Controlling Hot Forging Operation Of Ammunition Shell Body Via
Transkript
Controlling Hot Forging Operation Of Ammunition Shell Body Via
9-10 NİSAN 2015 [ULUSLARARASI KATILIMLI 1. SAVUNMA SANAYİ SEMPOZYUMU] KIRIKKALE ÜNİVERSİTESİ Controlling Hot Forging Operation Of Ammunition Shell Body Via PLC And Minimizing Human Borne Faults Ömer Boyacı,1, Necaattin Barışçı, 2 Faruk Ulamış 3 1 Maintenance Department , MKE Ammunition Factory, Kirikkale 71100, Turkey 2 Computer Engineering Department, Gazi University, Ankara 06500, Turkey 3 R&D Department , MKE Ammunition Factory, Kirikkale 71100, Turkey Summary—Hot forging operation comprises of heating steel billets by an induction furnace followed by centering and pressing process via a hydraulic press. In this study, hot forging operation controlled with conventional methods is designed with Programmable Logical Controllers. A robot manipulator is adapted to the system as well, minimizing human errors. Switchboard of hydraulic press is revised in accordance to PLC so mean time to repair is reduced and more uniform products are obtained. Shell body is one of the most important parts of the ammunition containing all the explosive for the detonation and determining the flight dynamics of ammunition. While processing shell body, first, steel billet heated and given its first form via hydraulic press. This process of forming shell body from stell billet is called Hot Forging. Figure-2 Conveying hot steel billet from induction furnace to hydraulic press By the adaptation of PLC in this control system, Shorter MTTR (Mean Time to Repair) Reduction in complexity and dimensions of the switchboard Reduction in power consumption is achieved and migrated to a more advanced automation schema [2]. The oil leakage in the piston is a common fault in the hydraulic system of the large forging hydraulic press. Xian-bin Fu and co-workers has studied on determining this leakage and prediction of malfunctions caused by it [3]. In this study, various PLC’s from different manufacturers are utilized (Telemecanique for induction furnace, ABB for robot manipulator, Allen Bradley for hydraulic press) and total number of I/O ports is more than 100. Oil leakage of hydraulic press piston is omitted. Operational sequence of PLC’s in the system is designed possible interference between PLC’s and quality of the work in mind. Moreover system utilizes a protection scheme for any possible faults in various steps of the process, preventing occurrences of gross faults. Figure-1 Before and after hot forging operation At today’s technology, especially in processes including high risk factors primary aim is removing the human element. Thus, while minimizing the defects caused by human factors, reducing the risk of industrial accidents. In this study, a hot forging operation system located in MKE Ammunition Factory and controlled with conventional control methods, is revised with Programmable Logical Controllers. The conveying operation of hot steel billet from induction furnace to hydraulic press by clamp through a personal is cancelled and a robot manipulator is adapted to the system. This adaptation of robot manipulator to the system will prevent possible problems listed below; Delays in the operation of conveying of the steel billet, from induction furnace to the hydraulic pres. Omission of lubrication or excessive lubrication of the mold and punch Occupational diseases that may result from continuous exposure to smoke [1]. * Corresponding author: faruk.ulamis@mkek.gov.tr References [1] Gün, Ayhan, Gök, Kadir “Otomasyon Temelleri ve Robot Kontrolü” Seçkin Yayıncılık, Ankara [2] Kurtulan Salman, “Plc ile Endüstriyel Otomasyon” Birsen Yayınevi, İstanbul [3] Xian-bin Fu, Bin Liu, Yu-cun Zhang, Li-na Lian “Fault diagnosis of hydraulic system in large forging hydraulic pres” Measurement 49 (2014) 390-396 28