A hugging bearing workshop and its arrangement method

Abstract

A kind of bearing workshop and its arrangement method, one side in workshop is operation area, the other side is transport area;Operation area, from the side of entrance to the direction of other side, is sequentially provided with dump area, centralized repair operation area, axle assembly operation area and tooling equipment fixed area, track is provided through transport area, axle with bearing box transport flatcar is provided on the track;The side of the centralized repair operation area close to transport area is provided with cantilever crane.The present application solves the layout of bearing workshop, and the layout of material area, equipment area and operation area in workshop is regularized;By reasonably designing layout and equipment fixation, the maximum degree reduces the cross of human route and walking waste.

Description

Technical Field

[0001] This invention relates to workshop layout, and more particularly to a bearing-holding workshop and its layout method. Background Technology

[0002] The existing bearing assembly workshop mainly handles the assembly of axle boxes and bearings for models such as HXD1B, HXD1C, and HXD3C. Due to layout design issues, the bearing room is quite chaotic, requiring frequent movement of personnel and materials. Important environmental indicators such as temperature, humidity, and dust levels fluctuate significantly, and the production process is inefficient, making it difficult to meet manufacturing requirements. Summary of the Invention

[0003] The technical problem to be solved by this invention is to provide a bearing assembly workshop and its layout method, which solves the problem of dividing the bearing assembly workshop into sections and lines, and standardizes the layout of material areas, equipment areas and work areas inside the workshop; through reasonable layout design and equipment placement, the intersection of personnel routes and waste of movement are minimized.

[0004] To solve the above-mentioned technical problems, the technical solution of the present invention is: a bearing assembly workshop, wherein one side of the workshop is a work area and the other side is a transportation area; within the work area, from the entrance side to the other side, there are sequentially arranged a transfer area, a centralized preparation work area, a bearing assembly work area, and a tooling equipment placement area. The transfer area is equipped with ring component transfer tooling and bearing box transfer and storage tooling. A large ring component transfer and preparation platform trolley is located on the side of the transfer area away from the transportation area. The centralized preparation work area is equipped with a bearing pressing platform and a bearing box preparation platform. A bearing transfer and preparation platform trolley is located on the side of the centralized preparation work area away from the transportation area. A grease injection trolley is located between the bearing transfer and preparation platform trolley and the large ring component transfer and preparation platform trolley. The bearing assembly work area is equipped with a bearing box bearing drop platform and a work material trolley. The equipment includes a work tool trolley, an electric hydraulic pump trolley, and a ladder. The tooling equipment placement area is concave and located on the periphery of the shaft assembly work area. On the side of the tooling equipment placement area away from the transportation area, there are material racks, explosion-proof cabinets, parking spaces for the electric hydraulic pump trolley, and eddy current induction heaters. On the side of the tooling equipment placement area closer to the transportation area, there are shaft box pressing fixtures, shaft box compaction fixtures, bearing compaction fixtures, bearing inner ring pressing fixtures, work material trolley parking spaces, and work tool trolley parking spaces. On the side of the tooling equipment placement area facing the entrance, there are placement spaces for industrial refrigerators, tool cabinets, lifting cabinets, and ladders. A track passes through the transportation area, and axle-mounted shaft box transport flatcars are installed on the track. A cantilever crane is installed on the side of the centralized preparation work area closer to the transportation area.

[0005] As an improvement, the transfer area is equipped with three ring component transfer fixtures and one axle box transfer and storage fixture; there are three large ring component transfer and preparation platform trolleys, two axle box transfer and preparation platform trolleys and one grease injection trolley; the centralized preparation operation area is equipped with two axle box pressing stations and six axle box preparation stations; the axle drop assembly operation area is equipped with six axle box drop stations.

[0006] A method for arranging a bearing workshop includes the following steps:

[0007] (1) Clarify the processes carried out in the bearing workshop;

[0008] (2) Clarify the main equipment and tooling required for each process;

[0009] (3) Clarify the workpieces and semi-finished products for each process;

[0010] (4) Clarify the flow routes of people, materials, and equipment between each process;

[0011] (5) Arrange the production line layout by dividing it into zones according to the process flow;

[0012] (6) Simulation of process verification.

[0013] As an improvement, in step (1), according to the workshop function settings, it is necessary to sort out the bearing assembly process that needs to be completed in the bearing room. The bearing assembly process is as follows:

[0014] (1.0) The axle enters the bearing space;

[0015] (1.1) Cleaning, preparation and grease injection of axle box accessories before assembly;

[0016] (1.2) Gearbox sealing ring assembly;

[0017] (1.3) Hot fitting of the inner ring of the toothed bearing;

[0018] (1.4) Press-fitting of the outer ring of the bearing;

[0019] (1.5) Assembly of the axle box;

[0020] (1.6) Hot fitting of inner ring of non-tooth side bearing;

[0021] (1.7) Assemble the sealing ring;

[0022] (1.8) Shaft assembly;

[0023] (1.9) Assemble the bearing housing to form the bearing space.

[0024] As an improvement, in step (2), by analyzing the work process content, the main equipment and tooling required for each process are extracted. The tooling and equipment required for each process are as follows:

[0025] (2.0) Process: The axle enters the bearing bay. Main tooling and equipment: cantilever crane, axle transfer flatcar, and parts storage tooling;

[0026] (2.1) Process: Cleaning, preparation and grease injection of axle box accessories before assembly. Main tooling and equipment: cantilever crane, high-pressure air nozzle and air duct, grease injection trolley;

[0027] (2.2) Process: Gearbox sealing ring assembly, main tooling and equipment: grease injection trolley;

[0028] (2.3) Process: Hot fitting of inner ring of toothed bearing, main tooling and equipment: eddy current induction heater, grease injection trolley;

[0029] (2.4) Process: Press fitting of bearing outer ring, main tooling and equipment: bearing press fitting tooling, oil cylinder, electric pump, grease injection trolley;

[0030] (2.5) Process: Assembly of the axle box, main tooling and equipment: cantilever crane, crane scale;

[0031] (2.6) Process: Hot fitting of the inner ring of the non-tooth side bearing, main tooling and equipment: eddy current induction heater, grease injection trolley;

[0032] (2.7) Process: Sealing ring assembly, main tooling and equipment: grease injection trolley;

[0033] (2.8) Process: Lead assembly, main tooling and equipment: cantilever crane, eddy current induction heater, crane scale, axle box compaction tooling;

[0034] (2.9) Process: Assemble the bearing housing from the bearing space. Main tooling and equipment: cantilever crane, bearing housing assembly and transfer flatcar.

[0035] As an improvement, in step (3), the workpieces involved in each process are extracted by analyzing the process of each process. The workpieces involved in each process are as follows:

[0036] (3.0) Process: The axle enters the bearing chamber, involving the axle with a large gear ring;

[0037] (3.1) Process: Cleaning, preparation and grease injection of axle box accessories before assembly, involving the following parts: axle box, shaft collar, gearbox sealing ring, and sealing ring;

[0038] (3.2) Process: Gearbox sealing ring assembly, involving the workpiece: gearbox sealing ring;

[0039] (3.3) Process: Hot fitting of the inner ring of the toothed bearing, involving the inner ring of the bearing;

[0040] (3.4) Process: Press fitting of bearing outer ring, involving the bearing outer ring;

[0041] (3.5) Process: Assembly of the axle box, involving the axle box;

[0042] (3.6) Process: Hot fitting of the inner ring of the non-tooth side bearing, involving the inner ring of the bearing;

[0043] (3.7) Process: Sealing ring assembly, involving the sealing ring;

[0044] (3.8) Process: Shaft assembly, involving the shaft assembly;

[0045] (3.9) Process: Assemble the bearing housing to form the bearing space. Workpiece involved: Bearing housing assembly.

[0046] As an improvement, in step (4), the routes of each element are designed to have no spatial or temporal intersections, and the routes are kept as short as possible. The flow path of the workpiece in each process is as follows:

[0047] (4.0) Assembly of axle with gear ring, flow route: axle with axle box transport flatcar, axle drop platform;

[0048] (4.1) Gearbox sealing ring, flow path: ring component transfer tooling, large ring component preparation workbench, shaft drop platform;

[0049] (4.2) Axle box, flow route: axle box transfer tooling, axle box preparation station, axle bearing pressing station, axle box preparation station, axle bearing pressing station, axle drop station;

[0050] (4.3) Inner ring of bearing, flow path: bearing packaging box, bearing inner ring preparation workbench, small eddy current induction heater, bearing drop platform;

[0051] (4.4) Bearing outer ring, flow path: bearing packaging box, bearing pressing platform, bearing dropping platform;

[0052] (4.5) Sealing ring, flow path: ring component transfer tooling, large ring component preparation workbench, shaft drop platform;

[0053] (4.6) Shaft guide, flow path: ring part transfer tooling, large ring part preparation workbench, heavy-duty heater, shaft drop platform;

[0054] (4.7) Fasteners, O-rings, flow path: material rack, work trolley, shaft drop position;

[0055] (4.8) Sealant, flow path: explosion-proof cabinet, working trolley, and shaft drop position;

[0056] (4.9) Axle assembly with axle box, moving route: axle drop platform, axle transport flatcar with axle box.

[0057] As an improvement, in step (5), an L-shaped flow production line is determined based on the existing process flow, and layout partitions are set, including four areas: material inlet / outlet area, centralized preparation operation, bearing assembly operation area, and tooling equipment placement area; wherein the material inlet / outlet area is specifically used for material storage and transfer; the centralized preparation operation area is specifically used for cleaning and grease injection operations before assembly of each component; the bearing assembly operation area is specifically used for bearing heating and bearing assembly operations; the tooling equipment placement area is placed against the wall and is specifically used for tooling equipment.

[0058] As an improvement, in step (6), the workshop layout is simulated and modeled to verify that the layout has the ability to solve production chaos, dirt, route intersections and production rhythm.

[0059] The beneficial effects of this invention compared to the prior art are:

[0060] 1. The work area is clearly divided into sections, with material area, equipment area and work area designed separately, and equipment is reasonably positioned as fixed equipment and mobile equipment;

[0061] 2. Materials on the trolley are fed into the bearing room in one go using special tooling, eliminating the need for frequent entry and exit of personnel and materials, thus ensuring the production environment indicators are met;

[0062] 3. The grease injection area is centrally located to reduce grease spillage and contamination between bearings.

[0063] 4. The equipment is arranged along the process flow, which shortens the travel route and distance for personnel, avoids the intersection of routes caused by the flow of personnel and materials, and reduces production waiting waste. Attached Figure Description

[0064] Figure 1 This is a layout diagram of the bearing workshop. Detailed Implementation

[0065] The present invention will now be further described with reference to the accompanying drawings.

[0066] like Figure 1As shown, a bearing assembly workshop has a work area on one side and a transportation area 6 on the other. Within the work area, from the entrance to the other side, there are sequentially arranged a storage area 1, a centralized preparation work area 2, a bearing assembly work area 3, and a tooling and equipment placement area 4. The storage area 1 is equipped with a ring component storage fixture 11 and a bearing box transfer and storage fixture 12; a total of three ring component storage fixtures 11 and one bearing box transfer and storage fixture 12 are provided in the storage area 1. On the side of the storage area 1 furthest from the transportation area, there are three large ring component transfer and preparation platform trolleys 23. The centralized preparation area 2 is equipped with bearing press-fitting platforms 22 and bearing box preparation platforms 21. The centralized preparation area 2 has two bearing press-fitting platforms 22 and six bearing box preparation platforms 21. On the side of the centralized preparation area 2 away from the transportation area, there is a bearing transfer and preparation platform trolley 25, with a total of two trolleys 25. A grease injection trolley 24 is located between the bearing transfer and preparation platform trolley 25 and the large ring component transfer and preparation platform trolley 23. The axle lowering assembly area 3 is equipped with bearing box lowering platforms 35, material trolleys 31, tool trolleys 32, electric hydraulic pump trolleys 33, and ladders 34. The axle lowering assembly area 3 has six bearing box lowering platforms 35. The material trolleys 31, tool trolleys 32, and electric hydraulic pump trolleys 33 are for follow-up operations. The ladders 34 are used for disassembling and assembling the axle end lifting screws. The tooling equipment placement area 4 is concave and located in the outer area of ​​the shaft assembly operation area 3. On the side of the tooling equipment placement area 4 away from the transportation area, there are material racks 44, explosion-proof cabinets 43, electric hydraulic oil pump trolley parking spaces 42, and eddy current induction heaters 41. On the side of the tooling equipment placement area 4 closer to the transportation area, there are pressing fixtures 47, work material trolley parking spaces 46, and work tool trolley parking spaces 45. The pressing fixtures include shaft box pressing fixtures, shaft box compaction fixtures, bearing compaction fixtures, and bearing inner ring pressing fixtures. On the side of the tooling equipment placement area 4 facing the entrance, there are industrial refrigerators, tool cabinets 48, lifting cabinets 49, and ladder placement spaces. A track passes through the transportation area 5, and a transport flatcar 51 with axle-mounted shaft boxes is mounted on the track. The centralized preparation operation area 2 is equipped with a cantilever crane 6 on the side near the transportation area. The cantilever crane 6 can cover the transfer area 1, the centralized preparation operation area 2 and the shaft assembly operation area 3.

[0067] The layout method of the bearing workshop includes the following steps:

[0068] (1) Clarify the processes involved in the bearing assembly workshop; based on the workshop's functional setup, it is necessary to identify the bearing assembly processes that need to be completed in the bearing assembly workshop. These processes are the concrete manifestations of the workshop's functional realization. The processes required by the workshop are shown in Table 1:

[0069] Table 1

[0070] 1 The axle enters the bearing space. 2 Cleaning, preparation, and grease application of axle box components before assembly 3 Gearbox sealing ring assembly 4 Hot fitting of inner ring of toothed bearing 5 Press fitting of bearing outer ring 6 axle box assembly 7 Hot fitting of inner ring of non-tooth side bearing 8 Sealing ring assembly 9 Shaft assembly 10 Assemble the bearing housing and bearing space

[0071] (2) Clarify the main equipment and tooling required for each process; by analyzing the work content of each process, extract the main equipment and tooling required for each process. These equipment and tooling are mainly divided into fixed equipment and mobile equipment. The workshop layout is constrained by the arrangement of fixed equipment. These constraints include the outline dimensions and working range of the equipment. At the same time, the dynamic arrangement of mobile equipment during the production process must also be considered. The tooling and equipment required for each process are shown in Table 2:

[0072] Table 2

[0073]

[0074] (3) Clarify the workpieces and semi-finished products for each process; by analyzing the process of each process, extract the main semi-finished products (workpieces) involved in each process, and consider factors such as the quantity, size, placement direction, and production cycle when arranging the workpieces between bearings. The workpieces for the process design are shown in Table 3:

[0075] Table 3

[0076]

[0077] (4) Clarify the flow routes of people, materials, and moving equipment between each process; in the layout design, the routes of each element should not intersect in time and space, and the routes should be as short as possible. Table 4 illustrates the flow of workpieces between processes as an example:

[0078] Table 4

[0079]

[0080]

[0081] (5) The production line layout is arranged in sections according to the process flow; Based on the existing process flow, an L-shaped flow production line is determined and the layout is divided into four areas: material inlet and outlet area, centralized preparation operation area, bearing assembly operation area and tooling equipment placement area; The material inlet and outlet area is specifically used for material storage and transfer; The centralized preparation operation area is specifically used for cleaning and grease injection before the assembly of each component; The bearing assembly operation area is specifically used for bearing heating and bearing assembly operation; The tooling equipment placement area is placed against the wall and is specifically used for tooling equipment.

[0082] (6) Simulation of process verification: By simulating and modeling the workshop layout, the workshop layout is verified to have the ability to solve production chaos, dirt, route intersection and production rhythm.

Claims

1. A method for arranging a bearing workshop, characterized in that, One side of the workshop is the work area, and the other side is the transportation area. Within the work area, from the entrance to the other side, there are sequentially arranged a transfer area, a centralized preparation area, a shaft assembly area, and a tooling and equipment placement area. The transfer area is equipped with ring component transfer tooling and shaft box transfer and storage tooling. A large ring component transfer and preparation platform trolley is located on the side of the transfer area away from the transportation area. The centralized preparation area has a shaft box pressing platform and a shaft box preparation platform. A shaft box transfer and preparation platform trolley is located on the side of the centralized preparation area away from the transportation area. A grease injection trolley is located between the shaft box transfer and preparation platform trolley and the large ring component transfer and preparation platform trolley. The shaft assembly area has a shaft box shaft dropping platform, a material trolley, a tool trolley, and an electric hydraulic oil pump. The tooling equipment placement area is concave and located on the periphery of the shaft assembly area. On the side of the tooling equipment placement area away from the transportation area, there are material racks, explosion-proof cabinets, electric hydraulic pump trolley parking spaces, and eddy current induction heaters. On the side of the tooling equipment placement area closer to the transportation area, there are shaft box pressing fixtures, shaft box compaction fixtures, bearing compaction fixtures, bearing inner ring pressing fixtures, material trolley parking spaces, and tool trolley parking spaces. On the side of the tooling equipment placement area facing the entrance, there are industrial refrigerators, tool cabinets, lifting cabinets, and ladder placement spaces. A track passes through the transportation area, and axle-mounted shaft box transport flatcars are mounted on the track. A cantilever crane is located on the side of the centralized preparation area closest to the transportation area. Includes the following steps: (1) Clarify the processes involved in bearing assembly in the bearing workshop; (2) Clarify the main equipment and tooling required for each process; (3) Clarify the workpieces and semi-finished products for each process; (4) Clarify the flow routes of people, materials, and equipment between each process; (5) Arrange the production line layout by dividing it into zones according to the process flow; (6) Simulation of process verification; In step (1), based on the workshop's functional settings, it is necessary to sort out the bearing assembly processes that need to be completed in the bearing assembly workshop. The bearing assembly processes are as follows: (1.0) The axle enters the bearing chamber; (1.1) Cleaning, preparation and grease injection of axle box accessories before assembly; (1.2) Gearbox sealing ring assembly; (1.3) Hot fitting of the inner ring of the toothed bearing; (1.4) Press-fitting of the outer ring of the bearing; (1.5) Assembly of the axle box; (1.6) Hot fitting of the inner ring of the non-tooth side bearing; (1.7) Assemble the sealing ring; (1.8) Shaft assembly; (1.9) Assemble the bearing housing to form the bearing space; In step (2), by analyzing the work process content, the main equipment and tooling required for each process are extracted. The tooling and equipment required for each process are as follows: (2.0) Process: The axle enters the bearing bay. The main tooling and equipment are: cantilever crane, axle transfer flatcar, and parts transfer tooling. (2.1) Process: Cleaning, preparation and grease injection of axle box accessories before assembly. Main tooling and equipment: cantilever crane, high-pressure air nozzle and air duct, grease injection trolley; (2.2) Process: Gearbox sealing ring assembly, main tooling and equipment: grease injection trolley; (2.3) Process: Hot fitting of inner ring of toothed bearing, main tooling and equipment: eddy current induction heater, grease injection trolley; (2.4) Process: Press fitting of bearing outer ring, main tooling and equipment: press fitting tooling for bearing, hydraulic cylinder, electric pump, grease injection trolley; (2.5) Process: Assembly of the axle box, main tooling and equipment: cantilever crane, crane scale; (2.6) Process: Hot fitting of the inner ring of the non-tooth side bearing, main tooling and equipment: eddy current induction heater, grease injection trolley; (2.7) Process: Sealing ring assembly, main tooling and equipment: grease injection trolley; (2.8) Process: Shaft assembly, main tooling and equipment: cantilever crane, eddy current induction heater, crane scale, shaft box compaction tooling; (2.9) Process: Assemble the bearing housing from the bearing space. Main tooling and equipment: cantilever crane, bearing housing assembly and transfer flatcar; In step (3), by analyzing the process of each operation, the workpieces involved in each operation are extracted. The workpieces involved in each operation are as follows: (3.0) Process: The axle enters the bearing chamber, involving the workpiece: the axle with a large gear ring; (3.1) Process: Cleaning, preparation and grease injection of axle box accessories before assembly, involving the following parts: axle box, shaft collar, gearbox sealing ring, and sealing ring; (3.2) Process: Gearbox sealing ring assembly, involving the gearbox sealing ring; (3.3) Process: Hot fitting of the inner ring of the toothed bearing, involving the inner ring of the bearing; (3.4) Process: Press fitting of bearing outer ring, involving the bearing outer ring; (3.5) Process: Assembly of the axle clamp box, involving the workpiece: axle clamp box; (3.6) Process: Hot fitting of the inner ring of the non-tooth side bearing, involving the inner ring of the bearing; (3.7) Process: Sealing ring assembly, involving the sealing ring; (3.8) Process: Shaft assembly, involving the shaft assembly; (3.9) Process: Assemble the bearing housing to form the bearing space, involving the workpiece: bearing housing assembly; In step (4), the routes of each element in the layout design do not intersect in time and space, and the routes are as short as possible. The flow path of the workpiece in each process is as follows: (4.0) Assembly of axle with gear ring, flow route: flatcar with axle clamp box for transport, axle drop platform; (4.1) Gearbox sealing ring, flow path: ring part transfer tooling, large ring part preparation workbench, shaft drop platform; (4.2) Axle box, flow route: axle box transfer tooling, axle box preparation station, axle bearing pressing station, axle box preparation station, axle bearing pressing station, axle drop station; (4.3) Inner ring of bearing, flow path: bearing packaging box, bearing inner ring preparation workbench, small eddy current induction heater, bearing drop platform; (4.4) Bearing outer ring, flow path: bearing packaging box, bearing pressing platform, bearing dropping platform; (4.5) Sealing ring, flow path: ring component transfer tooling, large ring component preparation workbench, shaft drop platform; (4.6) Shaft guide, flow path: ring part transfer tooling, large ring part preparation workbench, heavy-duty heater, shaft drop platform; (4.7) Fasteners, O-rings, flow path: material rack, work trolley, shaft drop position; (4.8) Sealant, flow path: explosion-proof cabinet, working trolley, and shaft drop position; (4.9) Assembly of axles with axle clamps, the route is: axle drop platform, axle-mounted axle clamp transport flatcar; In step (5), based on the existing process flow, an L-shaped flow production line is determined and a layout partition is set, including four areas: material inlet and outlet area, centralized preparation operation area, bearing assembly operation area, and tooling equipment placement area; among them, the material inlet and outlet area is specifically used for material storage and transfer; the centralized preparation operation area is specifically used for cleaning and grease injection operations before assembly of each component; the bearing assembly operation area is specifically used for bearing heating and bearing assembly operations; the tooling equipment placement area is placed against the wall and is specifically used for tooling equipment. In step (6), the workshop layout is simulated and modeled to verify its ability to solve problems such as production chaos, dirt, route intersections, and production rhythm.

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