Design and Implementation of PLC Based Special Purpose Machine for Surface Coating

Abstract

To improve the quality and efficiency of surface coating with the GTAW method a semi-automatic welding machine was designed based on PLC control. The control program using ladder logic can accomplish system management and control functions. This system could control welding travel speed up to 560 mm/min, measure and saves the current status of the surface temperature at the welding zone via infrared thermometer up to 1600 °C in real-time, has complete automatic fault diagnosis, modify the welding travel speed and save the inputted welding parameters. To evaluate the performance of the designed welding machine, several experiments have been conducted. An average of 377.5 HV0.2 microhardness was obtained from the surface of SAE (AISI) 1040 materials used in the experiments to a depth of 1 mm via the coating powders containing 64 wt% FeCrC + 16 wt% FeTi and 20 wt% Ni. The results from the experiments have shown that the designed PLC-based semi-automatic welding machine could be effective in determining the optimum conditions for surface coating and different welding processes.

Keywords

• Surface coating
• welding
• GTAW
• PLC control

Yüzey Kaplama için PLC Tabanlı Özel Amaçlı Makina Tasarımı ve Uygulaması

Abstract

GTAW yöntemi ile yüzey kaplamanın kalitesini ve verimliliğini artırmak için PLC kontrollü yarı otomatik bir kaynak makinesi tasarlanmıştır. Ladder mantığını kullanan kontrol programı, sistem yönetimi ve kontrol fonksiyonlarını gerçekleştirebilir. Bu sistem, 560 mm/dk'ya kadar kaynak hareket hızını kontrol edebilir, gerçek zamanlı olarak 1600 °C'ye kadar kızılötesi termometre ile kaynak bölgesindeki yüzey sıcaklığının mevcut durumunu ölçer ve kaydeder, tam otomatik arıza teşhisine sahiptir, kaynak ilerleme hızını düzenler ve girilen kaynak parametrelerini kaydedebilir. Tasarlanan kaynak makinesinin performansını değerlendirmek için çeşitli deneyler yapılmıştır. Deneylerde kullanılan SAE (AISI) 1040 malzemelerinin yüzeyinden ağırlıkça %64 FeCrC + ağırlıkça %16 FeTi ve ağırlıkça %20 Ni içeren kaplama tozları ile ortalama 377.5 HV0.2 mikrosertlik elde edilmiştir. Deneylerden elde edilen sonuçlar, tasarlanan PLC tabanlı yarı otomatik kaynak makinesinin, yüzey kaplama ve farklı kaynak işlemleri için optimum koşulların belirlenmesinde etkili olabileceğini göstermiştir.

Keywords

• Surface coating
• welding
• GTAW
• PLC control

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