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APPENDIX
Car assembly technique situation and the development trend of the market forecast
[abstract] the article expounds auto, engine, transmission, and other key parts assembly process equipment manufacture level of general situation and the present situation, and for the next five years of automotive assembly process equipment demand forecasting is analyzed. (priceless cows back I don't need to hesitate)
1. The engine, transmission, rear axle of key parts and whole vehicle assembly process equipment
1.1 engine assembly process equipment
With the rapid development of China's automotive industry, especially in the technology and the introduction of foreign second-hand equipment to make the engine of recycle, assembly equipment level increased significantly. Engine assembly technology and equipment are divided into five types: assembly and points assembly assembly line; Move over load equipment; Automatic tight equipment; Special assembly equipment and testing equipment.
1.1.1 engine assembly line type and development (mainstream capital real purpose, analysis found that the best profit opportunities!) Every domestic engine manufacturing enterprise the engine assembly line type more, can be reduced to roughly; Free groove + double chain bridge car type; Free groove + anti-shear traction ground track car type; Free groove + take with the ground plate stent; Free groove + anti-shear traction ground track car type + take with the stent board type; Hanging chain, etc. All of these are the main assembly line for compulsory water (continuous or batch), and the operation of the main assembly object is consistent with the synchronization), is called (synchronous assembly line or rigid assembly line. Along with the development of the car industry, engine assembly line is from rigid to the flexible assembly line assembly line direction development, flexible assembly line is characteristic of the assembly can beat within a certain range of free adjustment, can achieve more varieties mixed flow production and adapt to the change of production program. And because in the assembly operations assembly object and the assembly workers remained relatively static state, to ensure the high quality of the assembly and using special assembly equipment provides convenient conditions, is easy to realize the automation of the assembly. So of the introduction of domestic car motor assembly line adopted the flexible assembly line (i.e. asynchronous assembly line).
At present domestic used for engine assembly asynchronous assembly line, the main types have single GunGang type, friction for flexible roller type, double roller chain plate and scales, etc. Of General from the United States and Japan imported engine asynchronous assembly line for friction flexible roller type, such as faw two hair and days; Imported from German engine asynchronous assembly line for the single GunGang type, such as for Shanghai Volkswagen and faw Volkswagen. The big assembly (medium) asynchronous assembly line in China's development, along with introducing car technology and foreign second-hand equipment reuse and developed. Beijing internal combustion engine plant and faw engine plant in the 80 s were introduced American general motors 2.0 L engine production line and the Chrysler 488 engine production line, this two production lines in assembly and points of the assembly line is the assembly synchronous assembly line. This time can say flexible assembly line is China's small and medium-sized machinery in the assembly production to application after the new China, several large motor plant, such as Shanghai Volkswagen, faw Volkswagen, tianjin internal combustion engine factory assembly lines are used to introduce the engine of asynchronous assembly line. A few equipment manufacturer in China through the imported technology digestion absorption, already can be designed and made for the small and medium-sized machinery asynchronous assembly line, and used in the production. But with the introduction of equipment, there is still a gap compared, the main problems and technical difficulties is poor reliability, the roll and GunGang wear-resisting of low intensity, and affect the service life of equipment. At present the device is still to introduce primarily, therefore in this respect has yet to be developed further, the domestic equipment will make the cost of production line is greatly reduced and so in our country are wide development prospects.
1.1.2 engine assembly line of the special assembly equipment and testing equipment
The application of the flexible assembly line to ensure that products of high quality and high productivity special assembly machine created the conditions. In the car engine assembly used widely in the DuoTou set torque bolt (mother) tightening machine (also called assembly machine). Tight method using the control torque-corner method, this method is currently the world's most advanced threaded connection method. In addition to the valve to be automatic assembly machine, assembly manipulator, automatic glue machine, the equipment that the domestic engine assembly technology level close to the international advanced level. In the car engine assembly, some important joint surface (such as oil pan, water pump shell, etc and cylinder surface), the combined with rubber seal new craft, replace with the shim between surface, which simplifies the production process and also to improve the seal quality. In the key assembly procedure with special inspection after using automated detection equipment, location of assembly quality control, such as the crankshaft rotating torque and axial clearance check assembly sealing check etc.,
Main engine assembly equipment and the current domestic production level see table 1.
Table 1 engine assembly main equipment and the current domestic production level
Serial number device name domestic manufacturing level
1 engine assembly asynchronous assembly line can design and manufacture, but low quality, the service life is short,
2 the synchronization of cylinder assembly line current use of the equipment and the introduction of mainly.
3 the piston connecting rod asynchronous assembly line
4 gas door lock installed clamp pressure
5 the spark plug catheter pressure installed
6 piston assembly machine design and manufacturing, and domestic to reliable quality, but not now
7 the piston pin pressure have professional production factory, installed production to disperse, influence the overall level equipment
8 block turn connecting improve, current use of the equipment to domestic manufacturing primarily.
9 the piston insert the turntable
10 turn transfer carrier aircraft
11 engine Numbers printer
12 the Lord bearing cover bolts tight machine can design and manufacture, but low quality, high failure rate.
13 the connecting rod bolt tightened at home for some factory machine to save the investment of the key to tighten head
14 the oil pan is tighten bolts introduction, body part machine manufacture its own, basic can meet to use
15 to tighten bolts for cylinder head machine. Current use of the equipment for the introduction of more than 95%.
16 the flywheel bolt tight machine
17 after oil pan and oil seal glue machine can design and manufacture, but low quality, high failure rate.
At present domestic some factory as the key to save the investment of the measured seal
18 the crankshaft rotary torque testing machine without a try introduction, body parts manufacture its own, basic can meet
19 valve and catheter sealing testing machines use requirement. Current use of the equipment more than 95%
20 engine assembly and testing machine sealing introduction.
21 valve clearance adjustment machine
1.1.3 engine test equipment factory
The engine test engine products of the factory is final inspection, in large production, in order to increase the production efficiency and accuracy of the test data, the engine test-bed system to the factory automation system, automatic test bench development factory test-bed system mainly includes three aspects of content.
(1) test standard procedure control and various data automatic test. Through the program control, the engine can be set according to the program automatically according to the requirement of the specifications complete test and automatic measurement and data analysis, and all kinds of judgment measurement data stored in a computer inside.
(2) the test-bed automatic rapid convergence. Quick connection test in a very short time to finish the various pipe automatic quick connection; The engine test bench in the automatic positioning and clamping; The drive shaft automatic docking and a series of actions, and realize the test bench test installation of automation, reducing the connection in the test of auxiliary time.
(3) the engine automatic conveyer. The factory test automation is the third part of the content and automation test-bed for supporting the automatic conveyer line, line type generally USES the product put type friction roller conveyor line. It is equipped with transportation, storage and the function of automatic identification, the control system based on the bed put forward feeding sequence of test bench and the material on the slippery reservoir inventories, the judge recognition engine conveying the signs on the tray, automatic pilot test will be the engine to needed test bench or store material on the slippery, will test the qualified engine to referral point, test unqualified engine to repair station will be empty tray, automatic back to online points.
Automatic factory test-bed system in China, began in the 80 s, when some domestic large at the end of the car factory has introduced a small engine test-bed factory automation, such as Beijing jeep car limited company to introduce the Ingersoll rand automation test-bed. Some equipment manufacturer in digest imported technology basis, combining with the actual situation of China imported equipment, the generic now stand, test specification of procedure control, the test data of automatic testing technology and automatic transmission technology in our country is mature, and have a few manufacturer to design, manufacture and application in production. Technical difficulties is rapid convergence technology, especially the drive shaft rapid convergence of torsional vibration resistance and resistance to the excitedself vibration technology, this technology is to be further perfected. If the equipment can localization will make their cost greatly reduce prices for imported equipment, only one over ten, so in China will have broad development prospects.
附 錄
汽車裝配工藝現(xiàn)狀 發(fā)展趨勢(shì)和市場(chǎng)預(yù)測(cè)
[摘要]全面闡述了汽車整車、發(fā)動(dòng)機(jī)、變速器等關(guān)鍵零部件裝配工藝裝備概況及制造水平現(xiàn)狀,并對(duì)未來(lái)五年汽車裝配工藝裝備需求情況進(jìn)行了分析預(yù)測(cè)。(千金難買?;仡^ 我不需再猶豫)
1. 發(fā)動(dòng)機(jī)、變速器、后橋等關(guān)鍵零部件及整車裝配工藝裝備
1.1發(fā)動(dòng)機(jī)裝配工藝裝備
隨著中國(guó)汽車工業(yè)的快速發(fā)展,特別是引進(jìn)技術(shù)和國(guó)外二手設(shè)備的再利用,使發(fā)動(dòng)機(jī)裝配的設(shè)備水平大幅度提高。發(fā)動(dòng)機(jī)裝配工藝裝備主要分為五個(gè)類型:總成和分總成裝配線;移載翻轉(zhuǎn)設(shè)備;自動(dòng)擰緊設(shè)備;專用裝配設(shè)備和檢測(cè)設(shè)備。
1.1.1發(fā)動(dòng)機(jī)裝配線的型式及發(fā)展(剖析主流資金真實(shí)目的,發(fā)現(xiàn)最佳獲利機(jī)會(huì)!)國(guó)內(nèi)各發(fā)動(dòng)機(jī)制造企業(yè)所采用的發(fā)動(dòng)機(jī)裝配線型式較多,大致可歸納為;自由滾道+雙鏈橋架小車式;自由滾道+單鏈牽引地面軌道小車式;自由滾道+帶隨行支架地面板式;自由滾道+單鏈牽引地面軌道小車式+帶隨行支架地面板式;懸掛鏈?zhǔn)降?。以上各裝配線的主線皆為強(qiáng)制流水(連續(xù)或間歇),裝配對(duì)象與主線的運(yùn)行是一致的(同步),故稱為同步裝配線或剛性裝配線。隨著汽車工業(yè)的發(fā)展,發(fā)動(dòng)機(jī)裝配線正由剛性裝配線向柔性裝配線方向發(fā)展,柔性裝配線的特點(diǎn)是裝配節(jié)拍可以在一定的范圍內(nèi)自由調(diào)整,可以實(shí)現(xiàn)多品種混流生產(chǎn)并適應(yīng)生產(chǎn)綱領(lǐng)的變化。又由于在裝配作業(yè)時(shí)裝配對(duì)象和裝配工人保持相對(duì)靜止?fàn)顟B(tài),對(duì)保證裝配的高質(zhì)量及采用專門的裝配設(shè)備提供了方便的條件,便于實(shí)現(xiàn)裝配的自動(dòng)化。因此國(guó)內(nèi)引進(jìn)的轎車發(fā)動(dòng)機(jī)裝配線均采用了柔性裝配線( 即非同步裝配線)。
目前國(guó)內(nèi)用于發(fā)動(dòng)機(jī)裝配非同步裝配線主要型式有,縱置單滾杠式、摩擦式機(jī)動(dòng)輥道式、雙鏈滾輪式和鱗板式等。一般從美國(guó)和日本引進(jìn)的發(fā)動(dòng)機(jī)非同步裝配線為摩擦式機(jī)動(dòng)輥道式,如一汽二發(fā)和天內(nèi);從德國(guó)引進(jìn)的發(fā)動(dòng)機(jī)非同步裝配線為縱置單滾杠式,如上海大眾和一汽大眾。大總成(中型)非同步裝配線在中國(guó)的發(fā)展,是隨著引進(jìn)轎車技術(shù)和國(guó)外二手設(shè)備再利用而發(fā)展起來(lái)的。北京內(nèi)燃機(jī)廠和一汽第二發(fā)動(dòng)機(jī)廠在80年代末分別引進(jìn)的美國(guó)通用汽車公司2.0L發(fā)動(dòng)機(jī)生產(chǎn)線及美國(guó)克萊斯勒公司的488發(fā)動(dòng)機(jī)生產(chǎn)線, 該兩條生產(chǎn)線上總成和分總成裝配線采用的就是非同步裝配線。這一時(shí)間可以說(shuō)柔性裝配線已經(jīng)在中國(guó)中小型機(jī)械的裝配生產(chǎn)中得以應(yīng)用,以后國(guó)內(nèi)新建的幾個(gè)大型發(fā)動(dòng)機(jī)廠,如上海大眾、一汽大眾、天津內(nèi)燃機(jī)廠等發(fā)動(dòng)機(jī)裝配生產(chǎn)線均采用引進(jìn)的非同步裝配線。我國(guó)少數(shù)設(shè)備生產(chǎn)廠通過(guò)對(duì)引進(jìn)技術(shù)的消化吸收,已能自行設(shè)計(jì)和制造這種用于中小機(jī)械的非同步裝配線,并用于生產(chǎn)中。但與引進(jìn)的設(shè)備相比還有一定的差距,主要問(wèn)題和技術(shù)難點(diǎn)是可靠性差,輥?zhàn)雍蜐L杠耐磨強(qiáng)度低,影響設(shè)備的使用壽命。目前這種設(shè)備仍以引進(jìn)為主,因此在這方面還有待于進(jìn)一步研制,采用國(guó)產(chǎn)設(shè)備將使生產(chǎn)線的成本大大降低,因此在我國(guó)有廣泛的發(fā)展前景。
1.1.2發(fā)動(dòng)機(jī)裝配線上的專用裝配設(shè)備和檢測(cè)設(shè)備
柔性裝配線的應(yīng)用為確保產(chǎn)品高質(zhì)量、高生產(chǎn)率的專用裝配機(jī)創(chuàng)造了條件。在轎車發(fā)動(dòng)機(jī)裝配中普遍地采用了定扭矩的多頭螺栓(母)扭緊機(jī)(也稱裝配機(jī))。擰緊方法采用控制扭矩—轉(zhuǎn)角法,這種方法是目前世界上最先進(jìn)的螺紋連接方法。此外還采用氣門自動(dòng)裝配機(jī)、裝配機(jī)械手、自動(dòng)涂膠機(jī)等設(shè)備,這些設(shè)備的采用使國(guó)內(nèi)發(fā)動(dòng)機(jī)裝配技術(shù)水平接近了國(guó)外先進(jìn)水平。在轎車發(fā)動(dòng)機(jī)裝配中,一些重要的結(jié)合面(如油底殼、水泵殼等與缸體結(jié)合面),采用了涂密封膠新工藝,取代結(jié)合面間的墊片,既簡(jiǎn)化了生產(chǎn)工藝又提高了密封質(zhì)量。在關(guān)鍵的裝配工序后都設(shè)有專門的檢查工位,采用自動(dòng)化檢測(cè)設(shè)備控制裝配質(zhì)量,例如曲軸旋轉(zhuǎn)力矩及軸向間隙的檢查、總成密封性檢查等。發(fā)動(dòng)機(jī)裝配主要設(shè)備和目前國(guó)內(nèi)制造水平見表1。
表1 發(fā)動(dòng)機(jī)裝配主要設(shè)備和目前國(guó)內(nèi)制造水平
序號(hào) 設(shè)備名稱 國(guó)內(nèi)制造水平
1 發(fā)動(dòng)機(jī)總成非同步裝配線 能夠設(shè)計(jì)制造,但質(zhì)量不過(guò)關(guān),使用壽命短,
2 缸蓋非同步裝配線 目前使用的該類設(shè)備以引進(jìn)為主。
3 活塞連桿非同步裝配線
4 氣門鎖夾壓裝機(jī)
5 火花塞導(dǎo)管壓裝機(jī)
6 活塞環(huán)裝配機(jī) 國(guó)內(nèi)能夠設(shè)計(jì)制造,并且質(zhì)量可靠,但目前沒(méi)
7 活塞銷壓裝機(jī) 有專業(yè)生產(chǎn)廠,生產(chǎn)分散,影響設(shè)備整體水平
8 缸體翻轉(zhuǎn)機(jī) 提高,目前使用的該類設(shè)備以國(guó)內(nèi)制造為主。
9 活塞插入橫轉(zhuǎn)臺(tái)
10 翻轉(zhuǎn)移載機(jī)
11 發(fā)動(dòng)機(jī)編號(hào)打印機(jī)
12 主軸承蓋螺栓擰緊機(jī) 能夠設(shè)計(jì)制造,但質(zhì)量不過(guò)關(guān),故障率高。
13 連桿螺栓擰緊機(jī) 目前國(guó)內(nèi)一些廠為節(jié)約投資采用關(guān)鍵的擰緊頭
14 油底殼螺栓擰緊機(jī) 引進(jìn),機(jī)身部分自行制造,基本能滿足使用要
15 缸蓋螺栓擰緊機(jī) 求。目前使用的該類設(shè)備95%以上為引進(jìn)。
16 飛輪螺栓擰緊機(jī)
17 油底殼和后油封涂膠機(jī) 能夠設(shè)計(jì)制造,但質(zhì)量不過(guò)關(guān)、 故障率高。
目前國(guó)內(nèi)一些廠為節(jié)約投資采用關(guān)鍵的密封測(cè)
18 曲軸回轉(zhuǎn)力矩檢測(cè)機(jī) 試無(wú)件引進(jìn),機(jī)身部分自行制造,基本能滿足
19 氣門及導(dǎo)管密封性檢測(cè)機(jī) 使用要求。目前使用的該類設(shè)備95%以上為
20 發(fā)動(dòng)機(jī)總成密封性檢測(cè)機(jī) 引進(jìn)。
21 氣門間隙調(diào)整機(jī)
1.1.3發(fā)動(dòng)機(jī)出廠試驗(yàn)設(shè)備
發(fā)動(dòng)機(jī)出廠試驗(yàn)是發(fā)動(dòng)機(jī)產(chǎn)品的最后檢驗(yàn),在大量生產(chǎn)中,為了提高生產(chǎn)效率及試驗(yàn)數(shù)據(jù)的準(zhǔn)確性,發(fā)動(dòng)機(jī)出廠試驗(yàn)臺(tái)架系統(tǒng)向全自動(dòng)化臺(tái)架系統(tǒng)發(fā)展,全自動(dòng)出廠試驗(yàn)臺(tái)架系統(tǒng)主要包括三方面的內(nèi)容。
①試驗(yàn)規(guī)范的程序控制及各種數(shù)據(jù)的自動(dòng)測(cè)試。通過(guò)程序控制,發(fā)動(dòng)機(jī)可以按照設(shè)定的程序自動(dòng)按規(guī)范的要求完成試驗(yàn)并自動(dòng)進(jìn)行數(shù)據(jù)測(cè)量和判斷分析,并把各種測(cè)量數(shù)據(jù)儲(chǔ)存在計(jì)算機(jī)內(nèi)。
②試驗(yàn)臺(tái)架的自動(dòng)快速對(duì)接??焖龠B接試驗(yàn)臺(tái)能夠在極短時(shí)間內(nèi)完成各種管路的自動(dòng)快速連接;發(fā)動(dòng)機(jī)在臺(tái)架上的自動(dòng)定位和夾緊;驅(qū)動(dòng)軸的自動(dòng)對(duì)接等一系列動(dòng)作,實(shí)現(xiàn)測(cè)試臺(tái)架裝拆連接的自動(dòng)化,從而減少在試驗(yàn)臺(tái)上所占輔助時(shí)間。
③發(fā)動(dòng)機(jī)的自動(dòng)輸送。出廠試驗(yàn)自動(dòng)化的第三部分內(nèi)容就是與自動(dòng)化試驗(yàn)臺(tái)架配套的專用自動(dòng)輸送線,該線的型式一般采用積放式摩擦輥道輸送線。該線具有輸送、儲(chǔ)存以及自動(dòng)識(shí)別的功能,控制系統(tǒng)根據(jù)各臺(tái)架提出的上料先后順序和臺(tái)架外儲(chǔ)料滑臺(tái)上的備料情況,通過(guò)判斷識(shí)別發(fā)動(dòng)機(jī)輸送托盤上的標(biāo)志,自動(dòng)將預(yù)試的發(fā)動(dòng)機(jī)送到需要的臺(tái)架上或儲(chǔ)料滑臺(tái)上,將測(cè)試合格的發(fā)動(dòng)機(jī)送到下線點(diǎn),測(cè)試不合格的發(fā)動(dòng)機(jī)送到檢修工位,將空托盤自動(dòng)送回上線點(diǎn)。 全自動(dòng)出廠試驗(yàn)臺(tái)架系統(tǒng)在中國(guó)的發(fā)展,始于80年代末,當(dāng)時(shí)國(guó)內(nèi)一些大型汽車廠先后引進(jìn)了少量發(fā)動(dòng)機(jī)自動(dòng)化出廠試驗(yàn)臺(tái)架,如北京吉普汽車有限公司引進(jìn)美國(guó)英格索蘭自動(dòng)化試驗(yàn)臺(tái)架。一些設(shè)備生產(chǎn)廠在消化吸收引進(jìn)技術(shù)基礎(chǔ)上,結(jié)合中國(guó)的實(shí)際情況對(duì)引進(jìn)設(shè)備進(jìn)行仿制,就目前的情況看,試驗(yàn)規(guī)范的程序控制、試驗(yàn)數(shù)據(jù)的自動(dòng)測(cè)試技術(shù)及自動(dòng)輸送技術(shù)在我國(guó)已經(jīng)成熟,已有少數(shù)生產(chǎn)廠能夠設(shè)計(jì)、制造并應(yīng)用于生產(chǎn)中。技術(shù)難點(diǎn)是快速對(duì)接技術(shù),尤其是驅(qū)動(dòng)軸快速對(duì)接抗扭振和抗自激振動(dòng)等技術(shù),這項(xiàng)技術(shù)還有待進(jìn)一步完善。這套設(shè)備若能國(guó)產(chǎn)化將使其成本大大降低,價(jià)格僅為進(jìn)口設(shè)備的十分之一,因此在中國(guó)將有廣闊的發(fā)展前景。
12
畢業(yè)設(shè)計(jì)(論文)開題報(bào)告
設(shè)計(jì)(論文)題目:發(fā)動(dòng)機(jī)(DA465Q)缸蓋連接
螺栓自動(dòng)裝配裝置設(shè)計(jì)
院 系 名 稱: 汽車交通與工程學(xué)院
專 業(yè) 班 級(jí): 車輛 07-3班
學(xué) 生 姓 名: 呂佳文
導(dǎo) 師 姓 名: 林明
開 題 時(shí) 間: 2011年3月11日
指導(dǎo)委員會(huì)審查意見:
簽字: 年 月 日
SY-025-BY-3
畢業(yè)設(shè)計(jì)開題報(bào)告
學(xué)生姓名
呂佳文
系部
汽車工程系
專業(yè)、班級(jí)
車輛工程
07-3
指導(dǎo)教師姓名
林明
職稱
高工
從事
專業(yè)
車輛工程
是否外聘
□是√否
題目名稱
發(fā)動(dòng)機(jī)(DA465Q)缸蓋連接螺栓自動(dòng)裝配裝置設(shè)計(jì)
一、課題研究現(xiàn)狀,選題的目的、依據(jù)和意義
1、研究現(xiàn)狀
汽車發(fā)動(dòng)機(jī)裝配的自動(dòng)化程度,在一定程度上先知了汽車的自動(dòng)化生產(chǎn)水平。因此,提高汽車發(fā)動(dòng)機(jī)的自動(dòng)裝配生產(chǎn)選水準(zhǔn),是目前我們必須要解決的重要難題,近十余年,工業(yè)發(fā)達(dá)國(guó)家在產(chǎn)品需求多樣化,產(chǎn)品精度不斷提高和新技術(shù)不斷發(fā)展的推動(dòng)下,裝配作業(yè)自動(dòng)化技術(shù)得到了迅速的發(fā)展。自動(dòng)裝配線的制造和應(yīng)用也進(jìn)入了一個(gè)新的歷史時(shí)期。目前國(guó)外自動(dòng)裝配線制造以美國(guó)、日本等最為發(fā)達(dá)。其他國(guó)家,如聯(lián)邦德國(guó)、法國(guó)、英國(guó)、蘇聯(lián)、捷克、瑞士等也發(fā)展很快。當(dāng)代具有代表性的主要廠家有:美國(guó)Cross公司、日本的東芝機(jī)械與三協(xié)精機(jī)、法國(guó)的Renault公司、蘇聯(lián)的明斯克自動(dòng)線工廠等。自動(dòng)裝配設(shè)備的使用也以美國(guó)和日本為領(lǐng)先。據(jù)介紹,美國(guó)在1983年已擁有自動(dòng)裝配機(jī)近五十萬(wàn)太,占美國(guó)機(jī)床擁有量的8%左右。日本現(xiàn)役裝配機(jī)也在二萬(wàn)臺(tái)以上。
在機(jī)械裝配過(guò)程中,基礎(chǔ)件和裝配件的傳送、給料和裝配作業(yè)可部分地或全部地實(shí)現(xiàn)半自動(dòng)化或自動(dòng)化。機(jī)械裝配自動(dòng)化的主要目的是:保證產(chǎn)品質(zhì)量及其穩(wěn)定性,改善勞動(dòng)條件,提高勞動(dòng)生產(chǎn)率,降低生產(chǎn)成本。裝配自動(dòng)化的一般要求是:產(chǎn)品的生產(chǎn)批量較大;產(chǎn)品結(jié)構(gòu)的自動(dòng)裝配工藝性好,如裝配工作有良好的可分性,零件容易定向、定位,零件間聯(lián)接多用膠接和焊接代替螺紋聯(lián)接,避免使用墊片等調(diào)整件;采用自動(dòng)化裝配后應(yīng)具有較好的經(jīng)濟(jì)效果。裝配作業(yè)的自動(dòng)化程度往往需要經(jīng)過(guò)技術(shù)經(jīng)濟(jì)分析來(lái)確定。
2、工業(yè)機(jī)器人的應(yīng)用及其自動(dòng)裝配線
工業(yè)機(jī)器人由于可在一次動(dòng)作循環(huán)中靈活完成各種動(dòng)作,從而代替了裝配機(jī)中許多復(fù)雜部件的功能,使裝配機(jī)本身復(fù)雜程度大大降低。工業(yè)機(jī)器人有固定程序的,也有計(jì)算機(jī)控制的。由于計(jì)算技術(shù)的不斷發(fā)展與完善,采用計(jì)算機(jī)控制似乎已成為當(dāng)前發(fā)展的方向,其經(jīng)濟(jì)效益也為實(shí)踐證明是十分顯著的。如日本第二精工社利用STM-1000型機(jī)器人裝配汽車?yán)?,其廢品率較人工裝配時(shí)降低了一半,資金收回僅用3年。在一些工作條件惡劣、勞動(dòng)強(qiáng)度大的作業(yè)中,它可使工作效率成倍提高。如汽車制造業(yè)沖的車身焊接作業(yè)在美國(guó)、日本、法國(guó)等幾乎全部采用機(jī)器人,可24小時(shí)連續(xù)工作,生產(chǎn)效率提高了3~4倍。由于機(jī)器人具有動(dòng)作靈活性,抓手和工具系統(tǒng)的萬(wàn)能性及準(zhǔn)確性,全部采用工業(yè)機(jī)器人組成的裝配線,已經(jīng)出現(xiàn).
3、自動(dòng)裝配技術(shù)的發(fā)展方向
發(fā)展具有柔性及可進(jìn)行多品種裝配的自動(dòng)裝配線
由于自動(dòng)裝配線的供料裝置、裝配工作及其控制系統(tǒng)結(jié)構(gòu)復(fù)雜及動(dòng)作頻繁、互鎖嚴(yán)格等原因而經(jīng)常發(fā)生故障,降低了裝配線的工作效率。故近代裝配線中,各裝配工位間和分裝與總裝間采用柔性連接的非同步輸送裝置趨勢(shì)已成為發(fā)展方向。現(xiàn)代社會(huì)由于對(duì)產(chǎn)品需求多樣化,必須使產(chǎn)品不斷更新。為此,能進(jìn)行中小批量多品種裝配的自動(dòng)裝配線得到重視與發(fā)展。這一類型裝配線只稍作調(diào)整即可對(duì)“同族”性產(chǎn)品進(jìn)行自動(dòng)裝配。一般來(lái)說(shuō),它具有以下特征:廣泛采用“功能模塊式結(jié)構(gòu)技術(shù)”以適應(yīng)產(chǎn)品變化時(shí)能方便進(jìn)行調(diào)整;采用柔性連接的傳輸方式以適應(yīng)多品種和各工位節(jié)拍時(shí)間的變化需要;采用多個(gè)自由度裝配機(jī)器人、利用電子計(jì)算機(jī)控制,可對(duì)任意不同對(duì)象進(jìn)行預(yù)訂計(jì)劃的裝配,裝配程序也可利用動(dòng)作一次做示范作業(yè)循環(huán),然后將程序貯存到控制計(jì)算機(jī)中,從而簡(jiǎn)化程序的重新調(diào)整。
4、目的、依據(jù)和意義
微型及普及型汽車在我國(guó)有很大市場(chǎng),從0.9到1.6L,價(jià)格適合我國(guó)國(guó)情,適合正在發(fā)展的中國(guó)的現(xiàn)況。發(fā)動(dòng)機(jī)是汽車的重要零件之以,隨著現(xiàn)在的設(shè)計(jì)加工制造技術(shù)的發(fā)展,發(fā)動(dòng)機(jī)的裝配方法及技術(shù)手段等也在不斷發(fā)展,確定裝配工藝與裝夾方案及設(shè)計(jì),從而達(dá)到對(duì)發(fā)動(dòng)機(jī)裝配工藝進(jìn)一步的更深了解;
該畢業(yè)設(shè)計(jì)可以加強(qiáng)常用工具AutoCAD軟件的使用與掌握;加快了解汽車企業(yè)生產(chǎn)裝配工藝設(shè)計(jì),制造及應(yīng)用的過(guò)程。
二、設(shè)計(jì)(論文)的基本內(nèi)容、擬解決的主要問(wèn)題
1、研究的基本內(nèi)容
根據(jù)實(shí)際裝配與檢驗(yàn)過(guò)程的工藝要求,進(jìn)行了自動(dòng)裝配與檢驗(yàn)生產(chǎn)線可行性分析。并結(jié)合實(shí)際條件,確定了汽車發(fā)動(dòng)機(jī)缸蓋裝配與檢驗(yàn)工序的基準(zhǔn),生產(chǎn)用量和工時(shí)定額。在此基礎(chǔ)上,確立了最終的生產(chǎn)線。同時(shí),通過(guò)對(duì)國(guó)外同類汽車發(fā)動(dòng)機(jī)生產(chǎn)線參考和借鑒,針對(duì)以東安為代表的國(guó)內(nèi)特定的生產(chǎn)技術(shù)與勞動(dòng)條件,對(duì)其裝配與檢驗(yàn)工藝規(guī)程進(jìn)行了詳細(xì)設(shè)計(jì),最終確立了一套完整的適合國(guó)內(nèi)實(shí)際情況的汽車發(fā)動(dòng)機(jī)生產(chǎn)線。
(1)分析零部件圖,運(yùn)用各種知識(shí),機(jī)械設(shè)計(jì)原理選擇裝配路線,據(jù)實(shí)際生產(chǎn)條件確定工藝方案及確定幾個(gè)關(guān)鍵問(wèn)題(如:關(guān)鍵機(jī)構(gòu),裝置,等)
(2)通過(guò)分析擬定必要的保證清洗要求的設(shè)計(jì)內(nèi)容:螺栓抓取裝置的設(shè)計(jì),驅(qū)動(dòng)螺栓抓取裝置的傳動(dòng)機(jī)構(gòu)的設(shè)計(jì),整體支架的設(shè)計(jì)。
(3)通過(guò)分析設(shè)計(jì)符合實(shí)際的缸蓋連接螺栓自動(dòng)裝配裝置總體結(jié)構(gòu)設(shè)計(jì)
(4)通過(guò)分析,對(duì)檢查裝置進(jìn)行了結(jié)構(gòu)的設(shè)計(jì)和理論的分析
(5)完成二維和三維裝配圖;
(6)要有對(duì)相關(guān)項(xiàng)目進(jìn)行理論分析和設(shè)計(jì)計(jì)算。
(7)圖紙和說(shuō)明書要符合規(guī)范,標(biāo)準(zhǔn)化,清晰。
2、本課題研究的主要內(nèi)容
本項(xiàng)目研究的主要內(nèi)容是“汽車發(fā)動(dòng)機(jī)缸蓋連接螺栓自動(dòng)裝配裝置”的設(shè)計(jì)。并主要解決以下技術(shù)問(wèn)題:
1 螺栓抓取裝置的設(shè)計(jì)
2 驅(qū)動(dòng)螺栓抓取裝置的傳動(dòng)機(jī)構(gòu)的設(shè)計(jì)。
3 整體支架的設(shè)計(jì)
螺栓的裝配
使發(fā)動(dòng)機(jī)蓋和發(fā)動(dòng)機(jī)缸體的螺孔對(duì)正,放入墊片,擰緊螺桿,完成裝配。
總體裝置的構(gòu)思
本設(shè)計(jì)的任務(wù)是在汽車發(fā)動(dòng)機(jī)缸蓋的進(jìn)出氣門的氣密性檢測(cè)之后,醬缸蓋與缸體的連接螺栓自動(dòng)裝入發(fā)動(dòng)機(jī)缸蓋內(nèi)部的螺栓孔內(nèi)。設(shè)計(jì)的對(duì)象為東安465汽油發(fā)動(dòng)機(jī)的缸蓋,其上一共有10個(gè)螺栓,對(duì)稱排列在缸蓋兩側(cè),根據(jù)任務(wù)書上規(guī)定的60秒每件的生產(chǎn)能力,本設(shè)計(jì)選擇分兩次安裝螺栓,即每次5個(gè)的方案。
方案一 首先用機(jī)械手來(lái)完成螺栓的抓取和放下,其次用一個(gè)絲桿結(jié)構(gòu)來(lái)完成機(jī)械手的上下運(yùn)動(dòng)并用一個(gè)轉(zhuǎn)軸來(lái)完成四連桿機(jī)構(gòu)在水平面內(nèi)的轉(zhuǎn)動(dòng),最后由動(dòng)力裝置帶動(dòng)一個(gè)絲杠傳動(dòng)機(jī)構(gòu)來(lái)實(shí)現(xiàn)水平面內(nèi)的運(yùn)動(dòng)。
方案二 首先用機(jī)械手來(lái)抓取和放下連接螺栓,其次依靠氣壓,液壓傳動(dòng)后電傳動(dòng)驅(qū)動(dòng)傳動(dòng)機(jī)構(gòu)在導(dǎo)軌上來(lái)完成機(jī)械手的水平和豎直運(yùn)動(dòng)。
比較和綜合煩些上述兩個(gè)方案,機(jī)械手抓取螺栓的確定應(yīng)用的,而方案一的四連桿機(jī)構(gòu)和轉(zhuǎn)軸運(yùn)動(dòng)的穩(wěn)定性比較差,不能應(yīng)用,而絲杠傳動(dòng)由于穩(wěn)定性和精度比較高可以應(yīng)用,而驅(qū)動(dòng)初步定為氣壓傳動(dòng),因?yàn)檎麄€(gè)生產(chǎn)線大不部分應(yīng)用的是氣壓傳動(dòng),用起來(lái)比較方便。
設(shè)計(jì)方案為通過(guò)絲杠船東來(lái)帶動(dòng)機(jī)械手來(lái)完成水平運(yùn)動(dòng),而用氣壓來(lái)完成豎直運(yùn)動(dòng)。具體的設(shè)計(jì)可以大致分為以下三個(gè)部分:
1 螺栓抓取裝置的設(shè)計(jì)
2 驅(qū)動(dòng)螺栓抓取裝置的傳動(dòng)機(jī)構(gòu)的設(shè)計(jì)。
3 整體支架的設(shè)計(jì)
三、技術(shù)路線(研究方法)
首先,明確目標(biāo),我要做的是什么,研究的課題目的,意義
參考例1:
紙上談來(lái)終覺淺,觀察實(shí)物,在頭腦中留下深刻印象,閉上眼睛就能想出它的結(jié)構(gòu)
收集同類機(jī)構(gòu)的資料,研究分析其工作原理,優(yōu)缺點(diǎn)
在原有的基礎(chǔ)上,進(jìn)行創(chuàng)新,改革
在實(shí)物的基礎(chǔ)上進(jìn)行合理化構(gòu)思。
初步擬定設(shè)計(jì)方案,請(qǐng)老師批評(píng)指點(diǎn)
完成設(shè)計(jì),cad出圖,制造樣品機(jī),進(jìn)行生產(chǎn)效果,效率測(cè)試
如果,機(jī)構(gòu)生產(chǎn)效率低,精度差,則需要查缺補(bǔ)漏,改進(jìn)不足
如果,機(jī)構(gòu)合格則批量生產(chǎn),投入生產(chǎn)中
四、設(shè)計(jì)(論文)完成后應(yīng)提交的成果
1、相關(guān)零部件三維視圖;
2、二維裝配圖與三維各1套
3、裝置的主要零部件圖6張以上;
4、設(shè)計(jì)說(shuō)明書一份(1.5萬(wàn)字以上)
4、所有設(shè)計(jì)資料的電子文稿
五、進(jìn)度安排
(1)熟悉設(shè)計(jì)任務(wù)書,并了解相關(guān)材料(網(wǎng)上查閱),準(zhǔn)備資料,填寫開題報(bào)告;第1~3周(3月3日~3月23日)
(2)熟悉零部件圖紙(提出有相應(yīng)問(wèn)題),熟練掌握CAD2004以上版本及裝配工藝學(xué):第4~5周(3月24日~4月6日)
(3)據(jù)自己所學(xué)知識(shí)及工廠或其它裝配廠提出設(shè)計(jì)方法,確定設(shè)計(jì)方案及設(shè)計(jì)內(nèi)容,有改進(jìn)解決問(wèn)題的方法簡(jiǎn)單方案草圖(說(shuō)明問(wèn)題),輔助工具excel、word和CAD要有一定使用能力:第6~7周(4月7日~4月20日)
(4)螺栓抓取裝置的設(shè)計(jì),驅(qū)動(dòng)螺栓抓取裝置的傳動(dòng)機(jī)構(gòu)的設(shè)計(jì),整體支架的設(shè)計(jì)及中期檢查;第8~9周(4月21日~5月3日)
(5)二維裝配圖與三維的設(shè)計(jì):第10~11周(5月4日~5月18日)
(6)進(jìn)行理論分析和設(shè)計(jì)計(jì)算及裝置的主要零部件圖設(shè)計(jì):12~14周(5月19日~6月8日)
(7)總結(jié)設(shè)計(jì)及編寫說(shuō)明書,后期檢查審核及修改不足:第15~16周(6月9日~6月22日)
(8)畢業(yè)設(shè)計(jì)答辯準(zhǔn)備及答辯 第17周(6月23日~6月 29日)
六、參考文獻(xiàn)
[1] 齊志鵬主編.汽車傳感器和執(zhí)行器的原理與檢修.北京:人民郵電出版社,2006
[2] 騰伯樂(lè)主編.中國(guó)汽車工業(yè)50年回顧與跨世紀(jì)展望.武漢汽車工業(yè)大學(xué)學(xué)報(bào),2008.21(5)
[3] 邱宣懷主編.機(jī)械設(shè)計(jì).第四版.北京:高等教育出版社,2007
[4] 吳宗澤.羅圣國(guó)主編.機(jī)械設(shè)計(jì)課程設(shè)計(jì)(第二版).北京:高等教育出版社,2006
[5] 富成科.機(jī)械制造基礎(chǔ)[M].人民教育出版社,1991.1
[6] 徐灝.機(jī)械設(shè)計(jì)手冊(cè)[M].機(jī)械工業(yè)出版社,2002.8
[7] 成大先.機(jī)械設(shè)計(jì)手冊(cè).化學(xué)工業(yè)出版社,2002.11
[8] 熊志旺.SEAT發(fā)動(dòng)機(jī)曲軸的結(jié)構(gòu)及工藝性能分析研究[D].南京理工大學(xué),2004
[9] 臧杰.閆巖主編.汽車構(gòu)造.北京:機(jī)械工業(yè)出版社,2005.7
[10] 戴同.CAD/CAPP/CAM基本教程.北京:機(jī)械工業(yè)出版社,1997
[11] 盛曉敏.鄧朝輝,先進(jìn)制造技術(shù).北京:機(jī)械工業(yè)出版社。2000
[12] 費(fèi)仁員.Stefan Hesse (德)劉德忠.裝配自動(dòng)化.機(jī)械工業(yè)出版社.2007.7
[13] 王寶璽.賈慶祥主編.汽車制造工藝學(xué).北京:機(jī)械工業(yè)出版社.2007.3
[14] Zoran Kunica Bozo Vranjes. Towards automatic generation of plans for automated assembly? ?International Journal of Production Research.1999.5
[15] C. Pan; S. S. Smith; G. C. Smith. Automatic assembly sequence planning from STEP CAD files?. International Journal of Computer Integrated Manufacturing.2006.12
七、備注
指導(dǎo)教師意見:
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