裂解连杆螺栓自动装配系统研究与设计
摘要
发动机连杆裂解加工技术与传统连杆加工方法相比具有高质量、高效率、低成本、低能耗等显著优势,从而得到越来越广泛的应用。为促进连杆裂解加工新技术在国内的实施、应用与推广,本论文进行了裂解连杆螺栓自动装配系统的研究开发,其主要内容包括:
1、针对裂解连杆螺栓装配的特点,自主设计开发了适用于多品种裂解连杆的螺栓自动供料系统与自动上螺栓装置。
2、完成了裂解连杆定位夹紧装置结构设计。自行设计了独特的螺旋盘压紧机构,有效地保证了在连杆夹紧及定扭矩装配螺栓过程中连杆的杆、盖啮合部位不产生任何松动、错位。
3、数控定扭矩扳手传送装置结构设计。着重研究了定扭矩扳手的结构特点、使用要求及更换连杆品种时夹具的可调性与稳定性,以保证螺栓的装配质量。
The fracture splitting technology of connecting rod for vehicle engines is the most advanced technology for processing connecting rod, which appeared and was developed in the beginning of the 1990s. Compared with conventional processing method of connecting rod the fracture splitting technology is significant reform. This new technology is so ingenious in design, simple, convenient and easy to control in technology, efficient and low cost that it has become one of the important signs of the level of manufacturing industry of engine connecting rod. So many abroad large-scale automobile production companies as well as tool and equipment production companies have done plentiful research works in the fracture splitting technical field of connecting rods. The fracture splitting technology of connecting rod has become mature day by day. So far, the absolute majority of the domestic corporations of the connecting rods have continued to use the traditional connecting rods processing method which has so many shortcomings as low efficiency, complex technology processes, high cost and waste and so on. This has become the bottleneck of the development of the connecting rod industry and even the engine industry.
The research team leaded by Professor Yang Shenhua of Jilin University is doing a lot of research on the fracture splitting technology of connecting rod for
vehicle engines in order to carry out this new technology and apply it extensively at home. And China “863”Program “Engine connecting rod fracture manufacture technology and equipment”has been passed the application. The key items of the fracture splitting technology of connecting rod are automatic production of three core working procedure. They are machining of cracking notches, directed fracture separating and assembling bolts in required torque. Contents needed to be researched in this thesis are automatic assembling bolts system for fracture splitting connecting rods. Being one of the key techniques of the fracture splitting technology of connecting rod, assembling bolts is very important to the quality of fracture splitting connecting rod. During the fracture separating procedure, fracture splitting and restoration has been finished. But the bolts have not been inserted. During the assembling bolts procedure, the first step is that the bolts must be fed automatically by the hopper. The bolts for jointing the head and the end of connecting rod together are fed to fixture of connecting rod for inserting bolts by the hopper and feeding track. Secondly the equipment for inserting bolts pushes the bolts into the bolt hole of connecting rod automatically. Then the connecting rods which have bolts are carried from working position of inserting bolts to assembling bolts. At last bolts are tightened in required torque by stable torque wrench. The chief technical difficulty is how to position and clamp connecting rod whose head and end has already been restored in high precision. During the process of positioning and clamped, the connecting rod must be clamped firmly. Its head and end must keep meshing and can be loosened and moved wrongly. This question how to assure it is one of the key technical difficulties of fracture splitting connecting rod.
Furthermore, the equipment of feeding bolts must be chose properly in order to bolts whose direction and position is wrong can be distinguished and winkled out. The equipment of inserting bolts must insert two bolts into the bolt hole of connecting rod simultaneously and accurately. The course is so complex and difficult that the fault ratio in this part of automatic product line is rather high. Now only a few corporations have imported the automatic product line of fracture splitting connecting rod. The fault ratio in the course of feeding and inserting bolts has influenced the automated production more or less. In order to solve above-mentioned difficulties, this thesis has research and design on automatic assembling bolts system for fracture splitting connecting rods. The thesis include three parts that are automatic feeding bolts system, the equipment of inserting bolts and assembly system of stable torque wrench fastening. The main contents of the thesis are as follows: 1. Based on deeply studying the structural character and function of all parts of feeding system, automatic feeding bolts system that can apply to some kinds of connecting rod has been designed. It can meet with the desire of massive production. This feeding system has been jointed properly with the equipment of inserting bolts in order that bolts can be inserted into the bolt hole automatically and exactly. 2. In the thesis fixture of fracture splitting connecting rods for positioning and clamping is designed. It is one of key technologic equipments of fracture splitting connecting rods. It has a particular mechanism which can rotate for a certain angle as it moves up and down. The mechanism can assure that connecting rods are clamped firmly when bolts are tightened. During this course the head and end of connecting rod have not any offset and loose. It can prevent from falling scrap iron
1、针对裂解连杆螺栓装配的特点,自主设计开发了适用于多品种裂解连杆的螺栓自动供料系统与自动上螺栓装置。
2、完成了裂解连杆定位夹紧装置结构设计。自行设计了独特的螺旋盘压紧机构,有效地保证了在连杆夹紧及定扭矩装配螺栓过程中连杆的杆、盖啮合部位不产生任何松动、错位。
3、数控定扭矩扳手传送装置结构设计。着重研究了定扭矩扳手的结构特点、使用要求及更换连杆品种时夹具的可调性与稳定性,以保证螺栓的装配质量。
The fracture splitting technology of connecting rod for vehicle engines is the most advanced technology for processing connecting rod, which appeared and was developed in the beginning of the 1990s. Compared with conventional processing method of connecting rod the fracture splitting technology is significant reform. This new technology is so ingenious in design, simple, convenient and easy to control in technology, efficient and low cost that it has become one of the important signs of the level of manufacturing industry of engine connecting rod. So many abroad large-scale automobile production companies as well as tool and equipment production companies have done plentiful research works in the fracture splitting technical field of connecting rods. The fracture splitting technology of connecting rod has become mature day by day. So far, the absolute majority of the domestic corporations of the connecting rods have continued to use the traditional connecting rods processing method which has so many shortcomings as low efficiency, complex technology processes, high cost and waste and so on. This has become the bottleneck of the development of the connecting rod industry and even the engine industry.
The research team leaded by Professor Yang Shenhua of Jilin University is doing a lot of research on the fracture splitting technology of connecting rod for
vehicle engines in order to carry out this new technology and apply it extensively at home. And China “863”Program “Engine connecting rod fracture manufacture technology and equipment”has been passed the application. The key items of the fracture splitting technology of connecting rod are automatic production of three core working procedure. They are machining of cracking notches, directed fracture separating and assembling bolts in required torque. Contents needed to be researched in this thesis are automatic assembling bolts system for fracture splitting connecting rods. Being one of the key techniques of the fracture splitting technology of connecting rod, assembling bolts is very important to the quality of fracture splitting connecting rod. During the fracture separating procedure, fracture splitting and restoration has been finished. But the bolts have not been inserted. During the assembling bolts procedure, the first step is that the bolts must be fed automatically by the hopper. The bolts for jointing the head and the end of connecting rod together are fed to fixture of connecting rod for inserting bolts by the hopper and feeding track. Secondly the equipment for inserting bolts pushes the bolts into the bolt hole of connecting rod automatically. Then the connecting rods which have bolts are carried from working position of inserting bolts to assembling bolts. At last bolts are tightened in required torque by stable torque wrench. The chief technical difficulty is how to position and clamp connecting rod whose head and end has already been restored in high precision. During the process of positioning and clamped, the connecting rod must be clamped firmly. Its head and end must keep meshing and can be loosened and moved wrongly. This question how to assure it is one of the key technical difficulties of fracture splitting connecting rod.
Furthermore, the equipment of feeding bolts must be chose properly in order to bolts whose direction and position is wrong can be distinguished and winkled out. The equipment of inserting bolts must insert two bolts into the bolt hole of connecting rod simultaneously and accurately. The course is so complex and difficult that the fault ratio in this part of automatic product line is rather high. Now only a few corporations have imported the automatic product line of fracture splitting connecting rod. The fault ratio in the course of feeding and inserting bolts has influenced the automated production more or less. In order to solve above-mentioned difficulties, this thesis has research and design on automatic assembling bolts system for fracture splitting connecting rods. The thesis include three parts that are automatic feeding bolts system, the equipment of inserting bolts and assembly system of stable torque wrench fastening. The main contents of the thesis are as follows: 1. Based on deeply studying the structural character and function of all parts of feeding system, automatic feeding bolts system that can apply to some kinds of connecting rod has been designed. It can meet with the desire of massive production. This feeding system has been jointed properly with the equipment of inserting bolts in order that bolts can be inserted into the bolt hole automatically and exactly. 2. In the thesis fixture of fracture splitting connecting rods for positioning and clamping is designed. It is one of key technologic equipments of fracture splitting connecting rods. It has a particular mechanism which can rotate for a certain angle as it moves up and down. The mechanism can assure that connecting rods are clamped firmly when bolts are tightened. During this course the head and end of connecting rod have not any offset and loose. It can prevent from falling scrap iron
引文
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[2] 朱廷福,张会文.发动机主要零件的加工工艺和设备(一).组合机床与自动化加工技术,1997(1):27～43
[3] 朱廷福,张会文.发动机主要零件的加工工艺和设备(六).组合机床与自动化加工技术,1997(8):10～24
[4] 李绍忠. 连杆常用制造工艺及技术经济分析. 汽车工艺与材料,2000(4):10～13
[5] 寇淑清,杨慎华,邓春萍等. 裂解工艺——发动机连杆制造最新技术. 中国机械工程,2001(7):839～841
[6] 寇淑清,金文明,谷诤巍等. 内燃机连杆制造最新技术与发展趋势. 内燃机工程,2001(1):28～31
[7] 于永仁. 连杆裂解工艺. 汽车工艺与材料, 1998(9):9～11
[8] 寇淑清,杨慎华,赵勇等. 发动机连杆裂解加工及关键技术. 吉林大学学报(工学版),2004,34(1):85～90
[9] 阿尔冯. 凯斯勒专用机械制造有限公司. 裂分环形零件的装置.CN1268911A.
[10] 杨慎华,寇淑清,谷诤巍等. 发动机连杆裂解加工新技术. 哈尔滨工业大学学报,2000(3):129～131
[11] 石鑫. 裂痕扩展法剖分连杆. 汽车工艺与材料,1995(1):3～4
[12] 谢谈,余宁,蒋鹏等. 发动机连杆断裂剖分新技术.机械工艺师. 2000(4):19～20
[13] Shinsaku Fukuda, Hirohito Eto.Development of fracture splitting connecting rod. JASE Review,2002,23:101～104
[14] 徐兴尧. 国外凸轮轴和连杆生产新工艺. 汽车工艺与材料,1999(9):1～2
[15] 宋正元. 康明斯B 系列连杆工艺设计的研究与实践(续). 组合机床与自动化加工技术,1999(10):42～48
[16] 宋正元,康明斯B 系列连杆工艺设计的研究与实践(5).柴油机,2000(6):45～51
[17] YASUNAGA CORPORATION. Connecting rod fracture machine and method for fracture separating connecting rod using the machine. Uinited State Patent: 2000-253872
[18] 赵勇. 连杆裂解加工自动化装置研制.吉林大学硕士学位论文,2004
[19] 三通机械工具有限公司.用于连杆断裂设备的双夹紧装置.CN 1198374A.
[20] Ford Motor Company. Low-cost method of making cracked connecting rods comprised of forged wrought steel. Uinited State Patent: 5,105,538, 1992-4-12.
[21] Ford Motor Company. Machinable, storng, but crackable low ductility stell forging. Uinited State Patent: 5,135,587,1992-8-4.
[22] EX-Cell-O. Method and installation for machining machine parts having a bearing eye. Canada Patent: CA 2,055,401.
[23] Ex-Cell-O Machine Tools. Process and apparatus for manufacturing connecting rods.Uinited State Patent: 5,946,790,1999-9-7.
[24] Alfing Kessler Sondermaschinen Gmbh. Device for separting the rod and cap of a connecting rod by breaking.International Patent:WO 99/06169,1999-2-11.
[25] Alfing Kessler Sondermaschinen Gmbh.Method and apparatus for fracturing connecting rods. Uinited State Patent:5,169,046,1992-12-8.
[26] 特开平11—245122.
[27] 何约洁. 国外发动机连杆生产现状. 内燃机,1994(6):6～9
[28] 洪慎章,曾振鹏. 发动机连杆的粉末锻造工艺. 模具技术,2000(2):52～56
[29] 雷加骢. 连杆锻造工艺及设备. 锻压机械,1995(3):42～45
[30] Daniel Robat Ascometal , Marc Robelet Ascometal Creas. Steels for Connecting Rod Forgings with Optium Splittablity,北京:第十六届国际锻造会议文集,1999
[31] 曹正,史万福,王敢利等.高碳微合金非调制钢连杆研究.汽车工艺与材料,2000(12)::24～27
[32] Monica Bellgran, Christer Johansson. A method for the design of flexible assembly systems. International Journal of Production economics. 1995 (41):93～102
[33] 傅嘉澧,陶珍军,陈坤.螺栓装配自动化的关键技术研究.华南理工大学学报, 1994(8):36～40
[34] Fukuoka, Toshimichi; Xu, Quantuo .Analysis of the tightening process of bolted joint with bolt heater. Transactions of the Japan Society of Mechanical Engineers, Part A 1997,63(607)561-566
[35] 张佩勤王连荣等编著.自动装配与柔性装配技术.北京:机械工业出版社,2000
[36] 穆切涅科著.赵光宇译.自动装配机与自动装配线的设计基础.北京:机械工业出版社,1987
[37] 韩良,徐卫良. 振动料斗的研究状况与前景展望. 电子工业专用设备.1999(1):6～13
[38] 周梅芳.电磁振动料斗调试过程中易出现的问题及解决措施.扬州职业大学学报,2001(3):35～38
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