A gearbox automated intelligent assembly system and method

Abstract

The present invention discloses a gearbox automated intelligent assembly system and method, the system includes: a torque workstation, a multi-degree-of-freedom flip machine, a robot and a server; a torque workstation and a multi-degree-of-freedom flip machine form an assembly unit; each assembly unit is provided with a robot station and a manual station; one robot corresponds to more than one assembly unit; each torque workstation and each robot are connected to the server; the multi-degree-of-freedom flip machine is used to adjust the posture of the gearbox according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear entry, and the posture includes a horizontal state and a vertical state; and the gearbox is switched between the robot station and the manual station according to the three assembly operations; the torque workstation, the robot and the server are connected. The present invention integrates three assembly operations into one, makes the operation process more compact, reduces the time consumed by materials, streamlines the operators and improves efficiency, and realizes the intelligent management of maintenance data.

Description

Technical Field

[0001] The present invention relates to the technical field of gear box assembly, and more specifically, to an automated intelligent assembly system and method for a gear box. Background Art

[0002] Axle gearbox overhaul is an important part of axle overhaul, especially in advanced overhaul process, which has long overhaul process, many contents involved, high technical requirements and strong correlation factors. For example, the gearbox axle overhaul station of CRH3, 380B and CR400BF EMU advanced overhaul mainly includes three stations: gearbox assembly, large gear clearance adjustment and small gear assembly. At present, due to the lack of professional tightening system equipment and tooling, the gearbox axle assembly operation in the EMU advanced overhaul bogie workshop has the following problems:

[0003] First, the maintenance stations are scattered and inefficient. At present, the assembly process of the gearbox bearing clearance adjustment process is divided into three independent stations, namely the gearbox assembly, large gear clearance adjustment and small gear box entry station. The station layout is relatively scattered, and there is a distance between the stations, which increases the time for the transfer of parts between the stations; to complete the maintenance of the gear shaft at these three stations, at least three operators are required; the characteristics of manual operation are easy to get tired, and too much reliance on manual operation. When the operator is engaged in a large number of repetitive tasks, safety hazards are prone to occur, and the operation process consumes a lot of time and personnel costs.

[0004] Secondly, the operating tools are relatively primitive, the labor intensity is high, and there are safety hazards in the lifting operation. The maintenance of the gearbox shaft of the EMU is different from the maintenance of the wheelset. Since the wheels can roll on the ground track, there will be no major safety problems in the wheelset operation; however, the gearbox shaft is relatively heavy (nearly 1 ton), has large dimensions and irregular shapes. Therefore, according to the previous operation mode, the workpieces often need to be transferred by overhead crane between different processes at the same workstation or between different workstations. Frequent lifting of large and heavy workpieces will pose safety hazards both in terms of perception and actual operation scenarios, and there is a risk of workpieces falling.

[0005] Thirdly, the intelligent management of maintenance data is weak, and real-time guidance of the maintenance process is lacking. At present, on-site maintenance data is recorded manually, which is prone to human errors and cannot form a complete maintenance data flow for quality control, maintenance process analysis, and optimized maintenance management. Key workstations such as gearbox component maintenance, gearbox assembly, debugging, and assembly have a great impact on maintenance efficiency, but the existing technology requires high skills and proficiency of the operator, and cannot provide fast and real-time guidance for the maintenance process. Summary of the invention

[0006] In view of the above defects or improvement needs of the prior art, the present invention provides a gearbox automated intelligent assembly system and method.

[0007] The present invention provides a gear box automatic intelligent assembly system, wherein the gear box comprises a gear shaft, a gear assembly sleeved on the gear shaft, and a gear box body buckled on the outer periphery of the gear assembly; the gear assembly comprises a large gear and a small gear, the large gear is sleeved on the gear shaft, and the small gear meshes with the large gear; the gear box body comprises a matching upper box body and a lower box body; the gear box body is provided with a large gear bearing seat corresponding to the large gear, and the gear box body is provided with a small gear bearing seat corresponding to the small gear; comprising:

[0008] Torque workstations, multi-degree-of-freedom flip machines, robots and servers;

[0009] One torque workstation and one multi-degree-of-freedom turning machine form an assembly unit; each assembly unit is provided with a robot station and a manual station;

[0010] One robot corresponds to more than one assembly unit; each torque workstation and each robot are connected to the server;

[0011] The multi-degree-of-freedom turning machine is used to adjust the posture of the gearbox according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear entry, and the posture includes a horizontal state and a vertical state; and switch the gearbox between the robot station and the manual station according to the three assembly operations;

[0012] The torque workstation is used to obtain the operation data of the gearbox at the manual workstation and transmit the operation data to the server; the torque workstation is arranged at the manual workstation;

[0013] The robot is used to obtain the posture of the gear box at the robot station, tighten the bolts of the corresponding assembly operation according to the posture, and transmit the torque data of the bolts to the server.

[0014] Optionally, the gearbox is assembled: the gearbox is horizontally placed by the multi-degree-of-freedom turning machine at the manual workstation, and the upper box body and the lower box body are assembled by tightening the upper box body and the lower box body to complete the gearbox assembly, so that the lower box body and the upper box body form the gearbox body; the torque workstation obtains the tightening data of the bolts used to connect the upper box body and the lower box body in the tightening operation and transmits it to the server; the large gear bearing seat is pre-installed on the gearbox body by pre-tightening the gearbox body and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the upper box body and the lower box body in the tightening operation The pre-tightening data of the bolts used to connect the large gear bearing seat and the gear box body are collected and transmitted to the server; the robot initial tightening: the gear box in a horizontal state is switched from the manual station to the robot station, and the bolts used to connect the large gear bearing seat and the gear box body are tightened by the robot; the robot transmits the torque data of the bolts to the server; large gear clearance adjustment: the gear box is switched from the robot station to the manual station, and the gear box is switched from a horizontal state to a vertical state by the multi-degree-of-freedom flipping machine, and one of the large gear bearing seats is disassembled to complete the adjustment. The large gear clearance adjustment is completed; the torque workstation obtains the large gear clearance data of the large gear clearance adjustment and transmits it to the server; the large gear bearing seat is pre-installed on the gear box body through the pre-tightening operation of the gear box body and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server; small gear boxing: the small gear is installed in the gear box body to complete the small gear boxing and small gear clearance adjustment, and the torque workstation obtains the small gear clearance data of the small gear clearance adjustment and transmits it to the server The gear box body is pre-tightened by the manual workstation and the robot is used to tighten the bolts for connecting the large gear bearing seat and the gear box body, and the bolts for connecting the large gear bearing seat and the gear box body are tightened by the robot; the robot transmits the torque data of the bolts to the server.

[0015] Optionally, the multi-degree-of-freedom flipping machine includes a driving mechanism and a load-bearing frame for placing the gear box; at least two of the load-bearing frames are horizontally circumferentially installed on the driving mechanism, and the driving mechanism is used to provide a driving force for the load-bearing frame to rotate in a horizontal direction, so as to realize the switching of the gear shaft placed on the load-bearing frame between the robot workstation and the manual workstation; the driving mechanism is used to provide a driving force for the load-bearing frame to rotate in a vertical direction, so as to realize the switching of the gear shaft placed on the load-bearing frame between a horizontal state and a vertical state.

[0016] Optionally, the load-bearing frame includes a frame body, a load-bearing bracket, a limit bracket, a gear box bracket and a guide bracket; the load-bearing bracket is rotatably arranged on the frame body along the radial direction of the gear shaft to support the gear shaft in a horizontal state from bottom to top along the vertical direction;

[0017] The limiting bracket is rotatably arranged on the frame body along the radial direction of the gear shaft to limit the gear shaft in a vertical state; the gear box bracket is rotatably arranged on the frame body along the radial direction of the gear shaft to support the lower box body from bottom to top along the vertical direction to realize the combination of the lower box body and the upper box body; the guide bracket is arranged on the frame body, and the guide bracket can make reciprocating motion close to or away from the gear shaft in the vertical direction to support the gear shaft in a horizontal state from bottom to top along the vertical direction, or to hang the gear shaft in a vertical state along the radial direction of the gear shaft.

[0018] Optionally, the gear box bracket includes a box bracket, a second telescopic structure, a horizontal guide rail, a horizontal slider and a horizontal driving structure; the ninth end of the box bracket is rotatably provided on the frame body, and the tenth end of the box bracket is provided with a supporting groove for supporting the lower box; the horizontal guide rail is provided on the frame body; the horizontal slider is slidably connected to the horizontal guide rail; the horizontal driving structure is connected to the horizontal slider to enable the horizontal slider to slide on the horizontal guide rail along the axial direction of the gear shaft; the eleventh end of the second telescopic structure is connected to the frame body, and the twelfth end of the second telescopic structure is rotatably connected to the tenth end of the box bracket, and the second telescopic structure actuates the tenth end of the box bracket to rotate around the ninth end of the box bracket along the radial direction of the gear shaft to enable the supporting groove to approach or move away from the gear shaft.

[0019] Optionally, the manual workstation is further provided with a jacking device corresponding to the gear box, and the jacking device is used to jack up the gear shaft, and the jacking device is connected to the torque workstation; the torque workstation obtains the lifting force value of the jacking device to lift the gear shaft and transmits it to the server.

[0020] Optionally, the torque workstation includes a wireless torque wrench and a wireless torque workstation, the wireless torque wrench and the wireless torque workstation are wirelessly connected, and the wireless torque workstation is connected to the server for transmitting the operation data to the server; the wireless torque wrench is used for pre-tightening and tightening operations of bolts, collects pre-tightening data corresponding to the pre-tightening operation and tightening data corresponding to the tightening operation, and transmits the collected pre-tightening data and tightening data to the wireless torque workstation; the operation data includes pre-tightening data and tightening data; the wireless torque workstation is used for operation tool and operator information management, and transmits the acquired operation data to the server.

[0021] Optionally, the server obtains the posture of the gearbox adjusted by each of the multi-degree-of-freedom flipping machines according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear entry; and assigns the robot corresponding to each of the multi-degree-of-freedom flipping machines to a corresponding position according to the posture to tighten the bolts corresponding to the posture; and / or, each of the assembly units is provided with a safety protection device, which is arranged between the manual workstation and the robot workstation to make the manual workstation and the robot workstation independent of each other.

[0022] Optionally, it also includes an automatic sleeve changing device and a robot automatic verification device; the robot includes a robot body and a visual recognition sensor, an electric tightening shaft and a tightening shaft controller installed thereon; the electric tightening shaft is connected to the tightening shaft controller, and the tightening shaft controller is connected to the server; the automatic sleeve changing device is used to replace a sleeve that is replaceably installed on the electric tightening shaft and used to tighten bolts; the automatic sleeve changing device is connected to the server; the robot automatic verification device is used for automatic verification of the electric tightening shaft; the robot automatic verification device is connected to the server.

[0023] The present invention also provides a gearbox automated intelligent assembly method applicable to any one of the gearbox automated intelligent assembly systems described above, comprising the steps of:

[0024] Gearbox assembly: the gearbox is horizontally placed by the multi-degree-of-freedom turning machine at the manual workstation, and the upper case and the lower case are assembled to complete the gearbox assembly by tightening the upper case and the lower case, so that the lower case and the upper case form the gearbox; the torque workstation obtains the tightening data of the bolts used to connect the upper case and the lower case during the tightening operation and transmits it to the server; the large gear bearing seat is pre-installed on the gearbox by pre-tightening the gearbox and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gearbox during the pre-tightening operation and transmits it to the server;

[0025] Initial tightening by the robot: the gear box in a horizontal state is switched from the manual workstation to the robot workstation, and the bolts connecting the large gear bearing seat and the gear box body are tightened by the robot; the robot transmits the torque data of the bolts to the server;

[0026] Large gear clearance adjustment: the gear box is switched from the robot station to the manual station, and the gear box is switched from a horizontal state to a vertical state by the multi-degree-of-freedom flipping machine, and one of the large gear bearing seats is disassembled to complete the large gear clearance adjustment; the torque workstation obtains the large gear clearance data of the large gear clearance adjustment and transmits it to the server; the large gear bearing seat is pre-installed on the gear box body through the pre-tightening operation of the gear box body and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server;

[0027] Pinion gear entering the box: the pinion gear is installed in the gear box body to complete the pinion gear entering the box and the pinion gear clearance adjustment, and the torque workstation obtains the pinion gear clearance data of the pinion gear clearance adjustment and transmits it to the server; the pinion gear bearing seat is pre-installed in the gear box body through the pre-tightening operation of the gear box body and the pinion gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the pinion gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server;

[0028] Robot secondary tightening: the gear box is switched from the manual workstation to the robot workstation, and the robot is used to tighten the bolts connecting the large gear bearing seat and the gear box body and the bolts connecting the small gear bearing seat and the gear box body; the robot transmits the torque data of the bolts to the server.

[0029] In general, the above technical solutions conceived by the present invention can achieve the following beneficial effects compared with the prior art:

[0030] (1) By combining the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear insertion into one, the operation process is made more compact, the process and time of material handling, retrieval and lifting are reduced, the number of operators is reduced, the operation space is saved and the operation efficiency is improved.

[0031] (2) Compared with the original overhead hoisting operation mode, the multi-degree-of-freedom turning machine reduces the number and time of hoisting during the operation of adjusting the clearance of the large gear, ensures the safety and stability of manual operation, and improves work efficiency. More preferably, the multi-degree-of-freedom turning machine also realizes the partitioning of robot workstations and manual workstations, improves the safety of the operation of the present invention, and avoids the problem of human-machine interference during the robot operation process or the personal safety hazard of the robot to the operator.

[0032] (3) The multi-degree-of-freedom turning machine realizes the coordinated operation of manual and robot automated tightening systems, leaving complex and single work to manual work, and leaving large-scale, repetitive and labor-intensive work to robots, maximizing the respective advantages of robot and manual work, and improving work efficiency and accuracy. More optimally, the torque workstation can provide fast and real-time guidance for the gearbox maintenance process, ensuring the comfort of the entire maintenance process.

[0033] (4) Combined with multi-degree-of-freedom turning machines, robots, servers, intelligent tightening tools and measuring tools, the real-time collection, automatic calculation and automatic storage of gearbox component inspection information data are realized, which is convenient for data analysis and traceability. At the same time, the maintenance station is equipped with the conditions for access to the information management system to optimize maintenance management. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 A schematic diagram of the structure of an embodiment of the gearbox automated intelligent assembly system of the present invention;

[0035] Figure 2 for Figure 1 Another perspective structural diagram of;

[0036] Figure 3 for Figure 1 A schematic diagram of the main view structure;

[0037] Figure 4 for Figure 1 A schematic diagram of a top view structure of FIG.

[0038] Figure 5 It is a schematic structural diagram of an embodiment of the gearbox multi-degree-of-freedom turning machine of the present invention;

[0039] Figure 6 It is a schematic structural diagram of another embodiment of the gearbox multi-degree-of-freedom turning machine of the present invention;

[0040] Figure 7 for Figure 6 A schematic diagram of a top view structure of FIG.

[0041] Figure 8 It is a schematic structural diagram of another embodiment of the gearbox multi-degree-of-freedom turning machine of the present invention;

[0042] Fig. 9 It is a schematic diagram of the exploded structure of the gearbox of the EMU;

[0043] Fig.10 for Fig. 9 Schematic diagram of the combined structure.

[0044] In all the drawings, the same reference numerals represent the same technical features, specifically: 1-gear box, 11-gear shaft, 111-shoulder, 121-large gear, 122-small gear, 13-gear box, 131-lower box, 132-upper box, 141-large gear bearing seat, 142-small gear bearing seat, 2-multi-degree-of-freedom turning machine, 21-driving mechanism, 211-turntable, 212-driving frame, 213-rotating structure, 22-frame body, 23-load-bearing bracket, 231-swing arm, 232-connecting block, 233-first connecting arm, 234-second connecting arm, 235-first telescopic structure, 236-bracket, 237-abutment, 24-limiting bracket, 25- Gearbox bracket, 251-box bracket, 252-second telescopic structure, 253-horizontal guide rail, 254-horizontal slider, 26-guide bracket, 261-bracket body, 262-box bracket, 263-linear drive structure, 264-first arc clamp, 265-second arc clamp, 27-control cabinet, 28-hydraulic pump station, 3-torque workstation, 4-robot, 41-robot body, 42-visual recognition sensor, 43-electric tightening shaft, 44-robot track, 45-robot cable, 5-safety protection device, 6-automatic sleeve replacement device, 7-robot automatic verification device, 8-lifting device, 9-assembly unit, 91-robot station, 92-manual station. DETAILED DESCRIPTION

[0045] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0046] like Fig. 9 and 10 As shown, the gearbox 1 of the EMU includes a gear shaft 11, a gear assembly sleeved on the gear shaft 11, and a gear box body 13 buckled on the outer periphery of the gear assembly; the gear assembly includes a large gear 121 and a small gear 122, the large gear 121 is sleeved on the gear shaft 11, and the small gear 122 is meshed with the large gear 121; the gear box body 13 includes a matching upper box body 132 and a lower box body 131; the gear box body 13 is provided with a large gear bearing seat 141 corresponding to the large gear 121, and the gear box body 13 is provided with a small gear bearing seat 142 corresponding to the small gear 122.

[0047] In one embodiment of the present invention, Figure 1-8 As shown, a gearbox automated intelligent assembly system includes: a torque workstation 3, a multi-degree-of-freedom flip machine 2, a robot 4 and a server; a torque workstation 3 and a multi-degree-of-freedom flip machine 2 form an assembly unit 9; each assembly unit 9 is provided with a robot station 91 and a manual station 92; a robot 4 corresponds to more than one assembly unit 9; each torque workstation 3 and each robot 4 are connected to the server; the multi-degree-of-freedom flip machine 2 is used to adjust the posture of the gearbox 1 according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear entry, and the posture includes a horizontal state and a vertical state; and the gearbox 1 is switched between the robot 4 station and the manual station 92 according to the three assembly operations; the torque workstation 3 is used to obtain the operation data of the gearbox 1 at the manual station 92, and transmit the operation data to the server; the torque workstation 3 is set at the manual station 92; the robot 4 is used to obtain the posture of the gearbox 1 at the robot station 91, tighten the bolts of the corresponding assembly operation according to the posture, and transmit the torque data of the bolt to the server.

[0048] In practical applications, the present invention can specifically perform three assembly operations of the gearbox 1 (gearbox assembly, large gear clearance adjustment and small gear insertion) in sequence, and the specific steps are as follows:

[0049] Gearbox assembly: At the manual workstation 92, the gearbox 1 is horizontally positioned by the multi-degree-of-freedom turning machine 2, and the upper box body 132 and the lower box body 131 are assembled by tightening the upper box body 132 and the lower box body 131 to complete the gearbox assembly, so that the lower box body 131 and the upper box body 132 form a gearbox body 13; the torque workstation 3 obtains the tightening data of the bolts used to connect the upper box body 132 and the lower box body 131 in the tightening operation and transmits it to the server; the large gear bearing seat 141 is pre-installed on the gearbox body 13 by pre-tightening the gearbox body 13 and the large gear bearing seat 141; the torque workstation 3 obtains the pre-tightening data of the bolts used to connect the large gear bearing seat 141 and the gearbox body 13 in the pre-tightening operation and transmits it to the server.

[0050] Specifically, the lower box 131 and the upper box 132 are manually assembled directly by bolts, and the wireless torque wrench (or wired torque wrench) used for the tightening operation will transmit the tightening data of each bolt to the torque workstation 3, and the torque workstation 3 will transmit it to the server. In actual application, in order to facilitate the server to collect the tightening data of each bolt, the operator can install the bolts one by one according to the preset sequence. The specific installation sequence can be transmitted to the torque workstation 3 by the server to facilitate the operator to perform the operation according to the requirements, or the torque workstation 3 can automatically prompt the operator to perform the operation according to the requirements, etc., so as to achieve the matching of each bolt with the corresponding connection hole of the bolt, which is convenient for data storage, traceability, analysis, targeted maintenance and even replacement. After the lower box 131 and the upper box 132 are assembled, the operator pre-installs the two large gear bearing seats 141 on the gear box 13 respectively by using a wireless torque wrench (or wired torque wrench). The two large gear bearing seats 141 are arranged at both ends of the large gear 121 along the axial direction of the gear shaft 11. The wireless torque wrench (or wired torque wrench) used for pre-tightening of the large gear bearing seat 141 and the gear box 13 will transmit the pre-tightening data of each bolt to the torque workstation 3, and the torque workstation 3 will transmit it to the server. Similarly, in order to facilitate the server to collect the tightening data of each bolt, the operator can install the bolts one by one according to the preset sequence. The specific installation sequence can be transmitted to the torque workstation 3 through the server to facilitate the operator to perform the operation according to the requirements, or the torque workstation 3 can automatically prompt the operator to perform the operation according to the requirements, etc., to achieve the matching of each bolt with the corresponding connection hole of the bolt, which is convenient for data storage, traceability, analysis, targeted maintenance and even replacement.

[0051] Initial tightening by the robot: the horizontal gearbox 1 is switched from the manual station 92 to the robot station 91, and the bolts connecting the large gear bearing seat 141 and the gearbox body 13 are tightened by the robot 4; the robot 4 transmits the torque data of the bolt to the server.

[0052] Specifically, the multi-degree-of-freedom flipping machine 2 switches the gearbox 1 that has completed the gearbox assembly and is in a horizontal state from the manual station 92 to the robot station 91. The server dispatches the robot 4 corresponding to the multi-degree-of-freedom flipping machine 2 to the designated position to tighten the two large gear bearing seats 141 on both sides of the large gear 121 according to the program, instruction or production rhythm signal, and transmits the torque data of each bolt to the server. In order to facilitate the server to obtain the torque data of each bolt, the tightening sequence of the robot 4 during the bolt tightening operation is preferably carried out according to the pre-set rules, so as to achieve the matching of each bolt with the corresponding connection hole of the bolt, and facilitate data storage, traceability, analysis, and targeted maintenance and even replacement operations.

[0053] Large gear clearance adjustment: switch the gearbox 1 from the robot station 91 to the manual station 92, and switch the gearbox 1 from a horizontal state to a vertical state through the multi-degree-of-freedom flipping machine 2, and disassemble one of the large gear bearing seats 141 to complete the large gear clearance adjustment; the torque workstation 3 obtains the large gear clearance data of the large gear clearance adjustment and transmits it to the server; the large gear bearing seat 141 is pre-installed on the gearbox body 13 through the pre-tightening operation of the gearbox body 13 and the large gear bearing seat 141; the torque workstation 3 obtains the pre-tightening data of the bolts used to connect the large gear bearing seat 141 and the gearbox body 13 in the pre-tightening operation and transmits it to the server.

[0054] Specifically, after the robot 4 completes the initial tightening operation of the two large gear bearing seats 141, the multi-degree-of-freedom turning machine 2 switches the gear box 1 in the robot station 91 to the manual station 92, and switches the gear shaft 11 from a horizontal state to a vertical state. The operator removes the large gear bearing seat 141 that needs to be removed from the gear box body 13 and adjusts the large gear clearance. The clearance measuring tool for adjusting the large gear clearance transmits the large gear clearance data to the torque workstation 3, and the torque workstation 3 transmits it to the server. After the gear clearance is adjusted, the operator pre-installs the large gear bearing seat 141 on the gear box body 13 through bolts through a wireless torque wrench (or a wired torque wrench). The wireless torque wrench (or a wired torque wrench) transmits the pre-tightening data of each bolt to the torque workstation 3, and then the torque workstation 3 transmits it to the server.

[0055] Pinion entering the box: Install the pinion 122 in the gear box body 13 to complete the pinion entering the box and the pinion clearance adjustment. The torque workstation 3 obtains the pinion clearance data of the pinion clearance adjustment and transmits it to the server; the pinion bearing seat 142 is pre-installed in the gear box body 13 through the pre-tightening operation of the gear box body 13 and the pinion bearing seat 142; the torque workstation 3 obtains the pre-tightening data of the bolts used to connect the pinion bearing seat 142 and the gear box body 13 in the pre-tightening operation and transmits it to the server.

[0056] Specifically, after the adjustment of the large gear clearance is completed, the small gear is put into the gear box 1 at the manual station 92 when the gear box 1 is in a vertical state. After the small gear is put into the gear box, the small gear clearance is adjusted, and the small gear clearance data is transmitted to the torque workstation 3 through the clearance measuring tool for adjusting the small gear clearance (i.e., the clearance measuring tool for adjusting the large gear clearance), and then transmitted to the server by the torque workstation 3. After the small gear clearance is adjusted, the small gear bearing seat 142 provided on the small gear 122 along the axial direction of the gear shaft 11 is pre-installed on the gear box body 13 by bolts through a wireless torque wrench (or a wired torque wrench).

[0057] Robot secondary tightening: the gearbox 1 is switched from the manual workstation 92 to the robot workstation 91, and the robot 4 is used to tighten the bolts connecting the large gear bearing seat 141 and the gearbox body 13, and the bolts connecting the small gear bearing seat 142 and the gearbox body 13; the robot 4 transmits the torque data of the bolts to the server.

[0058] Specifically, the multi-degree-of-freedom flipping machine 2 switches the gear box 1 at the manual workstation 92 to the robot workstation 91, and the server dispatches the robot 4 corresponding to the multi-degree-of-freedom flipping machine 2 to the corresponding position to tighten the nuts of the large gear bearing seat 141 and the small gear bearing seat 142 respectively, and transmits the tightening data of each nut (torque value, tightening angle and tightening curve, etc.) to the server.

[0059] Optionally, the server obtains the posture of each multi-degree-of-freedom flip machine 2 according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear insertion; and assigns the robot 4 corresponding to each multi-degree-of-freedom flip machine 2 to the corresponding position according to the posture to tighten the bolts corresponding to the posture. The server can obtain the posture through the action of the multi-degree-of-freedom flip machine 2, the instruction input by the operator, the production rhythm or the preset program.

[0060] Optionally, the torque workstation 3 includes a wireless torque wrench, a clearance measuring tool and a wireless torque workstation. The wireless torque wrench, the clearance measuring tool and the wireless torque workstation are wirelessly connected, and the wireless torque workstation is connected to a server for transmitting operation data to the server; the wireless torque wrench is used for pre-tightening and tightening operations of bolts, collects pre-tightening data corresponding to the pre-tightening operation and tightening data corresponding to the tightening operation, and transmits the collected pre-tightening data and tightening data to the wireless torque workstation; the operation data includes pre-tightening data and tightening data; the clearance measuring tool is used to measure the clearance data of the large gear and the clearance data of the small gear; the wireless torque workstation is used for information management of operation tools and operators, and transmits the acquired operation data to the server. It is worth mentioning that the operation data of the present invention includes all data of manual operations, such as the tightening data of the nuts used to connect the upper box body 132 and the lower box body 131, the pre-tightening data of the gear box body 13 and the large gear bearing seat 141 twice before and after, the pre-tightening data of the gear box body 13 and the pinion bearing seat 142, the large gear clearance data, the pinion clearance data, the operator information, etc., so as to achieve the matching of the operator and the corresponding gearbox 1, which is convenient for the subsequent data traceability and accountability.

[0061] In actual application, the torque workstation 3 is an aluminum alloy structure, including a computer host, a display screen, a barcode scanner, a mouse and keyboard, and also includes a preload wrench, a tightening wrench, a handheld device, a clearance measuring tool, common tools and auxiliary materials for manual operation, which are used to manage and control the operation process through the operation process management software, so that the operator can perform the manual workstation 92 in sequence according to the operation video or prompts.

[0062] Optionally, the multi-degree-of-freedom flipping machine 2 includes a driving mechanism 21 and a load-bearing frame for placing the gear box 1; at least two load-bearing frames are horizontally circumferentially installed on the driving mechanism 21, and the driving mechanism 21 is used to provide a driving force for the load-bearing frame to rotate in a horizontal direction, so as to realize the switching of the gear shaft 11 placed on the load-bearing frame between the robot station 91 and the manual station 92; the driving mechanism 21 is used to provide a driving force for the load-bearing frame to rotate in a vertical direction, so as to realize the switching of the gear shaft 11 placed on the load-bearing frame between a horizontal state and a vertical state.

[0063] In practical applications, a workstation is provided for each load-bearing frame, thereby forming an even number of workstations arranged circumferentially and arranged in sequence with manual workstations 92 and robot workstations 91, and the drive mechanism 21 drives the load-bearing frame to rotate horizontally forward and reversely to realize the switching of the gearbox 1 between the manual workstation 92 and the robot workstation 91 corresponding thereto. For example, Figure 1-8As shown, the multi-degree-of-freedom turning machine 2 is provided with two load-bearing frames arranged relatively in the horizontal direction, so that each multi-degree-of-freedom turning machine 2 has a total of two workstations, namely, a manual workstation 92 and a robot workstation 91. When the gear shaft 11 needs to switch between the manual workstation 92 and the robot workstation 91, the driving mechanism 21 drives the load-bearing frame to rotate horizontally by 180°. More preferably, since the operator corresponds to the manual workstation 92 and the robot 4 corresponds to the robot workstation 91, there is no interference between the operations of the two. Therefore, a multi-degree-of-freedom turning machine 2 can realize the simultaneous operation of the manual workstation 92 and the robot workstation 91 (of course, the contents of the manual operation and the robot operation are different), thereby greatly improving the assembly efficiency of the present invention. It is worth noting that in another embodiment of the present invention, the two load-bearing frames can also be arranged at an angle less than 180°, but it should also fall within the scope of protection of the present invention. When a multi-degree-of-freedom turning machine 2 is provided with three or more load-bearing frames, the manual workstation 92 and the robot workstation 91 can be arranged correspondingly according to the operation characteristics of the present invention, which will not be described here.

[0064] Optionally, the load-bearing frame includes a frame body 22, a load-bearing bracket 23, a limiting bracket 24, a gear box bracket 25 and a guide bracket 26; the load-bearing bracket 23 is rotatably arranged on the frame body 22 along the radial direction of the gear shaft 11, so as to support the gear shaft 11 in a horizontal state from bottom to top along the vertical direction; the limiting bracket 24 is rotatably arranged on the frame body 22 along the radial direction of the gear shaft 11, so as to limit the gear shaft 11 in a vertical state; the gear box bracket 25 is rotatably arranged on the frame body 22 along the radial direction of the gear shaft 11, so as to support the lower box body 131 from bottom to top along the vertical direction to realize the combination of the lower box body 131 and the upper box body 132; the guide bracket 26 is arranged on the frame body 22, and the guide bracket 26 can make a reciprocating motion in the vertical direction approaching or moving away from the gear shaft 11, so as to support the gear shaft 11 in a horizontal state from bottom to top along the vertical direction, or to hang the gear shaft 11 in a vertical state along the radial direction of the gear shaft 11.

[0065] In actual application, when assembling the gearbox 1, first, the lower box body 131 is hoisted to the gearbox bracket 25, so that the gearbox bracket 25 supports the lower box body 131; then, the gear shaft 11 is hoisted and placed on the load-bearing bracket 23 and the guide bracket 26 in a horizontal state, so that the load-bearing bracket 23 and the guide bracket 26 support the gear shaft 11, and the lower box body 131 is located below the gear shaft 11; then, the gearbox bracket 25 is actuated to support the lower box body 131 from bottom to top in the vertical direction so that the lower box body 131 and the upper box body 132 are assembled to realize the assembly of the gearbox 1. Box, at this time, the upper box body 132 can be hoisted to the top of the lower box body 131, so as to facilitate the assembly of the upper box body 132 and the lower box body 131, install bolts, apply glue, and apply torque; then, the driving mechanism 21 is used to actuate the load-bearing frame to rotate in the horizontal direction, so that each load-bearing frame is switched to the next workstation, and the limit bracket 24 is actuated to surround the outside of the gear shaft 11, and then the load-bearing frame is actuated to rotate in the vertical direction through the driving mechanism 21, so that the gear shaft 11 is switched from a horizontal state to a vertical state, and the gear shaft 11 in the vertical state is hung on the guide bracket 26. Specifically, when the bolts of the bearing seats (large gear bearing seat 141 and small gear bearing seat 142) are tightened by the robot 4, the pre-tightening of the bearing seat bolts can be installed manually before horizontal rotation. When the driving mechanism 21 actuates the load-bearing frame to rotate horizontally to the next station (i.e., the robot station 91), the robot 4 tightens the bearing seat bolts to complete the torque application; then the load-bearing frame is rotated horizontally to the next station (the manual station 92), and then the limit bracket 24 is actuated to surround the outside of the gear shaft 11. Finally, the driving mechanism 21 is used to actuate the load-bearing frame to rotate in the vertical direction, so that the gear shaft 11 switches from a horizontal state to a vertical state, and is in a vertical state. The gear shaft 11 in the horizontal state is hung on the guide bracket 26; then, the large gear clearance adjustment operation is performed manually, and at this time the gear box bracket 25 is away from the gear shaft 11 along the radial direction of the gear shaft 11 (in actual application, the step of actuating the gear box bracket 25 to move away from the gear shaft 11 is completed before the large gear clearance adjustment operation is performed and after the gear shaft 11 is switched from the horizontal state to the vertical state); then, the small gear is put into the box manually, the gap is adjusted and the bolts are installed; then, the load-bearing frame is switched to the robot station 91 by horizontal rotation, and the robot 4 tightens the bolts of the bearing seat and the gear box body 13; then, it is rotated horizontally and switched to the manual station 92, and then the assembled gear box 1 can be hoisted away. Of course, if the present invention is applied to manual labor, the present invention can be set to two workstations, which can be integrated into two workstations or an even number of workstations (i.e., an even number of load-bearing frames) according to the horizontal and vertical states of the gear shaft 11. Of course, the three workstations of the gearbox assembly, large gear clearance adjustment, and small gear box assembly operations according to the present invention can be integrated into three workstations or workstations that are multiples of three (i.e., load-bearing frames that are multiples of three).Because the angle of the load-bearing frame switching station matches the angle between two adjacent load-bearing frames. If manual and robot 4 cooperate, the present invention is preferably configured as an even number of stations in which manual stations 92 and robot stations 91 are sequentially arranged.

[0066] Optionally, the driving mechanism 21 includes a driving motor, a turntable 211, gears, a reducer structure, a rotating structure 213 and a driving frame 212; the rotating structure 213 is arranged on the turntable 211, and the driving frame 212 is installed on the turntable 211 and is covered on the outside of the rotating mechanism; the driving motor is connected to the turntable 211 through the gear and the reducer structure to drive the turntable 211 to rotate in the horizontal direction to realize the switching of the load-bearing frame in different positions; the rotating mechanism is connected to the frame body 22 to drive the frame body 22 to rotate in the vertical direction to realize the switching of the gear shaft 11 between the horizontal state and the vertical state. In practical applications, the rotating mechanism can be a rotating mechanism that realizes rotation, such as a rotating motor or a servo motor.

[0067] Optionally, the load-bearing bracket 23 and the limiting bracket 24 have the same structure, both including a swing arm 231, a connecting block 232, a first connecting arm 233, a second connecting arm 234 and a first telescopic structure 235; the first end of the swing arm 231 is rotatably disposed on the frame body 22, and the second end of the swing arm 231 is provided with a bracket 236 corresponding to the gear shaft 11; the connecting block 232 is connected to the frame body 22; the third end of the first connecting arm 233 is rotatably disposed on the connecting block 232, and the fourth end of the first connecting arm 233 is rotatably connected to the fifth end of the second connecting arm 234; the fifth end of the second connecting arm 234 is connected to the seventh end of the first telescopic structure 235, the sixth end of the second connecting arm 234 is rotatably connected to the second end of the swing arm 231, and the eighth end of the first telescopic structure 235 is connected to the connecting block 232; the first telescopic structure 235 actuates the second connecting arm 234 to rotate around the fourth end of the first connecting arm 233 along the radial direction of the gear shaft 11 to achieve the bracket 236 approaching or moving away from the gear shaft 11.

[0068] In practical applications, the load-bearing bracket 23 and the position-limiting bracket 24 are preferably staggered and relatively arranged on both sides of the gear shaft 11 along the radial direction of the gear shaft 11, wherein the load-bearing bracket 23 is arranged below the gear shaft 11, and the position-limiting bracket 24 is arranged above the gear shaft 11, and the rotation of the gear shaft 11 in the vertical direction is preferably rotated by the load-bearing bracket 23 to the side of the position-limiting bracket 24, that is, the position-limiting bracket 24 is arranged on the same side of the rotation direction when the gear shaft 11 switches from a horizontal state to a vertical state. Of course, the structures of the load-bearing bracket 23 and the position-limiting bracket 24 may also be different. In another embodiment of the present invention, the position-limiting bracket 24 may be directly installed on the frame body 22 through a hinge structure that can manually or automatically adjust the rotation angle, so that the position-limiting bracket 24 can limit the gear shaft 11 manually or by program control.

[0069] Optionally, the first connecting arm 233 includes a first arm, a second arm and a connecting beam, one end of the connecting beam is connected to the first arm, the other end of the connecting beam is connected to the second arm, and the connecting beam is arranged between the third end of the first connecting arm 233 and the fourth end of the first connecting arm 233; the fifth end of the second connecting arm 234 is provided with an abutment portion 237 corresponding to the connecting beam on the side away from the gear shaft 11, so that the abutment portion 237 and the end surface of the second connecting arm 234 close to the gear shaft 11 are respectively abutted with the connecting beam to limit the rotation angle of the second connecting arm 234. The rotation angle can be limited by the abutment portion 237 and the second connecting arm 234 itself abutting against the connecting beam, and the mechanical control of the rotation of the load-bearing bracket 23 and the limiting bracket 24 is further ensured by the mechanical limit, so as to ensure that the load-bearing bracket 23 and the limiting bracket 24 move in place and accurately.

[0070] Optionally, the first telescopic structure 235 is disposed between the first arm and the second arm, thereby saving the space occupied by the load-bearing bracket 23 and the limiting bracket 24 and improving the structural compactness of the present invention.

[0071] Optionally, the guide bracket 26 includes a bracket body 261, a box support block 262 and a linear drive structure 263; the box support block 262 is provided with a first arc clamp 264 and a second arc clamp 265 that are snap-fitted corresponding to the gear shaft 11, and the first arc clamp 264 is connected to the box support block 262; the box support block 262 is slidably arranged on the bracket body 261, and the linear drive structure 263 is installed on the bracket body 261, and the linear drive structure 263 is connected to the box support block 262 to drive the box support block 262 to approach or move away from the gear shaft 11 along the radial direction of the gear shaft 11. In actual applications, the bracket body 261 is fixedly connected to the frame body 22 to ensure the structural strength of the connection between the guide bracket 26 and the frame body 22, and to ensure that the guide bracket 26 has the structural strength to suspend the gear box 1.

[0072] Optionally, the gear box bracket 25 includes a box bracket 251 and a second telescopic structure 252; the ninth end of the box bracket 251 is rotatably disposed on the frame body 22, and the tenth end of the box bracket 251 is provided with a supporting groove for supporting the lower box 131; the eleventh end of the second telescopic structure 252 is connected to the frame body 22, and the twelfth end of the second telescopic structure 252 is rotatably connected to the tenth end of the box bracket 251; the second telescopic structure 252 actuates the tenth end of the box bracket 251 to rotate around the ninth end of the box bracket 251 along the radial direction of the gear shaft 11, so as to realize the supporting groove approaching or moving away from the gear shaft 11.

[0073] Optionally, the housing bracket 251 is provided with a limiting mechanism corresponding to the gear housing 13 to limit the rotation of the gear housing 13 around the gear shaft 11. Since a bearing is provided between the gear housing 13 and the gear shaft 11, the inner ring of the bearing is connected to the large gear 121, and the outer ring of the bearing is connected to the gear housing 13, when the gear shaft 11 switches between the horizontal state and the vertical state, the limiting mechanism is used to limit the gear housing 13 to prevent the gear housing 13 from rotating around the gear shaft 11, thereby ensuring that the position of the gear housing 1 will not change during the entire assembly process, and ensuring the smooth assembly of the gear housing 1. Preferably, the limiting mechanism can be a card or a card slot that matches the structure of the gear housing 13.

[0074] In another embodiment of the present invention, Figure 1-4 As shown, different from the above embodiment, the gear box bracket 25 of this embodiment includes a box bracket 251, a second telescopic structure 252, a horizontal guide rail 253, a horizontal slider 254 and a horizontal driving structure; the ninth end of the box bracket 251 is rotatably arranged on the frame body 22, and the tenth end of the box bracket 251 is provided with a supporting groove for supporting the lower box 131; the horizontal guide rail 253 is arranged on the frame body 22; the horizontal slider 254 is slidably connected to the horizontal guide rail 253; the horizontal driving structure is connected to the horizontal guide rail 253; the horizontal driving structure is connected to the horizontal guide rail 253; the horizontal slider 254 ... The horizontal slider 254 is connected to enable the horizontal slider 254 to slide on the horizontal guide rail 253 along the axial direction of the gear shaft 11; the eleventh end of the second telescopic structure 252 is connected to the frame body 22, and the twelfth end of the second telescopic structure 252 is rotatably connected to the tenth end of the box bracket 251. The second telescopic structure 252 actuates the tenth end of the box bracket 251 to rotate around the ninth end of the box bracket 251 along the radial direction of the gear shaft 11 to enable the supporting groove to approach or move away from the gear shaft 11. The gear box bracket 25 can realize the movement of the gear box 1 along the axial direction of the gear shaft 11, and the guide bracket 26 for hanging the gear shaft 11 is fixedly connected to the frame body 22, thereby ensuring the structural strength of the present invention, and the upper end of the gear shaft 11 in a vertical state is suspended by the guide bracket 26, and the lower end of the gear shaft 11 can be limited by the limiting bracket 24, or the limiting bracket 24 and the load-bearing bracket 23 to avoid the gear shaft 11 from swinging, thereby ensuring the smooth assembly of the gear box 1, and fixing the upper end of the suspended gear shaft 11 is more stable and reliable than fixing the lower end of the supporting gear shaft 11.

[0075] In actual application, in order to avoid the gear shaft 11 from colliding with the guide bracket 26 and damaging the gear box 1 when the gear shaft 11 switches between the horizontal state and the vertical state, before the gear shaft 11 switches from the horizontal state to the vertical state, the load-bearing bracket 23 and the guide bracket 26 are actuated to move away from the gear shaft 11 in the radial direction of the gear shaft 11, so that the gear shaft 11 is only supported by the gear box bracket 25; the horizontal driving structure drives the horizontal slider 254 to move along the horizontal guide rail 253, so that the gear box bracket 25 moves along the axial direction of the gear shaft 11 in the horizontal state, so that the guide bracket 26 abuts against the shoulder 111 of the gear shaft 11 along the axial direction of the gear shaft 11. In this way, the smoothness of the switching of the gear shaft 11 between the horizontal state and the vertical state is ensured.

[0076] Optionally, the horizontal driving structure includes a motor and a roller matched with the horizontal guide rail 253, the motor is connected to the roller via a rotating shaft, and the motor drives the roller to move along the horizontal guide rail 253 to realize the horizontal slider 254 to move along the horizontal guide rail 253 along the axial direction of the gear shaft 11, thereby realizing the mutual abutment between the shoulder 111 of the gear shaft 11 and the guide bracket 26. Preferably, the two rollers are clamped on the horizontal guide rail 253 along the radial direction of the gear shaft 11. In practical applications, the roller and the horizontal guide rail 253 can be either rolling friction or sliding friction, and the roller and the horizontal guide rail 253 can be either meshing connection or sliding connection.

[0077] Optionally, the frame body 22 is provided with a limit block corresponding to the horizontal slider 254 to limit the sliding distance of the horizontal slider 254 on the horizontal guide rail 253. The horizontal slider 254 is provided with a manual adjustment mechanism to adjust the sliding of the horizontal slider 254 along the horizontal guide rail 253; the setting of the limit block avoids the gear shaft 11 from tilting due to uneven force (one end of the gear shaft 11 is heavy and the other end is light) caused by the transition displacement of the shaft section with the gear group toward the side away from the guide bracket 26, thereby ensuring the safety of the work site. Specifically, the manual adjustment mechanism includes a rotating hand wheel, which is connected to the roller through a rotating shaft, and the roller can be moved along the horizontal guide rail 253 by manually rotating the rotating hand wheel.

[0078] In another embodiment of the present invention, different from the above embodiment, the frame body 22 of the present embodiment is provided with a limit block corresponding to the horizontal slider 254 to limit the sliding distance of the horizontal slider 254 on the horizontal guide rail 253; the position of the limit block is adjustable to adjust the sliding distance of the horizontal slider 254 on the horizontal guide rail 253. The position of the limit block is adjustable, and the limit block can be adjusted according to the size of different gear boxes 1, so that the present invention can meet the assembly of gear boxes 1 of different sizes, so that the present invention meets different assembly requirements, improves the idle rate of the machine of the present invention, increases the scope of application of the present invention, and thus reduces the use cost of the present invention.

[0079] Optionally, the manual station 92 is further provided with a lifting device 8 corresponding to the gear box 1, and the lifting device 8 is used to lift the gear shaft 11, and the lifting device 8 is connected to the torque workstation 3; the torque workstation 3 obtains the lifting force value of the lifting device 8 lifting the gear shaft 11 and transmits it to the server. Of course, in another embodiment of the present invention, the lifting device 8 can be directly connected to the server to realize the transmission of the lifting force value, which should also fall within the protection scope of the present invention.

[0080] In practical applications, the first telescopic structure 235, the second telescopic structure 252, the linear drive structure 263, and the lifting device 8 can be a linear drive mechanism such as a telescopic rod drive structure, a linear motor, a hydraulic drive structure, or a screw substructure. Optionally, operations such as the rotation of the load-bearing frame in the horizontal direction and in the vertical direction can be achieved by buttons set on the control cabinet 27. The control cabinet 27 integrates the solenoid valves that control the various actions of the multi-degree-of-freedom turning machine 2, and integrates the buttons into the panel, and has a dedicated display screen that can display the working status of each component of the multi-degree-of-freedom turning machine 2. Of course, the above-mentioned movements can also be controlled by a program according to the production rhythm. When the above-mentioned hydraulic drive structure, the hydraulic drive structure is correspondingly provided with a hydraulic pump station 28, and the hydraulic pump station 28 is arranged on the outside of the multi-degree-of-freedom turning machine 2 and is protected by a fence.

[0081] Optionally, each assembly unit 9 is provided with a safety protection device 5, and the safety protection device 5 is provided between the manual workstation 92 and the robot workstation 91, so that the manual workstation 92 and the robot workstation 91 are independent of each other. In practical applications, the safety protection device 5 can be a protective fence, which is used to separate the manual workstation 92 and the robot workstation 91. In order to facilitate the operator to enter the robot workstation 91 to maintain the robot 4, the protective fence is provided with a door structure. Preferably, the door structure can be a mechanical structure or a door structure provided with a grating sensor. When an operator crosses the protective fence from the manual workstation 92 to the robot workstation 91, the robot 4 will automatically stop, which can prevent the robot operation from harming the operator and ensure the absolute safety of human-machine operation.

[0082] Optionally, it also includes an automatic sleeve changing device 6 and a robot automatic verification device 7; the robot 4 includes a robot body 41 and a visual recognition sensor 42, an electric tightening shaft 43 and a tightening shaft controller installed thereon; the electric tightening shaft 43 is connected to the tightening shaft controller, and the tightening shaft controller is connected to the server; the automatic sleeve changing device 6 is used to replace the sleeve that can be replaced and installed on the electric tightening shaft 43 and used to tighten the bolt; the automatic sleeve changing device 6 is connected to the server; the robot automatic verification device 7 is used for automatic verification of the electric tightening shaft 43; the robot automatic verification device 7 is connected to the server.

[0083] In actual applications, the models of the bolts used to connect the upper box body 132 and the lower box body 131, the bolts used to connect the gear box body 13 and the large gear bearing seat 141, and the bolts used to connect the gear box body 13 and the small gear bearing seat 142 may be inconsistent. When the robot 4 clamps the electric tightening shaft 43 to act on bolts of different specifications and sizes, the sleeve at the end of the electric tightening shaft 43 needs to be automatically replaced, which is completed by the visual recognition sensor 42 installed at the end of the robot 4 and the sleeve automatic replacement device 6.

[0084] The visual recognition sensor 42 can also be used to realize the functions of recognizing the posture and position of the gearbox 1, the position of the connection hole corresponding to the bolt, and recognizing the target sleeve position and empty position during robot verification and automatic sleeve replacement. The electric tightening shaft 43 is fixed to the end of the robot 4 through a clamping mechanism. The electric tightening shaft 43 and the tightening shaft controller are used in conjunction to tighten the nut, collect tightening data and tightening curves at present, and loosen the simulated bolts during automatic verification.

[0085] The robot automatic verification device 7 is preferably composed of an independent equipment indicator light, a simulated bolt, a calibration sensor, etc. It is used in conjunction with the visual recognition sensor 42, and can display the looseness and tightness of the simulated bolt through the indicator light, so as to prevent further tightening in the tightened state and prevent damage to the wrench. It can automatically complete the start and completion verification of the electric tightening shaft 43 at the end of the robot 4. At the same time, the robot automatic verification device 7 will transmit the verification data obtained by each automatic verification to the server, so that the server can compare the verification data with the torque data obtained by the robot 4 after the automatic verification of the bolt. When the torque data is greater than the verification data, it means that the nut is over-tightened, and the bolt is calibrated and sent to the torque workstation 3 together with the bolts that need to be re-operated later, and the operator is reminded to reverse the work or directly switch the gearbox 1 to the manual station 92. The operator loosens the bolt and pre-installs it again, and switches to the robot station 91 again to facilitate the robot 4 to tighten the nut again; when the torque data is less than the verification data, it means that the nut is too loose, and the server can control the robot 4 to continue to tighten the nut. This ensures that the entire assembly process is carried out efficiently and with high quality.

[0086] For example, Figure 1-4As shown, the robot automatic verification device 7 automatically sends the verification data of the electric tightening shaft 43 back to the server for qualification judgment; the torque workstation 3 uploads the operation data to the server through manual operation; the operator sends instructions to the server through the torque workstation 3, and then sends them to the robot 4 and the tightening shaft controller; the operator operates the multi-degree-of-freedom flip machine 2 to perform an action, and the multi-degree-of-freedom flip machine 2 sends the position signal information to the robot 4 and the robot track 44, and then the robot 4 moves to the working position and executes the relevant program; the multi-degree-of-freedom flip machine 2 sends the position signal to the server, and the server sends the program fragment to the tightening shaft controller, and then the electric tightening shaft 43 starts the operation; when the tightening operation of the electric tightening shaft 43 is completed, the collected torque data (torque value, tightening angle and tightening curve information) is sent back to the tightening shaft controller, and the tightening shaft controller sends the torque data back to the server for qualification judgment.

[0087] Preferably, when one robot 4 corresponds to more than one multi-degree-of-freedom flip machine 2 or at least two robots 4 are provided with more than one multi-degree-of-freedom flip machine 2 to form a work area, all manual workstations 92 are preferably arranged on the same side, and all robot 4 workstations are preferably arranged on the same side. In order to facilitate the construction of the work area, all robots 4 preferably share a robot track 44 and a robot cable 45. The operation of each robot 4 is controlled by the server, so that the server coordinates and reasonably arranges the corresponding robot 4 to the assembly unit 9 for tightening according to the accuracy of the assembly unit 9, ensuring that the assembly is completed efficiently and orderly. The robot cable 45 is a tank chain structure as a whole, which includes the robot 4, the robot track 44, the power supply line, the network cable, the signal line, etc., to ensure that the cable is not physically dragged and damaged, while ensuring the cleanliness and safety of the entire work area.

[0088] In actual application, the foundation of the multi-degree-of-freedom turning machine 2 is underground, the turntable 211 is connected to the foundation base plate through fastening bolts and anti-loosening gaskets, and is connected to the hydraulic pump station 28 through hydraulic pipelines; the various action joints and robotic arms of the multi-degree-of-freedom turning machine 2 are connected to the control cabinet 27 through solenoid valves and signal lines, and the positioning sensors of various postures of the multi-degree-of-freedom turning machine 2 are connected to the control cabinet 27 through signal lines; the robot track 44 is connected to the workshop floor through expansion bolts, and is connected to the robot 4 and the control cabinet 27 through signal lines and cables; the robot 4 is connected to the robot track 44 through a slide, and is connected to the robot control cabinet and the control cabinet 27 through cables and signal lines; the safety protection device 5 is connected to the robot control cabinet through power lines and signal lines.

[0089] The key technologies involved in this invention include: multi-degree-of-freedom turning machine 2 and robot linkage control technology, gear shaft four-axis clamping and positioning technology, and multi-degree-of-freedom turning machine 2 multi-degree-of-freedom linkage control technology.

[0090] (1) Multi-degree-of-freedom flip machine and robot linkage control technology:

[0091] The manual workstation 92 and the robot workstation 91 are separated by the safety protection device 5, thereby avoiding the risk of the robot 4 causing injuries to the operators; at the same time, with the help of the action of the multi-degree-of-freedom turning machine 2, the manual operation and the robot operation of the gearbox 1 maintenance are organically combined, some complex and single tasks are operated manually, and some large-scale and highly repetitive processes are completed by the robot 4, thereby optimizing the utilization efficiency of manual and robot 4; by adopting multiple sets of sensors and positioning devices, the actions of the multi-degree-of-freedom turning machine 2 and the actions of the robot 4 and the robot track 44 are carried out in an orderly manner, the time intervals of different processes are reasonably and fully utilized, the operation rhythm is scientifically allocated, and the linkage control of the robot 4 and the multi-degree-of-freedom turning machine 2 is realized, so that the manual and robot 4 operations are organically combined and run efficiently.

[0092] (2) Gear shaft clamping and positioning mechanism:

[0093] It is realized through the multi-degree-of-freedom linkage of the multi-degree-of-freedom turning machine 2; this module is developed for the assembly of the upper box body 132 and the lower box body 131 of a single set of gear shaft 11 and the adjustment of the large gear clearance in order to achieve the horizontal and vertical static posture of the gear shaft 11. By integrating mature and stable mechanisms such as hydraulic control technology, connecting rod mechanism, electro-hydraulic switching technology, hydraulic holding technology, automatic shoulder clamping and separation technology, the support positioning of the gear shaft 11 before the assembly of the gear box body 13 and the positioning and action switching of the workpiece after the assembly of the gear box body 13 are realized, which simplifies the operation process, improves the maintenance efficiency and ensures the assembly quality.

[0094] (3) Multi-degree-of-freedom linkage control technology for multi-degree-of-freedom flipping machines:

[0095] The process requirements and working posture of the gear shaft 11 in the three processes of gearbox assembly, large gear clearance adjustment and small gear entry are met by designing three large flipping actions of one horizontal 180° and two vertical 90°, and integrating two sets of gearbox 1 clamping and positioning modules to form a composite workpiece positioning, clamping and transposition technology. The main features of this technology are: first, the three previous working processes are integrated, and the working efficiency is improved by reasonably configuring the working steps and beats; second, this technology can realize the organic combination of manual work and robot work. By using the robot automated tightening system, compared with the previous working mode, only one operator is needed in a shorter working time to complete the maintenance of two sets of gear shafts 11, which doubles the working efficiency of gearbox 1 maintenance.

[0096] In another embodiment of the present invention, different from any of the above embodiments, when the gear box 1 is in a vertical state, the multi-degree-of-freedom turning machine 2 can support the gear shaft 11 at the lower end of the gear shaft 11 or support the shoulder 111 of the gear shaft 11, which should also fall within the protection scope of the present invention. Exemplarily, as in the above embodiment, when the load-bearing bracket 23 is provided with a first arc-shaped clamp 264 and a second arc-shaped clamp 265 that are snap-fitted, the shoulder 111 of the gear shaft 11 can be supported, thereby supporting the gear shaft 11 from bottom to top, which is different from the above gear shaft 11 being hung on the guide bracket 26.

[0097] In another embodiment of the present invention, the present invention further provides a gearbox automated intelligent assembly method applicable to any one of the above-mentioned gearbox automated intelligent assembly systems, comprising the steps of:

[0098] Gearbox assembly: the gearbox is horizontally placed by the multi-degree-of-freedom turning machine at the manual workstation, and the upper case and the lower case are assembled to complete the gearbox assembly by tightening the upper case and the lower case, so that the lower case and the upper case form the gearbox; the torque workstation obtains the tightening data of the bolts used to connect the upper case and the lower case during the tightening operation and transmits it to the server; the large gear bearing seat is pre-installed on the gearbox by pre-tightening the gearbox and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gearbox during the pre-tightening operation and transmits it to the server;

[0099] Initial tightening by the robot: the gear box in a horizontal state is switched from the manual workstation to the robot workstation, and the bolts connecting the large gear bearing seat and the gear box body are tightened by the robot; the robot transmits the torque data of the bolts to the server;

[0100] Large gear clearance adjustment: the gear box is switched from the robot station to the manual station, and the gear box is switched from a horizontal state to a vertical state by the multi-degree-of-freedom flipping machine, and one of the large gear bearing seats is disassembled to complete the large gear clearance adjustment; the torque workstation obtains the large gear clearance data of the large gear clearance adjustment and transmits it to the server; the large gear bearing seat is pre-installed on the gear box body through the pre-tightening operation of the gear box body and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server;

[0101] Pinion gear entering the box: the pinion gear is installed in the gear box body to complete the pinion gear entering the box and the pinion gear clearance adjustment, and the torque workstation obtains the pinion gear clearance data of the pinion gear clearance adjustment and transmits it to the server; the pinion gear bearing seat is pre-installed in the gear box body through the pre-tightening operation of the gear box body and the pinion gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the pinion gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server;

[0102] Robot secondary tightening: the gear box is switched from the manual workstation to the robot workstation, and the robot is used to tighten the bolts connecting the large gear bearing seat and the gear box body and the bolts connecting the small gear bearing seat and the gear box body; the robot transmits the torque data of the bolts to the server.

[0103] Preferably, the method further comprises the following steps: after the gearbox assembly is completed: the gearbox is switched from the robot station to the manual station by a multi-degree-of-freedom turning machine, and the gearbox is switched from the vertical direction to the horizontal direction; the gearbox is hoisted away by the multi-degree-of-freedom turning machine. The assembly of the entire gearbox is completed. The above steps are repeated to form a continuous operation of the gearbox assembly.

[0104] It will be easily understood by those skilled in the art that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A gearbox automated intelligent assembly system, the gearbox comprising a gear shaft, a gear assembly sleeved on the gear shaft, and a gearbox body buckled on the outer periphery of the gear assembly; the gear assembly comprises a large gear and a small gear, the large gear is sleeved on the gear shaft, and the small gear meshes with the large gear; the gearbox body comprises a matching upper housing and a lower housing; the gearbox body is provided with a large gear bearing seat corresponding to the large gear, and the gearbox body is provided with a small gear bearing seat corresponding to the small gear; the characteristic is that, include: Torque workstation, multi-degree-of-freedom flip machine, robot, server, automatic sleeve replacement device and robot automatic calibration device; One torque workstation and one multi-degree-of-freedom turning machine form an assembly unit; each assembly unit is provided with a robot station and a manual station; One robot corresponds to more than one assembly unit; each torque workstation and each robot are connected to the server; The multi-degree-of-freedom turning machine is used to adjust the posture of the gearbox according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear entry, and the posture includes a horizontal state and a vertical state; and switch the gearbox between the robot station and the manual station according to the three assembly operations; The torque workstation is used to obtain the operation data of the gearbox at the manual workstation and transmit the operation data to the server; the torque workstation is arranged at the manual workstation; The robot is used to obtain the position and posture of the gear box at the robot station, tighten the bolts of the corresponding assembly operation according to the position and posture, and transmit the torque data of the bolts to the server; The torque workstation includes a wireless torque wrench and a wireless torque workstation, the wireless torque wrench and the wireless torque workstation are wirelessly connected, and the wireless torque workstation is connected to the server for transmitting the operation data to the server; The wireless torque wrench is used for pre-tightening and tightening operations of bolts, collects pre-tightening data corresponding to the pre-tightening operation and tightening data corresponding to the tightening operation, and transmits the collected pre-tightening data and tightening data to the wireless torque workstation; the operation data includes pre-tightening data and tightening data; The wireless torque workstation is used for information management of working tools and working personnel, and transmits the acquired working data to the server; The server obtains the posture of each of the multi-degree-of-freedom flipping machines according to the three assembly operations of gearbox assembly, large gear clearance adjustment and small gear insertion; and assigns the robot corresponding to each of the multi-degree-of-freedom flipping machines to a corresponding position according to the posture to tighten the bolts corresponding to the posture; and / or, Each of the assembly units is provided with a safety protection device, and the safety protection device is provided between the manual workstation and the robot workstation, so that the manual workstation and the robot workstation are independent of each other; The robot comprises a robot body and a visual recognition sensor, an electric tightening shaft and a tightening shaft controller installed thereon; the electric tightening shaft is connected to the tightening shaft controller, and the tightening shaft controller is connected to the server; The automatic sleeve replacement device is used to replace the sleeve that can be replaced on the electric tightening shaft and used to tighten the bolt; the automatic sleeve replacement device is connected to the server; the robot automatic verification device is used for automatic verification of the electric tightening shaft; the robot automatic verification device is connected to the server.

2. The gearbox automated intelligent assembly system according to claim 1, characterized in that: Gearbox assembly: the gearbox is horizontally placed by the multi-degree-of-freedom turning machine at the manual workstation, and the upper case and the lower case are assembled to complete the gearbox assembly by tightening the upper case and the lower case, so that the lower case and the upper case form the gearbox; the torque workstation obtains the tightening data of the bolts used to connect the upper case and the lower case during the tightening operation and transmits it to the server; the large gear bearing seat is pre-installed on the gearbox by pre-tightening the gearbox and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gearbox during the pre-tightening operation and transmits it to the server; Initial tightening by the robot: the gear box in a horizontal state is switched from the manual workstation to the robot workstation, and the bolts connecting the large gear bearing seat and the gear box body are tightened by the robot; the robot transmits the torque data of the bolts to the server; Large gear clearance adjustment: the gear box is switched from the robot station to the manual station, and the gear box is switched from a horizontal state to a vertical state by the multi-degree-of-freedom flipping machine, and one of the large gear bearing seats is disassembled to complete the large gear clearance adjustment; the torque workstation obtains the large gear clearance data of the large gear clearance adjustment and transmits it to the server; the large gear bearing seat is pre-installed on the gear box body through the pre-tightening operation of the gear box body and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server; Pinion gear entering the box: the pinion gear is installed in the gear box body to complete the pinion gear entering the box and the pinion gear clearance adjustment, and the torque workstation obtains the pinion gear clearance data of the pinion gear clearance adjustment and transmits it to the server; the pinion gear bearing seat is pre-installed in the gear box body through the pre-tightening operation of the gear box body and the pinion gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the pinion gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server; Robot secondary tightening: the gear box is switched from the manual workstation to the robot workstation, and the robot is used to tighten the bolts connecting the large gear bearing seat and the gear box body and the bolts connecting the small gear bearing seat and the gear box body; the robot transmits the torque data of the bolts to the server.

3. The gearbox automated intelligent assembly system according to claim 1, characterized in that: The multi-degree-of-freedom turning machine includes a driving mechanism and a load-bearing frame for placing the gear box; At least two of the load-bearing frames are horizontally circumferentially installed on the driving mechanism, and the driving mechanism is used to provide a driving force for the load-bearing frame to rotate in a horizontal direction, so as to realize the switching of the gear shaft placed on the load-bearing frame between the robot workstation and the manual workstation; the driving mechanism is used to provide a driving force for the load-bearing frame to rotate in a vertical direction, so as to realize the switching of the gear shaft placed on the load-bearing frame between a horizontal state and a vertical state.

4. The gearbox automated intelligent assembly system according to claim 3, characterized in that: The load-bearing frame includes a frame body, a load-bearing bracket, a limit bracket, a gear box bracket and a guide bracket; The load-bearing bracket is rotatably arranged on the frame body along the radial direction of the gear shaft to support the gear shaft in a horizontal state from bottom to top along the vertical direction; The limiting bracket is rotatably arranged on the frame body along the radial direction of the gear shaft to limit the gear shaft in a vertical state; The gear box bracket is rotatably arranged on the frame body along the radial direction of the gear shaft, so as to support the lower box body from bottom to top along the vertical direction to realize the combination of the lower box body and the upper box body; The guide bracket is arranged on the frame body, and the guide bracket can make reciprocating motion in the vertical direction towards or away from the gear shaft to support the gear shaft in a horizontal state from bottom to top in the vertical direction, or to hang the gear shaft in a vertical state along the radial direction of the gear shaft.

5. The gearbox automated intelligent assembly system according to claim 4, characterized in that: The gear box bracket includes a box bracket, a second telescopic structure, a horizontal guide rail, a horizontal slide block and a horizontal driving structure; The ninth end of the box bracket is rotatably mounted on the frame body, and the tenth end of the box bracket is provided with a supporting groove for supporting the lower box; The horizontal guide rail is arranged on the frame body; The horizontal slider is slidably connected to the horizontal guide rail; the horizontal driving structure is connected to the horizontal slider to enable the horizontal slider to slide on the horizontal guide rail along the axis direction of the gear shaft; The eleventh end of the second telescopic structure is connected to the frame body, and the twelfth end of the second telescopic structure is rotatably connected to the tenth end of the box bracket. The second telescopic structure actuates the tenth end of the box bracket to rotate around the ninth end of the box bracket along the radial direction of the gear shaft to achieve the support groove approaching or moving away from the gear shaft.

6. The gearbox automated intelligent assembly system according to claim 1, characterized in that: The manual workstation is also provided with a lifting device corresponding to the gear box, and the lifting device is used to lift the gear shaft. The lifting device is connected to the torque workstation; the torque workstation obtains the lifting force value of the lifting device lifting the gear shaft and transmits it to the server.

7. A gearbox automated intelligent assembly method applicable to the gearbox automated intelligent assembly system according to any one of claims 1 to 6, characterized in that: Includes steps: Gearbox assembly: the gearbox is horizontally placed by the multi-degree-of-freedom turning machine at the manual workstation, and the lower case and the lower case are assembled by tightening the upper case and the lower case to complete the gearbox assembly, so that the lower case and the upper case form the gearbox; the torque workstation obtains the tightening data of the bolts used to connect the upper case and the lower case in the tightening operation and transmits it to the server; the large gear bearing seat is pre-installed on the gearbox by pre-tightening the gearbox and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gearbox in the pre-tightening operation and transmits it to the server; Robot initial tightening: Switch the horizontal gearbox from the manual workstation to the robot workstation. The robot tightens the bolts used to connect the large gear bearing seat and the gear housing through the robot; the robot transmits the torque data of the bolts to the server; Large gear clearance adjustment: the gear box is switched from the robot station to the manual station, and the gear box is switched from a horizontal state to a vertical state by the multi-degree-of-freedom flipping machine, and one of the large gear bearing seats is disassembled to complete the large gear clearance adjustment; the torque workstation obtains the large gear clearance data of the large gear clearance adjustment and transmits it to the server; the large gear bearing seat is pre-installed on the gear box body through the pre-tightening operation of the gear box body and the large gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the large gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server; Pinion gear boxing: installing the pinion gear in the gear box body to complete the pinion gear boxing and pinion gear clearance adjustment, the torque workstation obtains the pinion gear clearance data of the pinion gear clearance adjustment and transmits it to the server; the pinion gear bearing seat is pre-installed in the gear box body through the pre-tightening operation of the gear box body and the pinion gear bearing seat; the torque workstation obtains the pre-tightening data of the bolts used to connect the pinion gear bearing seat and the gear box body in the pre-tightening operation and transmits it to the server; Robot secondary tightening: the gear box is switched from the manual workstation to the robot workstation, and the robot is used to tighten the bolts used to connect the large gear bearing seat and the gear box body, and the bolts used to connect the small gear bearing seat and the gear box body; the robot transmits the torque data of the bolts to the server.

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