裂解发动机箱体主轴承座螺栓装配系统研究与设计
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摘要
裂解加工方法与传统加工方法相比,具有低成本、低能耗、高质量、高效率等明显优势,从而得到了广泛的应用。发动机箱体曲轴轴承座裂解技术是继承连杆裂解技术相关原理发展起来的新技术。该技术的发明将进一步推动裂解技术的发展,提高发动机箱体的产品质量,降低生产成本。本论文吸取了裂解连杆装备技术开发的经验,完成了裂解发动机主轴承座螺栓装配系统的研究与设计。主要内容包括有:
1.针对发动机箱体结构及螺栓装配的特点,完成了螺栓自动供料系统的设计。
2.完成了机械手自动抓取螺栓,输送到装配位置的自动上螺栓装置的设计,保证了螺栓输送的准确性,并且适用于不同型号发动机箱体的上螺栓输送。
3.完成了定扭矩螺栓装配系统的设计。重点研究了定扭矩扳手的结构特点和使用要求,选择合适的电动数控定扭矩扳手进行装配。设计了定扭矩扳手的安装与可调装置以满足不同型号发动机箱体螺栓的定扭矩装配,并且设计了合理驱动方式。
The fracture-splitting technology is a new technical for processing section parts which has been developed since the beginning of the 1990s. It is a grand renovation to the traditional processing method. This new method is full of imagination and ingenuity, and first used in engine connecting rod machining. As it simplified structural design of bolt hole and whole process technology, the method has many advantages, such as less working processing, small equipment investment, low manufacture cost, good product quality, high assembly precision, great carrying capacity and so on.
Along with the mature of the fracture-splitting technology of connecting rod of engines, many foreign companies dilated the research field in recent years. Crankcase bearing block of engine, Crank shaft flange, Cam disk, Strap, Bearing for printing machine are all produced by fracture splitting technology. Crankcase bearing block is one of the key parts of engine. It is difficult to cast and process in manufacturing. As fracture-splitting technology which changed the traditional method of separating processing of the bearing block and cap is used to process bearing block, the difficulties are solved. This technical got rid of the procedure of milling and complicated clamping device when processing the relevant faces. So Domestic and international researchers have paid a lot of attention on this technology. The investigation on this technology is on primary stage at home. After the research team of Jilin University have successfully produced the equipment for fracture-splitting connecting rod, they began to research on the field of fracture-splitting crankcase bearing block of engine. The team applied the patent "the method and equipment for facture splitting crankcase bearing block of engine" in 2005.
The key items of the fracture splitting technology 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 crankcase bearing block. Being one of the key techniques of the fracture splitting technology, assembling bolts is upmost important to the quality of fracture splitting crankcase bearing block.
During the fracture separating procedure, fracture splitting and restoration between bearing block and cap has been finished. But 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 cap and the crankcase bearing block together are fed to fixture of bearing block for inserting bolts by the hopper and feeding track. Secondly the manipulators for inserting bolts grasp the bolts into the bolt hole of bearing block automatically. Then the bearing block 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 all the bolts into the bolt hole in high precision. During the process of positioning, the manipulator must move steadily and its movement must be precise in order to insure the assembling quality of the next procedure. This question how to assure it is one of the key technical difficulties of fracture splitting bearing block. Furthermore, the equipment of feeding bolts must be chosen properly in order to bolts whose direction and position is wrong can be distinguished and winkled out. The manipulator of inserting bolts must insert all bolts into the bolt hole of bearing block simultaneously and accurately. The course is so complex and difficult that the fault ratio in this part of automatic product line is rather high. 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 bearing block. The thesis includes three parts which are automatic feeding bolts system, the manipulator 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 different kinds of engine has been designed. It can meet with the desire of massive production. This feeding system has been jointed properly with the manipulator of inserting bolts in order that bolts can be inserted into the bolt hole automatically and exactly.
2. The manipulator for carrying the bolts and insert them into the bolt holes is designed in the thesis. Considering two technical conditions, which is the high reduplicate movement precision during the inserting processing, and another is the applicability for different kinds of engine, certain adjusting device is provided and three-point grippers is chosen to grasp bolts. The three fingers move simultaneously so that the grippers can firm the centre automatic. The reasonable modular linear unit is set up in order to ensure the stability and precision of the procedure.
3. Transport of electric numerical control torque wrench fastening is designed. In order to assure assembling quality and precision, the structure character and require of adjust torque wrench fastening has been emphasized and studied deeply. In this part stability and adjustable mode of fixture has been considered as a design emphasis.
The automatic assembling bolts system for fracture splitting crankcase bearing block designed in this thesis can supply the gap of product lines imported from developed countries which can hardly changed the kind of engine. Because of advanced technology and well performance, it will have important meaning and play a positive role for accelerating technology renovation and promoting the industrialization of the crankcase bearing block fracture splitting technology in the domestic engine industry.
1.针对发动机箱体结构及螺栓装配的特点,完成了螺栓自动供料系统的设计。
2.完成了机械手自动抓取螺栓,输送到装配位置的自动上螺栓装置的设计,保证了螺栓输送的准确性,并且适用于不同型号发动机箱体的上螺栓输送。
3.完成了定扭矩螺栓装配系统的设计。重点研究了定扭矩扳手的结构特点和使用要求,选择合适的电动数控定扭矩扳手进行装配。设计了定扭矩扳手的安装与可调装置以满足不同型号发动机箱体螺栓的定扭矩装配,并且设计了合理驱动方式。
The fracture-splitting technology is a new technical for processing section parts which has been developed since the beginning of the 1990s. It is a grand renovation to the traditional processing method. This new method is full of imagination and ingenuity, and first used in engine connecting rod machining. As it simplified structural design of bolt hole and whole process technology, the method has many advantages, such as less working processing, small equipment investment, low manufacture cost, good product quality, high assembly precision, great carrying capacity and so on.
Along with the mature of the fracture-splitting technology of connecting rod of engines, many foreign companies dilated the research field in recent years. Crankcase bearing block of engine, Crank shaft flange, Cam disk, Strap, Bearing for printing machine are all produced by fracture splitting technology. Crankcase bearing block is one of the key parts of engine. It is difficult to cast and process in manufacturing. As fracture-splitting technology which changed the traditional method of separating processing of the bearing block and cap is used to process bearing block, the difficulties are solved. This technical got rid of the procedure of milling and complicated clamping device when processing the relevant faces. So Domestic and international researchers have paid a lot of attention on this technology. The investigation on this technology is on primary stage at home. After the research team of Jilin University have successfully produced the equipment for fracture-splitting connecting rod, they began to research on the field of fracture-splitting crankcase bearing block of engine. The team applied the patent "the method and equipment for facture splitting crankcase bearing block of engine" in 2005.
The key items of the fracture splitting technology 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 crankcase bearing block. Being one of the key techniques of the fracture splitting technology, assembling bolts is upmost important to the quality of fracture splitting crankcase bearing block.
During the fracture separating procedure, fracture splitting and restoration between bearing block and cap has been finished. But 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 cap and the crankcase bearing block together are fed to fixture of bearing block for inserting bolts by the hopper and feeding track. Secondly the manipulators for inserting bolts grasp the bolts into the bolt hole of bearing block automatically. Then the bearing block 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 all the bolts into the bolt hole in high precision. During the process of positioning, the manipulator must move steadily and its movement must be precise in order to insure the assembling quality of the next procedure. This question how to assure it is one of the key technical difficulties of fracture splitting bearing block. Furthermore, the equipment of feeding bolts must be chosen properly in order to bolts whose direction and position is wrong can be distinguished and winkled out. The manipulator of inserting bolts must insert all bolts into the bolt hole of bearing block simultaneously and accurately. The course is so complex and difficult that the fault ratio in this part of automatic product line is rather high. 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 bearing block. The thesis includes three parts which are automatic feeding bolts system, the manipulator 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 different kinds of engine has been designed. It can meet with the desire of massive production. This feeding system has been jointed properly with the manipulator of inserting bolts in order that bolts can be inserted into the bolt hole automatically and exactly.
2. The manipulator for carrying the bolts and insert them into the bolt holes is designed in the thesis. Considering two technical conditions, which is the high reduplicate movement precision during the inserting processing, and another is the applicability for different kinds of engine, certain adjusting device is provided and three-point grippers is chosen to grasp bolts. The three fingers move simultaneously so that the grippers can firm the centre automatic. The reasonable modular linear unit is set up in order to ensure the stability and precision of the procedure.
3. Transport of electric numerical control torque wrench fastening is designed. In order to assure assembling quality and precision, the structure character and require of adjust torque wrench fastening has been emphasized and studied deeply. In this part stability and adjustable mode of fixture has been considered as a design emphasis.
The automatic assembling bolts system for fracture splitting crankcase bearing block designed in this thesis can supply the gap of product lines imported from developed countries which can hardly changed the kind of engine. Because of advanced technology and well performance, it will have important meaning and play a positive role for accelerating technology renovation and promoting the industrialization of the crankcase bearing block fracture splitting technology in the domestic engine industry.
引文
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[2] 寇淑清,杨慎华,邓春萍,金文明. 裂解工艺-发动机连杆制造最新技术. 中国机械工程第 12 卷第 7 期 2001 年 7 月:893-841.
[3] 杨丹. 发动机箱体轴承座裂解加工数值模拟研究. 吉林大学硕士论文,2006.
[4] Fetouh, Mohamed A. Method for making a Split bearing assembly[P]: U S Patent, 4569109.
[5] 何东野,杨慎华,寇淑清. 发动机曲轴箱轴承座裂解加工新工艺. 热加工工艺技术及装备,2007,第九期:44-46.
[6] 杨慎华,寇淑清,赵勇,郑祺峰. 发动机曲轴箱体轴承座裂解加工方法及装置. 中国发明专利申请书:2004100110822. 4CN1611323A.
[7] Naylor DJ. Advances in Steel for Forging. 1997, No. 1-15.
[8] 谢谈,余宁,蒋鹏等. 发动机连杆剖分新技术. 机械工程师,2000(4):19-20.
[9] Shinsaku Fukuda, Hirohito Eto. Development of fracture splitting connecting rod. JASE Review, 2002, 23:101-104.
[10] 三通机械工具有限公司.用于连杆裂解设备的双夹紧装置.CN 1198374A.
[11] Ford Motor Company. Machinable, Storng, but crackable low ductility stell forging. Uivited State Patent: 5,135,587, 1992-8-4.
[12] EX-Cell-O.Method and installation for machining machine parts having a bearing eye.Canada Patent:5,35,87,992-8-4.
[13] EX-Cell-O. Machine Tools. Process and apparatus for manufacturing connecting rods. Uinited State Patent:CA2,055,401.
[14] Hahnel Michael (DE), Wisniewski Horst (DE). Device for fracture-splitting a workpiece [ P ]:U S Patent, US2002070257.
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[21] Fukuda, Shinsaku. Development of fracture splitting connecting rod. JSAE Review, 2002:101-104.
[22] General Motors Corpiration. Connecting rods fracture machine. Uinited State Patent:4768,694.
[23] R.A.Chernenkoff,D.W.Hall,S.Mocarski,M.Gagne.Material character-rization of powder-forged copper steels. SAE paper 910155,SAE Conference, Detroit,1991:87-104.
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[28] Liu, WenZhong.Alfing Laser Cracking Equipment Application.Automobile Technology&Mtereial.2005(11),0011-03.
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[30] Berthold Repgen. Optimized Connecting Rods to Enalle Higher Engine Performance and Cost Reduction[J]. SAE Paper, 9800882.
[31] 李森荣,王爱华,李念辛. 粉末锻造发动机连杆的发展. 粉末冶金工业,1995(5):185-188.
[32] Daniel Robat. Steel for Connecting Rod Forgings with Optimum Splittability. 16th International Forging Congress, Beijing, China, 1999(5):51-56.
[33] PM Industry News[J], international Journal of Powder Metallury, 2003, 39(4):8.
[34] 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.
[35] 李明惠. 汽车材料[M]. 北京:机械工业出版社,2002.
[36] 魏长青,费燕琼,杨汝清等. 机械人装配中一种自动送料与定位装置的设计. 组合机床与自动化加工技术. 2000(8):42-43,50.
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[2] 寇淑清,杨慎华,邓春萍,金文明. 裂解工艺-发动机连杆制造最新技术. 中国机械工程第 12 卷第 7 期 2001 年 7 月:893-841.
[3] 杨丹. 发动机箱体轴承座裂解加工数值模拟研究. 吉林大学硕士论文,2006.
[4] Fetouh, Mohamed A. Method for making a Split bearing assembly[P]: U S Patent, 4569109.
[5] 何东野,杨慎华,寇淑清. 发动机曲轴箱轴承座裂解加工新工艺. 热加工工艺技术及装备,2007,第九期:44-46.
[6] 杨慎华,寇淑清,赵勇,郑祺峰. 发动机曲轴箱体轴承座裂解加工方法及装置. 中国发明专利申请书:2004100110822. 4CN1611323A.
[7] Naylor DJ. Advances in Steel for Forging. 1997, No. 1-15.
[8] 谢谈,余宁,蒋鹏等. 发动机连杆剖分新技术. 机械工程师,2000(4):19-20.
[9] Shinsaku Fukuda, Hirohito Eto. Development of fracture splitting connecting rod. JASE Review, 2002, 23:101-104.
[10] 三通机械工具有限公司.用于连杆裂解设备的双夹紧装置.CN 1198374A.
[11] Ford Motor Company. Machinable, Storng, but crackable low ductility stell forging. Uivited State Patent: 5,135,587, 1992-8-4.
[12] EX-Cell-O.Method and installation for machining machine parts having a bearing eye.Canada Patent:5,35,87,992-8-4.
[13] EX-Cell-O. Machine Tools. Process and apparatus for manufacturing connecting rods. Uinited State Patent:CA2,055,401.
[14] Hahnel Michael (DE), Wisniewski Horst (DE). Device for fracture-splitting a workpiece [ P ]:U S Patent, US2002070257.
[15] 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.
[16] 倪森寿. 机械制造工艺与装备[M]. 北京:化学工业出版社,2002.
[17] 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.
[18] 李如松. 连杆及曲轴箱的断裂刨分工艺. 佳工机电网.
[19] Alfing Kessler Sondermaschinen Gmbh. Method and apparatus for fracturing connecting rods. Uinited State Patent:5,169,046, 1992-12-8.
[20] YASUNAGA CORPORATION. Connecting rod fracture machie and method for fracture separaing connecting rod using the machine. Uinited State Patent:2000-253872.
[21] Fukuda, Shinsaku. Development of fracture splitting connecting rod. JSAE Review, 2002:101-104.
[22] General Motors Corpiration. Connecting rods fracture machine. Uinited State Patent:4768,694.
[23] R.A.Chernenkoff,D.W.Hall,S.Mocarski,M.Gagne.Material character-rization of powder-forged copper steels. SAE paper 910155,SAE Conference, Detroit,1991:87-104.
[24] WHITTAKER D. The competition for automotive connecting rod markets[J]. Metal Powder Report. 2001.
[25] 吴际璋. 汽车构造[M]. 北京:人民交通出版社,1997.
[26] 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.
[27] 工业机械手设计基础.天津大学《工业机械手设计基础》编写组编.天津:天津科学技术出版社,1979,8:1-8;14-16.
[28] Liu, WenZhong.Alfing Laser Cracking Equipment Application.Automobile Technology&Mtereial.2005(11),0011-03.
[29] Ford Motor Company.Low-cost method of making craked connecting rods comprised of forged wrought steel.Uinited State Patent:5, 105, 538,1992-4-12.
[30] Berthold Repgen. Optimized Connecting Rods to Enalle Higher Engine Performance and Cost Reduction[J]. SAE Paper, 9800882.
[31] 李森荣,王爱华,李念辛. 粉末锻造发动机连杆的发展. 粉末冶金工业,1995(5):185-188.
[32] Daniel Robat. Steel for Connecting Rod Forgings with Optimum Splittability. 16th International Forging Congress, Beijing, China, 1999(5):51-56.
[33] PM Industry News[J], international Journal of Powder Metallury, 2003, 39(4):8.
[34] 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.
[35] 李明惠. 汽车材料[M]. 北京:机械工业出版社,2002.
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