A double-intermediate-shaft transmission shaft assembly mistake-proofing tool and method

Abstract

The present application relates to a kind of double intermediate shaft transmission shaft assembly mistake-proof tool and method;Solve the technical problem that the present method needs to adopt specific tool, complex structure, higher cost, and do not have the function of verifying the shaft system after completing tooth, assembly mistake-proof tool includes mounting plate;The first through-hole is set in the middle of the mounting plate, the diameter of the first through-hole is compatible with the diameter of the upper end of two shafts in double intermediate shaft transmission shaft system;Second through-hole is arranged on both sides of the first through-hole, the diameter of the second through-hole is compatible with the diameter of the upper end of two intermediate shafts in double intermediate shaft transmission shaft system respectively;The center of the first through-hole and the center of the two second through-holes are located on the same straight line, and the center distance of the first through-hole and the second through-hole is equal to the center distance of two shafts and corresponding intermediate shaft in double intermediate shaft transmission shaft system;The present application also proposes the assembly mistake-proof method based on the above tool.

Description

Technical Field

[0001] This invention relates to a tooling and method for assembling a dual intermediate shaft transmission shaft system, specifically to a tooling and method for preventing errors in assembling a dual intermediate shaft transmission shaft system. Background Technology

[0002] A new type of heavy-duty truck transmission features a dual intermediate shaft structure in its main gearbox. This structure allows for power distribution, with each intermediate shaft bearing only half of the total power. The gears on the input shaft and main shaft also bear half of the total power. This ensures that the forces on the main shaft are equal in magnitude and opposite in direction. The main shaft only bears torque, not bending moment, eliminating damage to the gear meshing area caused by main shaft deformation. This reduces gear meshing noise, increases gear life, extends the transmission's service life, and makes its operation more reliable.

[0003] Due to the structural characteristics of the transmission, the two intermediate shafts must evenly distribute the teeth on the two shafts when the main gearbox is engaged. Otherwise, it will be impossible to evenly distribute the power between the two intermediate shafts, resulting in abnormal noises and gear slippage in the transmission main gearbox.

[0004] Chinese patent CN105965425A discloses a method and apparatus for helical gear alignment in a transmission intermediate shaft assembly. The alignment apparatus includes an assembly fixture body, an intermediate shaft lifting fixture, and a shaft alignment fixture. The assembly fixture body is mainly responsible for the downward movement and conveying of the intermediate shaft during assembly. The intermediate shaft lifting fixture is used for initial positioning of the intermediate shaft in the assembly direction. The shaft alignment fixture axially positions the heated intermediate shaft gears using a positioning plate, and precisely aligns the heated intermediate shaft using a gear alignment gauge and a gear alignment gauge. The alignment method first initially positions the intermediate shaft using a matching alignment device, then heats the gears and grips and presses the intermediate shaft for heat assembly. The shaft alignment fixture axially positions the heated intermediate shaft gears and completes the precise alignment of the heated intermediate shaft. The heat assembly method ensures the positional accuracy of the intermediate shaft during assembly, and the helical gear accuracy is guaranteed after cooling. At the same time, the interference fit between the intermediate shaft and the gear also meets the requirements.

[0005] The gear-aligning method used in the aforementioned patent requires specific tooling, has a complex structure, high cost, and lacks the function of inspecting the shaft system after gear alignment. Summary of the Invention

[0006] The purpose of this invention is to solve the technical problems of existing gear-aligning methods, which require specific tooling, have complex structures, high costs, and lack the function of inspecting the shaft system after gear alignment. The invention provides a tooling and method for assembling a dual intermediate shaft transmission shaft system to prevent errors.

[0007] The technical solution adopted in this invention is:

[0008] A fault-prevention tooling for assembling a dual intermediate shaft transmission shaft system, characterized by the following features:

[0009] Including mounting plate;

[0010] The mounting plate has a first through hole in the middle, and the diameter of the first through hole is adapted to the diameter of the upper end of the two shafts in the dual intermediate shaft transmission system.

[0011] A second through hole is provided on both sides of the first through hole, and the diameter of the second through hole is adapted to the diameter of the upper end of the two intermediate shafts in the dual intermediate shaft transmission system.

[0012] The center of the first through hole and the centers of the two second through holes are on the same straight line, and the center distance between the first through hole and the second through hole is equal to the center distance between the two shafts and the corresponding intermediate shaft in the dual intermediate shaft transmission system.

[0013] Furthermore, it also includes two handheld grips located on one side of the mounting plate for holding the mounting plate;

[0014] Two handheld brackets are respectively positioned between the first through hole and the two second through holes;

[0015] The handheld device is U-shaped.

[0016] This invention also proposes a method for preventing errors in the assembly of a dual intermediate shaft transmission shaft system, which is characterized by including the following steps:

[0017] Step 1: Assembly of the dual intermediate shaft transmission shaft system

[0018] 1.1 Install a laser above the assembly station;

[0019] 1.2 After the two shafts of the dual intermediate shaft transmission shaft system arrive at the assembly station, turn on the laser and adjust the position of the laser so that the laser emitted by the laser passes through the extension line of the central axis of the two shafts along the gear plane of the two shafts.

[0020] 1.3 After marking the two tooth tips on the two axes that coincide with the laser, turn off the laser;

[0021] 1.4 Push the two intermediate shafts toward the second shaft from both sides so that the tooth grooves marked on the two intermediate shafts mesh with the two tooth tips marked on the second shaft. After positioning the intermediate shafts and the second shaft, the assembly of the dual intermediate shaft transmission shaft system is completed.

[0022] Step 2: Assembly and inspection of the dual intermediate shaft transmission shaft system

[0023] The above-mentioned double intermediate shaft transmission shaft system assembly error prevention tooling is inserted from above the double intermediate shaft transmission shaft system. If it falls smoothly, it means that the assembly is correct and the double intermediate shaft transmission shaft system flows into the next station. If there is jamming, it means that there is a misalignment in the assembly of the double intermediate shaft transmission shaft system, and step 3 is executed.

[0024] Step 3: Disassemble the dual intermediate shaft transmission system, find the cause and repair it, then return to step 1.2.

[0025] Furthermore, after the dual intermediate shaft transmission shaft system is correctly assembled, a visual inspection step is also included:

[0026] The dual intermediate shaft transmission shaft system flowing into the next station is photographed by a visual inspection camera. If the inspection is qualified, the subsequent operation is carried out. If the inspection is unqualified, an alarm is issued, the cause is found and repaired, and then the process returns to step 1.2.

[0027] Furthermore, step 3, before returning to step 1.2, also includes: removing the marks on the two axes.

[0028] The beneficial effects of this invention are:

[0029] 1. In this invention, laser alignment is used to divide the two shafts equally, ensuring the accuracy of the division. Based on this division, the intermediate shaft is assembled, realizing the rapid assembly of the dual intermediate shaft transmission shaft system.

[0030] 2. In this invention, based on the characteristics of the assembled shaft system, a shaft system assembly error-proof tooling is designed, which can not only inspect the assembled shaft system, but also inspect the incoming material of the intermediate shaft through the inspection results.

[0031] 3. In this invention, visual inspection is set up to achieve dual inspection of the assembled shaft axis, further ensuring the correctness of the shaft system assembly. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the shaft system of a dual intermediate shaft transmission;

[0033] Figure 2 This is a schematic diagram of the structure of the laser-segmented shaft system in an embodiment of the error-proof assembly method for the dual intermediate shaft transmission shaft system of the present invention;

[0034] Figure 3 This is a schematic diagram of the structure of an embodiment of the double intermediate shaft transmission shaft system assembly error prevention tooling of the present invention;

[0035] In the diagram, 1 is the second axis; 2 is the intermediate axis; 3 is the laser; 4 is the mounting plate; 5 is the handheld bracket; 6 is the first through hole; and 7 is the second through hole. Detailed Implementation

[0036] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0037] The design concept of this invention is as follows:

[0038] like Figure 1 As shown, this is a dual intermediate shaft transmission shaft system. The assembly of the dual intermediate shaft transmission shaft system needs to be carried out on an assembly pallet. When the pallet arrives at the shaft system assembly station, a laser is installed above the shaft system assembly station. The laser emits a linear laser 3 from the shaft system. By adjusting the position of the laser, the laser 3 passes through the center of the gear of the second shaft 1. Observe the two teeth on the second shaft 1 through which the laser 3 passes, which are the teeth that are 180° apart. Mark these two teeth as the marks for the shaft system assembly. After the assembly is completed, the assembled shaft system is inspected for error prevention using a uniquely designed tooling.

[0039] To achieve the above concept, this invention proposes a method for error-proofing the assembly of a dual intermediate shaft transmission shaft system, comprising the following steps:

[0040] Step 1: Assembly of the dual intermediate shaft transmission shaft system

[0041] 1.1 Install a laser above the assembly station;

[0042] 1.2 Placed on the shaft assembly pallet, after the second shaft 1 of the double intermediate shaft transmission shaft system arrives at the assembly station, as follows: Figure 2 As shown, turn on the laser and adjust its position so that the laser emitted by the laser 3 passes through the extension line of the axis of the second axis 1 (laser 3 passes through the extension line of the center of the second axis 1), and splits the gear of the second axis 1 in half.

[0043] 1.3 The operator observes and confirms that laser 3 passes through the two tooth tips on gear 1 of shaft 2 (i.e., the two tooth tips that are 180° apart), marks the two tooth tips as the reference for subsequent shaft assembly, and then turns off the laser.

[0044] 1.4 Push the two intermediate shafts 2 from both sides toward the second shaft 1, so that the tooth grooves marked on the two intermediate shafts 2 mesh with the two tooth tips marked on the second shaft 1 respectively. Push the two intermediate shafts 2 into place and position them to complete the assembly of the dual intermediate shaft transmission shaft system. At this time, the relative positions of the shaft centers of the two intermediate shafts 2 and the second shaft 1 are fixed.

[0045] Step 2: Inspect the results of the gear assembly of the dual intermediate shaft transmission shaft system.

[0046] After the shaft system is assembled, it is necessary to check whether the assembly is correct and whether the two intermediate shafts 2 evenly divide the teeth on the second shaft 1. A test plan for shaft system assembly errors needs to be designed: if the shaft system is assembled incorrectly, the relative positions of the shaft centers of the second shaft 1 and the two intermediate shafts 2 will change. In order to check the relative positions of the shaft centers of the second shaft 1 and the two intermediate shafts 2, a shaft system assembly error-proof fixture is designed so that the three round holes on the fixture correspond to the positions of the three shaft centers. When the fixture is put on from above the shaft system, the fixture will fall smoothly without any jamming. If the shaft system is assembled incorrectly, the fixture will jam during the falling process and will not fall smoothly, thus reminding the operator to re-check whether there is any misalignment of teeth in the shaft system assembly process.

[0047] Specifically: such as Figure 3 As shown, the double intermediate shaft gearbox shaft system assembly error prevention fixture includes a mounting plate 4 and two U-shaped handholds 5 mounted on one side of the mounting plate 4 for holding the mounting plate 4. A first through hole 6 is provided in the middle of the mounting plate 4, and stepped second through holes 7 are provided on both sides of the first through hole 6, with the large diameter end of the second through hole 7 facing the handholds 5. The position and size of the first through hole 6 and the second through hole 7 must meet the following requirements:

[0048] The diameter of the first through hole 6 is matched with the diameter of the upper end of the second shaft 1 in the dual intermediate shaft transmission system; the diameters of the two second through holes 7 are matched with the diameters of the upper ends of the two intermediate shafts 2 in the dual intermediate shaft transmission system; the line connecting the center of the first through hole 6 and the center of the two second through holes 7 is a straight line, and the distance between the centers of the first through hole 6 and the second through hole 7 is equal to the distance between the centers of the intermediate shaft 2 and the second shaft 1 in the dual intermediate shaft transmission system.

[0049] The first through hole 6 and the two second through holes 7 of the above-mentioned double intermediate shaft transmission shaft system assembly anti-error tooling are respectively inserted into the shaft ends of the second shaft 1 and the two intermediate shafts 2 from above the double intermediate shaft transmission shaft system. If the assembly anti-error tooling falls smoothly, it means that the intermediate shaft 2 and the two second shafts 1 are assembled correctly and there are no misaligned teeth. The shaft system assembly tray carries the double intermediate shaft transmission shaft system to the next station and executes step 4. If there is jamming, it means that there may be misaligned teeth after the double intermediate shaft transmission shaft system is assembled, and step 3 is executed.

[0050] Step 3: Disassemble the dual intermediate shaft transmission shaft system assembled in Step 2, leaving only shaft 1 on the shaft assembly tray. Find the cause and repair it. After the repair is completed, remove the markings on shaft 1 and return to Step 1.2.

[0051] Step 4: Visual inspection:

[0052] To conduct a secondary inspection of the assembled shaft system, a visual inspection camera is added. The tooth alignment marks on the two intermediate shafts 2 and the second shaft 1 should be such that the tooth groove of the marked tooth on the intermediate shaft 2 and the tooth tip of the marked tooth on the second shaft 1 are engaged. The camera captures the process of identifying the tooth alignment marks. If the tooth groove and the tooth tip of the marked tooth are not engaged, an NG alarm is triggered, and a manual inspection is conducted to check for misaligned teeth.

[0053] Specifically: Visual inspection is performed on the dual intermediate shaft transmission shaft system flowing into the next station. After the camera takes a picture, it is compared with the standard. If the comparison is consistent, the shaft system is correctly aligned and the operation of the next station is carried out. If they are inconsistent, the camera will alarm NG. The operator should manually intervene to find the cause and repair it before returning to step 1.2.

[0054] The shaft assembly and tooth alignment scheme proposed in this invention, compared with manual tooth counting and marking the tooth tips at 180° relative angles with a marker, can avoid the wasted time caused by counting teeth during shaft assembly, thus improving work efficiency. At the same time, laser guidance can ensure the accuracy of the tooth alignment process. The dual error prevention measures after shaft assembly can more efficiently detect the fault mode of shaft tooth alignment errors, discover errors as early as possible, and avoid subsequent disassembly and rework.

Claims

1. A method for preventing errors in the assembly of a dual intermediate shaft transmission shaft system, characterized by comprising the following steps: Step 1: Assembly of the dual intermediate shaft transmission shaft system 1.1 Install a laser above the assembly station; 1.2 After the two shafts (1) of the dual intermediate shaft transmission shaft system arrive at the assembly station, turn on the laser and adjust the position of the laser so that the laser (3) emitted by the laser passes through the extension line of the central axis of the two shafts (1) along the gear plane of the two shafts (1); 1.3 After marking the two tooth tips on the two axes (1) that coincide with the laser (3), turn off the laser; 1.4 Push the two intermediate shafts (2) from both sides toward the second shaft (1) so that the tooth grooves marked on the two intermediate shafts (2) mesh with the two tooth tips marked on the second shaft (1) respectively. After positioning the intermediate shafts (2) and the second shaft (1), the assembly of the double intermediate shaft transmission shaft system is completed. Step 2: Assembly and inspection of the dual intermediate shaft transmission shaft system A fault-prevention fixture for assembling a dual intermediate shaft transmission system is inserted from above. If it falls smoothly, the assembly is correct, and the dual intermediate shaft transmission system flows to the next station. If there is jamming, it indicates misalignment in the assembly of the dual intermediate shaft transmission system, and step 3 is executed. The double intermediate shaft transmission shaft system assembly error prevention tooling includes a mounting plate (4). The mounting plate (4) has a first through hole (6) in the middle. The diameter of the first through hole (6) is adapted to the diameter of the upper end of the second shaft (1) in the double intermediate shaft transmission shaft system. A second through hole (7) is provided on both sides of the first through hole (6). The diameter of the second through hole (7) is adapted to the diameter of the upper end of the two intermediate shafts (2) in the double intermediate shaft transmission shaft system. The center of the first through hole (6) and the center of the two second through holes (7) are on the same straight line. The center distance between the first through hole (6) and the second through hole (7) is equal to the center distance between the second shaft (1) and the corresponding intermediate shaft (2) in the double intermediate shaft transmission shaft system. Step 3: Disassemble the dual intermediate shaft transmission system, find the cause and repair it, then return to step 1.

2.

2. The method for preventing errors in the assembly of a dual intermediate shaft transmission shaft system according to claim 1, characterized in that, After the dual intermediate shaft transmission shaft system is correctly assembled, a visual inspection step is also included: The dual intermediate shaft transmission shaft system flowing into the next station is photographed by a visual inspection camera. If the inspection is qualified, the subsequent operation is carried out. If the inspection is unqualified, an alarm is issued, the cause is found and repaired, and then the process returns to step 1.

2.

3. The method for preventing errors in the assembly of a dual intermediate shaft transmission shaft system according to claim 1 or 2, characterized in that, Step 3, before returning to step 1.2, also includes: removing the markings on the two axes (1).

4. The method for preventing errors in the assembly of a dual intermediate shaft transmission shaft system according to claim 1, characterized in that, The double intermediate shaft gearbox shaft system assembly error prevention tooling also includes two hand-held brackets (5) set on one side of the mounting plate (4) for holding the mounting plate (4); the two hand-held brackets (5) are respectively set between the first through hole (6) and the two second through holes (7); the hand-held brackets (5) are U-shaped.

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