Electric drive axle gearbox differential assembly tool and assembly method

Abstract

The invention relates to an assembling tool and method for an electric drive axle gearbox differential mechanism. The assembling tool comprises an assembly boxing system and a positioning support system. The assembly boxing system comprises a hoisting bottom plate, a clamping jaw mechanism and a pre-positioning pin; the clamping jaw mechanism is used for clamping and releasing the differential mechanism assembly, a differential mechanism positioning shaft is arranged at the bottom of the clamping jaw mechanism, and the position of the differential mechanism positioning shaft corresponds to a rear shell hole of the differential mechanism assembly; the pre-positioning pin is arranged on one side of the clamping jaw mechanism, corresponds to a fork shaft hole of the differential mechanism assembly in position and is used for completing double-point positioning of the differential mechanism assembly together with the differential mechanism positioning shaft. The positioning support system comprises a box body positioning plate and a box body positioning assembly, and the box body positioning assembly is used for being matched and fixed with a gearbox body; a first positioning matching mechanism is arranged at the bottom of the hoisting bottom plate, a second positioning matching mechanism is arranged at the top of the box body positioning plate, and the first positioning matching mechanism and the second positioning matching mechanism are matched with each other and used for achieving coaxial positioning of the differential mechanism assembly and the gearbox body.

Description

Technical Field

[0001] The present invention relates to the technical field of differential production and assembly, and in particular to an electric drive axle gearbox differential assembly tool and an assembly method. Background Art

[0002] Pure electric heavy-duty commercial trucks currently use two main drive modes: central electric drive and electric drive axle to achieve vehicle power transmission. Among them, the electric drive axle has a greater development potential due to its smaller installation space advantage. An important feature of the electric drive axle is that the gearbox and the bridge housing are integrated into one, forming a compact design, which improves space utilization while also increasing assembly difficulty.

[0003] In the assembly process of the electric drive axle, the installation of the differential assembly is a key step. Since the differential assembly itself is large in size and heavy in weight, and requires precise positioning and installation, the traditional assembly method is difficult to ensure assembly quality and efficiency.

[0004] In the prior art, there are some differential assembly assembly and disassembly tools, which hook the differential assembly placed on the support through the lifting balance mechanism, install the locking anti-slip mechanism after lifting to a certain height, and then move the differential assembly to the inside of the main reducer housing by operating the lifting equipment. This type of tool can realize the disassembly and assembly of the differential assembly by a single person to a certain extent, but it is mainly suitable for the disassembly and assembly of the differential assembly of the traditional mechanical rear axle.

[0005] For integrated electric drive axles, the existing technology has obvious deficiencies: the existing tooling lacks a precise positioning mechanism during the insertion process, resulting in the inability to ensure the coaxiality with the mounting hole when the differential is lowered into the gearbox; secondly, the limit bolts and hooks of the hoisting balance mechanism need to be installed manually, affecting the assembly efficiency; in addition, the hooks of the hoisting balance mechanism are often located on the same side, and there is a risk of the differential assembly falling during the hoisting process. Summary of the invention

[0006] The invention discloses an electric drive axle gearbox differential assembly tool and an assembly method, aiming to solve the technical problems existing in the prior art.

[0007] The present invention adopts the following technical solutions:

[0008] On the one hand, an embodiment of the present invention provides an electric drive axle transmission differential assembly tool, including an assembly box entry system and a positioning support system;

[0009] The assembly boxing system includes a hoisting base plate and a clamping mechanism and a pre-positioning pin arranged at the bottom thereof; the clamping mechanism is used to clamp and release the differential assembly, and a differential positioning shaft is arranged at the bottom of the clamping mechanism, and its position corresponds to the rear housing hole of the differential assembly; the pre-positioning pin is arranged on one side of the clamping mechanism, and its position corresponds to the fork shaft hole of the differential assembly, and is used to complete the double-point positioning of the differential assembly together with the differential positioning shaft;

[0010] The positioning support system includes a box positioning plate and a box positioning assembly arranged on the top thereof, and the box positioning assembly is used to cooperate with and fix the gearbox box;

[0011] A first positioning and matching mechanism is provided at the bottom of the lifting base plate, and a second positioning and matching mechanism is provided at the top of the box positioning plate. The first positioning and matching mechanism and the second positioning and matching mechanism match each other to achieve coaxial positioning of the differential assembly and the gearbox box.

[0012] As a preferred technical solution, the first positioning and matching mechanism includes a pair of first positioning blocks and a pair of first fixing columns, wherein the pair of first positioning blocks are arranged at two diagonal corners of the hoisting base plate and extend downward; and the pair of first fixing columns are arranged at the other two diagonal corners of the hoisting base plate and also extend downward;

[0013] The second positioning and matching mechanism includes a pair of second positioning columns and a pair of second fixing columns. The pair of second positioning columns are arranged at two opposite corners of the box positioning plate and extend upward to match and connect with a pair of first positioning blocks; a pair of second fixing columns are arranged at the other two opposite corners of the box positioning plate and also extend upward to match and connect with a pair of first fixing columns.

[0014] As a preferred technical solution, the first positioning block and the second positioning column are configured as a plug-in structure, and the first fixing column and the second fixing column are configured as a plug-in structure.

[0015] As a preferred technical solution, the case positioning assembly includes a contoured positioning column and a case positioning block. The contoured positioning column extends upward to match the side profile of the gearbox case, and the case positioning block is arranged on the top surface of the case positioning plate to match the bottom profile of the gearbox case.

[0016] As a preferred technical solution, the clamping mechanism includes a guide rail base plate, a cylinder device and a differential clamping jaw;

[0017] The guide rail bottom plate is fixed to the bottom of the lifting bottom plate through a positioning connecting shaft, and the differential positioning shaft is arranged on the guide rail bottom plate;

[0018] The cylinder device is fixed to the guide rail bottom plate and is used to provide a power source for clamping and releasing;

[0019] The differential jaws are opened and closed by the drive of the cylinder device to complete the clamping and release of the differential assembly.

[0020] As a preferred technical solution, the clamping mechanism also includes a guide rail, a slider, a lifting and fixing plate, a lifting and fixing side plate, a clamping claw connecting plate and a clamping claw fixing plate;

[0021] The lifting fixed plate is connected to the cylinder device and is used to receive the driving force of the cylinder device; the lifting side plate is fixed to the lifting fixed plate; the clamping claw connecting plate and the clamping claw fixing plate are connected to the lifting side plate as a whole through a fixed shaft; the guide rail is fixed to the guide rail bottom plate, and the slider is fixed to the clamping claw fixing plate and is slidably connected to the guide rail;

[0022] The differential clamp is fixed on the clamp fixing plate. When the cylinder device drives the lifting fixing plate and the lifting side plate to rise and fall, the differential clamp clamps or releases the differential assembly by sliding between the guide rail and the slider.

[0023] As a preferred technical solution, the cylinder device includes a cylinder body, a cylinder lifting mechanism and a cylinder inlet and outlet quick plugs. The cylinder inlet and outlet quick plugs are used to intake and exhaust air into the cylinder body to realize the lifting action of the cylinder lifting mechanism.

[0024] As a preferred technical solution, the assembly box entry system also includes a pneumatic switch, a first lifting ring and a first handle;

[0025] The pneumatic switch is arranged on the lifting base plate, and is used to control the clamping and releasing of the clamping claw mechanism; the first lifting ring is fixed on the top of the lifting base plate, and is used to cooperate with the lifting equipment to complete the lifting of the differential assembly; the first handle is fixed on the lifting base plate through the handle mounting block, and is used to move the assembly into the box system.

[0026] As a preferred technical solution, the positioning support system also includes a second lifting ring and a second handle. The second lifting ring is fixed to the box positioning plate and is used to realize the transportation of the positioning support system through lifting equipment; the second handle is fixed to the box positioning plate through a handle mounting block and is used for short-distance movement of the positioning support system.

[0027] On the other hand, an embodiment of the present invention further provides an assembly method using the electric drive axle transmission differential assembly tool as described in any one of the above items, comprising the following steps:

[0028] Lift the assembly box system above the differential assembly, align the differential locating shaft with the differential rear housing hole, and align the pre-locating pin with the differential fork shaft hole to achieve double-point positioning of the differential assembly;

[0029] The driving claw mechanism clamps the bottom of the inner cavity of the differential assembly, and lifts the differential assembly and the assembly into the box system as a whole; the gearbox box is fixed on the positioning support system, and is precisely positioned through the box positioning component;

[0030] Lift the differential assembly and the assembly entry system as a whole above the positioning support system, and adjust the first positioning matching mechanism and the second positioning matching mechanism to align, ensuring that the differential assembly is coaxial with the gearbox housing;

[0031] Lower the assembly into the box system steadily to install the differential assembly into the transmission case;

[0032] Release the clamping state of the clamping claw mechanism and evacuate the assembly into the box system;

[0033] Tighten the differential assembly to complete the assembly.

[0034] One embodiment of the above invention has the following advantages or beneficial effects:

[0035] The present invention mainly provides an electric drive axle gearbox differential assembly tool and assembly method. Compared with the prior art, the embodiment of the present invention solves the problems of low positioning accuracy, difficult operation, low assembly efficiency, etc. existing in the traditional manual assembly of the electric drive axle differential through the coordinated cooperation of the assembly box entry system and the positioning support system.

[0036] Specifically, the tooling adopts a dual-point positioning method that combines a differential positioning shaft with a pre-positioning pin to achieve precise positioning and clamping of the differential assembly; the first positioning and matching structure at the bottom of the lifting base plate matches the second positioning and matching mechanism on the box positioning plate, ensuring the coaxial positioning of the differential assembly and the gearbox box, effectively preventing eccentricity and jamming during the assembly process; the pneumatically controlled clamping mechanism can stably clamp the differential assembly, and through the precise guidance of the guide rail and the slider, the differential assembly can be smoothly inserted into the box.

[0037] Furthermore, the contoured positioning column and the case positioning block in the case positioning assembly are precisely matched with the contour of the gearbox case, ensuring the stable fixation of the gearbox case during the assembly process; by providing lifting rings and handles, the movement and transportation of the tooling are facilitated, thereby improving the flexibility of the operation.

[0038] Through the present invention, accurate positioning, smooth loading and efficient assembly of the electric drive axle differential assembly process are achieved, and the operation can be completed by a single person, which significantly improves the assembly accuracy and efficiency, reduces the labor intensity of workers, reduces the risk of human errors and parts damage in the assembly process, and has good industrial practical value; at the same time, the assembly tool can also be used for the disassembly operation of the differential assembly, further expanding its application range. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments, which constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions explain the present invention and do not constitute improper limitations on the present invention. In the drawings:

[0040] Figure 1 A schematic structural diagram of an electric drive axle transmission differential assembly tool provided in a preferred implementation manner of Example 1 of the present invention;

[0041] Figure 2 This is a schematic structural diagram of an assembly box loading system provided in a preferred implementation manner of Example 1 of the present invention;

[0042] Figure 3 A schematic structural diagram of a positioning support system provided in a preferred implementation manner of Example 1 of the present invention;

[0043] Figure 4 A schematic structural diagram of a clamping mechanism provided in a preferred implementation manner of Example 1 of the present invention;

[0044] Figure 5 A front view of a clamping mechanism provided in a preferred embodiment of Example 1 of the present invention;

[0045] Figure 6 for Figure 5 AA section view;

[0046] Figure 7 A schematic diagram of the structure of a cylinder device provided in a preferred implementation manner of Example 1 of the present invention;

[0047] Figure 8 A front view of a cylinder device provided in a preferred embodiment of Example 1 of the present invention;

[0048] Fig. 9 for Figure 8 BB section view.

[0049] Description of reference numerals:

[0050] Assembly box entry system 10, pneumatic switch 11, clamping jaw mechanism 12, lifting and fixing plate 121, lifting side plate 122, clamping jaw connecting plate 123, clamping jaw fixing plate 124, differential clamping jaw 125, differential positioning shaft 126, guide rail 127, slider 128, guide rail bottom plate 129, cylinder device 1210, cylinder lifting mechanism 12101, cylinder body 12102, cylinder inlet and outlet air hole quick plug 12103, first lifting ring 13, first handle 14, lifting bottom plate 15, first positioning block 16, first fixing column 17, pre-positioning pin 18, positioning support system 20, box positioning plate 21, contoured positioning column 22, box positioning block 23, second lifting ring 24, second handle 25, second positioning column 26, second fixing column 27. DETAILED DESCRIPTION

[0051] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in conjunction with the specific embodiments of the present invention and the corresponding drawings. In the description of the present invention, it should be noted that the term "or" is usually used in the sense of including "and / or", unless the content clearly indicates otherwise.

[0052] In the description of the present application, the terms “first”, “second”, etc. are only used to distinguish the descriptions and should not be understood as indicating or implying relative importance.

[0053] Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0054] Example 1

[0055] At present, the electric drive axle transmission differential has the characteristics of difficult positioning and high assembly precision requirements during the assembly process. Due to the small clearance between the differential assembly and the transmission case, the traditional manual assembly method is prone to inaccurate positioning, jamming or damage to parts. In addition, the differential assembly is heavy, making manual handling and precise positioning difficult, which increases the labor intensity and safety risks of workers.

[0056] In order to achieve accurate positioning and smooth insertion of the differential assembly during assembly, an embodiment of the present invention provides an electric drive axle gearbox differential assembly tool, such as Figure 1 The assembly tooling includes an assembly entry system 10 and a positioning support system 20. During assembly, the assembly entry system 10 is located at the top for clamping the differential assembly, and the positioning support system 20 is located at the bottom for positioning and fixing the gearbox case.

[0057] In a preferred embodiment, the electric drive axle gearbox includes a housing and a differential assembly, wherein the housing has a cavity for accommodating the differential assembly, the opening of the cavity is located on one side of the housing, the bottom of the housing has a support surface with a specific contour for cooperating with the positioning support system 20, and the side of the housing has a number of positioning grooves and fixing holes for positioning and fixing after assembly; the differential assembly is mainly composed of a differential housing, an internal gear set and a shaft assembly, the rear of the differential housing is provided with a rear housing hole, and the side of the housing is provided with a fork shaft hole. During the assembly process, the differential assembly needs to be accurately installed in the cavity of the electric drive axle gearbox housing and maintain coaxiality to ensure the accuracy requirements of subsequent gear meshing and bearing installation.

[0058] like Figure 2In a preferred embodiment, the assembly box entry system 10 includes a lifting base plate 15, a clamping jaw mechanism 12, a pre-positioning pin 18 and a first positioning and matching mechanism, and the clamping jaw mechanism 12, the pre-positioning pin 18 and the first positioning and matching mechanism are all fixedly installed on the bottom of the lifting base plate 15; the lifting base plate 15 is used for lifting or daily transportation; the clamping jaw mechanism 12 is used to clamp and release the differential assembly, and a differential positioning shaft 126 is provided at the bottom of the clamping jaw mechanism 12, and its position corresponds to the rear housing hole of the differential assembly; the pre-positioning pin 18 is arranged on one side of the clamping jaw mechanism 12, and its position corresponds to the fork shaft hole of the differential assembly, and the pre-positioning pin 18 can jointly complete the double-point positioning of the differential assembly with the differential positioning shaft 126.

[0059] like Figure 3 In a preferred embodiment, the positioning support system 20 includes a box positioning plate 21, a box positioning assembly and a second positioning matching mechanism, and the box positioning assembly and the second positioning matching mechanism are both installed and fixed on the top of the box positioning plate 21; the box positioning plate 21 is used to place the gearbox box; the box positioning assembly is used to match and fix with the gearbox box; the second positioning matching mechanism and the first positioning matching mechanism match each other to achieve coaxial positioning of the differential assembly and the gearbox box.

[0060] In a preferred embodiment, the lifting base plate 15 is of a rectangular structure, preferably made of metal material; first lifting rings 13 are fixedly provided on both side areas of the top of the lifting base plate 15, and the first lifting rings 13 are used to cooperate with the lifting equipment in the factory to complete the lifting operation of the differential assembly; a first handle 14 is also provided on the side of the lifting base plate 15, and the first handle 14 is fixed to the lifting base plate 15 through a handle mounting block, which is used for the operator to hold and carry it daily, so as to achieve short-distance movement or precise positioning adjustment of the assembly box system 10; the bottom of the lifting base plate 15 is provided with mounting holes and mounting grooves for installing the clamping mechanism 12, the pre-positioning pin 18 and the first positioning matching mechanism. In this embodiment, the position, size and number of the mounting holes and mounting grooves are no longer specifically limited.

[0061] In a preferred embodiment, the box positioning plate 21 is also made of metal material, and a second handle 25 is provided on its side, which is also fixed by a handle mounting block, and is used by the operator to move the positioning support system 20 over a short distance; a second lifting ring 24 is also provided on the top of the box positioning plate 21, and the second lifting ring 24 is located on both sides of the positioning plate, and is used to realize the transportation and precise placement of the positioning support system 20 through the lifting equipment. Furthermore, a special mounting position / mounting hole for mounting the box positioning assembly and the second positioning matching mechanism is provided on the top of the box positioning plate 21, so as to ensure that the box positioning assembly can be precisely matched with the gearbox box, and at the same time ensure that the second positioning matching mechanism and the first positioning matching mechanism can be precisely aligned and matched.

[0062] Specifically, the position of the second positioning and matching mechanism matches the position of the first positioning and matching mechanism, and the setting position of the case positioning assembly is configured based on the specific contour of the gearbox case. It is not specifically limited in this embodiment, and those skilled in the art can make adaptive adjustments according to the actual shape of the gearbox case.

[0063] In a preferred embodiment, the first positioning and matching mechanism includes a pair of first positioning blocks 16 and a pair of first fixing columns 17, and the pair of first positioning blocks 16 are arranged at two opposite corners of the lifting base plate 15 and extend downward; a pair of first fixing columns 17 are arranged at the other two opposite corners of the lifting base plate 15 and also extend downward; the second positioning and matching mechanism includes a pair of second positioning columns 26 and a pair of second fixing columns 27, and the pair of second positioning columns 26 are arranged at two opposite corners of the box positioning plate 21 and extend upward, which are used to match and connect with the pair of first positioning blocks 16; a pair of second fixing columns 27 are arranged at the other two opposite corners of the box positioning plate 21 and also extend upward, which are used to match and connect with the pair of first fixing columns 17.

[0064] Preferably, the first positioning block 16 and the second positioning column 26 are configured as a plug-in structure, and the first fixing column 17 and the second fixing column 27 are configured as a plug-in structure.

[0065] In a preferred embodiment, the first positioning block 16 is cylindrical in structure, and a conical guide surface is provided at the bottom to facilitate initial alignment with the second positioning column 26; in order to achieve stable connection and positioning accuracy with the second positioning column 26, an annular groove may be further provided on the bottom surface of the first positioning block 16. The second positioning column 26 is also configured as a cylinder, and a groove is provided at the top, and the groove is adapted to the conical guide surface at the bottom of the first positioning block 16; an annular protrusion structure is further provided in the groove, and the annular protrusion is engaged and connected with the annular groove at the bottom of the first positioning block 16 to achieve high-precision positioning and stable connection.

[0066] In a preferred embodiment, the first fixing column 17 is also cylindrical, and its height can be configured to be flush with the first positioning block 16. A through hole is provided at the bottom of the first fixing column 17, and a positioning step is processed inside the through hole to cooperate with the top limit portion of the second fixing column 27. A limit portion is provided at the top of the second fixing column 27 to cooperate with the through hole at the bottom of the first fixing column 17 to achieve plug-in connection between the two.

[0067] Preferably, the plug-in structure of the first positioning block 16 and the second positioning column 26 can also be designed in other forms, such as the cooperation between a square boss and a square groove, the cooperation between a V-shaped groove and a wedge block, the cooperation between a dovetail groove and a dovetail guide rail 127, etc. These cooperation forms can all achieve precise positioning, but they have different emphases in resisting lateral forces and rotation. Technical personnel in this field can make adaptive adjustments and selections according to actual needs; in addition, other plug-in structures can also be selected between the first fixing column 17 and the second fixing column 27, such as a bolt connection or a snap-on connection structure, which will not be given one by one in this embodiment.

[0068] In a preferred embodiment, the box positioning assembly on the box positioning plate 21 includes a contoured positioning column 22 and a box positioning block 23, the contoured positioning column 22 extends upward to match the side profile of the gearbox box, and the box positioning block 23 is arranged on the top surface of the box positioning plate 21 to match the bottom profile of the gearbox box.

[0069] Preferably, the shape of the contoured positioning column 22 is set according to the side profile characteristics of the gearbox case, and its height, position and shape are not specifically limited in this embodiment. Those skilled in the art can adaptively configure it according to the profile of the gearbox case.

[0070] Preferably, at least two contoured positioning columns 22 are provided, which are respectively located on both sides of the housing positioning plate 21 to provide stable lateral support and prevent the gearbox housing from tilting or shifting during assembly.

[0071] Preferably, the case positioning block 23 is fixed to the top surface of the case positioning plate 21 through an embedded design, and the installation position is precisely determined according to the characteristic points of the bottom of the gearbox case. Its structure completely matches the bottom contour of the gearbox case, and the specific structure can be adaptively configured according to the gearbox case.

[0072] In a preferred embodiment, the case positioning block 23 is configured as a modular structure, which can be quickly replaced according to different models of gearbox cases, so as to improve the versatility of the tooling; preferably, the case positioning block 23 is installed using a quick-change structure and is fixed to the case positioning plate 21 by a quick locking device. When replacing, only the locking device needs to be operated without the use of tools, which greatly reduces the time for tooling adjustment.

[0073] like Figure 4 — Figure 5In a preferred embodiment, the clamping mechanism 12 includes a guide rail base plate 129, a cylinder device 1210, a differential clamping claw 125, a guide rail 127, a slider 128, a lifting and fixing plate 121, a lifting and fixing side plate 122, a clamping claw connecting plate 123 and a clamping claw fixing plate 124; wherein the guide rail base plate 129 is fixed to the bottom of the lifting base plate 15 through a positioning connecting shaft, and the differential positioning shaft 126 is arranged on the guide rail base plate 129; the cylinder device 1210 is fixed on the guide rail base plate 129, and is used to provide a power source for clamping and releasing; the lifting and fixing plate 121 is connected to the cylinder device 1210, and is used to receive the cylinder device The driving force of 1210; the lifting side plate 122 is fixed on the lifting fixed plate 121; the clamp connecting plate 123 and the clamp fixing plate 124 are connected to the lifting side plate 122 as a whole through a fixed shaft; the guide rail 127 is fixed on the guide rail bottom plate 129, and the slider 128 is fixed on the clamp fixing plate 124 and is slidably connected with the guide rail 127; the differential clamp 125 is fixed on the clamp fixing plate 124, and when the cylinder device 1210 drives the lifting fixed plate 121 and the lifting side plate 122 to rise and fall, the differential clamp 125 realizes the clamping or releasing of the differential assembly through the sliding between the guide rail 127 and the slider 128.

[0074] Preferably, the guide rail base plate 129 has a rectangular structure, and the guide rail base plate 129 is fixedly connected to the bottom of the lifting base plate 15 through multiple sets of positioning connecting shafts; the differential positioning shaft 126 is vertically fixed to the central position of the guide rail base plate 129, and is preferably configured as a cylindrical structure, whose diameter matches the size of the rear housing hole of the differential assembly, and the top is designed with a chamfer to facilitate guiding assembly.

[0075] like Figure 7 — Fig. 9 Preferably, the cylinder device 1210 includes a cylinder body 12102, a cylinder lifting mechanism 12101 and a cylinder air inlet and outlet quick plug 12103, and the cylinder air inlet and outlet quick plug 12103 is used to intake and exhaust air to the cylinder body 12102 to realize the lifting action of the cylinder lifting mechanism 12101; a pneumatic switch 11 is also provided on the top of the lifting base plate 15, and the pneumatic switch 11 is electrically connected to the cylinder device 1210. By controlling the position of the pneumatic switch 11, the operator can realize precise control of the cylinder lifting mechanism 12101 and complete the clamping and releasing actions of the clamp.

[0076] Preferably, a connection seat is provided in the center of the lifting fixed plate 121, which is fixedly connected to the cylinder lifting mechanism 12101; the lifting side plate 122 is connected to the lifting fixed plate 121 by high-strength bolts to form a stable lifting bracket structure; the lifting side plate 122 is provided with connection holes on both sides for installing the fixed shaft, and the clamping claw connecting plate 123 is connected to the lifting side plate 122 by the fixed shaft; the clamping claw fixing plate 124 is connected to the clamping claw connecting plate 123 by high-strength bolts to form a stable clamping claw support structure. A mounting seat for installing the slider 128 is provided at the bottom of the clamping claw fixing plate 124.

[0077] Preferably, the guide rail 127 adopts a linear guide rail 127 and is fixedly mounted on the guide rail base plate 129. The slider 128 matches the guide rail 127 to achieve corresponding linear motion. The slider 128 is fixed to the bottom of the clamping jaw fixing plate 124 by bolts. The configuration of the guide rail 127 and the slider 128 realizes the precise guidance of the clamping jaw mechanism 12, so that the differential clamping jaw 125 can move smoothly along a predetermined track during the clamping and releasing process to avoid stagnation and deviation.

[0078] In a preferred embodiment, the differential clamp 125 is configured as two pairs of symmetrically arranged clamp arms, forming a "cross-shaped" gripping mechanism, so that the differential assembly can be gripped from four directions at the same time, providing a uniformly distributed clamping force to prevent eccentricity and imbalance during the clamping process. Preferably, the gripping end of the clamp arm is designed with a contoured gripping surface that matches the shape of the differential assembly, and the gripping surface is covered with a non-slip rubber material to increase friction and prevent the differential assembly from slipping during the clamping process.

[0079] Specifically, the working principle of the clamping mechanism 12 is:

[0080] The operator activates the solenoid valve of the cylinder device 1210 by controlling the pneumatic switch 11 on the top of the lifting base plate 15. The solenoid valve controls the airflow direction of the cylinder inlet and outlet air quick plug 12103 to achieve pressure changes in the cylinder body 12102. When the pneumatic switch 11 controls the bottom air intake and the top exhaust of the cylinder body 12102, the cylinder lifting mechanism 12101 contracts, pushing the lifting fixed plate 121 to move downward, driving the lifting side plate 122, the clamping claw connecting plate 123 and the clamping claw fixing plate 124 to descend synchronously, and the clamping claw fixing plate 124 slides smoothly on the guide rail 127 through the slider 128, driving the differential clamping claw 125 to move downward and open, releasing the differential assembly; when the pneumatic switch 11 controls the top air intake and the bottom exhaust of the cylinder body 12102, the cylinder lifting mechanism 12101 extends, pushing the entire clamping claw mechanism 12 to move upward, and the clamping claw arm closes, so as to achieve a stable clamping of the differential assembly. The clamping force of the clamping jaws can be controlled accordingly by adjusting the working air pressure of the cylinder to ensure that the differential assembly can be firmly clamped without damaging the parts due to excessive clamping force.

[0081] Example 2

[0082] An embodiment of the present invention provides an electric drive axle transmission differential assembly method, which uses the electric drive axle transmission differential assembly tool in the above-mentioned embodiment 1 to perform assembly operations. The technical features already recorded in embodiment 1 are naturally inherited in this embodiment and will not be repeated.

[0083] In a preferred embodiment, the electric drive axle transmission differential assembly method comprises the following steps:

[0084] Step S310, hoist the assembly box system above the differential assembly, align the differential positioning shaft with the differential rear housing hole, and align the pre-positioning pin with the differential fork shaft hole to achieve double-point positioning of the differential assembly.

[0085] Specifically, first, the assembly box system 10 is lifted by connecting the hook of the lifting equipment to the first lifting ring 13 on the lifting base plate 15; then the operator controls the assembly box system 10 to move to the top of the differential assembly through the first handle 14; then the operator fine-tunes the assembly box system 10 based on visual inspection to make the axis of the differential positioning shaft 126 roughly aligned with the center line of the differential rear housing hole, and at the same time, make the axis of the pre-positioning pin 18 roughly aligned with the center line of the differential fork shaft hole; then slowly lower the assembly box system 10, and pause the lowering after the differential positioning shaft 126 enters the differential rear housing hole to a certain depth, and perform precise adjustments to ensure that the two-point positioning mechanism is completely aligned with the corresponding hole; finally, continue to slowly lower the assembly box system 10 until the differential positioning shaft 126 is fully inserted into the differential rear housing hole, and the pre-positioning pin 18 is fully inserted into the differential fork shaft hole, so as to achieve precise two-point positioning.

[0086] Step S320, driving the clamping mechanism to clamp the bottom of the inner cavity of the differential assembly, and lifting the differential assembly and the assembly box system as a whole; fixing the gearbox box body on the positioning support system, and accurately positioning it through the box body positioning component.

[0087] Specifically, the operator activates the cylinder device 1210 by controlling the pneumatic switch 11 on the top of the lifting base plate 15, so that the cylinder lifting mechanism 12101 extends, drives the differential clamp 125 to close, and clamps the bottom of the inner cavity of the differential assembly; after the operator confirms through visual inspection that the clamp has correctly clamped the differential assembly, the operator uses the lifting equipment control device to lift the differential assembly and the assembly box system 10 as a whole to the working height and out of the original placement position; then the operator places the gearbox case on the case positioning plate 21 of the positioning support system 20, so that the bottom contour of the gearbox case matches the case positioning block 23, and the side contour fits the contoured positioning column 22; then the operator adjusts the position of the gearbox case so that it falls completely into the preset positioning structure; finally, the operator uses the clamping device on the case positioning component to firmly fix the gearbox case in the positioning position to ensure that no displacement occurs during subsequent assembly.

[0088] Step S330, hoist the differential assembly and the assembly entry system as a whole above the positioning support system, adjust the first positioning matching mechanism and the second positioning matching mechanism to align, and ensure that the differential assembly is coaxial with the gearbox housing.

[0089] Specifically, the operator controls the lifting equipment to move the assembly entry system 10 that has clamped the differential assembly to just above the positioning support system 20, and then the operator uses the first handle 14 to accurately adjust the position of the assembly entry system 10 so that a pair of first positioning blocks 16 at the bottom of the lifting base plate 15 are roughly aligned with a pair of second positioning columns 26 at the top of the box positioning plate 21, and at the same time, a pair of first fixing columns 17 are roughly aligned with a pair of second fixing columns 27; then the operator controls the lifting equipment to slowly lower the assembly entry system 10 until the conical guide surface at the bottom of the first positioning block 16 is initially in contact with the raised structure at the top of the second positioning column 26; at this time, the assembly entry system 10 will automatically adjust its position under the guidance of the positioning structure, so that the positioning structure is gradually accurately aligned; finally, the operator ensures that the first positioning matching mechanism and the second positioning matching mechanism are completely aligned by fine-tuning the lifting equipment and manually adjusting the position of the assembly entry system 10, so as to achieve accurate coaxial positioning of the differential assembly and the gearbox case.

[0090] Step S340, smoothly lower the assembly into the box system to install the differential assembly into the transmission case.

[0091] Specifically, the operator first confirms that the first positioning and matching mechanisms and the second positioning and matching mechanisms are fully aligned, and that the differential assembly is coaxial with the gearbox housing; then the operator controls the assembly entry system 10 to descend smoothly at a relatively low speed through the hoisting equipment control device; when the outer edge of the differential assembly initially contacts the entrance of the gearbox housing, the operator observes carefully to confirm that there is no obstruction or interference; then the operator continues to descend slowly, using the deadweight and precise guidance of the assembly entry system 10 to allow the differential assembly to smoothly enter the gearbox housing along a predetermined trajectory; during the entire descent process, if any abnormal conditions are found, the operator immediately stops the descent and continues after troubleshooting the cause; finally, the differential assembly completely enters the gearbox housing and reaches the preset installation position.

[0092] Step S350, releasing the clamping state of the clamping mechanism and evacuating the assembly into the box system.

[0093] Specifically, the operator controls the pneumatic switch 11 on the top of the lifting base plate 15 to retract the cylinder lifting mechanism 12101, drive the differential clamp 125 to open, and release the differential assembly. After releasing the clamp, the operator visually confirms that the clamp has completely disengaged from the differential assembly. The operator then controls the lifting equipment to slowly lift the assembly box system 10 to separate the first positioning and matching mechanism from the second positioning and matching mechanism. Finally, the operator controls the lifting equipment to completely evacuate the assembly box system 10 from the working area and move it to a designated storage location or prepare for the next assembly operation.

[0094] Step S360, tighten the differential assembly to complete the assembly.

[0095] In this step, the operator first visually inspects the installed differential assembly to confirm that it is in the correct position and has no obvious deviation; then, according to the assembly process requirements, the operator uses special tools or equipment to tighten the differential assembly through the preset fastening points; after the fastening is completed, the operator uses a torque wrench to check the torque of each fastening point to ensure that the fastening force meets the design requirements; finally, the operator performs an assembly quality inspection, including the axial movement detection and rotational resistance detection of the differential assembly, to confirm that all assembly parameters meet the technical standards. After the assembly is completed, the operator records the relevant data of this assembly in the quality tracking system to provide a basis for subsequent processes and quality traceability.

[0096] Compared with the prior art, this embodiment realizes precise positioning, smooth loading and efficient assembly of the electric drive axle differential assembly process, significantly improves assembly accuracy and efficiency, reduces the labor intensity of workers, reduces the risk of human errors and parts damage during the assembly process, and has good industrial practical value; at the same time, the assembly tool can also be used for the disassembly operation of the differential assembly, further expanding its scope of application.

[0097] Although example embodiments have been described herein with reference to the accompanying drawings, it should be understood that the above example embodiments are merely exemplary and are not intended to limit the scope of the present application to this. Those of ordinary skill in the art may make various changes and modifications therein without departing from the scope and spirit of the present application. All these changes and modifications are intended to be included within the scope of the present application as required by the appended claims.

[0098] In the description provided herein, a large number of specific details are described. However, it is understood that the embodiments of the present application can be practiced without these specific details. In some instances, well-known methods, structures and techniques are not shown in detail so as not to obscure the understanding of this description.

[0099] Similarly, it should be understood that in order to streamline the present application and help understand one or more of the various inventive aspects, in the description of the exemplary embodiments of the present application, the various features of the present application are sometimes grouped together into a single embodiment, figure, or description thereof. However, the method of the present application should not be interpreted as reflecting the following intention: the claimed application requires more features than the features clearly stated in each claim. More specifically, as reflected in the corresponding claims, the inventive point is that the corresponding technical problem can be solved with features less than all the features of a single disclosed embodiment. Therefore, the claims following the specific embodiment are hereby explicitly incorporated into the specific embodiment, wherein each claim itself serves as a separate embodiment of the present application.

[0100] It will be understood by those skilled in the art that, except for mutually exclusive features, all features disclosed in this specification (including the accompanying claims, abstracts and drawings) and all processes or units of any method or device disclosed in this specification may be combined in any combination. Unless otherwise expressly stated, each feature disclosed in this specification (including the accompanying claims, abstracts and drawings) may be replaced by an alternative feature that provides the same, equivalent or similar purpose.

Claims

1. An electric drive axle gearbox differential assembly tool, characterized in that: Including assembly box system and positioning support system; The assembly box entry system includes a hoisting base plate and a clamping mechanism and a pre-positioning pin arranged at the bottom thereof; the clamping mechanism is used to clamp and release the differential assembly, and a differential positioning shaft is provided at the bottom of the clamping mechanism, and its position corresponds to the rear housing hole of the differential assembly; the pre-positioning pin is arranged on one side of the clamping mechanism, and its position corresponds to the fork shaft hole of the differential assembly, and is used to complete the double-point positioning of the differential assembly together with the differential positioning shaft; The positioning support system includes a box positioning plate and a box positioning assembly arranged on the top thereof, and the box positioning assembly is used to cooperate with and fix the gearbox box; A first positioning and matching mechanism is provided at the bottom of the lifting base plate, and a second positioning and matching mechanism is provided at the top of the box positioning plate. The first positioning and matching mechanism and the second positioning and matching mechanism match each other to achieve coaxial positioning of the differential assembly and the gearbox box.

2. The electric drive axle gearbox differential assembly tool according to claim 1, characterized in that: The first positioning and matching mechanism includes a pair of first positioning blocks and a pair of first fixing columns, wherein the pair of first positioning blocks are arranged at two opposite corners of the hanging base plate and extend downward; and the pair of first fixing columns are arranged at the other two opposite corners of the hanging base plate and also extend downward; The second positioning and matching mechanism includes a pair of second positioning columns and a pair of second fixing columns. The pair of second positioning columns are arranged at two opposite corners of the box positioning plate and extend upward to match and connect with the pair of first positioning blocks; a pair of second fixing columns are arranged at the other two opposite corners of the box positioning plate and also extend upward to match and connect with the pair of first fixing columns.

3. The electric drive axle gearbox differential assembly tool according to claim 2, characterized in that: The first positioning block and the second positioning column are configured as a plug-in structure, and the first fixing column and the second fixing column are configured as a plug-in structure.

4. The electric drive axle transmission differential assembly tool according to claim 1, characterized in that: The case positioning assembly includes a contoured positioning column and a case positioning block, wherein the contoured positioning column extends upward to match the side profile of the gearbox case, and the case positioning block is arranged on the top surface of the case positioning plate to match the bottom profile of the gearbox case.

5. The electric drive axle transmission differential assembly tool according to claim 1, characterized in that: The clamp mechanism comprises a guide rail base plate, a cylinder device and a differential clamp; The guide rail base plate is fixed to the bottom of the hoisting base plate through a positioning connecting shaft, and the differential positioning shaft is arranged on the guide rail base plate; The cylinder device is fixed to the guide rail bottom plate and is used to provide a power source for clamping and releasing; The differential clamp is opened and closed by the drive of the cylinder device to complete the clamping and releasing of the differential assembly.

6. The electric drive axle transmission differential assembly tool according to claim 5, characterized in that: The clamping mechanism also includes a guide rail, a slider, a lifting and fixing plate, a lifting and fixing side plate, a clamping claw connecting plate and a clamping claw fixing plate; The lifting fixed plate is connected to the cylinder device for receiving the driving force of the cylinder device; the lifting side plate is fixed to the lifting fixed plate; the clamping claw connecting plate and the clamping claw fixing plate are connected to the lifting side plate as a whole through a fixed shaft; the guide rail is fixed to the guide rail bottom plate, and the slider is fixed to the clamping claw fixing plate and is slidably connected to the guide rail; The differential clamp is fixed on the clamp fixing plate. When the cylinder device drives the lifting fixing plate and the lifting side plate to lift, the differential clamp clamps or releases the differential assembly by sliding between the guide rail and the slider.

7. The electric drive axle transmission differential assembly tool according to claim 5, characterized in that: The cylinder device comprises a cylinder body, a cylinder lifting mechanism and a cylinder inlet and outlet quick plug, wherein the cylinder inlet and outlet quick plug is used for intake and exhaust of the cylinder body to realize the lifting action of the cylinder lifting mechanism.

8. The electric drive axle transmission differential assembly tool according to claim 1, characterized in that: The assembly box entry system also includes a pneumatic switch, a first lifting ring and a first handle; The pneumatic switch is arranged on the lifting base plate, and is used to control the clamping and releasing of the clamping mechanism; the first lifting ring is fixed to the top of the lifting base plate, and is used to cooperate with the lifting equipment to complete the lifting of the differential assembly; the first handle is fixed to the lifting base plate through the handle mounting block, and is used for moving the assembly into the box system.

9. The electric drive axle transmission differential assembly tool according to claim 1, characterized in that: The positioning support system also includes a second lifting ring and a second handle. The second lifting ring is fixed to the box positioning plate and is used to position the support system for transportation through lifting equipment. The second handle is fixed to the box positioning plate through a handle mounting block and is used for short-distance movement of the positioning support system.

10. An assembly method using the electric drive axle transmission differential assembly tool as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: Lift the assembly box system above the differential assembly, align the differential locating shaft with the differential rear housing hole, and align the pre-locating pin with the differential fork shaft hole to achieve double-point positioning of the differential assembly; The driving claw mechanism clamps the bottom of the differential assembly inner cavity, and lifts the differential assembly and the assembly entry system as a whole; the gearbox case is fixed on the positioning support system, and is precisely positioned through the case positioning assembly; Lift the differential assembly and the assembly entry system as a whole above the positioning support system, and adjust the first positioning matching mechanism and the second positioning matching mechanism to align, ensuring that the differential assembly is coaxial with the gearbox housing; Lower the assembly into the box system smoothly to install the differential assembly into the transmission case; Release the clamping state of the clamping claw mechanism and evacuate the assembly into the box system; Tighten the differential assembly to complete the assembly.

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