NGHIEN CUTU-TRAO Ddi \/NGHIEN CLFU, IJNG DUNG ROBOT HAN D i HAN Dl/ai LOP THU6C RESEARCH AND APPLICATIONS OF WELDING ROBOT TO WELD UNDER THE DRUG LAYER Hoang Minh ThuanS Lirong Van Ti^n', Dao Quang Ki\ Luc Van Thirong' 'Tnrdng Cao dang Cong nghiep va Xay dung ^Hgc vien Ndng nghiep Viet Nam ^Phdng Thi nghiem Trong diem Cdng nghe Han va Xii ly Be mat, Vien Nghien ciiu Ca TOM TAT Bdi bdo gidi thieu ve kit qud ung dung Robot hdn de hdn du&i lap thuoc; nghien cuu dac diem cdng nghe hdn duoi lap thuoc, cdc thdng sd cdng nghe chu yeu Ket qud kiem tra (td chuc te vi, cung te vi) cua mdu nghien cuu thuc nghiem viec irng dung robot hdn Tir khda: Robot hdn, hdn tif ddng, hdn dual lap thuoc ABSTRACT TTiis article presents the application results of welding robot to weld under the drug layer; research on the characteristics of welding technology under drug layer, the main technological parameters, inspection results (microstructure, microscopic hardness) of experimental study samples in robot welding applications Keywords: Welding robot, automatic welding, welding under the drug layer ISSN 0866 - 7056 TAP CHi CO KHi VIET NAM, Sd 1+2 nam 2016 www.colchivietnam.vn ^ NGHIEN CUTU-TRAO Ddi DAT VAN DE Trong sir nghiep cdng nghiep hoa, hidn dai hoa dat nude van de tu dgng hoa san xuat cd vai ttd dac biet quan ttpng Robot cdng nghiep dugc su dung rat nhieu ttong cac ITnh vuc khac nhau, ttong cd nganh han Hien nay, sd lugng robot han chiem den 25% tdng sd robot cac loai, vi vay sd lugng robot han dugc thay the cac phuang phap ban khac rat nhieu cd cac tmh nang nhu: + Cd tinh tu dgng cao va nang suat cao; + Cd the thuc hien dugc cac dudng han phiic tap; + Chat lugng mdi han tdt va tinh thim my cao; + Cd the thuc hien cac thao tac lap di, lap lai lien tuc; + Giai phdng ngudi lao ddng khoi tac ddng cd hai han robot nang cao dp tin cay ciia mdi han Mptihi dugc lap trinh hap ly, cac robot se tao nhihig mdi han y nhu ttdn cac vat han cung kich thude va quy each Chuyen ddng cua que han dugc hr dpng hda se giam nguy co mac Idi ttong thao tac, vay giam phd pham va khdi lugng cdng viec ph^ lam lai Robot khdng nhiing lam viec nhanh hon ma cdn cd the hoat ddng lien tuc sudt ^DL hieu qua han nhieu so vdi mdt he thdng han tay Qua trinh ban dup'c tu ddng hda giai phoi^ ngudi cdng nhan khdi nhiing tac hai han tiep Xlic vdi biic xa hd quang, viy han noi^ chay, ddc, NOI DUNG NGHIEN ClTU 2.1 Robot han iTng dung chii ydu cua robot cdng nghiep la han va lip rap Gin 25% robot ttong cdng nghiep la robot han Cac robot lip rap chidm 33% sd robot ttdn thd gidi, cd mat nhigu nhit ttong cac nha may san xuit xe hoi va dd dien tu Mdt qua trinh han gdm nhidu thao tac lap di lap lai tten nhimg chi tidt gidng se thich hgp dd tu ddng hda Sd lugng chi tiet cin ban ttong qua trinh chd tao quydt dinh xem cd nen tu ddng hda qua trinh ban hay khdng Ndu bmh thudng phai didu chinh dd cac chi tidt an khap vai nhau, hoac cac mdi han qua rong hoac cd vi tri khac tren mdi chi tidt thi khdng thd tu dgng hda dugc Nhimg Igi ich ldn nhit ciia han tu ddng la cd chinh xac va nang suit cao Han bing ISSN 0866 - 7056 TAP CHl CO KHi VIET NAM, Sd l + n a m www.cokhivietnam.vn Hinh Robot NGHIEN COTU - TRAO D | 2.2 Han ho quang dirdl lop thu^c - Hd quang dugc bao bpc kin bdi thude han ndn khdng lam hai mat va da ciia thg han Han hd quang duoi ldp thude bao ve cdn Lugng khdi (khi dpc) sinh ttong qua ttinh han ggi la han hd quang chim (SAW - Submerged rat it so vai han hd quang tay Arc Welding) \k qua ttinh han nong chay ma hd quang chay giiia day han (dien cue han) va vat - De ca hoa va tu ddng hda qua trinh han ducfi mdt lop thude bao ve Han hd quang han dudi lop thude cd nhung dac didm: 2.3 Cac thdng so cdng nghe han - Nhiet lupmg hd quang rit tap trung va nhiet dp rat cao, cho phep han vcri tdc ldn Tnrdc tien hanh han cac thdng sd Vi vay, phuang phap han cd thd han nhiing cdng nghe phai dugc tinh toan lua chgn tnrdc va chi tidt CO chieu day lorn ma khong cin phai vat lap mdt quy trinh han hgp ly mep 2.3.1 Kich thif&c dien cue (ddy hdn) d^ Kich thude didn cue (dJ anh hudng tdi hinh dang mdi han va chieu sau ngau d mpt cudng ddng nhat dinh I wngwp Hinh Anh huong de din hinh ddng moi hdn vd chieu sdu ngdu cua moi hdn (I^ = 600A, V^ = 750mm/p U^ = 30v) Hinh Hdn ho quang duoi lop thuoc 2.3.2 Bien dp hdn - Chat lugng lien ket han cao bao ve tdt kim loai mdi han khdi tac dung cua oxi va nita ttong khdng xung quanh Kim loai mdi han ddng nhit vd phan hda hgc Ldp thuoc va xi han lam lien kdt ngudi cham ndn it bi thien tich Mdi ban cd hinh dang tdt, deu dan, it hi cac khuydt tat nhu khdng ngiu, rd khi, mit va bin tde - Giam tieu hao vat lieu (day han) Dien ap han anh hudng tdi chidu dai hd quang giua dau miit dien cue va viing kim loai ndng chay, neu didn ap cao thi chieu dai hd quang se lan va ngugc lai dien ap thap thi chidu dai hd quang ngan Dien ap han it anh hudng tdi tdc dap ciia dien cue ma nd anh hudng chii yeu tdi hinh dang tiet dien ngang cua mdi han va hinh dang bd mat mdi ban '^ ISSN 0866-7056 TAP CHi CO KHi VIET NAM, Sd 1+2 nam 2016 www.cokhivietnam.vn NGHIEN CUfU - TRAO 061 2.3.4 Tdc dp hdn Vdi sir ket hgp ciia cudng dp ddng di^n va dien ap han, su thay ddi cua tdc dp han se anh hudng tdi hinh dang ciia mdi han Ndu tdc dp ban tang thi nhiet cip tten dan vi dai cua m^i han se giam dong thdi kim loai didn day tren Hinh Anh hudng cua dien dp tdi chiiu ddi ho mdt dan vi dai cua giam se lam cho mdi han nh6 quang giUa ddu miit diin cue vd viing kim loai nong khdng dii dp chac chdy frf = 6mm I^ = 850A, V^ = 750mm/p) 2.3.3 Dong dien hdn SnmfMc Ddng dien ban la thdng sd quan ttgng nhit, bdi nd dieu khien tdc ndng chay ciia day ban do didu khien dugc tdc dip, dieu khien chieu sau ngau va lugng chay cua kim loai ca ban Khi ddng dien qua cao thi chieu sau ngau qua ldn, dd mdi han cd khuynh hudng chay thiing, nd ciing din tdi lang phi kim loai ban hinh phan Idi cua mdi han, dieu cung dan tdi tang su co ngdt gay irng suat va bien dang ban Ddng didn qua thap mdi han se khdng du ngau, khdng chay dd gay khuyet tat ban Mnm/sec lOmm/MC 20ninfuc Hinh Anh huong cua toe hdn den hinh dgng mdi hdn (d^ = 6mm U^ = 34v, I^ = 850A} 2.3.5 Tam vdi dien c^c (IJ Vdi mat ddng didn tten 125A/mm^ thi tim vdi dien cue la mpt thdng sd quan ttpng Ci mat dp ddng didn cao thi nhiet di?n trd ciia dien cue giiia bep h^n va dau miit di$n cue tang, dd tdc dp nong chay cua dien cyc ciing tang Vdi quy trinh ban thi tam vdi di?n cue bang 8-10 lan dudng kinh dien cue la hgp ly, ttong viec lap quy tiinh han can dieu chinh tam vdi dien circ hop ly dih dat tdc dg chay hpp ly nhat vdi tiing tri sd cua ddng didn Hinh Anh hu&ng cua cu&ng dg dong dien hdn (I) tdi hinh ddng vd kich thuac moi hdn (d^ = 6mm, U^ = 34v, V^ = 750mm/p) Hinh Tdm vai dien c^c (IJ ISSN 0866 - 7056 TAP CHi CO KHi V I £ T NAM, Sd 1+2 nam 2016 www.cokhivietnam.vn ^ NGHIEN CtfU - TRAO OOl KET QUA VA THAO LU^^N 3.1 Xay dirng quy trinh, han thii nghiem Quy trinh han tii dpng ducri lop thuac dugic lap dvra tren ca so ly thuyet cac tieu Afdi td chiec te vi viing kim logi ca bdn (KLCB) be chuin \h han cua Hiep hpi Han My (AWS D1.1) vaTCVN 6259-6:2003 Quy trinh han se duoc tijn hanh theo so sau (hinh 9) Anh to chiec ti vi vimg dnh huong nhiet (AHN) ben n.llaap;U»iitapUiUe >if iiiiiwiwtihiB]—^Q^Bhfcm Anh to chuc ti vi viing hdn ben du&i Hmh Cdc bu&ctienhdnh kiem tra quy trinh hdn Su dung mau thii de phan tich kdt qua; che dp han dugc tinh toan xac dinh nhu sau: Ddng didn ban I^ = 200A; dien ap ban U^ - 30V; tdc dp 30m/h Anh id chiec ti vi vung dnh hu&ng nhiet (AHN) ben phdi Day han GM-70S theo TCVN 6259-6:2003 SW3 cd dudng kinh 1,2mm; sii dung thude ban ndng chay 3.2 Ket qua kilm tra Anh td chuc te vi vimg kim loai ca bdn (KLCB) bin phdi 3.2.1 Kit qud phan tich td ehifc tS vi mdu hdn Hinh 10 Anh chup cdc viing phdn tich cda mdi hdn bdng kinh hiin vi soi noi Anh to chuc te vi viing hdn ben tren Nhan xet: - Mau han gdm cd ba viing: Kim loai ca ban, anh huong nhiet va han - Td chiic te vi viing kim loai co ban gdm ferit va peclit, cd cac dai peclit song song vdi phuamg can (vudng goc vdi mdi ban) - Td chiic td vi viing ban gdm cd ferit bidn hat thd vay quanh cac viing ferit kim/ bainit+ ferit da canh ban ^ ISSN 0866 - 7056 TAP CHi CO KHi VI£T NAM, Sd 1+2 nam 2016 www.cokhivietnam.vn NGHIEN CtfU - TRAO DOI 3.2.2 Bo dp cimg te vi (HV 1,0) Do dp Cling dpc theo dirong chinh giiia ciia mau IQioang each giiia cac vi tri a vung KLCB (1-2, 2-3, 3-4,16-17, 17-18, 18-19) la 2nrai; Khoang each giira cac vi tri a vung AHN (4-5, 5-6, 6-7, 13-14, 14-15, 15-16) la 0,5mm Vi tri 10 la tam vung han Hinh 12 Hdn tr^c Hinh 13 Hdn Piston KET LUAN Ket qua nghien ciiu iing d\mg Robot han de han dudi ldp thuoc da duac umg dung dk han mdt sd san pham ttong thuc tien Ket qud ki^m tta (td chiic td vi, dp ciing te vi) ciia mau nghiSn Cliu thuc nghiem ttong vide iing dung robot han cho ket qua tdt; Mau ban gom cd ba viing: kim loai CO ban, anh hudng nhiet va ban; Dp ciing ciia vung ban cao nhat, sau la dp ciing viing anh hudng nhiet, thap nhat la vung ndn Hinh 11 Sa vi tri do cimg Cac vi tri 8, 9, 10, 11, 12 la cac diim viing han do: Vi tri 8, 12 la di§m each ducmg nong chay (fijsion line) 2mm, vi tri 9, 11 la diem chinh giua cua 8-10 va 10-12 Bdng Ket qud dp cimg " S ^ ^" °S^' ^" D? Cling fHV) STT I5U ^ ^ • • ^ • 13 ^^^^^^H u 173,1 IB1.2 ô , .'18 171^ 19 161.1 ^ã'?W5^ '^-' '^"t'J.Sffi* 'r'vtfi^ ' • •tf9l4' ~ Nhdn xet: H 174,1 169,8 172.9 162.0 Dp cirng ciia vung han cao nhit, sau la dp Cling vung anh hudng nhiet, thip nhat la viing nen San pham iing dung: Ngay nhan bai: 12/12/2015 Ngay phan bien: 15/01/2016 Tai lieu tham khao: [1] Dao Quang Ke, Tang Ba Bai, Dao Nguyen Quang Linh, Hoang Van Chau (2014), Nghien cmt ddc dim link cong n^hi hdn tif dong che tao kit cau thep bdng thu hdn gom, T^p chi Co Viet Nam, s6 1+2 nam 2014., , [2] Dao Quang Ka, Luc Van Thirong, Hoang Van Cl^ (2013); Mot so ket qud nghien cmi thuc nghidm danh^ linh cdng nghe hdn cua thuSc hdn gom hdn ket thep ", Tuyen tap cac cong trinh khoa hgc Hgi nghi Khoa hoc Toan quoc v^ ca khi, NXB Khoa hgc Tit nhien va Cong nghe, Ha Noi [3] Ddo Quang KS va cong so (2012); Nghien ciiu chi ta ihuoc hdn gom bdng vdt lieu nuac de hdn ket ca thep thay the cho thude hdn nhgp ngogi; DS tai cSp Bp Giao due ya Dao t^o, ma s6 82012-11-12 [4] Nguyin Diic Thing (2009); Ddm bdo chdt limghan; NXB Khoa hpc vk Ky thuat Ha N$i [5] Ngo Le ThSng (2006); Cong nghe hdn di?n nong ch (tap 1,2); NXB Khoa hoc va Ky thu^t Ha Npi [6] Du an JICA-HIC; Robot hdn cong nghidp, NXB Lao dong Xa hOi [7] Lgp trinh cho Robot hdn Almega AX- V6 dihdn mQ dudng cong phuc tgp (2009), Luan van Thae sy ky thu?^ Tniong Dgi hoe Ky thuat Cong nghiep, Dai hgc Tiiai Nguyen [8] http://www.weldtec.com.vn ISSN 0866 7056 TAP CHi CO KHi VIET NAM Sd 1+2 nam 2016 www.cokhivietnam.vn ... NOI DUNG NGHIEN ClTU 2.1 Robot han iTng dung chii ydu cua robot cdng nghiep la han va lip rap Gin 25% robot ttong cdng nghiep la robot han Cac robot lip rap chidm 33% sd robot ttdn thd gidi, cd... quan ttpng Robot cdng nghiep dugc su dung rat nhieu ttong cac ITnh vuc khac nhau, ttong cd nganh han Hien nay, sd lugng robot han chiem den 25% tdng sd robot cac loai, vi vay sd lugng robot han... lien tuc; + Giai phdng ngudi lao ddng khoi tac ddng cd hai han robot nang cao dp tin cay ciia mdi han Mptihi dugc lap trinh hap ly, cac robot se tao nhihig mdi han y nhu ttdn cac vat han cung kich