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Otomobil gövde imalatı ve robot uygulamaları

Başlık çevirisi mevcut değil.

  1. Tez No: 75421
  2. Yazar: SABRİ ÇİMEN
  3. Danışmanlar: PROF. DR. MEHMET ÇAPA
  4. Tez Türü: Yüksek Lisans
  5. Konular: Makine Mühendisliği, Mechanical Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1998
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Makine Ana Bilim Dalı
  12. Bilim Dalı: İmalat Bilim Dalı
  13. Sayfa Sayısı: 107

Özet

“Otomobil Gövdesi İmalatı ve Robot Uygulamaları”başlıklı bu çalışmada öncelikle otomobil gövdesinin imalat safhaları, bu imalatta yaygın olarak kullanılan punta kaynak prosesi tanıtılmış; daha sonra robotların tercih nedenleri vurgulanmıştır. Çalışmanın sonraki aşamasında imalatta kullanılan robotların bileşenleri ve ekipmanları incelenmiş, robot programlanması ve robot hareketleri prensipleri ele alınmıştır. Çalışmanın sonunda ise bir robotun devreye alınma aşamaları sıralanmıştır. İlk bölüm ile kısa bir giriş yapıldıktan sonra ikinci bölümde, gövde imalatı bir atelye örnek alınarak genel hatlarıyla açıklanmış, daha sonra imalat safhaları detayları ile ele alınmıştır. İmalat safhaları operasyon sırası ile özetlenmiş, imalat mühendisliği açısından ilginç uygulamalar vurgulanmıştır. Her safhada kullanılan makina, ekipman ve özellikle robotların üzerinde durulmuştur. Bu bölümün sonunda doğrudan imalat ile ilgili olmayan ancak destek sağlayan ekipler tanıtılmıştır. Üçüncü bölümde, gövde imalatının çok büyük bir kısmını kapsayan, punta kaynak prosesi incelenmiştir. Bu proseste kullanılan makina tipleri ve özellikle son teknoloji ürünleri üzerinde durulmuştur. Dördüncü bölümde, komple bir punta kaynak robot istasyonunun bileşenleri, detayları ile incelenmiştir. Beşinci bölümde, robot programlama mantığı ele alınmıştır. Robota yaptırılması istenen hareketlerin oluşum prensipleri, programlama mantığı içersinde robotun nasıl hareket ettiği ve hangi parametrelerin sisteme tanıtılması gerektiği üzerinde durulmuştur. Altıncı bölümde, herhangi bir endüstriyel uygulamada robot kullanılmasının fizibilite çalışmaları incelenmiştir. Oldukça pahalı yatırımlar olan robotların kullanılıp kullanılmaması hakkında karar verilirken, sistemin donanım maliyeti, kurulduktan sonra getireceği ek fayda ve bunun yanında ek giderleri detaylarıyla ortaya koyulduktan sonra karar aşamasında bunların nasıl değerlendirileceği ele alınmıştır. Son bölümde ilk olarak imalatının robot ile yapılacağı bir parça grubu için yeni bir robot istasyonunun devreye alınma projesi, aşamaları ile tanıtılmıştır. Daha sonra, beşinci bölümde teorik olarak anlatılan fizibilite aşamaları, bu robot projesine uygulanmıştır. Son olarak ortaya çıkan sonuç yorumlanmıştır.

Özet (Çeviri)

In this work,“Automobile Body Manufacturing and Robot Applications”, first, body manufacturing steps and spot welding process which are widely used, are introduced. In the next step, hardware of a robot station, robot programming and movement principles are taken up. After theoretical study of feasibility of robot investment, a new robot's implementation steps are arranged in order and a real feasibility study was done at the end of the work. In the body shop of a car manufacturing plant, there are a lot of technologies used in order to obtain joints of sheet metals: spot welding, seam welding, MIG/MAG welding, brazing, sealing, clinching, bolt joints, etc. Among them, the widest joining process is spot welding with a 90% ratio. This process can be applied manually or by a robot. Body manufacturing process has the same main rules if we have a look around worldwide automobile industries. So, in this kind of work, the best way of studying the general of the subject and the details is working via a sample of a body shop. In this work also, the body shop producing Ford Escort model car's bodies in Ford Otosan Plant is selected as a sample. In this plant, despite low volume production sizes, flexible automation, robots and other related high technologies are widely used. This offered a very conform platform for this work. After a brief introduction in the first chapter, in the second chapter, body manufacturing is explained via the Ford Otosan Company's Escort Body Shop. First, the manufacturing steps are summarized, and then interesting applications about manufacturing techniques are focused. Especially, robot applications for each sub assembly group are underlined. At the end of this chapter, teams who are indirectly effective to the production are presented. In Escort Body Shop, there are six production teams. Four of them are about sub assemblies, two about main line:. Body side production team,. Engine compartment production team,. Underbody and detail sub-assemblies production team,. Body assembly production line team,. Door and hood top production team,. Closure lines and metal finish line.Underbody, body assembly production, closure line and metal finish line can be considered as the main line in the layout. Body side production, engine compartment production, door and hood top production stations are placed around this main line in order to supply it. There are four main teams, supporting the production:. Material handling team,. Quality systems team,. Fixture maintenance team,. General maintenance team. Body evaluation, SPC, 3-D measurement are included in quality systems team and these teams reports directly to the shop management. In the third chapter, spot welding process, which is the main manufacturing method used in body welding operations, is studied in details. First, the resistance welding is studied about its principles and types. The meaning of the main formulas, Joules equation, is explained for this technique. The working principle of a resistance welding machine is studied. On the next step, spot welding, which is a most widely used type of resistance welding is analysed in details:. Principles of spot welding,. Constitution of spot welding nugget,. Spot welding loop,. Classification of spot welding machines: Especially the new technologies for this process, advantages and disadvantages for each one are evaluated.. Spot welding process parameters. In the fourth chapter, the robotic station components are studied. Control unit, hardware, operation principles, communication between components, functions are studied in details for robot manipulator and welding control unit as the main components. The axes of the manipulator is identified. The working area of different types of robots is defined. Load diagram of a robot manipulator is explained by geometry and calculation of it. Robot control unit and teach box of the robot is introduced with the functions. The main unit, such as electronic unit, computer system, servo system, input/output system, security system and external axes are introduced also in order to explain the working logic of the system.The other components of a robotic system are:. Welding control unit: This is one of the most important components related directly with the process. This unit's hardware is introduced, then the control logic and its functions are explained. There are several facilities to use in order to have optimum control of the process parameters : stepper function, diagnostic function, constant current regulation function, etc.. Supply unit. Spot welding gun. Fixture. Tip dresser. Tool changer. Cable and pipes. Sensors In the fifth chapter, robot programming logic is explained: Program memory contains program and system modules. Program contains main module and other modules. Program data, main routine and other routines constitute main module. Program data and routines constitute modules. The next step is the study of robot coordinate systems and the motions. There are several alternative coordinate systems for user:. World coordinate system,. Base coordinate system,. User coordinate system,. Object coordinate system,. Displacement coordinate system. External coordinate system. Wrist coordinate system. Tool coordinate system During program execution, positioning instructions in the robot program control all movements. The main task of the positioning instructions is to provide the following information on how to perform movements:. The destination point of the movement. The interpolation method used to reach the destination point,. The velocity of the robot and external axes,. The zone data,. The coordinate systems.There are three interpolation types of the position and orientation of the tool: Joint interpolation, Linear interpolation Circular interpolation. Those movement parameters and interpolations are explained in details in this chapter. In the sixth chapter, the answer of the question“Is the robot investment feasible for any application? ”is searched. For this research, at first, the three items about investment shall be studied.. Initial investment cost,. Annual added expenditures such as qualified men cost, sofisticated maintenance cost.. Annual added incomes such as save of workers, increase of quality, decrease of repair and scrap costs, etc. Those three data are put in simple formulas in order to calculate the payback period of the investment. The upper management takes decision to investigate or not, up to the result got after this calculation. But, the result of economic analysis is not the only reason for robot preference. This is explained at the end of the chapter. In the last chapter, the steps of implementation project of a new robot station are arranged:. selection of hardware,. selection of place,. training,. robot programming,. parameter adjustment,. documentation,. sample production,. tests, readjustments,. buy-off of the system are some of those steps. At the next step, feasibility study is applied to this robot project. All values for each item are calculated or obtained up to the engineering records or experiences. The initial investment cost, annual added expenditures and annual added incomes areseparately calculated by the cost items. Then they are used in the formula that is mentioned in the previous chapter, and the result is obtained as payback period of the investment. The results are interpreted at the end of the chapter and in the“Results and Proposals”chapter.

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