Chain wheel laser alignment process and device

Abstract

The invention belongs to the field of chain wheel correction, and particularly relates to a chain wheel laser alignment process and device. The device comprises a laser transmitter; the laser transmitter is arranged on one side of the end face of the crankshaft chain wheel. A laser receiver; the laser receiver is arranged on one side of the end face of the target wheel to be corrected; one end of the connection receiver is connected with a data line; the other end of the data line is connected with an operation display; laser emitted by the laser emitter is irradiated to the position of the laser receiver, the deviation value of the laser in the vertical direction is recorded by operating the displayer, the positions of the crankshaft chain wheel and a target wheel to be corrected are adjusted according to the deviation value in the vertical direction, and alignment of the crankshaft chain wheel is conducted. The device is simple in structure, simple in chain wheel alignment process operation flow, high in correction efficiency, good in precision and good in repeatability.

Description

Technical Field

[0001] The present invention belongs to the field of sprocket alignment, and particularly relates to a sprocket laser alignment process and device. Background Art

[0002] During the assembly process of marine low-speed diesel engines, sprocket wire alignment is a key and complex process, and its accuracy directly affects the wear degree and service life of the sprocket after the main engine runs.

[0003] The existing sprocket alignment processes generally adopt wire alignment technology, which requires tools such as wires, heavy hammers, and calipers. The operation process is cumbersome and has significant defects: the wire is easily affected by factors such as environmental vibration and gravity sag, resulting in large measurement errors; the adjustment process is time-consuming and laborious, with low efficiency; data recording depends on manual interpretation, with strong subjectivity and poor repeatability. If the alignment accuracy is insufficient, it will lead to poor sprocket meshing, accelerated wear, and even cause main engine failures, affecting the safety of ship operation and the satisfaction of shipowners. Although the existing technology has tried to improve some problems through tool improvement or process optimization, it has not fundamentally solved the contradiction between measurement accuracy and efficiency. Therefore, there is an urgent need to develop a new type of sprocket alignment process device, which replaces the traditional wire with laser technology, and realizes fast and accurate alignment through high-precision optical measurement and digital feedback, thereby reducing maintenance costs and improving the reliability of the main engine. Summary of the Invention

[0004] In order to solve the problems of the existing sprocket alignment device, such as complex structure, cumbersome process operation flow, large measurement error, low efficiency, low accuracy, data recording depending on manual interpretation, and poor repeatability, the present invention proposes a sprocket laser alignment process, including the following steps:

[0005] S1: Equipment preparation:

[0006] Check the laser transmitter, laser receiver, connecting data cable, and operation display to ensure that each of their interfaces is not damaged;

[0007] S2: Beam calibration:

[0008] Perform beam parallelism calibration on the laser transmitter and the laser receiver. During calibration, place them on a horizontal calibration straightedge respectively, connect the laser receiver to the operation display through a data cable, start the laser transmitter so that its beam completely irradiates on the laser receiver. After the data on the operation display is stable, record the initial calibration data of the operation display. When the initial calibration data is zero, there is no error between the laser transmitter and the laser receiver, and the calibration is completed;

[0009] S3: Installation and positioning:

[0010] Fix the laser emitter on one side of the end face of the crankshaft sprocket. The beam of the laser emitter is parallel to the axis of the crankshaft sprocket. The laser receiver is installed on the same side end face of the tensioner and is connected to the control display through a data cable.

[0011] S4: Beam adjustment:

[0012] Adjust the direction of the laser emitted by the laser emitter so that it shoots towards the tensioner. Then adjust the direction of the laser receiver so that it receives the laser emitted by the laser receiver, and record the vertical direction deviation value between the crankshaft sprocket and the tensioner.

[0013] S5: Multi-pulley system alignment:

[0014] Repeat steps S3 - S5. The laser receiver is successively installed on the same side end face of the balance wheel and the large sprocket for alignment of the crankshaft sprocket with the balance wheel and the large sprocket. Adjust the position of the pulley system according to the vertical direction deviation value until the reading on the control display meets the preset vertical direction deviation value, and complete the alignment of the crankshaft sprocket.

[0015] According to a sprocket laser alignment process described above, in step S2: Conduct a beam parallel check on the laser emitter and the laser receiver. During the check, place them respectively on a horizontal calibration straightedge, connect the laser receiver to the control display through a data cable, start the laser emitter so that its beam completely irradiates on the laser receiver. After the data on the control display stabilizes, record the initial calibration data of the control display. When the initial calibration data is zero, there is no error between the laser emitter and the laser receiver, and the check is completed.

[0016] According to a sprocket laser alignment process described above, in step S4: Start the laser emitter, press the light-emitting button, and the laser beam shoots towards the tensioner.

[0017] Observe the laser landing point on the laser receiver. If it deviates from the center, rotate the horizontal adjustment knob of the laser receiver until the beam is centered. Synchronously fine-tune the vertical angle of the laser emitter to ensure that the beam is perpendicular to the end face.

[0018] According to an alignment device for a sprocket laser alignment process described above, it includes: a laser emitter for emitting laser; the laser emitter is arranged on one side of the end face of the crankshaft sprocket; a laser receiver for receiving the laser emitted by the laser emitter; the laser receiver is arranged on one side of the end face of the target pulley to be corrected; a horizontal calibration straightedge for beam parallel check of the laser emitter and the laser receiver; one end of the data cable is connected to the receiver, and the other end of the data cable is connected to a control display; by the position where the laser emitted by the laser emitter irradiates on the laser receiver, record the laser vertical direction deviation value through the control display, and adjust the positions of the crankshaft sprocket and the target pulley to be corrected according to the vertical direction deviation value to conduct alignment of the crankshaft sprocket.

[0019] According to the sprocket laser alignment device described above, a multi-directional adjustment mechanism is provided on the surface of the laser receiver, which can be fine-tuned in the horizontal and vertical directions to ensure that the light beam is received in the center.

[0020] According to the sprocket laser alignment device described above, the operation display is integrated with a data storage module to support real-time display, recording and export of deviation values.

[0021] According to the sprocket laser alignment device described above, the light beam parallelism check includes verifying the zero point error between the laser transmitter and the laser receiver, and operating the display to return to zero after calibration.

[0022] According to the sprocket laser alignment device described above, the data line is a shielded cable, which is resistant to electromagnetic interference and has a transmission signal error of less than 0.01%.

[0023] According to the sprocket laser alignment device described above, the adjustment mechanism of the laser receiver includes a damping bearing to achieve stepless and smooth rotation.

[0024] According to the sprocket laser alignment device described above, the preset laser vertical direction deviation value is ≤0.05mm, and when the limit is exceeded, the operating display triggers an alarm prompt.

[0025] The beneficial effects of the present invention are as follows:

[0026] 1. The present invention adjusts the direction of the laser emitted by the laser transmitter so that it shoots toward the balance wheel, and then adjusts the direction of the laser receiver so that it receives the laser emitted by the laser receiver, and records the vertical deviation value between the crankshaft sprocket and the balance wheel. The laser beam has high parallelism and strong anti-interference ability, which can eliminate errors such as wire sagging and shaking, improve accuracy, and improve the vertical deviation measurement accuracy to below the millimeter level, ensuring optimal sprocket engagement.

[0027] 2. The present invention realizes one-key calibration and real-time data feedback through the coordinated work of the laser transmitter, laser receiver and operation display, simplifies the operation steps, optimizes efficiency, and shortens the alignment time by more than 50%.

[0028] 3. The present invention does not require complicated tools. It only requires installing the laser component and adjusting the beam direction, which reduces the dependence on the operator's experience and is easy to operate.

[0029] 4. The present invention records the deviation value in digital form by manipulating the display, which is convenient for subsequent analysis and process optimization, and the data is traceable, thereby improving the quality control level.

[0030] The invention has wide adaptability: it is suitable for aligning various gear trains such as crankshaft sprockets, balance wheels, tensioners, etc., and is compatible with different models of diesel engines. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a schematic diagram of using a sprocket laser alignment device of the present invention to align the tensioning pulley.

[0032] Figure 2 It is a schematic diagram of using a sprocket laser alignment device of the present invention to align the balance wheel.

[0033] Figure 3 It is a schematic diagram of using a sprocket laser alignment device of the present invention to align the large sprocket.

[0034] In the figure: 1 - laser emitter, 2 - laser receiver, 3 - connecting data cable, 4 - control display, 5 - crankshaft sprocket, 6 - tensioning pulley, 7 - balance wheel, 8 - large sprocket. Specific implementation mode

[0035] Preferred implementation mode

[0036] Next, the technical solutions in the embodiments of the present application will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present application.

[0037] As Figure 1 shown: In this embodiment, a sprocket laser alignment process includes the following steps:

[0038] S1: Equipment preparation:

[0039] Check the laser emitter 1, laser receiver 2, connecting data cable 3 and control display 4 to ensure that there is no damage to their respective interfaces;

[0040] S2: Beam calibration:

[0041] Perform beam parallelism calibration on the laser emitter 1 and the laser receiver 2. During calibration, place them on a horizontal calibration ruler respectively, connect the laser receiver 2 to the control display 4 through the data cable 3, start the laser emitter 1 so that its beam completely irradiates on the laser receiver 2. After the data on the control display 4 is stable, record the initial calibration data of the control display 4. When the initial calibration data is zero, there is no error between the laser emitter 1 and the laser receiver 2, and the calibration is completed;

[0042] S3: Installation and positioning:

[0043] Fix the laser emitter 1 on one side of the end face of the crankshaft sprocket 5, with the beam of the laser emitter 1 parallel to the axis of the crankshaft sprocket 5. Install the laser receiver 2 on the same side of the end face of the tensioning pulley 6 and connect it to the control display 4 through the data cable 3;

[0044] S4: Beam adjustment:

[0045] Adjust the direction of the laser emitted by the laser emitter 1 so that it shoots towards the direction of the tensioner pulley 6, and then adjust the direction of the laser receiver 2 so that it receives the laser emitted by the laser receiver 2, and record the vertical direction deviation value between the crankshaft sprocket 5 and the tensioner pulley 6;

[0046] S5: Multi-pulley system collaborative alignment:

[0047] Repeat steps S3 - S5, and install the laser receiver 2 on the same side end face of the balance wheel 7 and the large sprocket 8 in sequence to align the crankshaft sprocket 5 with the balance wheel 7 and the large sprocket 8; adjust the position of the pulley system according to the vertical direction deviation value until the reading on the control display 4 meets the preset vertical direction deviation value, and complete the alignment of the crankshaft sprocket 5.

[0048] In step S2: Conduct a beam parallelism check on the laser emitter 1 and the laser receiver 2. When checking, place them on the horizontal calibration straightedge respectively, connect the laser receiver 2 to the control display 4 through the data cable 3, start the laser emitter 1 so that its beam completely irradiates on the laser receiver 2. After the data on the control display 4 is stable, record the initial calibration data of the control display 4. When the initial calibration data is zero, there is no error between the laser emitter 1 and the laser receiver 2, and the check is completed.

[0049] In step S4: Start the laser emitter 1, press the light-emitting button, and the laser beam shoots towards the direction of the tensioner pulley 6; observe the laser landing point of the laser receiver 2. If it deviates from the center, rotate the horizontal adjustment knob of the laser receiver 2 until the beam is centered; synchronously and finely adjust the vertical angle of the laser emitter 1 to ensure that the beam is perpendicular to the end face.

[0050] An alignment device for a sprocket laser alignment process, comprising: a laser emitter 1 for emitting laser; the laser emitter 1 is arranged on one side of the end face of the crankshaft sprocket 5; a laser receiver 2 for receiving the laser emitted by the laser emitter 1; the laser receiver 2 is arranged on one side of the end face of the target pulley to be corrected; a horizontal calibration straightedge for beam parallelism check of the laser emitter 1 and the laser receiver 2; one end of the data cable 3 is connected to the receiver 2; the other end of the data cable 3 is connected to a control display 4; the position where the laser emitted by the laser emitter 1 irradiates on the laser receiver 2 is used to record the laser vertical direction deviation value through the control display 4, and according to the vertical direction deviation value, adjust the positions of the crankshaft sprocket 5 and the target pulley to be corrected to conduct the alignment of the crankshaft sprocket 5.

[0051] The surface of the laser receiver 2 is provided with a multi-directional adjustment mechanism, which can be finely adjusted in the horizontal and vertical directions to ensure that the beam is centered for reception.

[0052] The control display 4 integrates a data storage module, which supports real-time display, recording and export of the deviation value.

[0053] The parallel check of the light beam includes verifying the zero error between the laser emitter 1 and the laser receiver 2. After calibration, operate the display 4 to zero the reading.

[0054] The data line 3 is a shielded cable, resistant to electromagnetic interference, and the transmission signal error is less than 0.01%.

[0055] The adjustment mechanism of the laser receiver 2 includes a damping bearing to achieve stepless smooth rotation.

[0056] The preset vertical deviation value of the laser is ≤ 0.05 mm. When the limit is exceeded, operate the display 4 to trigger an alarm prompt.

[0057] The specific implementation method of this embodiment:

[0058] Step 1: Component installation and calibration

[0059] Equipment preparation: Check the integrity of the laser emitter 1, laser receiver 2, data line 3 and operation display 4 to ensure that all interfaces are undamaged.

[0060] Step 2: Light beam check:

[0061] Place the laser emitter 1 and the laser receiver 2 on the horizontal calibration straightedge respectively, with a spacing of 1 - 2 meters;

[0062] Connect the laser receiver 2 and the operation display 4 through the data line 3. Start the light-emitting button of the laser emitter 1 and observe whether the laser beam completely covers the center of the laser receiver 2;

[0063] If the reading on the operation display 4 is non-zero, adjust the calibration knob of the laser emitter 1 until the reading is zero to complete the parallel calibration.

[0064] Step 3: Installation and positioning:

[0065] Clean the end faces of the crankshaft sprocket 5 and the tensioner pulley 6 to remove oil stains and rust;

[0066] Fix the laser emitter 1 on one side of the end face of the crankshaft sprocket 5 through a magnetic base to ensure stable installation;

[0067] Install the laser receiver 2 on the same side of the end face of the tensioner pulley 6 and connect the data line 3 to the operation display 4.

[0068] Step 4: Light beam adjustment:

[0069] Start the laser emitter 1 and press the light-emitting button. The laser beam shoots towards the tensioner pulley 6;

[0070] Observe the laser landing point of the laser receiver 2. If it deviates from the center, rotate the horizontal adjustment knob of the laser receiver 2 until the light beam is centered;

[0071] Synchronously and finely adjust the vertical angle of the laser emitter 1 to ensure that the light beam is perpendicular to the end face.

[0072] Data recording and correction:

[0073] After the reading of the manipulation display 4 stabilizes, record the current vertical deviation value;

[0074] If the vertical deviation value exceeds the threshold: ≤0.05 mm, gradually correct its position by adjusting the positioning bolt of the tensioning wheel 6;

[0075] After each adjustment, re-detect the vertical deviation value until the reading of the manipulation display 4 meets the requirements.

[0076] Step Five: Multi-gear train collaborative alignment:

[0077] Repeat the above steps. As shown in Figure 2 、 Figure 3 Move the receiver 2 to the end faces of the balance wheel 7 and the large sprocket 8 in sequence to complete the independent calibration of each gear train;

[0078] Comprehensively analyze multiple groups of data to ensure that the vertical deviation values between all gear trains are balanced and avoid local stress concentration.

[0079] Disassembly and acceptance. After alignment is completed, turn off the laser emitter 1, disconnect the data cable 3, disassemble each component and store them;

[0080] Export the recorded data in the manipulation display 4 to generate an alignment report for filing and future reference;

[0081] Start the main engine for trial operation, monitor the noise and vibration of the sprocket meshing, and verify the alignment effect.

[0082] To improve adaptability, the laser emitter 1 and the laser receiver 2 can be equipped with laser modules of different powers, suitable for dim or strong light environments;

[0083] The built-in algorithm of the manipulation display 4 can automatically calculate the deviation trend and recommend the adjustment direction to further reduce manual intervention;

[0084] Regularly perform temperature drift compensation calibration on the laser components to ensure long-term use accuracy.

[0085] Through the above implementation methods, this process realizes the high-efficiency, precision, and digitization of sprocket alignment, significantly improving the assembly quality and reliability of diesel engines.

[0086] The above is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and should be covered within the protection scope of the present invention.

Claims

1. A laser alignment process for sprockets, characterized in that, Including the following steps: S1: Equipment preparation: Check the laser emitter (1), laser receiver (2), connecting data cable (3) and control display (4) to ensure that their interfaces are not damaged; S2: Beam alignment: Perform beam parallel alignment on the laser emitter (1) and the laser receiver (2). During alignment, place them on a horizontal calibration straightedge respectively. Connect the laser receiver (2) to the control display (4) through the data cable (3). Start the laser emitter (1) so that its beam completely irradiates on the laser receiver (2). After the data on the control display (4) stabilizes, record the initial calibration data of the control display (4). When the initial calibration data is zero, there is no error between the laser emitter (1) and the laser receiver (2), and the alignment is completed; S3: Installation and positioning: Fix the laser emitter (1) on one side of the end face of the crankshaft sprocket (5). The beam of the laser emitter (1) is parallel to the axis of the crankshaft sprocket (5). Install the laser receiver (2) on the same side end face of the tensioner pulley (6) and connect it to the control display (4) through the data cable (3); S4: Beam adjustment: Adjust the direction of the laser emitted by the laser emitter (1) so that it shoots towards the tensioner pulley (6). Then adjust the direction of the laser receiver (2) so that it receives the laser emitted by the laser receiver (2), and record the vertical direction deviation value between the crankshaft sprocket (5) and the tensioner pulley (6); S5: Multi-pulley system collaborative alignment: Repeat steps S3 - S5. The laser receiver (2) is successively installed on the same side end face of the balance wheel (7) and the large sprocket (8) to perform alignment between the crankshaft sprocket (5) and the balance wheel (7), and the large sprocket (8); Adjust the position of the pulley system according to the vertical direction deviation value until the reading on the control display (4) meets the preset vertical direction deviation value, and complete the alignment of the crankshaft sprocket (5).

2. The sprocket laser alignment process according to claim 1, wherein: In step S2: Perform beam parallel alignment on the laser emitter (1) and the laser receiver (2). During alignment, place them on a horizontal calibration straightedge respectively. Connect the laser receiver (2) to the control display (4) through the data cable (3). Start the laser emitter (1) so that its beam completely irradiates on the laser receiver (2). After the data on the control display (4) stabilizes, record the initial calibration data of the control display (4). When the initial calibration data is zero, there is no error between the laser emitter (1) and the laser receiver (2), and the alignment is completed.

3. A sprocket laser alignment process according to claim 2, characterized in that: In step S4: Start the laser emitter (1), press the light-emitting button, and the laser beam shoots towards the tensioner pulley (6); Observe the laser landing point of the laser receiver (2). If it deviates from the center, rotate the horizontal adjustment knob of the laser receiver (2) until the beam is centered; Synchronously and slightly adjust the vertical angle of the laser emitter (1) to ensure that the beam is perpendicular to the end face.

4. The alignment device for the sprocket laser alignment process according to claim 3, characterized in that: Including: A laser emitter (1) for emitting laser; the laser emitter (1) is arranged on one end face side of a crankshaft sprocket (5); a laser receiver (2) for receiving the laser emitted by the laser emitter (1); the laser receiver (2) is arranged on one end face side of a target wheel to be calibrated; a horizontal calibration straightedge for beam parallelism verification between the laser emitter (1) and the laser receiver (2); one end of the receiver (2) is connected with a data line (3); the other end of the data line (3) is connected with a control display (4); by irradiating the position of the laser receiver (2) with the laser emitted by the laser emitter (1), recording the laser vertical direction deviation value through the control display (4), and adjusting the positions of the crankshaft sprocket (5) and the target wheel to be calibrated according to the vertical direction deviation value to perform alignment of the crankshaft sprocket (5).

5. A sprocket laser alignment device according to claim 4, characterized in that: A multi-directional adjustment mechanism is provided on the surface of the laser receiver (2), which can be finely adjusted in the horizontal and vertical directions to ensure centered reception of the beam.

6. The sprocket laser alignment device according to claim 5, wherein: The control display (4) integrates a data storage module, supporting real-time display, recording and export of deviation values.

7. A sprocket laser alignment device according to claim 6, characterized in that: The beam parallelism verification includes verifying the zero error between the laser emitter (1) and the laser receiver (2), and the indication of the control display (4) returns to zero after calibration.

8. A sprocket laser alignment device according to claim 7, characterized in that: The data line (3) is a shielded cable, resistant to electromagnetic interference, and the transmission signal error is less than 0.01%.

9. A sprocket laser alignment device according to claim 8, characterized in that: The adjustment mechanism of the laser receiver (2) includes a damping bearing to achieve stepless smooth rotation.

10. A sprocket laser alignment device according to claim 9, characterized in that: The preset laser vertical direction deviation value ≤ 0.05 mm, and when the limit is exceeded, the control display (4) triggers an alarm prompt.

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