Processing Method for Intake Installation Surface and Flange Holes of Diesel Engine Air Cooler

Abstract

The present invention discloses a processing method for the air intake mounting surface and flange holes of a diesel engine air cooler, comprising the following steps: 1) Measuring the machine tool coordinates of the rotation center of the rotary table; 2) Measuring the machine tool coordinates of the origin of the workpiece coordinate system on the top surface of the air cooler; 3) Calculating the distance AB between the rotation center A of the rotary table and the positioning center point B of the air intake mounting surface and flange holes of the diesel engine air cooler, and calculating the angle α between AB and the parallel line of the horizontal center line of the rotary table; 4) Rotating the rotary table counterclockwise by 45°, calculating the machine tool coordinates of point B, and further obtaining the origin coordinates of point B in the workpiece coordinate system; 5) Compiling a numerical control program to process the air intake mounting surface and flange holes of the diesel engine air cooler. The present invention not only has accurate measurement and calculation results, high automation degree, convenient processing and high processing efficiency, but also has good workpiece size consistency and can effectively guarantee the processing accuracy of the workpiece.

Description

Technical Field

[0001] The present invention relates to a numerical control machining method for a diesel engine air cooler, in particular to a machining method that can quickly and accurately obtain the workpiece coordinate system origin coordinates of the air cooler intake installation surface and the flange hole center positioning points on a numerical control machine tool, belonging to the technical field of numerical control machining. Background Art

[0002] The air cooler is one of the important parts of a medium-speed diesel engine, and its quality directly affects the overall performance and service life of the diesel engine. As Figure 1 shown, according to the functional design requirements of the diesel engine, the air cooler is provided with a top surface 10, an intake installation surface 20, and a window surface 30. The top surface 10 is used to install the supercharger, and the intake installation surface 20 is an inclined surface for installing the supercharger outlet pipe. The top surface 10 and the intake installation surface 20 form an angle β = 45°. Since the reference surface of the intake installation surface 20 is an abstract spatial three-dimensional positioning surface rather than an actual specific planar positioning surface, it can usually only be machined by two methods. One is to rely on a fitter to draw the intake installation surface and the flange hole center positioning point B on a conventional machine tool by scribing, which is simply impossible to achieve. The other is to use a machining center to machine the intake installation surface 20 and the flange holes. However, since the top surface 10 and the intake installation surface 20 form an angle of 45°, the workbench needs to be rotated by 45° during the machining process. After the workbench is rotated, the positioning surfaces P1 and P2 of the intake installation surface 20 and the flange holes become two relative inclined surfaces and cannot be measured. When establishing the workpiece coordinate system of the intake installation surface 20 and the flange hole center point B, it is impossible to complete the work by relying on a probe, a mandrel, and a gauge block, etc., and the machining is very inconvenient. Summary of the Invention

[0003] The purpose of the present invention is to provide a machining method for the intake installation surface and flange holes of a diesel engine air cooler, which can quickly and accurately obtain the workpiece coordinate system origin coordinates of the air cooler intake installation surface and the flange hole center positioning points through the machine tool coordinate system, and the machining is very convenient.

[0004] The present invention is achieved through the following technical solutions:

[0005] A machining method for the intake installation surface and flange holes of a diesel engine air cooler includes the following steps:

[0006] 1) Measure the X0-axis coordinate -D1 and the Z0-axis coordinate -D2 of the rotation center A of the rotary workbench on the machine tool in the machine tool coordinate system through a square box and a standard gauge block;

[0007] 2) Support the window surface of the diesel engine air cooler face - down on the equal - height pads of the rotary table. At this time, the top surface of the air cooler faces the machine tool spindle. Establish the workpiece coordinate system of the top surface of the air cooler, and measure the X0 - axis coordinate - D3, Y0 - axis coordinate - D4, and Z0 - axis coordinate - D5 of the origin O of the workpiece coordinate system of the top surface of the air cooler in the machine tool coordinate system through a standard gauge block and a standard mandrel.

[0008] 3) According to the characteristics of a right - angled triangle, calculate the distance AB between the rotation center A of the rotary table and the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler, and calculate the included angle α between AB and the parallel line BD of the horizontal center line of the rotary table.

[0009] 4) Rotate the rotary table counter - clockwise by 45° around the rotation center A. At this time, the air intake installation surface of the diesel engine air cooler faces the spindle. According to the characteristics of a right - angled triangle, calculate the X0 - axis coordinate - D6, Y0 - axis coordinate - D7, and Z0 - axis coordinate - D8 of the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler in the machine tool coordinate system. Run the macro program in the machine tool to obtain the origin coordinate of the workpiece coordinate system of the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler.

[0010] 5) Compile the numerical control program to machine the air intake installation surface and flange holes of the diesel engine air cooler.

[0011] The object of the present invention can also be further realized by the following technical measures.

[0012] For the above - mentioned machining method of the air intake installation surface and flange holes of the diesel engine air cooler, when measuring the coordinates of the rotation center A of the rotary table on the machine tool in the machine tool coordinate system in step 1), follow the following steps:

[0013] a) First, support the square box in the middle of the rotary table and level the front side P of the square box. Mount a standard mandrel on the machine tool spindle, then move the machine tool spindle to the safe distance from the right - hand side M of the square box, and at the same time move the machine tool spindle along the feed direction to the safe distance from the front side P of the square box. At this time, slowly move the machine tool spindle to the left, and insert the standard gauge block between the standard mandrel and the right - hand side M of the square box. While moving the machine tool spindle, move the standard gauge block up and down until the standard gauge block can just be placed between the standard mandrel and the right - hand side M of the square box, and record the machine tool X0 - axis coordinate - D11 at this time.

[0014] b) Retract the machine tool spindle to the safe distance, then move the machine tool spindle to the left and along the feed direction at the same time, so that the machine tool spindle is at the safe distance from the front side P of the square box. Slowly move the machine tool spindle along the feed direction, insert the standard gauge block between the standard mandrel and the front side P of the square box. While moving the machine tool spindle, move the standard gauge block up and down so that the standard gauge block can just be placed between the standard mandrel and the front side P of the square box, and record the machine tool Z0 - axis coordinate - D12 at this time.

[0015] c) Rotate the rotary table clockwise by 180°. Using the same method, measure that the coordinate of the X0 axis of the machine tool corresponding to the right side M of the square box at this time is -D13, and the coordinate of the Z0 axis of the machine tool corresponding to the rear side Q of the square box is -D14;

[0016] Then D1 = (D11 + D13) / 2, D2 = (D12 + D14 - L1) / 2 - H - L

[0017] L1 is the width of the square box, H is the thickness of the standard gauge block, and L is the length of the standard mandrel.

[0018] For the machining method of the intake installation surface and flange holes of the diesel engine air cooler described above, in step 3), let the intersection of the vertical center line of the rotary table and BD be point C, connect AC, draw a perpendicular line from the origin O of the workpiece coordinate system on the top surface of the air cooler to BD, and the foot of the perpendicular is D. Draw a straight line OE such that OE is parallel to the horizontal center line of the rotary table, and the intersection of OE and AC is point E. Given that the distance from the positioning center point B of the intake installation surface and flange holes of the diesel engine air cooler to the top surface of the diesel engine frame is H1, the distance from the top surface of the air cooler to the top surface of the diesel engine frame is H2, and the distance from the positioning center point B of the intake installation surface and flange holes of the diesel engine air cooler to the flywheel end face of the diesel engine frame is H3, then

[0019] EC = H1 - H2, DC = OE = D3 - D1, AE = D2 - D5, BD = H3

[0020] In the right triangle ABC, AC = AE + EC, BC = BD - DC

[0021] Therefore, tanα = AC / BC, and α = arctan(AC / BC), AB = AC / sin(α).

[0022] For the machining method of the intake installation surface and flange holes of the diesel engine air cooler described above, in step 4), draw a straight line BF parallel to the X axis of the machine tool coordinate system through point B, and draw a perpendicular line from point A to BF, and the foot of the perpendicular is F. Then in the right triangle ABF:

[0023] ∠ABF = α - γ, AF = AB sin(α - γ), BF = AB cos(α - γ), γ = 45°

[0024] Therefore, D6 = D1 - BF, D7 = D4 + N, D8 = D2 - AF;

[0025] N is the perpendicular distance from point B to the X axis of the workpiece coordinate system on the top surface of the air cooler.

[0026] In the present invention, the coordinates of the positioning center point B of the air intake mounting surface and flange holes of the diesel engine air cooler in the machine tool coordinate system are obtained through measurement and calculation. Then, the origin of the workpiece coordinate system of point B is obtained by running a macro program. Finally, a program is compiled according to the coordinates of the origin of the workpiece coordinate system of point B to machine the air intake mounting surface and flange holes of the diesel engine air cooler. Not only are the measurement and calculation results accurate, but also the automation degree is high, the machining is convenient, the machining efficiency is high, and the dimensional consistency of the workpiece is good, which can effectively ensure the machining accuracy of the workpiece. The workpiece of the present invention can be supported at any position on the rotary table without any restrictions. When machining inclined planes with a certain angle on both sides on a machining center, the method of the present invention can be adopted, and the application range is wide and the popularization is good.

[0027] The advantages and features of the present invention will be illustrated and explained through the non-limiting description of the following preferred embodiments, which are given only as examples with reference to the accompanying drawings. Description of the Drawings

[0028] Figure 1 is a schematic structural diagram of a diesel engine air cooler;

[0029] Figure 2 is a schematic structural diagram of step 1) of the present invention;

[0030] Figure 3 is a schematic structural diagram of steps 2) and 3) of the present invention;

[0031] Figure 4 is Figure 3 an enlarged view in the direction A of

[0032] Figure 5 is a schematic structural diagram of step 4) of the present invention;

[0033] Figure 6 is Figure 5 an enlarged view in the direction B of Detailed Embodiment

[0034] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0035] In this embodiment, the side of the square box facing the machine tool spindle is the front, and the opposite side is the rear. The side on the same side as the origin of the X0 axis of the machine tool spindle is the right, and the opposite side is the left.

[0036] The machining method of the air intake mounting surface and flange holes of the diesel engine air cooler of the present invention includes the following steps:

[0037] 1) Measure the X0 axis coordinate -D1 and Z0 axis coordinate -D2 of the rotation center A of the rotary table 3 on the machine tool in the machine tool coordinate system (X0, Y, Z0) through the square box 1 and the standard gauge block 2;

[0038] The measurement is carried out according to the following steps:

[0039] a) As shown in Figure 2 , first support the square box 1 in the middle of the rotary table 3 and square up the front side P of the square box 1. A standard mandrel 5 is sleeved on the machine tool spindle 4. Then move the machine tool spindle 4 to the safe distance from the right side M of the square box 1, and at the same time move the machine tool spindle 4 along the feed direction to the safe distance from the front side P of the square box 1. At this time, slowly move the machine tool spindle 4 to the left, and at the same time insert the standard gauge block 2 between the standard mandrel 5 and the right side M of the square box 1. While moving the machine tool spindle 4, move the standard gauge block 2 up and down until the standard gauge block 2 can just be placed between the standard mandrel 5 and the right side M of the square box 1, and record the machine tool X0-axis coordinate -D11 at this time;

[0040] b) Retract the machine tool spindle 4 to the safe distance, and then move the machine tool spindle 4 to the left and along the feed direction at the same time, so that the machine tool spindle 4 is at the safe distance from the front side P of the square box 1. Slowly move the machine tool spindle 4 along the feed direction, insert the standard gauge block 2 between the standard mandrel 5 and the front side P of the square box 1. While moving the machine tool spindle 4, move the standard gauge block 2 up and down so that the standard gauge block 2 can just be placed between the standard mandrel 5 and the front side P of the square box 1, and record the machine tool Z0-axis coordinate -D12 at this time;

[0041] c) Rotate the rotary table 3 clockwise by 180°. At this time, the rear side Q of the square box faces the machine tool spindle 4, and its right side M turns to the left. Use the same method to measure the machine tool X0-axis coordinate corresponding to the right side M of the square box 1 at this time as -D13, and the machine tool Z0-axis coordinate corresponding to the rear side Q of the square box 1 as -D14;

[0042] Then D1 = (D11 + D13) / 2, D2 = (D12 + D14 - L1) / 2 - H - L

[0043] L1 is the width of the square box 1, H is the thickness of the standard gauge block 2, and L is the length of the standard mandrel 5.

[0044] 2) As shown in Figure 3 and Figure 4 , support the window surface of the diesel engine air cooler downward on the equal-height pads of the rotary table 3. At this time, the top surface 10 of the air cooler faces the machine tool spindle 4, establish the workpiece coordinate system (X, Y, Z) of the top surface 10 of the air cooler, and measure the X0-axis coordinate -D3, Y0-axis coordinate -D4, and Z0-axis coordinate -D5 of the origin O of the workpiece coordinate system of the top surface of the air cooler in the machine tool coordinate system through the standard gauge block 2 and the standard mandrel 5;

[0045] 3) According to the characteristics of a right triangle, calculate the distance AB between the center of rotation A of the rotary table 3 and the positioning center point B of the air intake installation surface 20 and the flange holes of the diesel engine air cooler, and calculate the angle α between AB and the parallel line BD of the horizontal center line of the rotary table 3;

[0046] As shown Figure 3 in the figure, let the intersection point of the vertical center line of the rotary table 3 and BD be C, connect AC, draw a perpendicular line from the origin O of the workpiece coordinate system on the top surface of the air cooler to BD, and the foot of the perpendicular is D. Draw a straight line OE parallel to the horizontal center line of the rotary table 3. The intersection point of OE and AC is E. Given that the distance from the intake installation surface 20 of the diesel engine air cooler and the positioning center point B of the flange holes to the top surface of the diesel engine frame is H1, the distance from the top surface 10 of the air cooler to the top surface of the diesel engine frame is H2, and the distance from the intake installation surface 20 of the diesel engine air cooler and the positioning center point B of the flange holes to the end face of the flywheel end of the diesel engine frame is H3, then

[0047] EC = H1 - H2, DC = OE = D3 - D1, AE = D2 - D5, BD = H3

[0048] In the right triangle ABC, AC = AE + EC, BC = BD - DC

[0049] Therefore, tanα = AC / BC, and α = arctan(AC / BC), AB = AC / sin(α).

[0050] 4) As shown Figure 5 and Figure 6 in the figure, rotate the rotary table 3 counterclockwise by 45° around the rotation center A. At this time, the intake installation surface 20 of the diesel engine air cooler faces the main shaft. According to the characteristics of the right triangle, calculate the X0-axis coordinate -D6, Y0-axis coordinate -D7, and Z0-axis coordinate -D8 of the positioning center point B of the intake installation surface 20 of the diesel engine air cooler and the flange holes in the machine tool coordinate system. Run the macro program in the machine tool to obtain the workpiece coordinate system origin coordinates (X1, Y1, Z1) of the positioning center point B of the intake installation surface 20 of the diesel engine air cooler and the flange holes;

[0051] Draw a straight line BF parallel to the X0-axis of the machine tool coordinate system through point B, and draw a perpendicular line from point A to BF, and the foot of the perpendicular is F. Then in the right triangle ABF:

[0052] ∠ABF = α - γ, AF = AB sin(α - γ), BF = AB cos(α - γ), γ = 45°

[0053] Therefore, D6 = D1 - BF, D7 = D4 + N, D8 = D2 - AF;

[0054] N is the perpendicular distance from point B to the X-axis of the workpiece coordinate system on the top surface of the air cooler.

[0055] 5) Compile the numerical control program to machine the intake installation surface and flange holes of the diesel engine air cooler.

[0056] In addition to the above embodiments, the present invention may also have other implementation manners. Any technical solutions formed by equivalent replacement or equivalent transformation fall within the protection scope required by the present invention.

Claims

1. A processing method for the air intake mounting surface and flange holes of a diesel engine air cooler, characterized in that, Including the following steps: 1) Measure the X0-axis coordinate -D1 and Z0-axis coordinate -D2 of the rotation center A of the rotary table on the machine tool in the machine tool coordinate system by using a square box and standard gauge blocks. 2) Support the window surface of the diesel engine air cooler face down on the equal-height pads of the rotary table. At this time, the top surface of the air cooler faces the machine tool spindle. Establish the workpiece coordinate system of the top surface of the air cooler, and measure the X0-axis coordinate -D3, Y0-axis coordinate -D4, and Z0-axis coordinate -D5 of the origin O of the workpiece coordinate system of the top surface of the air cooler in the machine tool coordinate system by using standard gauge blocks and standard mandrels. 3) According to the characteristics of a right triangle, calculate the distance AB between the rotation center A of the rotary table and the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler, and calculate the angle α between AB and the parallel line BD of the horizontal center line of the rotary table. Let the intersection point of the vertical center line of the rotary table and BD be C. Connect AC. Draw a perpendicular line from the origin O of the workpiece coordinate system of the top surface of the air cooler to BD, and the foot of the perpendicular is D. Draw a straight line OE such that OE is parallel to the horizontal center line of the rotary table. The intersection point of OE and AC is E. Given that the distance from the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler to the top surface of the diesel engine frame is H1, the distance from the top surface of the air cooler to the top surface of the diesel engine frame is H2, and the distance from the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler to the end face of the flywheel end of the diesel engine frame is H3, then EC = H1 - H2, DC = OE = D3 - D1, AE = D2 - D5, BD = H3 In the right triangle ABC, AC = AE + EC, BC = BD - DC Therefore, tanα = AC / BC, and α = arctan(AC / BC), AB = AC / sin(α); 4) Rotate the rotary table counterclockwise by 45° around the rotation center A. At this time, the air intake installation surface of the diesel engine air cooler faces the spindle. According to the characteristics of a right triangle, calculate the X0-axis coordinate -D6, Y0-axis coordinate -D7, and Z0-axis coordinate -D8 of the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler in the machine tool coordinate system. Run the macro program in the machine tool to obtain the origin coordinates of the workpiece coordinate system of the positioning center point B of the air intake installation surface and flange holes of the diesel engine air cooler. Draw a straight line BF parallel to the X-axis of the machine tool coordinate system through point B, and draw a perpendicular line from point A to BF, and the foot of the perpendicular is F. Then in the right triangle ABF: ∠ABF = α - γ, AF = AB sin(α - γ), BF = AB cos(α - γ), γ = 45° Therefore, D6 = D1 - BF, D7 = D4 + N, D8 = D2 - AF; N is the vertical distance from point B to the X-axis of the workpiece coordinate system of the top surface of the air cooler. 5) Compile the numerical control program to machine the air intake installation surface and flange holes of the diesel engine air cooler.

2. The machining method of the intake mounting surface and flange holes of the diesel engine air cooler according to claim 1, characterized in that: When measuring the coordinates of the rotation center A of the rotary table on the machine tool in the machine tool coordinate system in step 1), follow the following steps: a) First, support the square box in the middle of the rotary table and level the front side P of the square box. Mount a standard mandrel on the machine tool spindle. Then, move the machine tool spindle to the right to a safe distance from the right side M of the square box, and at the same time, move the machine tool spindle along the feed direction to a safe distance from the front side P of the square box. At this time, slowly move the machine tool spindle to the left, and insert a standard gauge block between the standard mandrel and the right side M of the square box. While moving the machine tool spindle, move the standard gauge block up and down until the standard gauge block can just be placed between the standard mandrel and the right side M of the square box, and record the machine tool X0-axis coordinate -D11 at this time; b) Retract the machine tool spindle to a safe distance, and then move the machine tool spindle to the left and along the feed direction at the same time, so that the machine tool spindle is at a safe distance from the front side P of the square box. Slowly move the machine tool spindle along the feed direction, insert the standard gauge block between the standard mandrel and the front side P of the square box. While moving the machine tool spindle, move the standard gauge block up and down so that the standard gauge block can just be placed between the standard mandrel and the front side P of the square box, and record the machine tool Z0-axis coordinate -D12 at this time; c) Rotate the rotary table clockwise by 180°. Using the same method, measure the machine tool X0-axis coordinate corresponding to the right side M of the square box at this time as -D13, and the machine tool Z0-axis coordinate corresponding to the rear side Q of the square box as -D14; Then D1 = (D11 + D13) / 2, D2 = (D12 + D14 - L1) / 2 - H - L L1 is the width of the square box, H is the thickness of the standard gauge block, and L is the length of the standard mandrel.

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