B GIO DC V O TO CNG HA X HI CH NGHA VIT NAMTRNG HBK H NI c lp T do Hnh phcNHIM V THIT K TT NGHIPH v tn sinh vin:Nguyn Trng Phi Phm Ngc HiuKiu Qu Cnh Trn Ngc hngNguyn Anh Dng Trn Hong MnhNguyn Duy Hip V Hoi NamHong Anh ThngKha : 47 Khoa : C kh Ngnh : C in tI. TI : Nghin cu, thit k, ch to h thng MiniCIMII. NI DUNGChng I. Tng quan v h thng CIM.Chng II. Cu trc h thng CIM.Chng III. Thit k my CNC.Chng IV. Thit k robot.Chng V. Thit k h thng bng ti.Chng VI. Xy dng h iu khin cho h thng CIM.Ph lc bn v.Ph lc chng trnh iu khinIII. Tp th cn b hng dn: GS.TS. Trn Vn chTS. Nguyn Huy NinhIV. Ngy giao nhim v thit k n .V. Ngy hon thnh n Ngy .thngnm 2006CH NHIM B MNCN B HNG DN n tt nghip C in t 3 - K47B GIO DC V O TOTRNG I HC BCH KHOA H NIBN NHN XT TT NGHIPH v tn sinh vin:Nguyn Trng Phi Phm Ngc HiuKiu Qu Cnh Trn Ngc HngNguyn Anh Dng Trn Hong MnhNguyn Duy Hip V Hoi NamHong Anh ThngKha : 47 Khoa : C kh Ngnh : C in tTp th cn b hng dn:GS.TS. Trn Vn chTS. Nguyn Huy Ninh1. Ni dung thit k n tt nghip.NGHIN CU - THIT K - CH TO H THNG MINICIMChng I. Tng quan v h thng CIM.Chng II. Cu trc h thng CIM.Chng III. Thit k my CNC.Chng IV. Thit k robot.Chng V. Thit k h thng bng ti.Chng VI. Xy dng h iu khin cho h thng CIM.Ph lc cc bn v.Ph lc chng trnh iu khin.2 n tt nghip C in t 3 - K472. Nhn xt.a) Nhn xt ca cn b hng dn:.......................................................................................................... ................................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. ......3 n tt nghip C in t 3 - K47b) Nhn xt ca cn b duyt......................................................................................................................... .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. .............................................................................................................................. ......4 n tt nghip C in t 3 - K47LI NI UH thng sn xut tch hp CIM (Computer Intergrade Manufacturing) l h thng sn xut tin tin nht hin nay v ang ngy cng c ng dng rng ri trn th gii. Khi nim v CIM tin s Joseph Harrington a ra vo nhng nm 1973. Mc d khi nim ca ng v CIM cha c hon chnh, ngy nay danh t CIM tr nn rt quen thuc trong cch ni v sn xut. CIM tr thnh chin lc nn tng ca tch hp cc thit b v h thng sn xut thng qua cc my tnh hoc cc b vi x l t ng. So vi cc h thng sn xut truyn thng, CIM c nhiu u im vt tri hn hn. H thng CIM khng nhng lm tng nng sut v cht lng sn phm, h gi thnh ca sn phm m cn c kh nng linh hot cao, p ng c nhng thay i nhanh chng ca th trng. Trong ni dung n tt nghip ca sinh vin ngnh c in t, vi s hng dn tntnh ca ccthyhngdnGS.TS.Trn Vnch,TS. Nguyn Huy Ninh b mn Cng ngh Ch to my, trng i hc Bch khoa H Ni. Chng em chn ti Nghin cu, thit k h thng MiniCIM ph hp vi kh nng cng nh thi gian thc hin. thc hin ti,trc ht chng em nghin cu, kho st v cc h thng CIM v dang c ng dng, sau la chn h thng ph hp thit k v ch to. Qu trnh thit k, ch to c kh v qu trnh thit k h thng iu khin c tin hnh ng thi. n c chia lm6 chng, mi chng c tch ra cc phn nh hn, ng thi c km theo ph lc v cc bn v v ph lc v chng trnh iu khin.Chng I. Tng quan v h thng CIM.Chng II. Cu trc h thng CIM.Chng III. Thit k my CNC.Chng IV. Thit k robot.Chng V. Thit k h thng bng ti.Chng VI. Xy dng h iu khin cho h thng CIM.Ph lc bn v.Ph lc chng trnh iu khinSau thi gian thc hin, ti hon thnh kt qu bc u t c nhng thnh cng nht nh.5 n tt nghip C in t 3 - K47Chng em xin chn thnh cm n cc thy c trong b mn Cng ngh Ch to my gip chng em trong qu trnh thc hin ti. c bit l cc thy GS.TS. Trn Vn ch, TS. Nguyn Huy Ninh tm huyt hng dn chng em. Chng em xin chn thnh cm n s gip ca cc cn b phng th nghim FMS & CIM, xng c kh b mn Cng ngh Ch to my, khoa C kh, trng i hc Bch khoa H Ni gip chng em hon thnh ti.Nhm SV thc hin nNguyn Trng PhiKiu Qu CnhNguyn Anh DngPhm Ngc HiuNguyn Duy HipTrn Ngc HngTrn Hong MnhV Hoi NamHong Anh Thng6 n tt nghip C in t 3 - K47MC LCCHNG I. TNG QUAN V H THNG CIM..............................................14I. Cc khi nim c bn v CIM........................................................... .............141.1.nh ngha CIM..................................................................................... ....141.2. Cc thnh phn c bn ca CIM....................................................... ..........14II.S pht trin ca CIM........................................................................ ..........192.1.S pht trin ca CIM trn th gii.............................. .............................192.1.1. Lch s pht trin ca CIM................................................ ..................192.1.2. Hng pht trin ca CIM..................................................... ..............202.2. S pht trin ca cc h thng CIM Vit Nam........................................25III. ng dng v hiu qu ca CIM ......................................................... .........253.1. ng dng ca CIM....................................................................... ..............253.2. Hiu qu ca CIM....................................................... ...............................26CHNG II. CU TRC H THNG CIM................................................ .......27I. My CNC........................................................................................ ...............28II. Robot................................................................................. ...........................302.1. ng dng robot cng nghip trong h thng CIM. ........................... .........312.2. Cc yu cu i vi cc robot hot ng trong h thng CIM....................31III. H thng vn chuyn tch tr.................................................................. .....333.1. Thit b k thut ca h thng vn chuyn - tch tr........................... ........333.2. H thng vn chuyn - tch tr chi tit gia cng ca CIM..........................343.2.1. Chc nng ca h thng vn chuyn - tch tr chi tit gia cng...........343.2.2. Phn loi h thng vn chuyn - tch tr chi tit......................... .........353.3. H thng vn chuyn - tch tr dng c ca CIM......................... ..............373.3.1.Chc nng ca h thng vn chuyn - tch tr dng c........................373.3.2. Mt s loi h thng vn chuyn - tch tr dng c.............................373.4. iu khin h thng vn chuyn - tch tr...................................... ............384.1. Thnh phn ca kho cha t ng............................................. .................404.2. Cc loi kho cha t ng....................................................... ...................404.2.1. Dng gi cn cu................................................................................. .404.2.2. Dng cn cu cu..................................................................... ............414.2.3.Dng gi trng lc.......................................................... ......................424.3. B tr cc kho cha t ng trong h thng CIM.......................................42V. H thng iu khin............................................................... .......................455.1. B iu khin logic kh lp trnh PLC trong cc h thng CIM.................455.2. Phn mm tch hp.................................................................... .................48VI. H thng kim tra............................................................................ ............516.1. Cc dng kim tra.......................................................................... .............516.2. Cu trc ca h thng kim tra t ng..................................... .................526.2.1. Mc cao................................................................................. ..............526.2.2. Mc trung bnh................................................................. ...................527 n tt nghip C in t 3 - K476.2.3. Mc thp.......................................................................................... ....536.3. Ch hot ng ca h thng kim tra t ng...................................... ..536.4. Kim tra trng thi k thut ca cc phn t v mun trong CIM............546.5. Cc thit b kim tra trong CIM......................................................... .........556.5.1. Cc loi attric.............................................................................. .......556.5.2. Cc my o kim t ng................................................... .................57VII. H thng lp rp t ng...................................................................... ......597.1. Cu trc ca h thng lp rp t ng................................. .......................597.2. Cc hnh thc t chc lp rp t ng.................................... ....................607.2.1. Lp rp c nh...................................................................... ..............607.2.2. Lp rp di ng............................................................................. .......60CHNG 3: THIT K MY CNC.......................................................... ..........61A - TNG QUAN V MY CNC................................................ ....................61I. Lch s pht trin............................................................ ...............................611.1 Lch s................................................................................................ .........611.2. Mt s my NC............................................................. .............................63II. Th no l my CNC.Cc khi nim c bn .................... ............................642.1. Khi nim.............................................................................. .....................642.2. Trc my CNC......................................................................................... ...652.3. Nguyn tc xc nh h trc ta ca my CNC. ...................................65III. H thng iu khin my CNC trong cng nghip......................................663.1. Phn cng h iu khin my CNC.............................................. ..............673.1.1B x l trung tm (CPU)..................................................................... .673.1.2.B nh............................................................................. .....................683.1.3 H thng truyn dn ( BUS)......................................... ........................683.1.4.Truyn dn Servo. .......................................................................... ......693.2. Phn mm. ................................................................................... ..............703.2.1. Phn mm iu khin ......................................................................... .703.2.2. Phn mm ghp ni ............................................... .............................703.2.3. Postprocessor ......................................................................... .............703.2.4. Phn mm ng dng ....................................................... ....................70IV.Nguyn tc lp trnh gia cng trn my CNC v cc phng php nhp d liu. .............................................................................................................. .....704.1. Lp trnh gia cng................................................................................. ......704.2. Cc phng php nhp d liu............................................ .......................73V. Khc bit gia NC v CNC............................................................... ............75VI.Mt s my CNC trong cng nghip................................................ ............766.1. My khoan....................................................................................... ...........766.2. My tin.................................................................................................... ..776.3. My phay.................................................................................. ..................796.4. My hn im................................................................................ .............826.5. My ct dng tia la in............................................... ............................82VII. S lc v ngn ng lp trnh G-code.......................... .............................838 n tt nghip C in t 3 - K477.1. Cc lnh c bn dng trn nn my khoan/phay................................ .........837.2. Chu trnh gia cng mt s chi tit ................................................... ...........847.3. Chu trnh gia cng hc trn................................................ ........................857.4. Chu trnh gia cng hc ch nht.................................................. ...............877.5. Mt s quy nh c bn...................................................... ........................88VIII. Phng php iu khin my CNC trong cng nghip.................. ...........928.1. Cc im gc, im chun................................................................. .........928.1.1. im gc ca my M...................................................................... .....928.1.2. im chun ca my R.............................................................. ..........928.1.3. im gc ca phi W im gc chng trnh P v im g t C.......938.1.4. im gc ca dng c.............................................. ...........................948.2. Cc h thng iu khin my CNC............................................................ .968.3. Cc ch tiu gia cng ca my CNC.................................... .....................1008.3.1. Thng s hnh hc.............................................. ...............................1008.3.2.Thng s gia cng............................................................................. ..1018.3.3. Nng sut gia cng........................................... .................................1018.3.4. chnh xc ca my CNC.............................. ................................1028.3.5. tin cy ca my CNC................................................ ...................1038.3.6. Tnh vn nng ca my CNC................................................... ..........104B - CC PHNG N XY DNG M HNH MY CNC.......................106I. La chn phng n di chuyn ca cc trc ta ................................ ......1061.1. Phng n phi c nh............................................................ ................1061.2. Phng n phi di chuyn trn trc Y , dng c gia cng di chuyn theo 2 trc X v Z...................................................................................................... .1071.3. Phi di chuyn theo 2 trc X v Y, dng c gia cng di chuyn theo trc Z........................................................................................................................ ..1081.4. So snh 3 phng n.............................................................................. ...109II. La chn c cu truyn ng..................................................... .................1102.1. Vt me ai c thng .................................................. .............................1102.2. Vit me ai c bi .......................................................................... ..............1112.3. Phng n dng ai............................................................ ......................113III. La chn loi khoan..................................................... .............................114IV. La chn c cu dn hng cc trc :................................................. .......117V. Kt lun....................................................................................... ................119C - KT CU C KH CHNH CA MY CNC V QUY TRNH GIA CNG CC CHI TIT IN HNH............................................... ...............120I. Kt cu chung ca my CNC.............................................. .........................1201.1. Phn c nh......................................................................... ....................1221.2. Phn di chuyn dc theo trc Z................................ ................................1221.3. Phn di chuyn dc theo trc X. ............................................ ..................1231.4. Phn di chuyn dc theo trc Y........................................................ .......123II.Cc chi tit chnh trong my CNC.......................................... .....................1242.2. Chi tit dn hng trung gian.............................................. .....................1259 n tt nghip C in t 3 - K472.3. Chi tit sng trt mang c trc Z....................................... .....................1262.4. Chi tit rnh trt mang c trc Z.......................................................... ...1272.5. Chi tit bn my.............................................................................. ..........1272.6. Chi tit Et kp phi..................................................................... ............128III.Quy trnh cng ngh gia cng cc chi tit in hnh :...................... ...........1283.1 Thit k quy trnh cng ngh gia cng g ng c....................................1283.1.1. Xc nh ng li cng ngh............................................. ..............1283.1.2. Lp qui trnh cng ngh...................................................... ...............1283.1.3. Thit k nguyn cng..................................................................... ....1293.2 Thit k quy trnh cng ngh gia cng sng trt.................................... ..1363.2.1.Xc nh ng li cng ngh........................................... ...............1363.2.2. Lp qui trnh cng ngh...................................................... ...............1363.3.3.Thit k nguyn cng.................................................................... ....137D - NGUYN L IU KHIN MY CNC...................................... ...........142I. S khi ca h thng iu khin ............................................................. 1421.1. Khi ngun............................................................................... ................1421.2. Khi my tnh............................................................................. ..............1421.3. Khi Vi iu khin.............................................................................. ......1431.4. Khi cch ly quang.................................................................... ...............1431.5. Khi mch cng sut v Role ng in ng c khoan..........................1431.6. Khi c cu chp hnh............................................. ................................143II.Cc phng php iu khin gia cng (cc phng php ni suy ):............144CHNG 4: THIT K ROBOT CHO H THNG........................................148A - KHI NIM V PHN LOI ROBOT.................................. .................148I. Khi nim v Robot..................................................... ................................1481.1. Robot v Robotics....................................................... .............................1481.2. Robot cng nghip............................................................................. .......1501.3. Bc t do ca Robot ( DOF: Degrees of Freedom )............................. .....1511.4. H to ( coordinate frames )................................ ................................1511.5. Trng cng tc ca robot ( Workspace or range of motion )...................1521.6. Kt cu chung ca Robot cng nghip..................................................... .153II. Phn loi Robot........................................................................................ ...1552.1. Phn loi theo kt cu................................................................. ..............1552.2. Phn loi theo kiu iu khin..................................................... .............1552.3. Phn loi theo h thng truyn ng...................................................... ...1552.4. Phn loi robot theo ng dng.................................................... ..............156III. Vai tr ca robot trong h thng MiniCIM.................... ............................1563.1. Yu cu i vi robot cng nghip.......................................... .................1563.2. c tnh cng ngh ca robot cng nghip................................... ............156B - TNH TON V THIT K ROBOT....................... ...............................162I. Cc thng s k thut ca Robot..................................................... .............162II. ng hc cho robot.................................................................................. ...1632.1.Cc php bin i thun nht.............................................................. .....16310 n tt nghip C in t 3 - K472.2.H ta thun nht................................................................... .............1632.3. Cc php bin i ............................................................... .....................1642.3.1.Php bin i tnh tin (Translation)......................................... ........1642.3.2.Php quay (Rotation) quanh cc trc to .....................................1652.3.3.Php quay tng qut......................................................................... .1652.3.4.Bi ton ngc : tm gc quay v trc quay tng ng................1682.3.5.Php quay Euler................................................................ ................1702.4. Phng trnh ng hc robot................................................ ....................1722.4.1.B thng s Denavit-Hartenberg (DH)........................... ..................1742.4.2.c trng ca cc ma trn A : ........................................... ...............1752.4.3.Xc nh T6 theo cc ma trn An : ............................................... ....1762.4.4.Trnh t thit lp h phng trnh ng hc ca robot : ...................1772.4.5.Thit lp phng trnh ng hc ca robot....................... ................1782.4.6.Gii h phng trnh ng hc ca robot......................................... .180III. Trnh by nguyn l hot ng ca robot................... ...............................182IV. Tnh ton, thit k mt s chi tit in hnh ca robot...............................1834.1. Mt s chi tit in hnh ca robot. ............................. ............................1834.2. Thit k quy trnh cng ngh gia cng mt s chi tit ca robot...............1854.2.1. Quy trnh cng ngh gia cng khi V ( c cu tay kp )....................1854.2.2. Quy trnh cng ngh gia cng gi trt........................ .....................203V. C cu tay kp ca robot................................................................ .............2045.1. Khi nim v phn loi tay kp................................ ................................2045.2. Kt cu ca tay kp............................................................................... ....2055.2.1. Tay kp c kh.................................................................................... 2055.2.2. Tay kp chn khng v in - t.................................... ....................2085.2.3. Tay kp dng bung n hi............................................... ...............2095.2.4. Tay kp thch nghi.............................................................................. 2105.3.Tnh ton tay kp robot.................................................................. ..........2105.3.1. Tnh lc tip xc.............................................................. ..................2115.3.2. Tnh lc dn ng........................................................... ...................2115.3.3. Tnh ng sut tip xc....................................... ................................212C -H THNG IU KHIN CA ROBOT................................ ...............213I. H thng chp hnh................................................................................ ......2131.1. Ngun in cp................................................................................. ........2131.2. Khuych i cng sut....................................................................... .......2131.3. ng c................................................................................ ....................2141.4. Xilanh kh nn................................................................ ..........................2151.5. Truyn ng ng c kh........................................................... ...............215II. H thng cm bin dng trong robot...................................................... .....2162.1. Cc khi nim v c trng c bn v cc loi cm bin................... .......2162.1.1. Khi nim v phn loi cm bin............................................... ........2162.1.2. ng cong chun ca cm bin...................................... .................2182.1.3. Cc c trng c bn ca cm bin.................................................... 22011 n tt nghip C in t 3 - K472.2. La chn cm bin.................................................... ...............................2252.2.1. Cm bin t cm..................................................................... ...........2252.2.2. Cm bin h cm.......................................................... .....................228III.H iu khin ca robot................................................................. ...........2313.1.H thng iu khin kh nn..................................................... ...............2313.1.1.u, nhc im ca kh nn............................................... ..............2313.1.2.My nn kh - Thit bphn phi kh nn:......................... ..............2313.1.3. Cc phn t trong h thng iu khin..............................................2323.1.1. Van iu khin dng kh........................................ ............................2403.1.4.H thng kh nn trong robot............................................. ...............2413.2. H thng iu khin in.............................................................. ............2413.2.1. Gii thiu v ng c DC.................................................. ................2413.2.2. Gii thiu v ng c bc............................................................... .2423.2.3. Mch iu khin robot dng vi iu khin AVR Atmega88-20PU.....256CHNG 5. THIT K BNG TI. ................................ ...............................269A - GII THIU CHUNG V THIT K.................................................... ..269I. Gii thiu chung v cng dng v phn loi my chuyn lin tc...............269II. Chn loi bng ti....................................................................... ................270III.Chn c cu dn ng .................................................... ...........................2733.1 La chn loi ng c in......................................... ..............................2733.2. La chn cp bnh rng truyn ng............................................... .........2743.3. H thng iu khin kh nn...................................................... ...............274IV. Thit k bng ti......................................................... ...............................2764.1. Gii thiu s lc cu to ca bng ti........................................... ..........2764.2 Gia cng c chi tit pallet.......................................................... ................2824.2.1.Phn tch chc nng v iu kin lm vic ca chi tit.....................2824.2.2. Phn tch tnh cng ngh trong kt cu ca chi tit.................. ..........2834.2.3. Xc nh dng sn xut............................................................ ..........2834.2.4.Xc nh phng php ch to phi.................................................. 2834.2.5. Xc nh th t cc nguyn cng.................................................... ...283B IU KHIN BNG TI................................................................ ........289I.L do dng PLC............................................................................... .............289II. Tng quan v PLC............................................................... .......................2912.1.Gii thiu chung v cc b PLC............................................ ..................2912.2. Cc b PLC thng gp.......................................................................... ..2912.3. Chc nng ca cc b PLC............................................................... ........2922.4. Cc b phn c bn ca PLC........................................................ ............2922.5. S hot ng ca PLC theo vng qut chng trnh................................293III. K thut lp trnh iu khin PLC............................................... ...............2953.1.Khi nim v lp trnh PLC................................................... ..................295Cc loi ngn ng lp trnh cho PLC........................................................ ...296Cc bc tin hnh lp mt chng trnh PLC....................................... .....297Cc hm logic c bn ca PLC............................................................ ........29812 n tt nghip C in t 3 - K47IV. Tm hiu v PLC S7200...................................................................... .......2994.1. Cu hnh cng......................................................................................... ..2994.2. Cu trc b nh........................................................... ...........................3004.2.1Phn chia b nh................................................ ...............................3004.2.2. Vng d liu................................................................. .....................3004.2.3. Vng i tng...................................................................... ............3044.3. Thc hin chng trnh.......................................... ................................3054.4. Cu trc chng trnh ca S7_200.......................................................... 305V. Ngn ng lp trnh ca S7_200.......................................................... .........3075.1. Phng php lp trnh............................................................................ .3075.2. Bng lnh ca S7-200.................................................................. ...........3075.3. C php lnh ca S7_200............................................... ........................3175.3.1.Ton hn v gii hn cho php......................... ................................3175.3.2.Lnh vo/ra.......................................................................... .............3185.3.3.Cc lnh ghi/xa gi tr cho tip im..............................................3195.3.4.Cc lnh logic i s Boolean..................................................... ......3195.3.5.Cc lnh tip im c bit:....................................................... .......3205.3.6.Cc lnh so snh....................................................... ........................3205.3.7.Lnh nhy v lnh gi chng trnh con....................................... ....3225.3.8.Cc lnh can thip vo thi gian vng qut......................................3235.3.9.Cc lnh v iu khin Timer........................................................... .3245.3.10. Cc lnh iu khin Counter............................................ ................3265.3.11. Cc lnh v s hc................................................... ........................3275.3.12. Lnh tng, gim mt n v v lnh gi tr thanh ghi......................3295.3.13. Cc lnh dch chuyn ni dung nh............................... ...............3315.3.14. Cc lnh lm vic vi mng........................................................ .....3315.3.15. Cc lnh dch chuyn thanh ghi..................................... ..................3325.3.16. Cc lnh lm vic vi bng:(ch c trong CPU214).................... .....3345.3.17. Cc lnh tm kim: Ch s dng i vi CPU214............................3355.3.18. Cc hm i d liu........................................................... ..............3355.3.19. Xy dng cu trc vng lp............................................ .................3365.3.20. ng h thi gian thc............................................ ........................3365.3.21. Truyn thng trn mng nhiu ch................... ...............................3375.3.22. Ngt v x l ngt.......................................................................... ..3385.3.23. S dng ngt truyn thng................................................... ............3415.3.24. S dng b m tc cao..................................................... .........3415.3.25. S dng hm pht xung tc cao............................... ...................344VI. Chng trnh iu khin bng ti (dng S7-200)......................................34413 n tt nghip C in t 3 - K47CHNG I. TNG QUAN V H THNG CIMI. Cc khi nim c bn v CIM.1.1.nh ngha CIM.CIM (Computerize Integrate Manufacturing ). L h thng sn xut tch hp c s tr gip ca my tnh. C nhiu nh ngha khc nhau v CIM v cc nh ngha li c nhiu ngha khc nhau, ty thuc vo mc ch ng dng ca n. Sau y l mt vi nh ngha v CIM.CngtyCc h thngtngv my tnhCASA(The Computer and AutomatedSystems Association)cahi nhngnhsnxut SME(Societyof Manufacturing Engineers) nh ngha: CIM l mt h thng tch hp c kh nng cung cp s tr gip ca my tnh cho tt c cc chc nng thng mi, bao gm cc hot ng t khu tip nhn n t hng cho n cung cp sn phm ca mt nh my sn xut.T in ca cng ngh tin tin AMT nh ngha: CIM l mt nh my t ng ha ton phn, ni m tt c cc qu trnh sn xut c tch hp v c iu khin ca my tnh.Cng ty my tnh ca M IBM cho rng: CIM l mt ng dng, c kh nng cung cp c s nhn thc cho vic tch hp dng thng tin ca thit k sn phm, ca k hoch sn xut, ca vic thit lp v iu khin cc nguyn cng.Hng SIMENS ca c li cho rng: CIM khng phi l mt sn phm hon thin m l mt chin lc v l mt khi nim t cc mc ch th trng ca mt nh my.1.2. Cc thnh phn c bn ca CIM.CIM l mt cng ngh tin tin qun l cng ty sn xut thng qua dng thng tin. Cng ngh thng tin l mt cng c tch hp rt mnh v l c s h tng t mc ch trong mt x nghip tch hp. Trong th gii hin nay cng ngh thng tin ng vai tr quyt nh trong qun l x nghip. ng thi s pht trin ca cc tiu chun lin kt c nh hng ln n CIM v m ng cho vic tch hp ha.Cc cng ngh tch hp trong CIM rt a dng v bao gm nhiu lnh vc cng ngh phc tp khc nhau. Tuy nhin y ch cp n mt s cng ngh tin tin ca CIM.T ng ha vn phng: l vic t ng ha cc qu trnh ca vn phng bng cc cng ngh thch hp. N c th c xem nh mt my tnh m t hu ht cc ti liu vn phng c truyn i cc mng ni kt tt c cc thit b sn xut v cc cng ngh ca mt cng ty no bng cc h thng thng tin qun l. T ng ha vn phng cho php:14 n tt nghip C in t 3 - K47- To ra nhiu thng tin thng mi.- Quay vng nhanh cc t liu thng mi.- Gim sai s trong qun l.- Gim mt bng lm vic.- Phc v khch hng tt hn- Kh nng ra quyt nh tt hn.- Gim s nhn vin vn phng.- Nng cao trnh ca nhn vin vn phng.Thit k c s tr gip ca my tnh CAD: - Nng cao nng sut v gim thi gian thit k sn phm.- Gim thi gian thit k dng c v g c 12 25%.- Nng cao cht lng thit k, do nng cao c cht lng sn phm.- To ra c ti liu c cht lng cao.- Loi tr c cc cng vic lp li.- Tit kim thi gian v gim gi thnh khi ch to sn phm mi.- Tiu chun ha tt hn.- Hon thin giao din gia thit k v sn xut.- Gim thi gian tr li kt qu u thu.My iu khin s CNC: My iu khin s CNC l thit b c kh nng gia cng chi tit theo mt chng trnh lp sn cho mi kch thc mong mun v theo mt quy trnh cng ngh lp sn. Cc my CNC c trang b mn hnh v bn phm, do vic vit v din gii chng trnh c th c thc hin trc tip trn my. Cc my CNC cho php loi tr nh hng ca cng nhn v nng cao cht lng sn phm. Cc my CNC c s dng cho nhiu mc ch khc nhau nh: Gia cng, lm sch, nh bng, kim tra, nn p, rn hoc dp.Sn xut c s tr gip ca my tnh CAM: Cho php thc hin nhiu dng nguyn cng khc nhau khi thay i chng trnh iu khin. CAM c th kt hp vi cc dng cng ngh khc nh CAD, NC, c s d liu v thit b kim tra cht lng to thnh nhng phn t chnh ca CIM. H thng CAM c th bao gm: Robot, cc my NC v FMS. u im ca h thng CAM l:- Tng nng sut lao ng.- Nng cao cht lng sn phm.- Gim din tch sn xut.- p ng nhu cu ca khch hng nhanh hn.15 n tt nghip C in t 3 - K47- Ci thin iu kin lm vic ca cng nhn v loi tr nhng iu kin lm vic nguy him.Kim tra cht lng c s tr gip ca my tnh: Bao gm qu trnh gim st v qu trnh o kim tra sn phm. H thng kim tra cht lng c s tr gip ca my tnh CAQC (Computer Aided Quality Control) cho php:- Gim thi gian gim st qu trnh sn xut.- Gim chi ph gin tip cho cc gim st vin.- Gim chi ph tng i t cht lng sn phm xung 50 90%.- Nng cao cht lng sn phm.- Gim cng vic lp li trong qu trnh kim tra cht lng sn phm.- Ci thin iu kin lm vic.H thng bo qun v tm kim t ng: L h thng x l vt liu cp pht chi tit cho cc khu vc v tm kim chi tit t cc khu vc. H thng bo qun v tm kim t ng cho php:- Kim tra vt liu bng my tnh, xc nh trng thi v v tr ca vt liu.- Thng qua mng iu khin cc h thng ph tr v CIM.- Gim ph phm gia cng.- Loi tr qu trnh x l lp li i vi vt liu.- Tng nng sut lao ng.- Gim thi gian lp rp (khong 25%).Cng ngh nhm:L mt khi nim sn xut khi m cc chi tit c gia cng theo nhm da vo c tnh kt cu hoc quy trnh cng ngh. Cc chi tit c ghp nhm theo c tnh kt cu c coi l h chi tit thit k v cc chi tit c ghp nhm theo c tnh gia cng c coi l h chi tit gia cng. Vic ghp cc nhm chi tit theo c tnh ny cho php thc hin nhng cng vic ging nhau mt cch hiu qu nht. ng dng cng ngh nhm to iu kin thun li cho vic t chc h thng CIM, ng thi cng ngh nhm cn cho php:- Hon thin khu thit k va tng tnh tiu chun ha ca thit k.- Gim khi lng cng vic trong khu x l vt liu.- Gim 20% 80% thi gian sn xut.- Gim 15% 20% khi lng lao ng.- Gim 20% 30% chi ph dng c ct.- Gim 20% 60% thi gian chun b sn xut.- Gim 15% 30% thi gian t hng v cp hng.16 n tt nghip C in t 3 - K47- n gin ha vic lp quy trnh sn xut v rt ngn chu k sn xut.- Hon thin qu trnh kim tra cht lng sn phm.- Kh nng thch ng nhanh vi th trng, do gim c thi gian t hng v thi gian cp hng.- Tng cng s hp tc gia cc t chc ca cng ty.- Nng cao nng sut lao ng.- Gim 15% 70% ph liu sn xut.Lpquytrnhcngnghcstrgipcamytnh:CAPP(Computer Aided Process Planning) l xc nh th t nguyn cng vi nhiu thng s cng ngh ch to hoc lp rp. CAPP cho php lp c quy trnh mi gia cng chi tit, thay i quy trnh ang c ng dng c quy trnh mi tin tin hn hoc thc hin cc cngvic lpchngtrnh nomt cch nhanh chng v thun tin. CAPP cho php: - Gim thi gian thit k sn phm mi.- Gim chi ph cho vic tip nhn chi tit mi.- Gim thi gian thit k dng c ct.- Tng kh nng khai thc h thng CIM.- Gim thi gian lp quy trnh cng ngh.- Gim s lng dng c ct b hng.Tbogiacng:CM(CellularManufacturing)lthit b snxut thng dng ch to cc chng loi chi tit khc nhau.Cng ngh nhm trong quy trnh sn xut to ra CM. H thng sn xut ca mt cng ty c t chc thnh cc t bo gia cng. Cc t bo gia cng bao gm: My gia cng v cc quy trnh ch to mt loi chi tit no . T bo gia cng cho php:- Gim ng k thi gian gia cng chi tit.- Gim 20 30% khi lng lao ng.- Gim 15 30% chi ph cho thit k x thut.- Gim thi gian chun b sn xut.- t hiu qu cao trong x l vt liu.- Nng cao cht lng sn phm.- n gin ha vic lp quy trnh cng ngh ch to v quy trnh kim tra.Robot: Cc li ch m robot em li:- Tng nng sut lao ng.- Nng cao cht lng sn phm.17 n tt nghip C in t 3 - K47- Gim ph liu v chi ph cho nhng cng vic lp li.- Gim chi ph cho nguyn cng kim tra cht lng sn phm.- Gim chi ph lao ng trc tip.- C kh nng thc hin nhiu nguyn cng khc nhau.H thng FMS:FMS c coi l phin bn u tin ca CIM, ng dng h thng FMS cho php:- Tng tnh linh hot khi gia cng cc loi chi tit khc nhau.- X l nhiu loi vt liu khc nhau.- H thng sn xut tip tc hot ng khi c mt my ngng hot ng.- Hon thin sc lao ng ca con ngi.- Hon thin qu trnh kim tra cht lng snphm.- Gim 50% gi thnh sn xut.- Gim 30% chi ph cho dng c ct.- Gim 50 90% khi lng lao ng.- Tng h s s dng my.- Nng cao cht lng sn phm.- Gim ph liu.- Gim 42% din tch mt bng sn xut.- Nng cao nng sut lao ng ti 200 350%.18 n tt nghip C in t 3 - K47II.S pht trin ca CIM.2.1.S pht trin ca CIM trn th gii.2.1.1. Lch s pht trin ca CIM.Vo nm 1954, NC c a vo sn xut v sau , vo nm 1955 s pht trin ca cng c x l lp trnh t ng m u cho s xut hin ca CAM. CAD bt u xut hin vo khong nm 1960 vi cng ngh thit k cao nh c s tr gip ca my tnh. Vi s xut hin ca vi mch vo u nhng nm 1970, my tnh bt u c ng dng trong tt c cc lnh vc ca sn xut. Khi nim v CIM c tin s Joseph Harrington a ra vo nhng nm 1973. Mc d khi nim ca ng v CIM cha c hon chnh, ngy nay danh t CIM tr nn rt quen thuc trong cch ni v sn xut. CIM tr thnh chin lc nn tng ca tch hp cc thit b v h thng sn xut thng qua cc my tnh hoc cc b vi x l t ng.Mc ch hin thc lu di ca CIM c th t c thng qua vic lp k hoch pht trin tm v m ca cc cng ty. S tch hp c hiu qu i hi kin thc chuyn su v tt c cc qu trnh cng ngh v hiu bit su sc v cc thit b sn xut ca cng ty. cho vic ng dng CIM c hiu qu th vic tch hp cc cng ngh tin tin AMT phi c thc hin thng qua cc my tnh. My tnh ch hot ng nh cc ta ph ca cng ngh. Tuy nhin, khng c my tnh th vic tch hp s khng c hiu qu.B quc phng Ha k ng mt vai tr quan trng trong vic m ng cho cng ngh CIM. Nm 1975 h bt u lp chng trnh sn xut c tr gip ca my tnh ca lc lng khng qun AFCAM( Air Force Computer Aided Manufacturing). Chng trnh ny cho php tip cn tt hn i vi cng ngh sn xut. Nh kt qu m sn xut c tr gip ca my tnh tch hp ICAM (Intergrated Computer Aided Manufacturing) c xy dng vo nm 1976 ti phng th nghim vt liu ca khng qun Hoa K di s ch o ca y ban k thut v Vinhnlmquc gia NAEC(National Academyof Enegineering Comittee) v sn xut c s tr gip ca my tnh CAM. Sau khi b chng trnh ICAM vo nm 1985, khng qun Hoa k bt u xy dng chng trnh CIM. Cng ty Cc h thng t ng v my tnh CASA ca hi nhng nh sn xut SME c thnh lp vo nm 1975 tp trung kin thc trong lnh vc my tnh v t ng ha cho s pht trin ca sn xut. L mt hi khoa hc v o to, CASA/SME truyn b khi nim v CIM vi ng o qun chng v xy dng vng trn nh my CIM nhm cung cp cho cng nghip sn xut mt ci nhn ng n v CIM. Hi ng k thut ca CASA/SME thng nht 5 vn c bn ca vng trn CIM nh sau: Qun l sn xut v qun l ngun nhn lc, sn xut v qu trnh, lp k hoch sn xut v kim tra, nh my t ng ha v qun l ngun thng tin. Vng trn CIM m t kha cnh tch hp ca CIM i vi quan im v qun l sn xut. CIM c nhng u im sau y:19 n tt nghip C in t 3 - K47- Tnh linh hot ca sn phm, ca sn lng v ca vt liu.- Nng cao nng sut v cht lng ca gia cng.- Hon thin giao din gia thit k v sn xut.- Gim lao ng trc tip v lao ng gin tip.- Thit k c nng sut v chnh xc cao.- Tiu chun ha cao v s dng vt liu hp l.- Tit kim thi gian v mt bng sn xut.- To c s d liu chung loi tr cc b phn cha d liu c lp.- Loi tr cc cng vic lp li khng cn thit.- Gim thi gian gim st sn xut v s cn b thc hin cng vic ny.- C u im cnh tranh i vi cc i th cnh tranh.Khi nim v CIM c a ra trong thi gian u c v nh khng t c tngthct, tuynhinvi cngnghngynayth CIMt cmcch khng my kh khn. Tng lai ca k thut l ng dng CIM vi tc ng ca tr tu. Sn xut tr tu l con ng ca tng lai. V vy, cng ngh sn xut v cc h thng CIM s bao gm c tr tu gip cc nh my ch to ra cc sn phm c cht lng cao, gi thnh h.2.1.2. Hng pht trin ca CIM.CIM o.Sn xut o l khi cc n v sn xut c lin kt vi nhau trn phm vi ton cu gii quyt tt c cc vn t sn xut n phn phi sn phm. Ngy ngay c nhiu s lin kt ton cu trong rt nhiu cc lnh vc cng nghip. Do , nh my o c nh ngha nh mt mng lin kt ton cu v ch c nh my o mi m bo c s cnh tranh v th trng ton cu. T khi nim nh my o ngi ta a ra khi nim v CIM o. Nghin cu v CIM o v ng dng n trong phm vi ton cu tr nn bc thit. ng dng CIM o l mt bc tin quantrngtrongsnxuttnglaicLin(nm1977)khixng.Tuy nhin, vothi imnycngcrt nhiucngtrnhvnh myoca Makatsoris v Besant c cng b. CIM o c th thch ng vi sn xut v phn b ton cu. Trung tm nghin cu cng ngh sn xut tin tin ca trng i hc tng hp nam Australia a ra khi nim v vng trn CIM o. Vng trn CIM o ny m t cc iu kin th trng ton cu. 20 n tt nghip C in t 3 - K47Hnh 1.1. Vng trn CIM o21 n tt nghip C in t 3 - K47Ch thch cc khi nim: Global Competition & EnvironmentalConcerns (S cnh tranh ton cu v nhng quan tm ti vn mi trng)Mass Customisation (S lng khch hng)Shorter Product Life Cycles (Chu k vng i ngn ca sn phm)Innovation & Faster Respone (S i mi v p ng nhanh)Global Manufacturing Systems(H thng sn xut ton cu)Strategic Planning & Control (Hoch nh chin lc v iu khin)Virtual Eterprise (Cc nh my o)Interconnected ATMS (Lin kt qua li gia cc cng ngh tin tin)Dedicated&Distributedbut InterconnectedManagement (Phnnhv nhanh nhy nhng phi lin kt qua li trong qun l)InterconnectedGlobal &Local Functional Units(Ccnv snxut c lin kt tng khu vc v trn phm vi ton cu)Global Information & Communication Links (S lin kt v thng tin v giao tip ton cu)Shared Data (Chia s d liu)Integrated Enterprise Infrastructure (Kt cu h tng tch hp ca cc nh my sn xut)Khi nim v vng trn CIM o cng nh vng trn CIM c cc nh sn xut SME ( Society of Manufacturing Engineers) pht trin v n c gii thch nh sau ( Gii thch c bt u t vng trn ngoi cng):Vng ngoi m t tnh trng th gii hin ti, l cnh tranh ton cu, s quan tm mi trng, hng ha tha mn nhu cu ca khch hng, chu k ch to sn phm ngn, yu cu sng to sn phm v tr li nhanh.Vng th hai m t cc h thng ton cu, l cc nh my o, cc h thng sn xut ton cu v nhng hoch nh sn xut mang tnh chin lc.Vng th ba gii thch cch thc thc hin, l s lin kt ton cu v sn xut, s lin kt ca cc cng ngh tin tin, s chuyn mn ha v phn phi ring bit nhng c qun l chung.Vng th t m t s cn thit ca thng tin v lin kt ton cu, ng thi s cn thit phi phn chia d liu gia cc h thng.Vng trung tm m t kt qu ca CIM nh mt nh my tch hp ton cu thng qua cu trc tch hp.22 n tt nghip C in t 3 - K47toiukinthunli chovicutvoCIMvgipnncng nghip sn xut, nhiu nh nghin cu tm ra nhng gii php ng dng CIM. Di y l mt s hng nghin cu v CIM:- Hp l ha CIM v chin lc qun l CIM.- Nh my tch hp cho CIM vi gianh gii a l.- Mng lin kt ca CIM.- Cng c v cng ngh tin tin cho vic ng dng CIM.- M hnh h thng sn xut.-ngdngtr tunhnto AI(Artifical Intelligence)nhFuzzylogic, mng notron tch hp tr tu ton phn cc h thng sn xut.Ch tiu hp l ha v chin lc qun l CIM c nghin cu theo chiu hng: Ccnghincuutptrungvovicmbochonhqunlcc nguyn tc ng dng CIM trong mi trng sn xut ca mnh.Ch tiu nh my tch hp cho CIM vi gianh gii a l c nghin cu theo cu trc v m hnh ha ca nh my tch hp, theo hp tc CAD/CAM ton cu thng qua cc h thng ph tr ca CIM.Ch tiu mng lin kt ca CIM bao gm ng dng mng trn phm vi rng v Internet cho CIM, tng cng thng tin bng gi liu tch hp mi quan h gia khch hng v nh sn xut, cc d liu qun l trong cc h thng CIM.Ch tiu cng c v cng ngh tin tin cho vic ng dng CIM c nghin cu v robot, t ng ha v sn xut tr tu. Ch tiu m hnh h thng sn xut c nghin cu v tch hp cc m hnh thng tin vi cc m hnh chc nng ca CIM, m hnh m phng tch hp ca CIM v cc h thng thit k ca CIM.Ch tiu ng dng tr tu nhn to bao gm cc hng nghin cu v ng dng cc mng notron trong t ng ha sn xut, h thng hoch nh tr tu v cc m hnh thch nghi ca CIM.Cc hng nghin cu pht trin CIM:Trong phm vi nghin cu v hp l ha CIM v chin lc qun l CIM, s pht trin ca h thng thng tin qun l thc y vic ng dng h thng tr gip ra quyt nh DSS trong mi trng ra quyt nh theo nhm. Hn na, s thay i nhanh chng ca cng ngh v tr thc tc ng n cc m hnh tnh v lc hu ca x nghip. V vy, hp l ha v ti u ha u t cho nh my ocnchthngtrgipraquyt nhtheonhmGDSS(GroupDecision Support Systems ). 23 n tt nghip C in t 3 - K47H thng GDSS cho php tnh hiu qu ca cc cng ngh tin tin AMT trong c cu t chc ton cu. ng thi h thng GDSS gip cc nh ra quyt nh phn tch hiu qu u t ca mt cng ty hay x nghip no .S pht trin nhanh chng ca cng ngh cho php to ra nn sn xut ton cu vi nhiu nh my, x nghip c phn b trn cc vng lnh th khc nhau.Gn y ngi ta thc hin nhiu ti nghin cu khc nhau nhm mc ch pht trin CIM. Cc hng nghin cu l:- Nghin cu v nh my tch hp ca CIM.- Nghin cu v mng lin kt v Internet ca CIM.- Nghin cu v robot v t ng ha ng dng vo CIM.- Nghin cu v hp l ha v ti u ha CIM.- Nghin cu kh nng ng dng ca CIM o v sn xut tr tu.24 n tt nghip C in t 3 - K472.2. S pht trin ca cc h thng CIM Vit Nam.Nhp pht trin ca sn xut t ng ha ton phn FMS & CIM ph thuc vo nhiu yu t, trong hai yu t: Lc lng lao ng c trnh chuyn mn cao v ngun ti chnh ng vai tr quan trng nht. FMS & CIM l nhng h thng sn xut c mc t ng ha cao, chng v ang c ng dng rng ri cc nc cng nghip pht trin. Tuy Vit nam sn xut t ng ha mi ch giai on u ca s pht trin, nhng hon thnh s nghip cng nghip ha v hin i ha t nc th vic nghin cu, pht trin v ng dng cc h thng FMS & CIM v ang c quan tm c bit.Hin nay CIM cn l mt khi nim kh mi m i vi cc nh my ti Vit Nam. Hu nh khng thy s ng dng ca cc h thng CIM trong sn xut m ch c mt s rt t cc h thng Mini CIM c s dng trong o to ti mt s trng i hc v k thut. Tiu biu l h thng MiniCIM ca trng i hc Bch khoa H ni.Tuy nhin vi ln sng u t rt mnh ang trn vo Vit nam sau khi gia nhp WTO, cc h thng sn xut t ng ton phn ang pht trin nhanh chng v trong tng lai CIM s c ng dng vo sn xut. bt kp vi s pht trin nhanh ca nn cng nghip th gii, vic o to ra mt i ng cn b vn hnh v qun l c kin thc v CIM l rt quan trng. V vy vic ging dy v FMS & CIM ang c c bit tr trng ti cc trng i hc k thut ca Vit nam.III. ng dng v hiu qu ca CIM .3.1. ng dng ca CIM.Thit lp mt h thng sn xut tch hp c s tr gip ca my tnh CIM l mt vn khng n gin n khng ch ph thuc vo kh nng ti chnh ca cng ty m cn ph thuc vo i ng nhn lc ca cng ti do vic ng dng mt h thng CIM vo sn xut ca mt cng ty phi c xem xt mt cch cn thn. Thc t khi m sn xut pht trin, nhu cu ca khch hng thay i thng xuyn v khng ngng nng cao, s cnh tranh mnh ca nhiu cng ty trn phm vi ton cu th yu cu ng dng mt h thng CIM cho sn xut l rt cn thit. Trong h thng CIM chc nng thit k v ch to c gn kt vi nhau cho php khp kn chu trnh ch to sn phm v to ra sn phm mt cch nhanh chng bng cc quy trnh sn xut linh hot v hiu qu. Vi h thng CIM, n c kh nng cung cp s tr gip my tnh cho tt c cc chc nng thng mi, bao gm cc hot ng t khu tip nhn n t hng cho n cung cp, phn phi sn phm ca mt nh my.CIM tham gia vo mi trng sn xut cng nghip: iu khin robot . lp rp, gia cng, sn ph nh bng, gia cng hn, kim sot cht lng sn phm, ng gi, vn chuyn v phn pht hng ho .25 n tt nghip C in t 3 - K47CIM tham gia vo cc qu trnh cng ngh: thit k v sn xut c tr gip my tnh(CAD/CAM) . Lp k hoch sn xut v quy trnh cng ngh c tr gip ca my tnh ( Computer Aided Process Planning / Computer Aided Engineering (CAPP/CAE).CIM bao gm mng v cc h thng: cc phn cng v phn mm truyn thng trong nh my, qun l thng tin d liu bao gm c vic thu thp, lu tr v truy xut d liu.CIM tham gia vo vic ci thin khng ngng cc qu trnh sn xut: lp k hochv kim sot nguyn liu u vo, cc h thng theo di v kim sot cht lng, cc k thut v phng php thanh tra gim st nh lp k hoch v qun l ngun lc sn xut,lp k hoch v qun l ngun lc cng ty, kim tra cht lng ton b v phng thc sn xut p ng kp thi s thay i nhanh chng ca cc chng loi sn phm.3.2. Hiu qu ca CIM.H thng CIM c th to ra li nhun vng chc cho ngi s dng hn l cc h thng sn xut thng thng khc. CIM cho php mt nh my sn xut thch ng nhanh chng vi s thay i ca th trng v cung cp cc hng pht trin c bn ca sn phm trong tng lai. Vi s tr gip ca cc my tnh trong CIM, cc hot ng phn on ca qu trnh sn xut c tch hp thnh mt h thng sn xut thng nht, hot ng tri chy vi s gim thiu thi gian v chi ph sn xut ng thi nng cao cht lng sn phm. Trong h thng CIM cho php s dng ti u cc thit b, nng cao nng xut lao ng, lun ng dng cc cng ngh tin tin v gim thiu sai s gy ra bi con ngi, kinh nghim s dng CIM cho thy nhng li ch in hnh sau y:+ Nhanh chng cho ra i sn phm mi k t lc nhn n t hng: + Gim 15-30% gi thnh thit k.+ Gim 30-60% thi gian ch to chi tit.+ Tng nng sut lao ng ln ti 40-70%+ Nng cao cht lng sn phm, gim c 20-50% ph phm.+ Qun l vt t hng ho st thc t hn. + Tng kh nng cnh tranh ca sn phm v p ng nhu cu th trng.+Hon thin c phng php thit k sn phm, v d: s dng phng php phn t hu hn cng vi my tnh cho php thc hin php tnh nhanh hn 30 ln so vi cc phng php thng thng khc cho nhiu phng n thit k khc nhau.26 n tt nghip C in t 3 - K47CHNG II. CU TRC H THNG CIMMt cch tng qut CIM c th c hiu l mt chin lc t c mc ch th trng ca nh my. l mt khi nim dng ch mt phng thc sn xut tin tin da trn nhng thnh tu ca cng ngh thng tin. CIM cho php thit lp nn mt h thng sn xut ton cu c kh nng p ng nhanh nht nhu cu ca th trng, t c hiu qu kinh t cao, ng dng nhanh chng cc sng kin v cc cng ngh mi vo sn xut. CIM chnh l hng pht trin tt yu ca sn xut hin nay. Tuy vy vic p dng CIM vo sn xut cng gp rt nhiu kh khn, c bit l i vi nn sn xut cn yu ca Vit Nam. p dng c CIM vo sn xut ph thuc vo rt nhiu yu t, l kh nng ti chnh ca nh sn xut, nng lc ca ngi lao ng, nng lc qun l, kh nng tip cn vi cng ngh mic bit l CIM phi c p dng mt cch ng b v trit . V ch khi no c p dng ng b v trit th CIM mi thc s pht huy c ti a nhng li th m n mang li so vi nhng cng ngh sn xut khc. i vi lnh vc sn xut ni ring. CIM c hiu l mt h thng sn xut t ng ton phn. Tt c cc b phn ca h thng u c tch hp v iu khin qua phn mm tch hp. Mt h thng CIM c bn bao gm cc my CNC, robot, h thng vn chuyn tch tr, kho cha, h thng kim tra v h thng iu khin.Hnh 2.1. S h thng CIM27 n tt nghip C in t 3 - K47I. My CNC.My CNC l mt trong nhng b phn c bn nht khng th thiu trong mt h thng CIM. Chng ta bit trc th h my CNC c my cng c thng thng v my cng c NC. My cng c thng c iu khin trc tip bi tay ngi cng nhn nn cht lng v nng sut gia cng ph thuc rt nhiu vo tay ngh ca cng nhn. My iu khin s NC th vic iu khin my c quyt nh bi cc chng trnh lp sn. My CNC l mc pht trin cao t cc my NC. My CNC c 1 my tnh thit lp phn mm iu khin cc chc nng my. Cc chng trnh gia cng c c v lu vo b nh s dng cho vic iu khin qu trnh gia cng. My CNC c th thc hin cc chc nng: ni suy ng thng, cung trn, mt xon, mt parabol v bt k mt bc 3 no. My CNC c th b chiu di v ng knh ca dng c. chnh xc ca cc chi tit khi gia cng khng cn ph thuc vo tay ngh ca cng nhn.Do cht lng sn phm sn xut ra n nh v t nng sut cao. Cc chuyn ng ct v chuyn ng to hnh ca cc my CNC c nguyn tc khng khc so vi cc my cng c truyn thng. Cc my CNC cng c mt quy chun v h ta xc nh cc chiu chuyn ng ca my. im khc bit ln nht gia cc my CNC v cc my cng c truyn thng, l kh nng thay th dng c t ng ca my CNC. Chnh kh nng ny lm tng nng sut ca cc my CNC ln rt nhiu so vi cc my cng c thng thng. Cng chnh v vy nn dng c v lp dng c ca cc my CNC u phi c cc im chun g lp t ng, chng u c ch to theo tiu chun chung vi yu cu rt cao v chnh xc, vt liu, kch thc.Cc my CNC c th phn chia theo loi v theo h thng iu khin: Theo loi my cng tng t nh cc my cng c truyn thng, chia ra cc loi nh my khoan CNC,my phay CNC, my tin CNC v cc trung tm gia cng CNC. Cc trung tm CNC c kh nng thc hin gia cng nhiu loi b mt v s dng nhiu loi dng c khc nhau. Phn chia theo h iu khin c th phn ra cc loi:- Cc my iu khin im ti im: Vi cc loi my ny, trong qu trnh gia cng, ngi ta cho nh v nhanh dng c n ta yu cu v trong qu trnh dch chuyn nhanh dng c, my khng thc hin vic ct gt. Ch n khi t c ta theo yu cu th mi thc hin cc chuyn ng ct gt. V d nh my khoan, khot, my hn im,my t, dp- Cc my iu khin on thng: l cc my c kh nng gia cng trong qu trnh thc hin dch chuyn theo cc trc. C ngha l dng c s thc hin cc chuyn ng ct gt trong qu trnh dch chuyn song song theo cc trc ta . 28 n tt nghip C in t 3 - K47- Cc my iu khin ng: l cc my m dng c c kh nng thc hin gia cng theo c ng bt k trong mt phng hoc trong khng gian ty thuc vo ng iu khin l phng hay khng gian m s trc c iu khin ng thi l khc nhau. T chia ra cc my 2 trc, 3, 4, 5 trc (tc l c s trc c iu khin ng thi theo quan h rng buc).+ My 2D: Cho php dch chuyn dng c trong mt mt phng nht nh no , v d trn my tin dng c s dch chuyn trong mt phng xoz to nn ng sinh khi tin cc b mt, trn my phay 2D dng c s thc hin cc chuyn ng trong mt phng xoy to nn cc ng rnh hay cc mt bc c bin dng bt k.+ My 3D: Cho php dch chuyn dng c trong mt phng ng thi to nn mt ng cong hay mt mt cong trong khng gian bt k. iu ny tng ng vi qu trnh iu khin ng thi c 3 trc ca my theo mt quan h rng buc no ti tng thi im to nn mt vt qu o ca dng c theo yu cu.+ iu khin 2D1/2: Cho php dch chuyn dng c theo 2 trc ng thi to nn mt ng cong phng, cn trc th 3 c iu khin chuyn ng c lp. iu khc bit ca phng php iu khin ny so si iu khin 2D l ch 2 trc c iu khin ng thi c th thay i c v tr cho nhau.+ iu khin 4D, 5D: Trn c s ca iu khin 3D ngi ta b xung cho dng c hoc chi tit c thm 1 hoc 2 chuyn ng quay xung quanh mt trc no theo mt quan h rng buc vi cc chuyn ng trn cc trc khc ca my 3D. Vi kh nng nh vy, c th thc hin gia cng c b mt phc tp mt cch d dng hn so vi gia cng trn my 3D. Mt khc, v l do cng ngh nn c nhng b mt khng th thc hin c vic gia cng bng 3D v c th tc ct s khc nhau hoc s c nhng im c tc ct bng 0 (nh ca dao phay u cu) hay li ct ca dng c khng th thc hin c vic gia cng nh mong mun (v d khi gc ct khng thun li hay c th b vng vo thn dao v cc phn cn li ca chi tit)Tm li ty vo yu cu gia cng m c th chn cc loi my CNC c s bc t do khc nhau nhm t hiu qu s dng cng nh mc ch kinh t l ln nht. Vic chn cc my CNC trong h thng CIM l vn ht sc quan trng. Yu cu t ra l phi cn bng gia vic pht huy tnh linh hot ca h thng v li ch kinh t ca h thng. Nu ta chn cc my CNC c s bc t do t s lm gim tnh linh hot ca h thng do kh c kh nng gia cng cc chi tit phc tp. Nhng nu chn my CNC c s bc t do qu ln c th khng s dng ht cc kh nng ca my v lm gim li ch kinh t. V cc my CNC c s bc t do ln c gi cao hn rt nhiu so vi cc my CNC c s bc t do thp hn. l do vic phi hp chuyn ng ca cng nhiu trc th vn iu khin s tr nn phc tp hn rt nhiu so vi iu khin c lp cc trc.29 n tt nghip C in t 3 - K47II. Robot.Nhu cu nng cao nng sut v cht lng sn phm ngy cng i hi ng dng rng ri cc phng tin t ng ho sn xut. c bit l trong cc h thng CIM, tnh t ng ho ca h thng sn xut tch hp v yu cu linh hot trong vic thay i sn phm i hi ng dng mt s lng ln cc robot cng nghip thc hin cc chc nng ch yu nh cp phi cho cc trung tm gia cng, gp cc chi tit ra sau khi gia cng, thc hin qu trnh lp rp t ng. Hnh 2.2. Robot trong h thng CIMtiuchunhocngvicthitk, Robotcchialmbaphnchnh: ngun cung cp nng lng, b iu khin v phn tay my. Mi phn trong ba phn chnh trn bao gm nhiu b phn v cc b phn c th bin i p ng tiu chun v cc thng s thit k ca mi Robot nht nh.Tu theo ch tiu phn loi c th c rt nhiu kiu phn loi robot.- Phn loi theo s bc t do: Robot 1, 2, 3, ... bc t do- Phn loi theo h nng lng:+ Robot hot ng theo nng lng in+ Robot hot ng theo nng lng thu lc+ Robot hot ng theo nng lng kh nn+ Robot hot ng theo nng lng mt tri- Phn loi theo phng php iu khin:+ Robot c iu khin s (CNC)+ Robot c iu khin logic kh trnh (PLC)+ Robot c iu khin tr tu nhn toCm bin ngoiCm bin niH thng iu khinH thng truyn dn ngDng c thao tcMy tnh30 n tt nghip C in t 3 - K47+ Robot c iu khin thch nghi- Phn loi theo h truyn ng: Phc thuc vo ngun ng lc ta c th phn ra: + Robot vi truyn ng gin tip+ Robot vi truyn ng trc tip- Phn loi theo cp chnh xc:+ Cp chnh xc tuyt i+ Cp chnh xc lp li2.1. ng dng robot cng nghip trong h thng CIM. Robot l thnh phn khng th thiu trong cc my CNC. Cc robot c kh nng thc hin nhiu cng vic khc nhau vi tnh linh hot cao v chnh xc m bo yu cu.Trong h thng sn xut CIM, cc nguyn cng chnh c thc hin t ng trn cc trung tm gia cng l cc my CNC. Cc nguyn cng ph nh cp, tho phi trn my CNC, a chi tit t v tr ny n v tr kia trong h thng sn xut, ... c thc hin nh cc robot cng nghip. Cc robot ny thc hin cc nguyn cng : gp phi t cc kho cha, vn chuyn v g t chng ti vng gia cng, sau li tho cc chi tit gia cng, vn chuyn v xp chng vo thng cha hoc cc trm trung gian thc hin cc nguyn cng tip theo. Ngoi ra, trong h thng CIM cc robot cng nghip cn c ng dng rng ri thc hin cc cng on lp rp t ng hay ng dng trong cc qu trnh kim tra sn phm trong dy chuyn sn xut...S lng cc robot, chnh xc v tnh vn nng ca cc robot trong h thng CIM cn phi c xc nh mt cch hp l m bo nng sut v hiu qu kinh t ca h thng. Cc robot c chnh xc v tnh vn nng cng ln gi thnh s cng cao nhng b li chng c kh nng thc hin cc cng vic phc tp vi chnh xc cao, ch cn mt robot cng c th phc v c nhiu loi my CNC cng lc v t phi hiu chnh robot khi chi tit gia cng thay i. i vi nhng cng vic thc hin ti ch c nh v mang tnh lp li th nn la chn nhng robot chuyn mn ha, cc loi robot ny c nng sut lm vic cao v gi thnh khng qu t.2.2. Cc yu cu i vi cc robot hot ng trong h thng CIM. p ng cc yu cu hot ng trn trong h thng CIM cc robot cng nghip cn c nhng tnh nng sau: - Thc hin cc nguyn cng mt cch t ng.- D iu chnh khi thay i i tng sn xut bng cch thay i chng trnh lp cho robot. C kh nng thc hin nhiu cng vic vi nhiu loi chi tit khc nhau.31 n tt nghip C in t 3 - K47- Phi c kt ni vo mng truyn thng ca h thng.- C kh nng thc hin cc thao tc mt cch nh nhng vi chnh xc cao. - m bo lm vic n nh theo chu trnh trong thi gian di.- C kh nng trang b thit b kim tra t ng cht lng gia cng v c phn mm lp trnh ring. Cc yu cu ny ch mang tnh tng qut, i vi cc nhim v c th th cc yu cu i vi robot phi thay i ph hp vi cng vic v tng hiu qu kinh t khi s dng.32 n tt nghip C in t 3 - K47III. H thng vn chuyn tch tr.H thng vn chuyn tch tr c nhim v vn chuyn phi, chi tit, dng c, phoi trong h thng, tch tr cc bn thnh phm trong qu trnh di chuyn gia cc nguyn cng trong quy trnh cng ngh.3.1. Thit b k thut ca h thng vn chuyn - tch tr.Thit b k thut ca h thng vn chuyn - tch tr chia lm 2 nhm: nhm thit b chnh, nhm thit v ph.- Nhm thit b chnh:+ Cc loi bng ti.+ Cc rbt vn chuyn.+ Cc c cu vn chuyn bng kh nn.+ Cc c cu vn chuyn bng thu lc.+ Cc kho cha.+ Cc gi .+ Cc my xp ng.+ Cc rbt cng ngh.+ Cc my tnh.+ Cc b vi x l.+ Cc attric.+ Cc trm iu khin.- Nhm thit b ph:+ Cc c cu nh hng.+ Cc c cu xc nh a ch (xc nh v tr).+ Cc thanh y.+ Cc c cu tho, gt.+ Cc tch.+ Cc bn nng h.+ Cc bn quay.+ Cc my nng h.33 n tt nghip C in t 3 - K47+ Cc phu rung.+ Cc xe ti vn chuyn.+ Cc c cu (my) tip liu.+ Cc thng cha.Mt s loi bng ti trong h thng CIM:a s cc loi bng ti c gn h truyn ng in, c th l ng c bc (servo) hoc khng (ng c in thng).Vi h bng ti gn ng c servo th c kh nng iu khin chnh xc, linh hot hnh trnh ca chi tit (c vn chuyn trn bng ti) thng qua vic iu khin s vng quay ca ng c servo. Khi c th dng chi tit ti bt k v tr no trn bng ti.Vi h bng ti s dng ng c in thng, vic iu khin v tr ca chi tit l thng qua cc trm dng t trn h bng ti. Mun dng chi tit ti bao nhiu v tr th trn h bng ti phi c bng y trm dng. Khi chi tit n gn mi trm dng no , n s tc ng n thit b cm bin hnh trnh bo cho trm ng l c i tng i vo. Thng tin ny gip cho c cu kp gi chi tit hot ng v tch chi tit ra khi dng vn chuyn ca h bng ti.So snh 2 h bng ti trn cho thy l h bng ti s dng ng c servo c nhiu u im hn s dng ng c in thng thng. l s linh hot v chnh xc v v tr dng chi tit trn bng ti, s n gin v kt cu ca trm dng v cc c cu ph tr. Tuy vy s dng ng c servo gi thnh ca bng ti s tng ln. Do ty vo trng hp c th c th la chn cc loi bng ti khc nhau cho ph hp.3.2. H thng vn chuyn - tch tr chi tit gia cng ca CIM3.2.1. Chc nng ca h thng vn chuyn - tch tr chi tit gia cngH thng vn chuyn-tch tr chi tit gia cng ca CIM thc hin cc chc nng sau:- Vn chuyn cc chi tit gia cng (phi) trong thng cha hoc trn cc v tinh ti cc v tr tip nhn b xung vo tch c dung lng nh t cnh cc my.-Lutrtrongcctchcdunglnglnccchi tit dtrgiacc nguyn cng trn cc v tinh hoc trn thng cha v theo lnh ca my tnh vn chuyn chng ti v tr tip nhn tip tc gia cng.- Vn chuyn cc chi tit c gia cng trn cc my ti v tr tho chi tit v chuyn cc v tinh t do v v tr cp phi hoc tch tr.- Vn chuyn cc chi tit c gia cng ti v tr kim tra (kim tra gia cc nguyn cng) v chuyn chng v v tr tip nhn gia cng tip.34 n tt nghip C in t 3 - K473.2.2. Phn loi h thng vn chuyn - tch tr chi titH thng vn chuyn - tch tr chi tit c thit k ch yu theo 3 phng n: loi gi tch tr vi my xp ng, loi bng ti tch tr v phng n t hp (gm bng ti tch tr v gi tch tr vi my xp ng c treo thm gi hoc cc xe ti di chuyn trn ng ray).Di y chng ta s nghin cu mt s h thng vn chuyn - tch tr c dung lng va v nh dng cho cc v tinh ca Nht Bn v Hoa K c lp t cnh cc my CNC nhiu nguyn cng trong h thng CIM.Hnh 2.3.. tch v tinh vi xe ti di ng ca hng Hitachi Seiki(Nht Bn)1: Cc v tinh ; 2: tch ; 3: ng ray ; 4: Xe ti di ng ; 5: My nhiu nguyn cng ; 6: C c cu quay ; 7: Bn quay.Hnh 2.3 l h thng vn chuyn - tch tr (magazin) vi xe ti di ng ca hng Hitachi Seiki (Nht Bn). Di chuyn cc v tinh 1 t cc v tr ca tch 2 ti c cu quay 6 t ng thay i cc v tinh trn my nhiu nguyn cng 5 v ngc li c thc hin bng xe ti di ng 4 vi truyn ng bng xch hoc dy cp. Xe ti c trang b c cu tip nhn cp pht cc v tinh v c di chuyn trn ng ray 3. Trong tch c v tr vi bn quay 7 c dng g v tho cc chi tit gia cng v ni kt vi c cu vn chuyn bn ngoi h thng CIM.Xe ti di ng khc bng ti tch tr ch l trn bng ti tch tr tt c cc v tinh c di chuyn cng lc, cn xe ti di ng c th chn mt v tinh bt k cp cho my gia cng. Kt cu ca xe ti di ng khng phc tp, n gin khi vn hnh v c s dng rng ri trong cc h thng vn chuyn - tch tr nh 35 n tt nghip C in t 3 - K47mt c cu vn chuyn, m bo mi lin kt gia tch (magazin) v tinh v cc ch lm vic ca cng nhn.H thng vn chuyn - tch tr vi xe ti di ng cho php phc v mt s my nhiu nguyn cng v c th c s dng vn chuyn nhiu loi chi tit gia cng khc nhau.Hnh 2.4 l h thng vn chuyn - tch tr vi bng ti tch tr trong CIM ca hng Cincinnati Milacron (Hoa K). H thng CIM ny c 4 my CNC nhiu nguyn cng 4 v h thng vn chuyn - tch tr cc v tinh vi bng ti tch tr con ln 1 khp kn v cc tch con ln ph tr gim xung 6 t cnh mi my ca CIM. Ngoi ra mi my cn c trn bn mt v tr ch b xung 3 cho v tinh, n cho php gim thi gian dng ca my khi thay i v tinh.Hnh 2.4. H thng vn chuyn-tch tr v tinh trong CIM ca hng CincinnatiMilacron (M). 1: Bng ti tch tr con ln; 2: C cu quay; 3: V tr bn b xung; 4: Cc my nhiu nguyn cng; 5: C cu tip nhn-cp pht; 6: tch con ln ph tr; 7:V tr cp chi tit; 8: V tr tho chi tit.Di chuyn v tinh t cc nhnh dc ca bng ti sang cc nhnh ngang v t cc nhnh ngang sang cc nhnh dc c thc hin bng cc c cu quay 2. Di chuyn ca v tinh t cc tch gim xung sang v tr ch ca my v ngc li c thc hin nh cc c cu tip nhn - cp pht 5 pc t i din cc v tr ch ca cc my. Bng ti tch tr trung tm c cc nhnh to thnh mt b phn vi cc v tr cp chi tit 7 v tho chi tit 8.36 n tt nghip C in t 3 - K473.3. H thng vn chuyn - tch tr dng c ca CIM.Hiu qu gia cng trnmy CNC ca h thng CIM ph thuc rt nhiu vo s thay i cc dng c m cc ch tiu cng ngh ca chng l: tui bn, chng loi chi tit gia cng. T chc vn hnh dng c ct trong h thng CIM bao gm:- Tip nhn dng c ct v dng c ph.- Sp xp theo di trng thi ca dng c khi gia cng chi tit v thay i dng c kp thi.- Gi gn v bo qun dng c 1 cch c h thng .3.3.1.Chc nng ca h thng vn chuyn - tch tr dng c.- T ng vn chuyn v phn pht dng c cho cc my gia cng ca CIM.- Thc hin cp v tho dng c t cc magazin ca cc my khi chuyn i i tng gia cng v lu gi chng cc tch trung tm.- a cc dng c ra ngoi t cc my ca CIM hiu chnh v mi sc.- a vo cc my ca CIM cc dng c mi.3.3.2. Mt s loi h thng vn chuyn - tch tr dng c.Cc my CNC nhiu nguyn cng u c cc magazin dng c ( tch dng c) sp t dng c v cc c cu t ng thay i dng c theo 1 trnh t nh l t magazin ti trc chnh ca my v ngc li.Cc magazin dng c c dung lng t 12 - 60 dng c. Khi s dng c < 12 ngi ta dng u revonve. Magazin c dung lng t 12 - 30 chic c thit k theo kt cu dng trng (a), cn magazin c s lng >50 c thit k theo kt cu dng xch.37 n tt nghip C in t 3 - K47Hnh 2.5. H thng vn chuyn-tch tr dng c dng xch ca hng HitachiSeiki(Nht Bn). 1: tch dng c; 2: Magazin( cha) dng c; 3: My;4: V tinh;5: c cu tip nhn.Cc magazin dng c 2 c lp t trong tch 1 ca h thng. gia cng chi tit, mt trong s cc magazin dng c c t ng g trn c cu tip nhn 5 c lp t trn tr ng ca my 3. Tr ny c cc sng trt di chuyn u trc chnh. Khi 1 chi tit khc trn v tinh 4 c chuyn ti my th magazin dng c (v tr B) quay tr v v tr t do (v tr C) ca tch, cn t tch (v tr A) magazin dng c khc c chuyn ti c cu tip nhn 5 gia cng chi tit va c chuyn ti. thay i magazin dng c, tr ng ca my di chuyn theo to X cho ti khi trc ca c cu tip nhn 5 trng vi trc ca 1 trong cc magazin dng c nm trong tch 1. Qu trnh thay i magazin dng c c thc hin 1 cch t ng theo lnhca ccuiukhin shoc camy tnhhoct trmiu khin trung tm.3.4. iu khin h thng vn chuyn - tch tr.iu khin h thng vn chuyn tch tr c chia ra lm hai mc.Mc 1 (Cc c cu t ng khu vc iu khin thit b vn chuyn, cc my xp ng, cc rbt vn chuyn):Mc ny gii quyt vic iu khin truyn ng ca cc h thng vn chuyn, nh v chnh xc c cu vn chuyn ti ch lm vic, dng c cu vn chuyn khi c tn hiu bo hng hc, cp v tho cc tch tr, x l v truyn tn hiu kim tra v chun on.- Cc thit b k thut ca mc 1 gm:+ Cc attric xc nh lung hng (c th c hay khng)+ Cc attric v tr ca c cu vn chuyn+ Cc attric o mc ca cc tch tr+ Cc attric o lc+ Cc attric an ton: tip xc, khng tip xc, dung lng, cm bin, o bin dng, quang in+ Cc thit b o+ Cc my vi tnhMc 1 c thit k theo mun c n nh cao, tn hiu u ra c chun ho, c th kim tra tch cc chnh xc hot ng ca cc thit b. S dng my vi tnh iu khin cho php thc hin cc chc nng iu khin logic (theo a ch, ngt ng, chuyn ch lm vic ca c cu truyn ng, iu khin ca c cu truyn ng) bng cc chng trnh.38 n tt nghip C in t 3 - K47Mc 2 (iu khin lung hng ca sn xut):Mc ny gii quyt vic iu khin hnh trnh chuyn ng ca c cu vn chuyn, kim tra v chun on cc sai s, tnh ton chuyn ng ca hng ho.Cc c cu iu khin mc 1 phi t ng ho hon ton qu trnh vn chuyn, tch hp vi h thng iu khin ca mc 2, c tnh linh hot vi s thay i lung hng vn chuyn. Nh my vi tnh cho php ni kt mc iu khin 1 vi mc iu khin 2 v to cho h thng c tnh linh hot.H thng t ng kim tra v chun on hot ng ca h thng vn chuyn - tch tr, tp hp thng tin trng thi ca h thng v cc phn t iu khin (trng thi ban u v trng thi hin hnh), x l thng tin ny theo thut ton nh, ra quyt nh v kh nng hot ng tip tc ca cc phn t trong h thng vn chuyn - tch tr, truyn thng tin v sai s cho cng nhn trm iu khin.39 n tt nghip C in t 3 - K47IV. Kho cha.Kho cha t ng l ni tip nhn, lu tr cc vt liu u vo (phi), cc thit b ph tr, cc chi tit thnh phm, ph phm v cht thi ca qu trnhsn xut. Qua ta c th qun l c s lng ca phi ban u, thnh phm v ph phm, t nh gi c nng sut sn xut, cht lng sn phm. ng thi a ra s hiu chnh v thng s k thut ca qu trnh gia cng m bo hiu qu ca h thng CIM.4.1. Thnh phn ca kho cha t ng.Kho cha t ng bao gm cc thnh phn sau:- Khu lu gi hng ho.- Khu tip nhn v chuyn hng ho ti h thng vn chuyn.- Khu xp t cc chi tit hoc sn phm trong thng cha.- Khu tip nhn v chuyn hng ho t khu lu gi.V a s cc kho cha t ng c ch to theo kiu gi , nn chng c kt cu gm cc thnh phn sau:- Cc c cu gi : L ni cha hng ho- Cc my xp ng t ng.- Cc thng cha.- Cc c cu cp v tho cc thng cha.- Cc c cu vn chuyn thng cha t tch ti h thng vn chuyn v ngc li.- Cc thit b iu khin t ng kho cha: iu khin cc my xp d hng ho 1 cch chnh xc t thng cha ti cha ang trng (c th cha hng trn gi ).4.2. Cc loi kho cha t ng.4.2.1. Dng gi cn cu.Vi kt cu gm 1 my cn cu nng h hng ho t cc gi cha ti cc tch v ngc li rt linh hot. Tuy nhin c hn ch l dung lng cha khng ln. Song do c kh nng t ng ho cao, vi li din tch nh gn nn c s dng ph bin trong cc h thng CIM cng nh FMS. 40 n tt nghip C in t 3 - K47Hnh 2.6. Cc s ca cc kho cha t ng c dng gi cn cu .B: chiu rng ca gi, BP : chiu rng ca bc dng cho my cn cu .LH : chiu di tch tr, H: chiu cao kho cha, hH : chiu cao tch tr1: my cn cu , 2: gi, 3: tch tr.4.2.2. Dng cn cu cuVi 1 my cn cu dng cu c th di chuyn ngang, dc, ln xung v c th quay quanh 1 trc nn rt linh hot khi xp d hng ho. Dng kho cha cn cu cu khc phc c nhc im ca dng gi cn cu l dung lng ln hn nhiu. Dng cn cu cu c n 3 gi, 4 gi hoc 6 gi cha hng trong khi dng gi cn cu ch c 1 hoc 2 gi cha l cng. Nhng do c nhiu gi cha nn din tch mt bng ln, v nng sut ca my cn cu cu khng cao nn ch s dng cho sn xut hng lot nh.Hnh 2.7. Cc s ca cc kho cha t ng c dng cn cu cu.41 n tt nghip C in t 3 - K47a: Loi c 3 gi ; b: Loi c 4 gi ;1: my cn cu dng cu ; 2: cc gi.4.2.3.Dng gi trng lc.Vi kt cu gi nghing li dng trng lc cp v thot phi t u cao ny sang u thp kia. Ti 2 u ca gi nghing c cc b trt t ng tip nhn phi. Dng kho cha ny ch dng cho 1 s loi chi tit nht nh, do tnh linh hot khng cao.Hnh 2.8. Kho cha t ng c dng gi trng lc.1: B trt t ng ; 2: Gi trng lc ; 3: C cu cp thot phi(chi tit)4.3. B tr cc kho cha t ng trong h thng CIM.Cc kho cha t ng c t gn cc thit b cng ngh (cc my CNC). Khi y cc my cn cu t ng (ca kho cha t ng) khng ch thc hin vic xp t m cn cp pht vt t, phi v sn phm hon thin. Do tit kim c din tch sn xut, nng cao n nh ca c h thng vn chuyn - kho cha, tng nng sut v h gi thnh sn phm.42 n tt nghip C in t 3 - K47Hnh 2.9. Mt bng kho cha t ng c dng gi cn cu.1: Phn din tch b tr cc my ; 2: Cc c cu cp pht v tch; 3: B phn kim tra u vo ; 4: Kho cha t ng ; 5: Kho cha t hp (cha vt liu, phi,dng c, thng cha, sn phm ); 6: Hng di chuyn ca vt liu, phi, thng cha rng, dng c ; 7: Li ra ca thnh phm v ph phm8: B phn kim tra.Hnh 2.10. S mt bng kho cha c dng cn cu cu.1, 2, 3, 5, 6, 7, 8 (xem hnh2.9.): Phn din tch b tr cc my;2: Cc c cu cp pht v tch ; 3: B phn kim tra u vo ;43 n tt nghip C in t 3 - K474: Kho cha ; 9: Li ra ca cht thi sn xut.Hnh 2.11. S mt bng kho cha dng gi trng lc.1: ng vo vt liu, phi, thng cha rng, dng c; 2: B phn kim tra u vo ; 3: Cc c cu cp pht v tch tr ; 4: Cc kho cha phi, dng c, sn phm ; 5: Cc rbt vn chuyn ; 6: B phn b tr cc my gia cng; 7: B phn kim tra ; 8: Li ra ca thnh phm v ph phm.44 n tt nghip C in t 3 - K47V. H thng iu khin.H iu khin ca h thng CIM gm c phn cng v phn mm. Phn cng ca h iu khin l mch iu khin cc thit b ca h thng CIM. Hin nay phn cng ca cc h thng CIM u s dng cc b PLC. Cc b PLC c rt nhiu u im v l s la chn ti u cho cc h thng CIM, l kh nng lm vic trong mi trng cng nghip, c kh nng iu khin nhiu loi thit b, c kh nng lp trnh linh hot, kch thc nh gn, cc u vo/ra ln.Phn mm ca h thng iu khin chnh l phn mm tch hp CIM SOFT. Phn mm c nhim v kt ni tt c cc thnh phn ca h thng, thc hin giao tip gia ngi s dng v h thng, thc hin cng vic iu khin ton b hot ng ca h thng.5.1. B iu khin logic kh lp trnh PLC trong cc h thng CIMPLC c pht trin da trn c s k thut Vi X L, hay ni mt cch khc s pht trin cao ca k thut my tnh l nn tng cho PLC ra i. N cho php ta thc hin linh hot cc thut ton iu khin s thng qua mt ngn ng lp trnh, thaychovicphith hin thutton bngmchs.Ngy nay trong cng nghip PLC (cn c gi l cc my tnh cng nghip) ngy cng c s dng rng ri nh tnh linh hot ca mt b iu khin s nh gn, d thay i thut ton v c bit d trao i thng tin vi mi trng xung quanh, nh vi cc PLC khc, vi cc thit b ph tr trong h thng v vi my tnh.Cc chc nng iu khin ca PLC c th c phn loi thnh 4 dng sau:- iu khin on-off (on-off control)- iu khin dy (sequential control)- iu khin phn hi (feedback control)- iu khin s chuyn ng (motion control)Cc b PLC cung cp h iu khin thch hp cho cc my mc v cc ng dng trong cng nghip, ch vi mt my tnh lp trnh cho PLC, thay v phi s dng cc thit b phn cng cng knh nh: cc cun Rle v cc cng tc in. Cc b PLC c th iu khin thch hp vi bt k loi my mc hay h thngcng nghip no nh:- Cc Robot.- iu khin mi trng trong cc cng trnh xy dng.- Cc dy chuyn lp rp.- Cc h thng an ton.- Cc dy truyn t ng.45 n tt nghip C in t 3 - K47V c bn, chc nng ca b iu khin Lgic kh lp trnh cng ging nh chc nng ca b iu khin thit k trn c s cc Rle hoc cc thnh phn in t khc nhng PLC mang tnh nh gn v linh hot hn trongvic thay i cc ng dng iu khin m khng phi thay i phn cng iu khin. Sau y l cc chc nng chnh ca PLC: -Thu nhn cc tn hiu u vo v phn hi (t cc cm bin, cc cng tc hnh trnh).- Lin kt, ghp ni li v ng m mch ph hp vi chng trnh.- Tnh ton v son tho cc lnh iu khin trn c s so snh cc thng tin thu c t cc u vo.a cc lnh iu khin n cc a ch thch hp u raHnh 2.12. Chc nng ca PLC46Nt bm vcng tc lgicgii hnB quan st bo ng v du nhn v nhit B khng ch p sut, nhit v cc thng sngun u vo th cngu voCc munca PLCuraMch ghp phiB x lLu tr chng trnhchc nng phCun tnVanMch ghp phiPLC n tt nghip C in t 3 - K47Cc u im khi s dng PLC:PLC c trng cho mt my tnh c s tiu tn in p l rt thp, tc truy cp cao v tnh linh ng trong vic thay i ng dng iu khin. Bng cch thay th cc b phn c kh bng mt b PLC, vic iu khin mt qu trnh cng ngh s tr nn nhanh hn, r hn v do em li hiu qu cao hn. C nhiu l do cho thy PLC l mt s la chn tt hn so vi vic s dng cc cun rle hay l mt my tnh chun dng cho vic iu khin. - Chim t khng gian: Mt b PLC yu cu t khng gian hn mt my tnh hoc mt bng Rle vi cng mt cng vic thc hin.-Gi thnh thp hn:Gi mua mt b PLC ch bng c 4 hoc 5 ci rle, nhng n li c th thay th cng vic ca hng trm rle.- Bn vng trong mi trng lm vic cng nghip : V bc ca mt b PLC c to ra vi cng c th bn vng trong mi trng lm vic khc nghit trong mt nh my. Trong khi , v cc my tnh khng c ch to p ng c cc yu cu ny.- S dng giao din kt ni trc tip: Cc my tnh tiu chun yu cu mt h thng phc tp v b hn ch trong vic giao din hay kt ni vi nhng thit b khc. Trong khi giao din ca mt b PLC cho php kt ni trc tip vi cc thit b khc.- D dng trong vic lp trnh: Cc b PLC thng s dng mt ngn ng lp trnh gi l logic bc thang. y l mt ngn ng c to nn da trn nhng tiu chun cng nghip v cc biu tng trong cc h thng phn cng rle, v cc tiu chun ny th tr nn quen thuc vi nhng nh k thut trong cng nghip. -Tnh linh hot:Vic thay i cc thit b phn cng iu khin lun lun phc tp hn so vi vic thay i phn mm (thay i chng trnh lp trnh) khi m cc ng dng ca ta thay i. Cc b PLC cho php chng ta kh nng linh hot trong vic thay i cc ng dng cn thc hin bng cch thay chng trnh lp cho b iu khin PLC. Trong khi ta ch cn lp li chng trnh theo ng ng dng yu cu v thay i kt ni cc u vo, u ra th vi mt b cc rle, khi mun thay i ng dng ta phi mt rt nhiu thi gian cho cng vic ni cc dy dn v thay i cu trc mch. 47 n tt nghip C in t 3 - K475.2. Phn mm tch hp.Phn mm nhim v c chc nng thc hin cc giao tip gia ngi s dng vi ton b h thng CIM, iu khin cc chc nng ca h thng cng nh chc nng ca tng b phn trong h thng. Mi hng sn xut khc nhau u xy dng cho mnh nhng phin bn khc nhau ca phn mm tch hp. Mt phn mm tch hp c bn gm cc chc nng sau:- Inventory Management: Qun l vt t hng ho- Product Planning: Lp k hoch sn xut- Manufacturing Management: Qun l qu trnh gia cng- Product Scheduling: t lch sn xut- System Communication: Truyn thng ca h thng- Station Programming: Lp trnh cho rbt- User PLC Programming: Lp trnh PLC ng dng- Facilities Layout: S b tr c trm ca h thng.- System Simulation: S m phng theo h thng- System Operation: Hot ng ca h thng.Qun l vt t hng ha.y l ni cha cc thng tin xc nh tng vt t s dng trong h thng, cc thng tin gm c: + S hiu vt t: lm m trong chng trnh iu khin robot.+ M t vt t: Tn vt t.+ Kiu gia cng: Kiu phi th, kiu mua sn, kiu bn thnh phm, kiu ch to, kiu thnh phm.+ n v tnh.+ t thi gian gia cng d tnh+ Gi tin ca sn phm.Cc thng tin v vt t do c nhp vo v sau qu trnh tnh ton phn mm c th a ra cc thng tin gip cn bng vt t m bo hiu qu kinh t ca sn xut.Lp k hoch sn xut.L ni xc nh tin trnh chung t xc lp cc bc cng ngh cho sn phm. T cc thng tin v vt t u vo v sn phm u ra, h thng s xc nh quy trinh cng ngh gia cng chi tit, loi my gia cng chi tit. Nh m h thng CIM c c s linh hot, nng sut v hiu qu kinh t cao.Cc chi tit khc nhau s c gia cng trn s lng my khc nhau ty thuc vo yu cu ca sn phm. Cng trn mt dy chuyn h thng CIM c th cng lc gia cng 48 n tt nghip C in t 3 - K47nhiu loi chi tit vi quy trnh cng ngh khc nhau,thi gian gia cng khc nhau, yu cu sn phm khc nhau.Qun l qu trnh gia cng.Phn ny thc hin chc nng lu gi, thay i lng chi tit gia cng ca h thng, lng chi tit s gia cng trong thi gian ti. Khi h thng CIM c s c v phi ngng gia cng sa cha th cc thng tin ny s c s dng tip tc thc hin cng vic gia cng khi h thng CIM sn xut tr li. t lch sn xut.L ni xc nh lch thi gian cho qu trnh sn xut, cho cc trung tm gia cng. Thi gian bt u gia cng, thi gian kt thc gia cng, thi gian pht cho 1 ngy no ca mi trung tm gia cng. Cng c th t lch sn xut cho h thng trong mt thi gian di thc hin gia cng cc n t hng vi s lng ln.Truyn thng ca h thng.Cho bit s kt ni gia cc mun trong h thng CIM, trng thi ca tng mun cng nh tng trm c sn sng hay cha. Ti y c th kim tra cc u vo ra, kim tra s lin thng gia cc trm trong CIM. Chc nng ny cho php gim s lng nhn vin kim tra ca h thng CIM v ch cn qua mn hnh c th xc nh c cc trng thi lm vic ca mt h thng CIM ln. Vic kim tra ny c phn mm tin hnh lin tc trong c qu trnh gia cng cng nh qu trnh chun b ca h thng CIM qua c th x l kp thi, gim s c ca h thng.Lp trnh cho robot.Chc nng ny ca phn mm tch hp cho php lp trnh cho cc robot mt cch nhanh chng ty theo nhim v ca cc robot khi gia cng cc chi tit khc nhau.Lp trnh PLC.Cc ng dng ca PLC cng c lp trnh ngay trn phn mm tch hp. Kh nng ny gip cho vic lp trnh tr nn d dng hn v khng cn s dng cc chng trnh lp trnh i km vi cc PLC.S b tr cc trm ca h thng CIMCc phn mm tch hp khng ch c kh nng iu khin tch hp cc thnh phn ca h thng CIM m cn c kh nng th hin di dng m phng hnh dng, v tr tng quan ca cc thnh phn, cc trm trong h thng CIM. N gip cho giao tip gia ngi s dng v h thng tr nn d dng hn. C c iu ny l do mi h thng CIM u c mt phn mm tch hp i km.Do cc h thng CIM c tnh linh hot cao, c th thm hay bt cc thnh phn nn cc phn mm tch hp cng phi c kh nng p ng iu ny. Mi khi h 49 n tt nghip C in t 3 - K47thng c s thay i th cn b xung s thay i vo phn mm tch hp. Cc phn mm tch hp c h tr cc cng c ngi s dng c th thc hin cc thay i ny mt cch d dng.S m phng h thng.Ngoi vic m phng li hnh dng v v tr tng quan gia cc thnh phn trong h thng CIM, phn mm tch hp cn c kh nng m t hot ng ca cc thnh phn. Trc khi thc hin sn xut thc, phn mm tch hp s m phng hot ng ca h thng trnh gp s c khi sn xut tht. iu ny cho php ht thng CIM gim ti a cc s c do li lp trnh gy ra.Hot ng ca h thng.Trong qu trnh h thng hot ng, cc tn hiu t h thng lun c phn mm tch hp thu nhn v theo di x l kp thi cc s c. Nh c chc nng ny m h thng CIM c th gim ti a nhn cng m vn m bo c yu cu gim st lin tc trong qu trnh sn xut.50 n tt nghip C in t 3 - K47VI. H thng kim tra.H thng kim tra t ng th hin kh nng t ng ho cao v khng c s tham gia ca con ngi. Trong h thng CIM, h thng kim tra c cc chc nng: - Nhn v trnh thng tin v cc tnh cht, trng thi k thut v cch b tr khng gian ca cc i tng c kim tra, ng thi kim tra trng thi ca mi trng cng ngh v iu kin sn xut.- So snh gi tr thc t vi gi tr danh ngha ca thng s.- Truyn thng tin v s khng tng thch vi cc m hnh ca qu trnh sn xut kp thi hiu chnh trn cc cp iu khin khc nhau ca h thng CIM.- Nhn v trnh thng tin v thc hin chc nng.H thng kim tra t ng ca CIM phi m bo cht lng sn phm bng cch kim tra vt liu, phi, dng c, g, ch ct, th sn phm, cc thng s ca thit b cng ngh v sn phm trn tt c cc giai on ca qu trnh ch to. Ngoi ra phi m bo hiu qu cao nht ca CIM bng cch kim tra v chun on cc rbt cng ngh, cc thit b gia cng t ng, k thut tnh ton v k thut lp trnh.6.1. Cc dng kim traDu hiu phn loi Dng kim traMc ch kim traCht lng sn phmKh nng lm vic ca thit bNhimvcgii quytTip nhnD phngChun onTc ng vi i tngTch cc: trc tip v gin tipTh ng: sau mi nguyn cng, sau vi nguyn cngThng s: nh lng, dung saiChc nng hot ngGii quyt kt cuBn trong (t kim tra)Bn ngoiThc hintheothi gian Lin tc (trong qu trnh hot ng)Chu k51 n tt nghip C in t 3 - K47Ngoi cc dng kim tra trn, cn phi kim tra cc iu kin sn xut, gn lin vi k thut an ton (iu kin sn xut thng thng l cc yu t tc ng bn ngoi nh: nhim bi, nhit v m khng kh). Kim tra m bo an ton cho ngi cng nhn, gi cho thit b khng b hng hc v nhm t cht lng sn phm cao nht. 6.2. Cu trc ca h thng kim tra t ng.C 3 mc: mc cao, trung bnh, thp. H thng kim tra t ng cho php xc nh i tng v thit b kim tra i tng vi tng mc (cao, trung bnh, thp).6.2.1. Mc cao.m bo kim tra tng hp tt c cc t bo t ng (mun t ng) phi hp hot ng, iu chnh v sa cha, truyn ti thng tin ti trm iu khin ca CIM v gii quyt cc nhim v sau:- Tip nhn, x l v tng hp thng tin t mc thp hn( t cc t bo t ng).-Kimtrakhi lngvcht lngsnphmvcungngvt chtk thut(vt liu, dng c, ...).- Kim tra cc nguyn cng c thc hin trn cc t bo t ng.- T kim v kim tra hot ng ca mc thp hn.i tng kim tra mc cao l tt c cc t bo t ng in hnh( t bo gia cng, vn chuyn, kho cha, okim tra, t bo th nghim) v ch lm vic ca cng nhn. thit b kim tra l t hp my tnh iu khin trn c s cc my tnh nh.6.2.2. Mc trung bnh.m bo kim tra t bo t ng v truyn ln mc cao thng tin tng hp v tnh cht, trng thi k thut v v tr khng gian ca cc i tng c kim tra v ca cc b phn ca t bo t ng. H thng kim tra t ng mc trung bnh gii quyt cc nhim v sau:- Tip nhn v x l thng tin v cc thng s c kim tra, v cc thng s hot ng ca t bo t ng, v cc thng s ca mi trng cng ngh v truyn thng tin ln mc cao.- Kim tra cht lng gia cng trn cc t bo t ng.- Kim tra cc nguyn cng.- T kim v kim tra hot ng ca mc thp hn.i tng kim tra mc ny l t bo t ng (gm tt c cc h thng t ng c s). Thit b kim tra l t hp my tnh iu khin trn c s cc my tnh nh. 52 n tt nghip C in t 3 - K47T hp my tnh iu khin gm: cc my tnh, thit b ni kt vi cc u cui xa v mng my tnh ni b v cc thit b nng cao n nh ca h thng. 6.2.3. Mc thp.m bo kim tra i tng gia cng, trng thi k thut v v tr khng gian ca cc b phn ca my CNC, ca rbt cp phi, ca thit b kim tra t ng. H thng kim tra t ng mc thp gii quyt cc nhim v sau:- Tip nhn v x l thng tin v cc thng s c kim tra v truyn thng tin ln mc trung bnh.- Kim tra hot ng ca cc b phn my.- Truyn thng tin ti h thng phc v chun on cc hng hc ca dng c v thit b.i tng kim tra l cc thnh phn ca h thng t ng c s nh c cu iu khin, c cu chuyn i, c cu chp hnh, i tng gia cng.Thit b kim tra l cc attric o lc ct (dng cho cc my ct kim loi), cc attric xc nh v tr (dng cho rbt), attric hnh trnh (dng cho rbt vn chuyn), cc attric nhit , attric p sut, attric m, ...(dng cho kim tra mi trng cng ngh).6.3. Ch hot ng ca h thng kim tra t ng.Ch khi ng.Ch khi ng bt u t vic hi (kim tra) tt c cc phn t v cc h thng ca CIM. Khi h thng kim tra t ng thc hin vic chun on trng thi k thut ca cc phn t v h thng, pht hin u ra ca tt c cc h thng v tr ban u, kim tra hot ng ca lnh ny, kim tra s tn ti v m s ca cc phi v dng c. Trong qu trnh kim tra cc khuyt tt s b loi b.Ch lm vicHthngkimtratngchophpkimtracht lngchtosn phm,kim tradng sn phm,kim tra dngc,nng lng, thng tin, kim tra hot ng ca cc h thng ph tr (lm sch phoi, ra chi tit, lm lnh, vn chuyn phoi, ht bi, cp dung dch trn ngui, iu ho khng kh, ...), kim tra trng thi k thut ca tt c cc phn t v cc h thng trong CIM.Ch iu chnhThng tin iu khin c chuyn ti my tnh ca mc cao (mc kim tra cao nht trong h thng kim tra t ng). Thng tin iu khin ny cho php iu chnh li cc h thng kim tra mc trung bnh v mc thp. My tnh ca mc thp xc nh tt c cc thng s cn kim tra ca i tng gia cng.53 n tt nghip C in t 3 - K47Ch dng theo k hochy l ch hot ng c bit, n cho php khi ng tip theo khng phi t thi im lm vic ban u ca h thng, m t thi im n c dng theo k hoch. Ch ny, qu trnh gia cng trn cc my c kt thc, h thng t ng thc hin vic tho v g chi tit, a cc b nh v t ng v v tr ban u, ghi trng thi ca CIM trn bng t, ngt tt c cc trm cp nng lng. Nhim v ca h thng kim tra t ng trong trng hp ny l kim tra qu trnh x l tn hiu iu khin. Ngoi ra, v cc h thng ca CIM ngng hot ng nn c th tin hnh vic chun on cc h thng v iu phi thng tin cho cc th iu chnh v cc th sa cha.Ch dng sa cha hng hcCh ny c thc hin vi tt c cc mc kim tra ca h thng kim tra t ng. Vi mc thp, ch ny xut hin bng gii hn ca ph phm cho php v bng sai s ca cc thng s ca h thng t ng c s hoc ca cc thit b kim tra. Tn hiu v tnh trng phi dng sa cha t cc mc kim tra c chuyn ti mc kim tra cao hn v c x l trm iu khin ca CIM.6.4. Kim tra trng thi k thut ca cc phn t v mun trong CIM n nh ca CIM c m bo bng n nh ca cc phn t trong h thng v bng kim tra thng xuyn kh nng lm vic ca my, ca g, ca dng c, ca rbt, ca kho cha, ca cc thit b iu khin v my tnh. C 2 phng php kim tra:-Kim tra trc tip: S dng khi cc thng s c o trc tip, v d: chnh xc nh v, mn ca dng c ct. Cn phi c thit b kim tra chuyn dng cho a s cc thng s.- Kim tra gin tip: S dng khi trng thi k thut ca i tng c th c nh gi theo chc nng hot ng ca n, v d: nu h thng kim tra ghi nhn khng c s sai s th iu ny cho thy trng thi ca dng c ct l bnh thng.Di y l cc thng s cn xc