Gear shaft coupling press-fitting device and press-fitting method thereof

Abstract

The invention relates to a gear shaft coupler press fitting device which comprises a first bearing, a shaft, a transmission pinion, a second bearing, a first supporting plate, a half coupler, a second supporting plate, a first fixing plate, a piston rod, a connecting plate, a base and a second fixing plate. The half coupling penetrates and is fixed to the shaft, the first supporting plate, the second supporting plate, the first fixing plate and the second fixing plate are all welded to the base, and the piston rod extends out of a hole of the first fixing plate, penetrates into a hole of the half coupling and abuts against the end face of the shaft; the pressure sensor is installed in a blind hole of the piston rod, and the displacement sensor is fixed to the first fixing plate through two fixing bolts. According to the scheme, manual press fitting is replaced with mechanical press fitting, pressure is adjusted in a self-adaptive mode, efficiency is high, precision is high, and the labor intensity of workers is greatly relieved.

Description

Technical Field

[0001] This invention relates to a pressing device, specifically a pressing device for gear shaft couplings, belonging to the fields of hydraulic technology and mining machinery. It is particularly suitable for efficient, precise, and safe pressing operations of gear shaft couplings with large shaft diameters and long shaft bodies. Background Technology

[0002] This invention relates to the field of mechanical assembly technology, specifically to a press-fitting and disassembly device and method for gear shafts and couplings (especially half-couplings) in the transmission system of large mining machinery (such as ball mills). In large mining equipment, such as the MQS2736 wet grate ball mill used by Meishan Mining, the transmission system typically uses a small gear driving a large gear on the outer edge of the ball mill cylinder. As a key piece of equipment in the ball mill, the support bearing of the transmission pinion shaft inevitably wears under long-term high-load operation, leading to increased bearing vibration and temperature, requiring periodic bearing replacement. When replacing the bearing, the half-coupling on the pinion shaft must first be disassembled. However, the pinion shaft of such ball mills is characterized by a large shaft diameter (Φ190mm) and a long shaft length (1.8m). Existing press-fitting technology faces significant difficulties:

[0003] 1. Huge pressing force required: Disassembling and installing such a large interference fit coupling requires extremely high pressing or pressing force (usually requiring a press of 200 tons or more).

[0004] 2. Poor equipment adaptability: Ordinary workshop presses are often unable to be directly used for pressing such long shaft components due to limitations in worktable size, stroke or tonnage.

[0005] 3. High outsourcing costs and long cycles: Each disassembly or installation of the coupling requires transporting the entire pinion shaft assembly to a specialized outsourcing factory with large press capabilities. A single outsourcing press-fitting process typically takes 3 to 5 days, which not only severely prolongs the equipment maintenance cycle and affects production continuity, but also incurs high costs, with an average annual cost of around 150,000 yuan.

[0006] 4. High labor intensity, low precision, and high risk: If on-site manual or simple mechanical pressing is attempted, not only will the efficiency be low and the precision be difficult to guarantee, but the labor intensity of the operators will also be extremely high, and there will be high safety risks (such as workpiece breakage, tool damage, etc.).

[0007] Therefore, there is an urgent need to develop a special device that can be used directly at the equipment maintenance site for press-fitting large-diameter, long-shaft gear couplings, in order to solve the aforementioned issues of efficiency, cost, accuracy, and safety. Summary of the Invention

[0008] This invention addresses the technical problems existing in the prior art by providing a gear shaft coupling press-fitting device and its press-fitting method. The technical solution is ingeniously designed and compact in structure, and the press-fitting device is designed with a hydraulic system. Through the combination of hydraulic components and sensors, the press-fitting pressure and press-fitting stroke can be arbitrarily set to meet the requirements of multiple applications.

[0009] To achieve the above objectives, the technical solution of the present invention is as follows: a gear shaft coupling press-fitting device, the device comprising a first bearing, a shaft, a transmission pinion, a second bearing, a first support plate, a half coupling, a second support plate, a first fixing plate, a piston rod, a connecting plate, a base, and a second fixing plate. The first bearing, the second bearing, and the transmission pinion are all mounted on the shaft. The half coupling is inserted and fixed on the shaft. The first support plate, the second support plate, the first fixing plate, and the second fixing plate are all welded to the base. The piston rod extends from the hole in the first fixing plate, passes through the hole in the half coupling, and presses against the end face of the shaft. A pressure sensor is installed in the blind hole of the piston rod, and a displacement sensor is fixed to the first fixing plate by two fixing bolts. Furthermore, the pressing device is equipped with a hydraulic system, the hydraulic system circuit of which includes a hydraulic cylinder, hydraulic oil pipes, a relief valve, a hydraulic oil pump, a proportional solenoid valve, a pressure gauge, a motor, a filter element, and a coupling. The lower end of the filter element is connected to the oil tank via a hydraulic oil pipe, and the upper end is connected to the lower port of the hydraulic oil pump. The upper port of the hydraulic oil pump is connected to the lower left port of the proportional solenoid valve, the upper left port of the proportional solenoid valve is connected to the rodless chamber of the hydraulic cylinder via a hydraulic oil pipe, and the upper right port of the proportional solenoid valve is connected to the rod chamber of the hydraulic cylinder via a hydraulic oil pipe. The relief valve and the pressure gauge are connected to the upper port of the hydraulic oil pump via hydraulic oil pipes. The hydraulic oil pump is connected to the motor via a coupling.

[0010] Furthermore, a blind hole with a matching diameter is machined at the top of the piston rod, and a thread is machined at the bottom of the hole. The pressure sensor is screwed onto the thread. The displacement sensor is fixed to the first fixing plate by two fixing bolts, and the magnetic ring is installed on the piston rod. The displacement stroke of the piston rod is calculated accordingly through the signal sensing between the two.

[0011] Furthermore, the first support plate is fixed to the connecting plate by two connecting bolts A, the second support plate is fixed to the connecting plate by two connecting bolts B, the first fixing plate is fixed to the connecting plate by two connecting bolts C, and the second fixing plate is fixed to the connecting plate by two connecting bolts D; the left side of the hydraulic cylinder is fixed to the first fixing plate by four connecting bolts E, and the right side of the hydraulic cylinder is fixed to the second fixing plate by four connecting bolts F.

[0012] Furthermore, the pressing method is as follows:

[0013] Coupling press-out:

[0014] 1. Hoist the ball mill gear shaft assembly to this pressing platform, and use the U-shaped slots G of the first and second support plates to hold the ball mill gear shaft in place, and connect the connecting plates.

[0015] 2. Input the press-fit pressure into the control module;

[0016] 3. Start the motor to make the hydraulic oil pump work;

[0017] 4. The control module energizes the right end of the proportional solenoid valve, causing the hydraulic cylinder to move;

[0018] 5. The hydraulic cylinder piston rod extends out from the hole in the fixed plate, enters the hole in the half coupling, and presses against the cross-section of the shaft;

[0019] 6. The hydraulic system continues to pressurize, and the piston rod slowly pushes the shaft out of the hole in the half coupling;

[0020] 7. When the pressure sensor detects no pressure, the shaft and coupling are separated; the control module energizes the left end of the proportional solenoid valve, the piston rod retracts, and the entire process is completed.

[0021] Coupling press-in:

[0022] 1. Hoist the ball mill gear shaft assembly to this pressing platform, slightly insert the half coupling into the shaft, and support the half coupling through the U-shaped grooves of the first and second support plates;

[0023] 2. Fix the other end of the shaft so that it cannot move axially;

[0024] 3. Input the pressing pressure and pressing stroke into the control module;

[0025] 4. Start the motor to make the hydraulic oil pump work;

[0026] 5. The control module energizes the right end of the proportional solenoid valve, causing the hydraulic cylinder to move;

[0027] 6. The piston rod of the hydraulic cylinder extends out from the hole in the fixed plate and presses against the end face of the half coupling;

[0028] 7. The hydraulic system continues to pressurize. When the pressure sensor detects that the set pressure has been reached, the current set pressure is maintained and continuously output. The piston rod slowly pushes the half coupling into the shaft hole. When the displacement sensor detects that the pressing stroke has been reached, the control module controls the proportional solenoid valve to stop the hydraulic oil pump from loading, thus completing the reinstallation of the coupling and shaft.

[0029] 8. The control module energizes the left end of the proportional solenoid valve, causing the piston rod to retract and completing all actions in the process.

[0030] This solution mechanizes the pressing of gear shaft couplings. Depending on the site conditions, it can be either pressed or pressed without the need for maintenance personnel, reducing labor intensity; it shortens the maintenance cycle, as a single pressing operation that used to take 3-5 days can now be completed in just one day; the pressing pressure can be adjusted arbitrarily according to the specific site conditions, making it widely applicable; and it improves maintenance efficiency, as the device and method can eliminate equipment failures and restore equipment operation in a short time.

[0031] Compared with the prior art, the present invention has the following significant advantages:

[0032] 1. High efficiency and convenience, on-site operation: The device has a compact design and can be used directly on the equipment maintenance site, completely avoiding the cumbersome process of sending the heavy gear shaft assembly for pressing; the maintenance cycle has been greatly shortened from the original 3-5 days to less than 1 day, which greatly improves the availability of equipment.

[0033] 2. Mechanized operation reduces labor intensity and risk: Hydraulic drive replaces manual hammering or simple machinery, providing stable and powerful pressing force. Operators only need to input pressing parameters, greatly reducing labor intensity and eliminating safety hazards caused by manual intervention (such as workpiece splashing, tool breakage, etc.).

[0034] 3. Controllable pressure and wide applicability: The hydraulic system is equipped with a proportional solenoid valve and pressure gauge, which can accurately set and display the press-fitting pressure. This allows the device to flexibly adapt to the needs of different sized couplings, different interference fits, and different working conditions (press-in or press-out), making it highly versatile.

[0035] 4. Stable structure and precise positioning: The rigid overall frame composed of the base, support plate, fixing plate and connecting plate, as well as the U-shaped groove on the support plate and the guide hole on the first fixing plate, ensures the precise positioning and stable support of the gear shaft assembly and half coupling during the working process, effectively prevents off-center load, ensures the straightness and concentricity of the pressing process, improves the pressing quality and avoids damage to the workpiece.

[0036] 5. Two-way operation: By controlling the proportional solenoid valve, the same device can complete both the pressing out (disassembly) and pressing in (installation) of the coupling, making it fully functional.

[0037] 6. Significant economic benefits: It eliminates the high cost of outsourcing press-fitting (approximately RMB 150,000 per year), and at the same time, it greatly reduces production losses caused by equipment downtime due to the significantly shortened maintenance time, resulting in outstanding overall economic benefits.

[0038] 7. Improved maintenance quality and efficiency: Precise and controllable pressure and stroke, along with stable positioning, ensure reliable press-fit quality. The fast and efficient press-fit process allows equipment malfunctions to be repaired and operational again in a short time. Attached Figure Description

[0039] Figure 1 Structural diagram of the press fitting device

[0040] Figure 2 Fixed connection plate structure diagram

[0041] Figure 3 Hydraulic system diagram

[0042] Figure 4 Sensor installation diagram

[0043] Figure 5 Control system schematic diagram

[0044] In the diagram: 1. First bearing, 2. Shaft, 3. Transmission pinion, 4. Second bearing, 5. First support plate, 6. Half coupling, 7. Second support plate, 8. First fixing plate, 9. Hydraulic cylinder, 10. Piston rod, 11. Connecting plate, 12. Base, 13. Second fixing plate, 14. Hydraulic oil pipe, 15. Overflow valve, 16. Hydraulic oil pump, 17. Proportional solenoid valve, 18. Pressure gauge, 19. Bolt connection hole, 20. Piston rod through hole, 21. Motor, 22. Filter element, 23. Coupling, 24. Pressure sensor, 25. Magnetic ring, 26. Displacement sensor, 27. Fixing bolt, 28. Wiring harness, 29. Control module connecting bolt A, connecting bolt B, connecting bolt C, connecting bolt D, connecting bolt E, connecting bolt F, U-shaped groove G. Detailed Implementation

[0045] To enhance understanding of the present invention, the embodiments will be described in detail below with reference to the accompanying drawings.

[0046] Example 1: See Figure 1 , Figure 2A gear shaft coupling press-fitting device includes a first bearing 1, a shaft 2, a transmission pinion 3, a second bearing 4, a first support plate 5, a half-coupling 6, a second support plate 7, a first fixing plate 8, a hydraulic cylinder 9, a piston rod 10, a connecting plate 11, a base 12, and a second fixing plate 13. The first bearing 1, the second bearing 4, and the transmission pinion 3 are all mounted on the shaft 2. The half-coupling 6 is inserted and fixed to the shaft 2. The first support plate 5, the second support plate 7, the first fixing plate 8, and the second fixing plate 13 are all welded to the base 12. The first support plate 5 is fixed to the connecting plate 11 by two connecting bolts A. The second support plate 9... Support plate 7 is fixed to connecting plate 11 by two connecting bolts B, first fixing plate 8 is fixed to connecting plate 11 by two connecting bolts C, and second fixing plate 13 is fixed to connecting plate 11 by two connecting bolts D. The left side of hydraulic cylinder 9 is fixed to the first fixing plate 8 by four connecting bolts E, and the right side of hydraulic cylinder 9 is fixed to the second fixing plate 13 by four connecting bolts F. Piston rod 10 extends from the hole in the first fixing plate 8, passes through the hole in half-coupling 6, and presses against the end face of shaft 2. Pressure sensor 24 is installed in the blind hole of piston rod 10, and displacement sensor 26 is fixed to the first fixing plate 8 by two fixing bolts 27. This scheme realizes the mechanization of press-fitting of gear shaft couplings. Depending on the site conditions, it can be either pressed or pushed, without the need for maintenance personnel intervention, reducing labor intensity; it shortens the maintenance cycle, from 3-5 days for external press-fitting to only one day; the press-fitting pressure can be adjusted arbitrarily according to the specific site conditions, with a wide range of applications; it improves maintenance efficiency, and using this device and method can eliminate equipment failures and restore equipment operation in a short time.

[0047] Working principle explanation:

[0048] The working principle of this gear shaft coupling press-fitting device and its press-fitting method is as follows:

[0049] Coupling ejection: First, fix the half coupling, extend the hydraulic cylinder piston rod, insert it into the half coupling hole, press against the shaft cross-section, and slowly push the shaft out of the half coupling hole to complete the separation of the coupling and the shaft.

[0050] Coupling installation: First, fix the shaft, align the hole and slightly insert the coupling into the shaft. Extend the piston rod of the hydraulic cylinder, press against the end face of the coupling, and slowly push the coupling into the shaft to complete the reinstallation of the coupling and shaft.

[0051] This example demonstrates how the process works:

[0052] from Figures 1 to 5 As can be seen, the specific working process of the gear shaft coupling press-fitting device and its press-fitting method of the present invention is as follows:

[0053] Coupling press-out:

[0054] 1. Hoist the ball mill gear shaft assembly to this pressing platform, and use the U-shaped slots G of the support plates 5 and 7 to hold the ball mill gear shaft in place, and connect the connecting plate 11.

[0055] 2. Input the pressing pressure in control module 29;

[0056] 3. Start motor 21 to make hydraulic oil pump 16 work;

[0057] 4. The control module 29 energizes the right end of the proportional solenoid valve 17, causing the hydraulic cylinder 9 to actuate;

[0058] 5. The hydraulic cylinder piston rod 10 extends out of the hole in the fixed plate 8 and into the hole in the half coupling 6, pressing against the cross-section of the shaft 2; 6. The hydraulic system continues to pressurize, and the piston rod 10 slowly pushes the shaft 2 out of the hole in the half coupling 6.

[0059] 7. When the pressure sensor 24 senses no pressure, the shaft and coupling have separated; the control module 29 energizes the left end of the proportional solenoid valve 17, and the piston rod 10 retracts, completing all actions of the process.

[0060] Coupling press-in:

[0061] 1. Hoist the ball mill gear shaft assembly to this pressing platform, and slightly insert the half coupling 6 into the shaft 2. Support the half coupling 6 through the U-shaped groove G of the support plates 5 and 7.

[0062] 2. Fix the other end of shaft 2 so that it cannot move axially;

[0063] 3. Input the pressing pressure and pressing stroke in the control module 29;

[0064] 4. Start motor 21 to make hydraulic oil pump 16 work;

[0065] 5. Control module 29 energizes the right end of proportional solenoid valve 17, causing hydraulic cylinder 9 to actuate;

[0066] 6. The hydraulic cylinder piston rod 10 extends out from the hole in the fixed plate 8 and presses against the end face of the half coupling;

[0067] 7. The hydraulic system continues to pressurize. When the pressure sensor 24 detects that the set pressure has been reached, it maintains the current set pressure output. The piston rod 10 slowly pushes the half coupling 6 into the hole of the shaft 2. When the displacement sensor 26 detects that the pressing stroke has been reached, the control module 29 controls the proportional solenoid valve 17 to stop the hydraulic oil pump from loading, completing the reinstallation of the coupling and shaft. 8. The control module 29 energizes the left end of the proportional solenoid valve 17, causing the piston rod 10 to retract, completing all actions of this process.

[0068] It should be noted that the above embodiments are not intended to limit the scope of protection of the present invention. Equivalent transformations or substitutions made based on the above technical solutions all fall within the scope of protection of the claims of the present invention.

Claims

1. A gear shaft coupling press-fitting device, characterized in that, The device includes a first bearing, a shaft, a transmission pinion, a second bearing, a first support plate, a half-coupling, a second support plate, a first fixed plate, a piston rod, a connecting plate, a base, and a second fixed plate. The first bearing, the second bearing, and the transmission pinion are all mounted on the shaft. The half-coupling is inserted into and fixed on the shaft. The first support plate, the second support plate, the first fixed plate, and the second fixed plate are all welded to the base. The piston rod extends from the hole in the first fixed plate, passes through the hole in the half-coupling, and presses against the end face of the shaft. A pressure sensor is installed in the blind hole of the piston rod, and a displacement sensor is fixed to the first fixed plate by two fixing bolts.

2. The gear shaft coupling press-fitting device according to claim 1, characterized in that, The pressing device is equipped with a hydraulic system, the hydraulic system circuit of which includes a hydraulic cylinder, hydraulic oil pipes, a relief valve, a hydraulic oil pump, a proportional solenoid valve, a pressure gauge, a motor, a filter element, and a coupling. The lower end of the filter element is connected to the oil tank via a hydraulic oil pipe, and the upper end is connected to the lower port of the hydraulic oil pump. The upper port of the hydraulic oil pump is connected to the lower left port of the proportional solenoid valve, the upper left port of the proportional solenoid valve is connected to the rodless chamber of the hydraulic cylinder via a hydraulic oil pipe, and the upper right port of the proportional solenoid valve is connected to the rod chamber of the hydraulic cylinder via a hydraulic oil pipe. The relief valve and the pressure gauge are connected to the upper port of the hydraulic oil pump via hydraulic oil pipes. The hydraulic oil pump is connected to the motor via a coupling.

3. The gear shaft coupling press-fitting device according to claim 1, characterized in that, A blind hole of matching diameter is machined at the top of the piston rod, and a thread is machined at the bottom of the hole. The pressure sensor is screwed onto the thread. The displacement sensor is fixed to the first fixing plate by two fixing bolts, and the magnetic ring is installed on the piston rod. The displacement stroke of the piston rod is calculated by sensing the signal between the two.

4. The gear shaft coupling press-fitting device according to claim 2, characterized in that, The first support plate is fixed to the connecting plate by two connecting bolts A, the second support plate is fixed to the connecting plate by two connecting bolts B, the first fixing plate is fixed to the connecting plate by two connecting bolts C, and the second fixing plate is fixed to the connecting plate by two connecting bolts D; the left side of the hydraulic cylinder is fixed to the first fixing plate by four connecting bolts E, and the right side of the hydraulic cylinder is fixed to the second fixing plate by four connecting bolts F.

5. The gear shaft coupling press-fitting device according to claim 2, characterized in that, The pressing method is as follows: Coupling press-out 1) Hoist the ball mill gear shaft assembly to this pressing platform, and use the U-shaped slots G of the first and second support plates to hold the ball mill gear shaft in place, and connect the connecting plates. 2) Input the press-fit pressure in the control module; 3) Start the motor to make the hydraulic oil pump work; 4) The control module energizes the right end of the proportional solenoid valve, causing the hydraulic cylinder to move; 5) The piston rod of the hydraulic cylinder extends out from the hole in the fixed plate, enters the hole in the half coupling, and presses against the cross section of the shaft; 6) The hydraulic system continues to pressurize, and the piston rod slowly pushes the shaft out of the hole in the half coupling; 7) When the pressure sensor detects no pressure, the shaft and coupling have separated; the control module energizes the left end of the proportional solenoid valve, causing the piston rod to retract, completing the entire process. Coupling press-in, 1) Hoist the ball mill gear shaft assembly to this pressing platform, slightly insert the half coupling into the shaft, and support the half coupling through the U-shaped grooves of the first and second support plates; 2) Fix the other end of the shaft so that it cannot move axially; 3) Input the pressing pressure and pressing stroke into the control module; 4) Start the motor to make the hydraulic oil pump work; 5) The control module energizes the right end of the proportional solenoid valve, causing the hydraulic cylinder to move; 6) The piston rod of the hydraulic cylinder extends out from the hole in the fixed plate and presses against the end face of the half coupling; 7) The hydraulic system continues to pressurize. When the pressure sensor detects that the set pressure has been reached, the current set pressure is maintained and continuously output. The piston rod slowly pushes the half coupling into the shaft hole. When the displacement sensor detects that the pressing stroke has been reached, the control module controls the proportional solenoid valve to stop the hydraulic oil pump from loading, thus completing the reinstallation of the coupling and shaft. 8) The control module energizes the left end of the proportional solenoid valve, causing the piston rod to retract, thus completing the entire process.

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