發(fā)動(dòng)機(jī)（DA465Q）缸蓋連接螺栓自動(dòng)裝配裝置設(shè)計(jì)
發(fā)動(dòng)機(jī)（DA465Q）缸蓋連接螺栓自動(dòng)裝配裝置設(shè)計(jì),發(fā)動(dòng)機(jī)（DA465Q）缸蓋連接螺栓自動(dòng)裝配裝置設(shè)計(jì),發(fā)動(dòng)機(jī),da465q,缸蓋,連接,螺栓,自動(dòng),裝配,裝置,設(shè)計(jì)
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)。(千金難買牛回頭 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)降取Ｒ陨细餮b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(jiàn)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。快速連接試驗(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。
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