho Chi Minh 'Tnlorng Dai hpc Ihu Dau Mpt - Binh Duong TOM TAT ^ Mdy dem hao tay tU ddng hoat dong theo nguyen ly rulo cuon mdt nda bao tay ket hap vd chuyen dong cua bdng tdi di xep vd dim bao tay thdng hdng Nhdng hao tay dUdc tao thdnh td nh khuon canh tay Cac cdm bien dem so lUdng hao tay vd so bao tay thilu tren mdn hinh HMI M dlfng ddng cd servo, dim dong thdi hai hdng bao tay nen cai thien dugc toe donggoi Todn bd h cua mdy dUdc dieu khien bdi bd dilu khiln trung tdm PLC Tii khoa: Mdy dim sdn pham, bao tay ABSTRACT This automatic gloves counting machine working is based on the principle of rollers combine the movement of the conveyor belt for plucking the half sheded gloves, and then stack and count th These gloves are made up of hand-arm mold The glove sensors count and display the missing glov bers from human machine interface (HMI) It uses the servo motor, double directions counting, im the packing speed The system of the machine is controlled hy PLC controller Keyword: Gloves, counting machine GIOI THl£U Bao tay rat quan trpng lao dpng sdn xuat hdng Con ngifdi thUcfng xuyen ti^p xiic vdi cac hoa chat dpc hai nhU: Dau md, dung m6i, thuoc bap ve thUc vat, cac hoa chat dpc hai, Vi vay, viec sii dung bap tay de tranh tiep xiic tr^ic ti^p vdi mdi trUdng lam viec lam tang nguy hiem den ngUdi lap dpng la can thiet Hi?n nay, cupc song cang dUoc nang cao, si,i am hieu ve nhiJng tac hai anh hudng den siic khde Clang cdng cao hon, nen Udc tinh hdng nam 50 ty ddi gdng tay difpc tieu thu tren khap the gi6i trpng co nU6c ta De dap iing dupc nhu cau SLi dung bao tay thi phai tang nang suat san xuat, nhUng d nUcfc ta van phai sit dung nhieu nhan cong tiep xuc trUc tiep vao qua trinh san xuat dan den nang xuat san xuat thap, Vi the, tam quan trpng cua van de nghien ciiu la giam nhan cong tiep xiic trUc tiep vcfi moi trUdng lam viec, giam cac khau san xuat de tang nang xuat dap iing nhu cau thi trUdng tieu thu bap tay va sd dung giao dien ngUdi diing HMI (HumanMachine Interface) hien sd bao tay thi€u tr^n man hinh lam cho ngUdi sd dung de dang ddng goi Cau ko chuan, can chinh sda !ai ^ TAPCHlCOKHlVIETNAM,Sd 12nam2013 QQ NGHIEN cflu - TRAO Ddi THIET KE CO KHf t l ] , [4] Tfl nhflng thi^u sdt va dfla theo nguyen ly chuyen ddng cua day chuyen san xuat bao tay ciing nhfl k^ thfla flu nhflpc diem cua phfldng phap kep bang nen, nhdm tac gia (nhdm) da dfla phflpng an de bo sung va hoan chmh nhflng thieu sdt tfl phflpng an kep dd la phflpng phap cudn vdi sP dd nguyen ly (hinh 3) Hinh 1: Lay bao tay thdnh pham bang tay Trfldc day, phflpng phap lay bao tay la phUPng phap thu cdng, ddi hdi ngfldi cdng nhan phai nhanh tay viec lay bao tay Nang suat va hieu qua cua phflpng phap cdn thap va ngfldi tham gia san xuat tiep xuc lien tuc vdi mdi trUdng lam viec dpc hai vdi nhiet dp cao (hinh 1) Nguyen ly hoat ddng cua may: Khi bao tay dflpc dfla den cd tin hieu cam bien se lam cho ddng ca dien (1) chay truyen chuyen ddng qua bp banh rang (2), bd banh rang truyen ddng cho bd dai (4) la cho rulo (6) quay vdng dflng nhd tin hieu cam bien de cudn bao tay tfl day chuyen xudng bang tai xep (5) Ddng thdi Iflc bang tai xep (5) chuyen ddng qua lai de bao tay cuon xudng nam thang hang, gpn gang Khi du lUpng bao tay can lay dat cho may thi bang tai x^p (5) cd nhiem vu chuyen sd bao tay tren bang tai xep (5) qua bang tai dan (9) den nPi ddng gdi.[4l Hinh 2: Lay bao tay thdnh pham bang phtiOngphdp kep nen Van de dat la phai thay the ngfldi qua trinh lay bao tay de tang suat san xuat bao tay de tang hieu qua kinh te Luc dd ddi may lay bao tay sfl dung phflpng phap kep cd cP cau gidng nhfl chiec kiem dung nen de kich ca cau kim kep bao tay vdi chuyen ddng quay trdn keo bao tay xudng bang tai (hinh 2) Phflpng phap cd Uu diem la bao tay xep thang hang, ca cau don gian Nhflng nhflpc diem phflpng phap phat tieng dn Idn, dd sfl va dap vao lam cho cP cau thieu chinh xac theo thdi gian lam viec, ddi kep trat bao tay La mdt san pham san xuat tfl Dai Loan vdi chi phi kha cao May dung nen de kep bao tay dan den lflc truyen tai thap ^ Hinh 3: Sd nguyin lyphtidngphdp cuon bao tay 1-Ddng cd diin 2_ Bdnh rdng 3_Pully dai 4_Ddy dai 5_Bdng tdi xip 6_Rulo 7_6 dd 8_Truc 9_Bang tdi ddn He thdng dien dieu khien: sfl dung PLC (Programmable Logic Controller), bien tSn dieu khien ddng cP pha, ddng cP AC SERVO, cam bien de he thong hoat ddng linh hoat, on djnh va nang suat nhat Tfl nhflng y tfldng va so nguyen ly khai quat qua trinh hoat ddng cua may bao tay nhdm da di den thiet ke cP va he thong di?n dieu khien cho may Thiet ke dfla mdi ISn lay bao tay tfl day chuyen, nen viec lay bao tay tfl d3y chuyen rat phflc tap, ddi hdi cP cau cudn bao tay phai phu hpp vdi khoar^ each nhflng khudn bao tay sfl cua day chuyen (hinh 4) TAP C H i CO KHi VIET NAM, S6 12 nam 2013 NGHIEN CUTU - TRAO D O I ; '• Md hinh thiet ke CP 3D may dem bao tay tu dpng dupe gidi thieu tren hinh BaoEiai \i:p j j ^ A J ^ iidan ^ HJnh 5: Khodng cdch cdc khudn bao tay sti Chieu dai tinh tfl canh tay thfl nhat den canh tay thfl tfl la 750mm Vi vay, nhdm chpn chieu dai cua rulo la 850mm de dam bao cac bao tay khdng hi rpi ngoai Do cd hai hang day chuyin canh tay nen so rulo dflpc sfl dung la: cai (hinh 5) PSfc -;^::;:::^ ITinh Thiet kemdy dem bao tay md hinh 3D THIET KE HE THONG DIEU KHIEN 151 3.1 He thong dien Hinh Rulo cuon keo bao tay Vl chieu dai bao tay la 250 mm, de rulo cd thi xip dupe bao tay thi chu vi tiep xuc vdi bao tay phai Idn hPn ho?ie bang 250 mm, nen chu vi nfla dfldng trdn cua rulo: C = TTR > 250mm R>^ ^ 97.62mm Tfl md hinh thiet ke ca tren, chiing tdi da chpn thiet bi va thiet ke he thdng dien phu hpp vdi cp cau cd dap flng yeu cau ket hpp vdi day chuyen san xuat bao tay hien cd cua cdng ty He thdng dien dflpc thiet ke nhieu module va he thdng dieu khien lap trinh dflpc, can thay ddi nhiem vu dieu khien thi chi can thay ddi chflOng trinh nap vao bd nhd bp dieu khien (Hinh 8) Do dd, chpn ban kinh rulo R = 80mm Cac rulo dflpc phu ben ngoai bang cao su day 10mm, vi cao su cd dp ma sat cao de cudn bao tay xudng, va cac ranh tren ldp cao su de qua trinh cudn bao tay khdng hi no bao tay neu lam bang nhfla hoac vat lieu khac de xay hien tflpng trflpt trpn Cac cap rulo dflpc thiet ke qua bd banh rang de gi^m tdc dp va tang momen De dam bao ldp cao su khdng tich khdi phan thep ben trong, thi phan cung rulo tiep xuc vdi bao tay phai Idn hon Vl dfldng trdn Bang tai dan dflPc thiet ke vdi kich thfldc U 1100x1100x800 (mm) Idn hpn khoang cAch bao tay hang trfldc va hang sau dflpc rulo cudn n i m xuong bang tai xep, vdi muc dich de nhan hai hang bao tay tfl bang tai xep den khu vflc ddng gdi TAP CHi Hinh 8: He thdng dieu khien mdy dim bao tay CO KHi V I £ T NAM Sd 12 nam 2013 NGHIEN cflu-TRAOedi Trong SP mach dien he thdng (hinh 9), ngudn cung cap la ngudn pha 380V cho bien ap chuyen doi 220V cung cap cho cac ddng cP, mach ngudn 24VDC, den bao, cdi bao, coil contactor Trong dd, nguon 24VDC la ngudn cung cap cho cac thiet bi nhfl: PLC, ngudn HMI, cam bien, PLC nhan tin hieu vao tfl cac cam bien, nut nhan va giao tiep vdi HMI de ngd dieu khien cac relay va xuat xung dieu khien ddng cp AC SERVO HMI hien thi so bao tay dem va so bao tay thieu de ngfldi sfl dung de dang ddng gdi Sensor tac ddng ngd vao PLC de dieu khien ngat tin hieu dpng cp va dem san pham theo yeu cau Hinh 9: Sd mach diin hi thdng Relay gdm relay ddng ngat dflpc dieu khien bdi ngd PLC, dd relay de dieu khien ddng ngat contactor dieu khien ddng CO pha (2 ddng eo dflpc inverter (bien tan) dieu khien toe dp de cap rulo cudn bao tay, dpng ca cdn lai dung de dieu khien bang tai dan de dfla bao tay tdi khu vflc ddng gdi), relay cdn lai dieu khien Light/Buzzer bao hieu sd bao tay gan du Ddng cP AC SERVO dflpc dung de dieu khien vi tri dao chieu bang tai xep nhan bao tay tfl rulo cudn xudng lam cho bao tay thang hang va gpn gang Cac nut nhan STOP, START, RESET E.STOP, CONVEYOR BELT ngUdi dung thao tac trflc tiep tren bangdieu khien hoac tren man hinh giao dien HMI de dieu khien boat ddng cua may khien tuan tU cua may dem bao tay tfl ddng la lap bieu tuan tfl diiic nang the hien cac bfldc thflc hien qua trinh day, cac d vudng the hii cac bfldc qua trinh vudng kep la bfldc dau tien cua chu trinh Qua trinh diiac thflc hien tfl dau den cuoi theo thfl tfl cac bUdc Cac d hmh chfl nhat the hien cac bfldc xuat tin hieu Dieu kien de chuyen sang bfldc ki tiep dflpc viet ke ben vach ngang cat dfldng chuyen tilp giiJa hai bfldc (hinh 10) Ban dau he thdng chd khdi ddng, dflpc khdi ddng, thi cam bien quang (CBl) va cam bien quang (CB2) chd bao tay tfl day chuyen (2 ben), cd tin hieu bao tay tfl day chuyen cam bien quang I (CBI) va cam bien quang (CB2) dem bao tay ddng thdi lflc cam bien quang (CB3) dem canh tay cho tdi cd gia tri bang thi relay kich cap rulo quay cuon bao tay xuong bang tai xep Luc dd, bang tai xep thflc hien dao chieu (cd counter d i m lan dao chieu) nhan bao tay tfl rulo keo xudng Counter d i m sd Ian quay rulo cd gia tri bang 23 thi cdi keu va den nhap nhay bao hieu so lUpng bao tay gan du theo yeu cau Counter tiep tuc dem sd lan dao chieu bang tai xep neu counter bang 48 lan thi bang tai xep chay thang dfla bao tay qua bang tai dSn tdi ndi ddng gdi, luc dd thi counter d i m so lan rulo quay du 25 thi hien sd bao tay thieu tren HMI (Human-Machine-Interface) va qua trmh dfldc lap lai tfl dau Luc do, nhan nut bang tai dan chay lay bao tay hang sau 3.2 Dieu khien may dem bao tay [2] Bfldc dau tien de thiet ke he thdng dieu TAP CHi CO KHi VIET NAM, Sd 12 nam 2013 Hinh 10: Bieu tuan tu chtic ndng NGHIEN Cflu-TRAOBPI T H T J C NGHIfiM VA THAO L U A N tinh nang: 4.1 Thong s6 ky thuat - Rut bao tay on dinh, khdng hi rach bao tay; - Nang suat 10.000 bao tay/gid; - Giao dien HMI dpn gian d l sfl dung; - Hien thi sd bao tay dem dflpc chu ky (100 cai/25 lan rut) va so bao tay thieu; - May hoat ddng chinh xac thdi gian lien tuc (3 ca) Bdng Thong so ky thuat mdy dem bao tay DaixRongxCao 2500x1200x800 (mm) 10.000 bao tay/gid 220V-50HZ PLC HMI 2KW Cuon va xep thang hang va khdng lam rach bao tay Dim chinh xac so bao tay, thdng bao so tdng so bao tay dem dflpc va so bao tay thieu moi chu ky Nang suat Ngu6nd(p B$ dieu khiln Giao diln vSn hanh Cong suat tilu thii Ccf cau cudn bao tay Co cSu dim bao tay Hinh 13: ThUc nghiem vd hiiu chinh mdy KET L U A N Hinh 11: Thti nghiem mdy dem bao tay trin ddy chuyin sdn xudt ^ LE QUAN TECHNOLOGY CO LW fOBAOWJlWO* lo"lJ) Ifll " l U i • 1 1 1 1 , Q •il*" Da che tao cdng may dim bao tay tfl ddng dfla tren yeu cau thflc te thiet ke mdt he thdng ca va dieu khien thich hpp de lay va d i m bao tay tren day chuyen, mang hieu qua kinh te Viec flng dung kit qua nghien cflu da di vao thflc te va cd y nghia rat quan trpng day chuyen san xuat bao tay May dim bao tay cd the thay the cdng nhan lam viec d khau rut xep va dem bao tay pham • START! ' RESET ' Ngay nhan bai: 05/11/2013 Ngay phan bien: 10/12/2013 Ngfldi phan biln: PGS.TS Dao Quang Kl, Khoa Co - Dien, Trfldng Dai hpc Ndng nghiep Ha Ndi fl "m - Tai lieu tham khao: Hinh 12: Thti nghiem mdy dem bao tay tren ddy chuyin vd giao diin HMI 4.2 Ket qua Mdy dem bao tay da dflpc thflc nghiem trln day chuyen san xuat (hinh 11) nham danh gid hoat ddng cung nhfl viec hieu chinh may (hinh 13) Qua thdi gian h i | u chinh, may dim bao tay da hoat dpng tdt tren day chuyen vdi cac [1], Trinh Chat, Le Van Uyen, Tinh todn thiet kehe ddn ddng cd (xap 1,2), NXB Giao due [2] Nguyin Ngpc Can, Ky thudt dieu khien tti ddng, NXB Trfldng Dai hpc Bach khoa TP Ho Chi Minh [3] Nguyen Trpng Hiep, Chi tiet mdy (tap 1), NXB Giao due [4] Nguyen Dac Lpc, Ninh Dflc Tdn, So tay Cdng nghi Che tao mdy (tap 1,2), NXB Khoa hgc va Ky thu^t [51 S7-200 Programmable Controller - SIEMENS TAP C H i C O K H i V I £ T NAM, Sd 12 nam 2013 ... mdy dem bao tay DaixRongxCao 2500x1200x800 (mm) 10.000 bao tay/ gid 220V-50HZ PLC HMI 2KW Cuon va xep thang hang va khdng lam rach bao tay Dim chinh xac so bao tay, thdng bao so tdng so bao tay dem... - Rut bao tay on dinh, khdng hi rach bao tay; - Nang suat 10.000 bao tay/ gid; - Giao dien HMI dpn gian d l sfl dung; - Hien thi sd bao tay dem dflpc chu ky (100 cai/25 lan rut) va so bao tay thieu;... ly (hinh 3) Hinh 1: Lay bao tay thdnh pham bang tay Trfldc day, phflpng phap lay bao tay la phUPng phap thu cdng, ddi hdi ngfldi cdng nhan phai nhanh tay viec lay bao tay Nang suat va hieu qua