Gearbox shaft assembly method and system

Abstract

The application relates to a gearbox shaft assembly method and system, which is used for shaft assembly of an axle gear of a front shell assembly and an intermediate axle gear of an intermediate axle assembly. The gearbox shaft assembly method comprises the following steps: an actuator drives the intermediate axle assembly to move to a preset position above the front shell assembly; the actuator drives the intermediate axle gear on the intermediate axle assembly to move downward to a shaft assembly trigger position; a servo motor drives the axle gear of the front shell assembly to rotate, and the actuator drives the intermediate axle gear on the intermediate axle assembly to move downward; a controller collects real-time torque of an output end of the servo motor, and the controller controls actions of the actuator and the servo motor according to a relationship between the real-time torque and a preset torque threshold value, so that the axle gear of the front shell assembly rotates to a preset distance angle, and the intermediate axle gear on the intermediate axle assembly moves downward to a shaft assembly target position. The application realizes closed-loop control of torque, has high assembly success rate, and is beneficial to improving work efficiency.

Description

Technical Field

[0001] This application relates to the field of automatic gearbox assembly technology, and in particular to a gearbox shaft assembly method and system. Background Technology

[0002] The meshing and docking of the front housing assembly and the intermediate shaft assembly during the gearbox assembly process has always been a challenge in the assembly process. The challenges mainly lie in the numerous actions and complex changes during the assembly process, the low success rate of assembly on the first attempt, the need for repeated docking, and the extended cycle time. Summary of the Invention

[0003] Therefore, it is necessary to provide a gearbox coupling assembly method and system to address the problem of poor gearbox assembly performance.

[0004] One aspect of this application provides a gearbox shaft assembly method for assembling a primary shaft gear of a front housing assembly with an intermediate shaft gear of an intermediate shaft assembly. The gearbox shaft assembly method includes the following steps:

[0005] The actuator drives the intermediate shaft assembly to move to a preset position; wherein, the preset position is configured as the position where the vertical projection of the pitch circle of the intermediate shaft gear on the intermediate shaft assembly is tangent to the pitch circle of the first shaft gear of the front housing assembly;

[0006] The actuator drives the intermediate shaft gear on the intermediate shaft assembly to move to the engagement trigger position; wherein, the engagement trigger position is configured as the position where the intermediate shaft gear on the intermediate shaft assembly contacts the first shaft gear of the front housing assembly;

[0007] The servo motor drives the gear on one shaft of the front housing assembly to rotate, while the actuator drives the gear on the intermediate shaft assembly to continue moving downwards; and

[0008] The controller collects the real-time torque of the servo motor's output rotation, and controls the actions of the actuator and the servo motor according to the relationship between the real-time torque and a preset torque threshold, so that the first shaft gear of the front housing assembly rotates to a preset distance angle, and the intermediate shaft gear on the intermediate shaft assembly moves downward to the target position of the engagement shaft.

[0009] In one embodiment, in the step where the controller controls the operation of the actuator and the servo motor according to the relationship between the real-time torque and the preset torque threshold, when the controller determines that the real-time torque is within the preset torque threshold, the controller controls the servo motor to drive the first shaft gear of the front housing assembly to rotate to a preset distance angle, and controls the actuator to drive the intermediate shaft assembly to move downward to the target position of the shaft engagement.

[0010] In one embodiment, in the step where the controller controls the action of the actuator and the servo motor according to the relationship between the real-time torque and the preset torque threshold, when the controller determines that the real-time torque is greater than the maximum value of the preset torque threshold, the controller controls the actuator to drive the intermediate shaft assembly to move upward by an adjustment distance, and then the controller collects the real-time torque of the output end of the servo motor again until the real-time torque is within the preset torque threshold.

[0011] In one embodiment, in the step where the controller controls the action of the actuator and the servo motor according to the relationship between the real-time torque and the preset torque threshold, when the controller determines that the real-time torque is less than the minimum value of the preset torque threshold, the controller controls the actuator to drive the intermediate shaft assembly to move downward by an adjustment distance, and then the controller collects the real-time torque of the output end of the servo motor again until the real-time torque is within the preset torque threshold.

[0012] In one embodiment, the preset torque threshold is 0.2 Nm to 1.5 Nm.

[0013] In one embodiment, after the step of the servo motor driving the first shaft gear of the front housing assembly to rotate, and the actuator driving the intermediate shaft gear on the intermediate shaft assembly to continue moving downward, the step further includes:

[0014] As the intermediate shaft gear on the intermediate shaft assembly continues to move downward, the controller collects the real-time force value of the intermediate shaft gear on the intermediate shaft assembly in the vertical direction, and controls the action of the actuator and the servo motor according to the relationship between the real-time force value and the preset force value, so that the first shaft gear of the front housing assembly rotates to a preset distance angle, and the intermediate shaft assembly moves downward to the target position of the shaft engagement.

[0015] In one embodiment, before the step actuator moves the intermediate shaft assembly to a preset position above the front housing assembly, the step further includes: the actuator moves the front housing assembly and places the front housing assembly on the assembly platform.

[0016] In one embodiment, the preset distance angle of rotation of the shaft gear of the front housing assembly is 360° / Z.

[0017] In one embodiment, the actuator is configured as a robot.

[0018] Another aspect of this application provides a gearbox coupling assembly system for coupling a primary shaft gear of a front housing assembly with an intermediate shaft gear of an intermediate shaft assembly; the gearbox coupling assembly system includes:

[0019] An actuator configured to move the front housing assembly and the intermediate shaft assembly;

[0020] A servo motor is configured to rotate a gear on one shaft that drives the front housing assembly; and

[0021] The controller is configured to acquire the real-time torque of the output rotation of the servo motor, and control the action of the actuator and the servo motor according to the relationship between the real-time torque and a preset torque threshold, so that the first shaft gear of the front housing assembly rotates to a preset angle, and the intermediate shaft gear on the intermediate shaft assembly moves downward to the target position of the engagement shaft.

[0022] The gearbox gearbox assembly method provided in this application achieves closed-loop control of the tooth-matching torque between the primary gear of the front housing assembly and the intermediate gear of the intermediate shaft assembly. It has a high assembly success rate, is safe and reliable, easy to operate, and helps to improve work efficiency. Attached Figure Description

[0023] Figure 1 A flowchart illustrating a gearbox coupling assembly method according to an embodiment of this application is shown.

[0024] Figure 2 This diagram illustrates the structure of the gearbox shaft assembly method provided in one embodiment of this application after the gearbox shaft assembly is completed.

[0025] Figure 3 It shows Figure 2 A schematic diagram of the structure along the K-axis.

[0026] Icon labels:

[0027] 10-Front shell assembly;

[0028] 11-Spindle gear;

[0029] 20-Intermediate shaft assembly;

[0030] 21-Intermediate shaft gear. Detailed Implementation

[0031] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0032] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0033] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0034] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0035] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0036] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0037] During the assembly of the primary shaft gear of the front housing assembly and the intermediate shaft gear of the intermediate shaft assembly, both are helical gears. Therefore, it is impossible to directly press the intermediate shaft gear of the intermediate shaft assembly into the front housing assembly to mesh with it. This results in numerous assembly actions, complex changes in parameters, a low success rate for first-time assembly, the need for repeated connections, and extended cycle time.

[0038] See Figure 1 , Figure 1 This paper illustrates a flowchart of a gearbox coupling assembly method according to an embodiment of the present application. The method includes:

[0039] In step S100, the actuator drives the intermediate shaft assembly 20 to a preset position above the front housing assembly 10; wherein, the preset position is configured as the position where the vertical projection of the pitch circle of the intermediate shaft gear 21 on the intermediate shaft assembly 20 is tangent to the pitch circle of the first shaft gear 11 of the front housing assembly 10.

[0040] In step S200, the actuator drives the intermediate shaft gear 21 on the intermediate shaft assembly 20 to move downward to the shaft engagement trigger position; wherein, the shaft engagement trigger position is configured as the position where the intermediate shaft gear 21 on the intermediate shaft assembly 20 contacts the first shaft gear 11 of the front housing assembly 10.

[0041] In step S300, the servo motor drives the first shaft gear 11 of the front housing assembly 10 to rotate, while the actuator drives the intermediate shaft gear 21 on the intermediate shaft assembly 20 to continue to move downward.

[0042] In step S400, the controller acquires the real-time torque of the servo motor's output rotation, and controls the actions of the actuator and the servo motor based on the relationship between the real-time torque and a preset torque threshold, so that the first shaft gear 11 of the front housing assembly 10 rotates to a preset distance angle, and the intermediate shaft gear 21 on the intermediate shaft assembly 20 moves downward to the target engagement position. The structure for completing the gearbox engagement assembly can be found in [reference needed]. Figure 2 and Figure 3 As shown, Figure 2 This diagram illustrates the structure of the gearbox shaft assembly method provided in one embodiment of this application after the gearbox shaft assembly is completed. Figure 3 It shows Figure 2 A schematic diagram of the structure along the K-axis.

[0043] The gearbox gearbox assembly method provided in this embodiment achieves closed-loop control of the tooth torque between the primary gear 11 of the front housing assembly 10 and the intermediate gear 21 of the intermediate shaft assembly 20. It has a high assembly success rate, is safe and reliable, easy to operate, and helps to improve work efficiency.

[0044] The force control technology used in this embodiment is an emerging robot control technology in recent years. However, due to the complexity of mechanical analysis in the production environment, the application scenarios of force control must be simple, which further limits the application scope of force control technology. The implementation of force control involves force perception and force analysis. In order to control parameters such as the direction and speed of the robot, a digital model needs to be established. Parameters such as pressure and torque are input into the digital model, and the change values ​​are calculated through the digital model to guide the robot to adjust its posture and trajectory, thereby improving equipment efficiency and product qualification rate, and achieving the level of intelligent production.

[0045] In this embodiment, the process of meshing the primary gear 11 of the front housing assembly 10 with the intermediate gear 21 of the intermediate shaft assembly 20 can be divided into three stages: the contact stage, the gear engagement stage, and the engagement stage. In step S200, the real-time torque is at its maximum when the primary gear 11 of the front housing assembly 10 and the intermediate gear 21 of the intermediate shaft assembly 20 first contact, and then gradually decreases; this process can be considered the contact stage. Generally, the real-time torque within the contact stage can be 0.7 Nm to 1.5 Nm. In step S300, as the friction decreases after the primary gear 11 of the front housing assembly 10 and the intermediate gear 21 of the intermediate shaft assembly 20 gradually reach the meshing position, the real-time torque can even drop to 0.2 Nm until the primary gear 11 of the front housing assembly 10 touches the intermediate gear 21 of the intermediate shaft assembly 20, and the real-time torque can rise to above 0.95 Nm, at which point the gear engagement ends; this process can be considered the gear engagement stage. In step S400, as the intermediate shaft gear 21 on the intermediate shaft assembly 20 moves downward, the first shaft gear 11 of the front housing assembly 10 makes tooth contact with the intermediate shaft gear 21 of the intermediate shaft assembly 20. At this time, in order to overcome the friction between the first shaft gear 11 of the front housing assembly 10 and the intermediate shaft gear 21 of the intermediate shaft assembly 20 and maintain a constant position, a torque is generated to counteract the change in radial force. The real-time torque gradually decreases as the intermediate shaft gear 21 on the intermediate shaft assembly 20 continues to engage. This process can be regarded as the engagement segment.

[0046] Optionally, the actuator can be configured as a robot.

[0047] It should also be noted that, considering the weight, volume, shape, and distance from the robot's end effector to the direction of the robot's torque, the weight of the larger end effector must be compensated during the robot's descent. Otherwise, the acceleration of the robot during descent may have a significant impact on the gearbox shaft assembly. Furthermore, the distance between the end effector and the direction of the robot's torque will reduce the robot's mobility and further amplify the impact of gravitational acceleration on the gearbox shaft assembly.

[0048] In one embodiment, in step S400, when the controller determines that the real-time torque is within the preset torque threshold, the controller controls the servo motor to drive the first-axis gear 11 of the front housing assembly 10 to rotate to a preset distance angle, and controls the actuator to drive the intermediate shaft assembly 20 to move downward to the target position of the shaft engagement. The preset torque threshold is 0.2 Nm to 1.5 Nm, and the preset distance angle of rotation of the first-axis gear 11 of the front housing assembly 10 is 360° / Z.

[0049] In one embodiment, in step S400, when the controller determines that the real-time torque is greater than the maximum value of the preset torque threshold, the controller controls the actuator to move the intermediate shaft assembly 20 upward by an adjustment distance. Then, the controller again collects the real-time torque of the servo motor's output rotation and determines whether the real-time torque is within the preset torque threshold. If the real-time torque is still not within the preset torque threshold, the above adjustment process is repeated until the real-time torque is within the preset torque threshold. The preset torque threshold is 0.2 Nm to 1.5 Nm, and the preset distance angle of rotation of the first shaft gear 11 of the front housing assembly 10 is 360° / Z. The adjustment distance can be set as needed and is not limited here.

[0050] In one embodiment, in step S400, when the controller determines that the real-time torque is less than the minimum value of the preset torque threshold, the controller controls the actuator to move the intermediate shaft assembly 20 downward by an adjustment distance. Then, the controller again collects the real-time torque of the servo motor's output rotation and determines whether the real-time torque is within the preset torque threshold. If the real-time torque is still not within the preset torque threshold, the above adjustment process is repeated until the real-time torque is within the preset torque threshold. The preset torque threshold can be 0.2 Nm to 1.5 Nm, and the preset distance angle for the rotation of the first shaft gear 11 of the front housing assembly 10 is 360° / Z. The adjustment distance can be set as needed and is not limited here.

[0051] In one embodiment, after step S300, the following step is further included:

[0052] As the intermediate shaft gear 21 on the intermediate shaft assembly 20 continues to move downward, the controller collects the real-time force value of the intermediate shaft gear 21 on the intermediate shaft assembly 20 in the vertical direction, and the controller controls the action of the actuator and the servo motor according to the relationship between the real-time force value and the preset force value, so that the first shaft gear 11 of the front housing assembly 10 rotates to a preset distance angle, and the intermediate shaft assembly 20 moves downward to the target position of the shaft engagement.

[0053] Specifically, the controller collects the real-time force value of the intermediate shaft gear 21 on the intermediate shaft assembly 20 in the vertical direction. If the force value is within the preset value, the controller controls the actuator to drive the intermediate shaft assembly 20 to move downward to the target position of the shaft engagement. At the same time, the controller controls the servo motor to drive the first shaft gear 11 of the front housing assembly 10 to rotate to the preset distance angle.

[0054] Specifically, if the real-time force value of the intermediate shaft gear 21 on the intermediate shaft assembly 20 in the vertical direction is not within the preset force value, the controller controls the actuator to move the intermediate shaft assembly 20 upward by an adjustment distance. Then, the controller collects the real-time force value of the intermediate shaft gear 21 on the intermediate shaft assembly 20 in the vertical direction again and determines whether the real-time force value is within the preset force value. If the real-time force value is still not within the preset force value, the above adjustment process is repeated until the controller collects the real-time force value of the intermediate shaft gear 21 on the intermediate shaft assembly 20 in the vertical direction within the preset force value.

[0055] In one embodiment, before step S100, the method further includes the step of: the actuator driving the front housing assembly 10 to move and placing the front housing assembly 10 on the assembly platform.

[0056] One embodiment of this application provides a gearbox coupling assembly system for coupling a primary gear 11 of a front housing assembly 10 with an intermediate gear 21 of an intermediate shaft assembly 20. The gearbox coupling assembly system includes an actuator, a servo motor, and a controller. The actuator is configured to move the front housing assembly and the intermediate shaft assembly 20; the servo motor is configured to drive the primary gear 11 of the front housing assembly 10 to rotate; the controller is configured to acquire the real-time torque of the servo motor's output rotation and control the actions of the actuator and the servo motor according to the relationship between the real-time torque and a preset torque threshold, so that the primary gear 11 of the front housing assembly rotates to a preset angle, and the intermediate gear 21 on the intermediate shaft assembly 20 moves downward to the coupling target position. Furthermore, the controller is also configured to control the opening and closing of the actuator and the servo motor.

[0057] The controller can be a Programmable Logic Controller (PLC), a digital electronic device with a microprocessor used for automation control. It can load control instructions into its memory for storage and execution. A PLC is modularly composed of an internal CPU, instruction and data memory, input / output units, a power supply module, and digital / analog units. A PLC can receive (input) and send (output) various types of electrical or electronic signals and use them to control or monitor almost all kinds of mechanical and electrical systems.

[0058] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0059] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for assembling a gearbox shaft, characterized in that, The gearbox gear for the front housing assembly is coupled to the intermediate shaft gear for the intermediate shaft assembly. The coupling assembly method includes the following steps: The actuator drives the intermediate shaft assembly to move to a preset position; wherein, the preset position is configured as the position where the vertical projection of the pitch circle of the intermediate shaft gear on the intermediate shaft assembly is tangent to the pitch circle of the first shaft gear of the front housing assembly; The actuator drives the intermediate shaft gear on the intermediate shaft assembly to move to the engagement trigger position; wherein, the engagement trigger position is configured as the position where the intermediate shaft gear on the intermediate shaft assembly contacts the first shaft gear of the front housing assembly; The servo motor drives the gear on one shaft of the front housing assembly to rotate, while the actuator drives the gear on the intermediate shaft assembly to continue moving downwards; and The controller collects the real-time torque of the servo motor's output rotation, and controls the actions of the actuator and the servo motor according to the relationship between the real-time torque and a preset torque threshold, so that the first shaft gear of the front housing assembly rotates to a preset distance angle, and the intermediate shaft gear on the intermediate shaft assembly moves downward to the target engagement position; In the step described above, when the controller controls the operation of the actuator and the servo motor based on the relationship between the real-time torque and the preset torque threshold, if the controller determines that the real-time torque is within the preset torque threshold, the controller controls the servo motor to drive the first shaft gear of the front housing assembly to rotate to a preset distance angle, and controls the actuator to drive the intermediate shaft assembly to move downward to the target position of the shaft engagement.

2. The gearbox shaft assembly method according to claim 1, characterized in that, In the step where the controller controls the action of the actuator and the servo motor according to the relationship between the real-time torque and the preset torque threshold, when the controller determines that the real-time torque is greater than the maximum value of the preset torque threshold, the controller controls the actuator to drive the intermediate shaft assembly to move upward by an adjustment distance, and then the controller collects the real-time torque of the output end of the servo motor again until the real-time torque is within the preset torque threshold.

3. The gearbox shaft assembly method according to claim 1, characterized in that, In the step where the controller controls the operation of the actuator and the servo motor based on the relationship between the real-time torque and the preset torque threshold, when the controller determines that the real-time torque is less than the minimum value of the preset torque threshold, the controller controls the actuator to drive the intermediate shaft assembly to move downward by an adjustment distance, and then the controller collects the real-time torque of the output end of the servo motor again until the real-time torque is within the preset torque threshold.

4. The gearbox shaft assembly method according to claim 1, characterized in that, The preset torque threshold is 0.2 Nm to 1.5 Nm.

5. The gearbox shaft assembly method according to claim 1, characterized in that, After the servo motor drives the one-axis gear of the front housing assembly to rotate, and the actuator drives the intermediate shaft gear on the intermediate shaft assembly to continue moving downward, the following step is also included: As the intermediate shaft gear on the intermediate shaft assembly continues to move downward, the controller collects the real-time force value of the intermediate shaft gear on the intermediate shaft assembly in the vertical direction, and controls the action of the actuator and the servo motor according to the relationship between the real-time force value and the preset force value, so that the first shaft gear of the front housing assembly rotates to a preset distance angle, and the intermediate shaft assembly moves downward to the target position of the shaft engagement.

6. The gearbox shaft assembly method according to claim 1, characterized in that, Before the actuator moves the intermediate shaft assembly to a preset position above the front housing assembly, the procedure further includes the step of: the actuator moves the front housing assembly and places the front housing assembly on the assembly platform.

7. The gearbox shaft assembly method according to any one of claims 1 to 6, characterized in that, The preset distance angle for the rotation of the shaft gear of the front housing assembly is 360° / Z.

8. The gearbox shaft assembly method according to any one of claims 1 to 6, characterized in that, The actuator is configured as a robot.

9. A gearbox shaft assembly system, characterized in that, The gearbox shaft assembly system is used for assembling the primary shaft gear of the front housing assembly with the intermediate shaft gear of the intermediate shaft assembly. The gearbox coupling assembly system includes: An actuator configured to move the front housing assembly and the intermediate shaft assembly; A servo motor is configured to rotate a gear on one shaft that drives the front housing assembly; and The controller is configured to acquire the real-time torque of the output rotation of the servo motor, and control the action of the actuator and the servo motor according to the relationship between the real-time torque and a preset torque threshold. When the controller determines that the real-time torque is within the preset torque threshold, the controller controls the servo motor to drive the first shaft gear of the front housing assembly to rotate, so that the first shaft gear of the front housing assembly rotates to a preset angle, and the intermediate shaft gear on the intermediate shaft assembly moves downward to the target position of the engagement shaft.

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