A gear processing device for new energy vehicles

Abstract

This invention discloses a gear processing device for new energy vehicles, including a base and a feeding mechanism, a conveying mechanism, a chamfering mechanism, and a blanking mechanism mounted thereon. The chamfering mechanism consists of an upper chamfering assembly and a lower chamfering assembly positioned opposite each other. The upper chamfering assembly is integrated into the conveying mechanism and also functions as a clamping and conveying unit. It includes an upper positioning seat with a first positioning shaft section, a drive unit, and a clamping assembly with a built-in electromagnet module and spring. The lower chamfering assembly is fixed to the base and includes a lower chamfering seat with a lower grinding surface and a lower positioning seat. This invention achieves simultaneous chamfering of the upper and lower end faces of the gear teeth in one operation through the grinding surfaces integrated in the upper and lower chamfering seats, effectively avoiding secondary clamping errors and significantly improving processing efficiency and consistency. The device also features a chip suction system and a baffle, optimizing the working environment, and can be configured with a dual-station conveying system to further realize parallel production, making it suitable for automated precision machining of gears for new energy vehicles.

Description

Technical Field

[0001] This invention belongs to the field of gear processing technology, and specifically relates to a gear processing device for new energy vehicles. Background Technology

[0002] As a core component in the field of mechanical transmission, the chamfering of gear tooth edges plays a crucial role in reducing stress concentration, improving fatigue strength, ensuring smooth transmission, and facilitating assembly. In the field of new energy vehicles, even more stringent requirements are placed on gear processing efficiency, precision, and consistency.

[0003] Currently, the conventional process for chamfering the tooth edges of gears mainly relies on single-machine, single-sided machining. This means that after chamfering one end face of the gear, the gear must be removed from the fixture, flipped, and repositioned before chamfering the other end face. This double-clamping process not only significantly reduces production efficiency and fails to meet the demands of large-scale automated production, but also inevitably introduces repetitive positioning errors, making it difficult to guarantee the consistency of the chamfers at both ends of the gear, directly affecting product quality and reliability.

[0004] Therefore, there is an urgent need in this field for an automated chamfering processing device that integrates high efficiency, precision, and stability, and is especially suitable for gear production lines of new energy vehicles, so as to achieve high-quality and high-efficiency one-time synchronous forming of the tooth edges on both ends of the gear. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution.

[0006] A gear processing device for new energy vehicles includes a base platform on which a chamfering mechanism is mounted. The chamfering mechanism includes an upper chamfering assembly and a lower chamfering assembly. The upper chamfering assembly includes an upper chamfering seat, an upper positioning seat, a clamping assembly, and a drive unit. The lower chamfering assembly includes a lower chamfering seat and a lower positioning seat.

[0007] The upper chamfering seat is provided with an upper receiving groove, and the connection between the bottom wall and the side wall of the upper receiving groove forms an upper grinding surface for chamfering the tooth edge of the upper end face of the gear. An upper positioning seat is rotatably mounted on the upper chamfering seat, and the upper positioning seat is provided with a first positioning shaft section that extends into the upper receiving groove and is used to pass through the mounting hole in the middle of the gear. A clamping assembly is disposed on the first positioning shaft section and is used to clamp the gear by tightening the mounting hole. A drive unit is connected to the upper positioning seat and is used to drive the upper positioning seat and the clamped gear to rotate together.

[0008] The lower chamfering seat is disposed opposite to the upper chamfering seat. The lower chamfering seat has a lower receiving groove, and the connection between the bottom wall and the side wall of the lower receiving groove forms a lower grinding surface for chamfering the tooth edge of the lower end face of the gear. The lower positioning seat is rotatably mounted on the lower chamfering seat and located in the lower receiving groove. It is used to radially position the gear together with the first positioning shaft section when the gear falls. By tightening the inner hole of the gear with the clamping assembly of the upper positioning seat and driving it to rotate with the drive unit, and by the coordinated radial limiting of the lower positioning seat, the gear is ensured to be accurately positioned and rotate stably during the chamfering process, effectively improving the machining accuracy and surface quality of the chamfer.

[0009] In a preferred embodiment of a gear processing device for new energy vehicles, the clamping assembly includes an electromagnet module, a limiting block, a stop block, a guide rod, and a spring. The electromagnet module is disposed inside the first positioning shaft section. The limiting block is slidably disposed radially along the first positioning shaft section and opposite to the electromagnet module; the electromagnet module is configured to attract the limiting block when energized. The stop block is slidably disposed radially along the first positioning shaft section and located outside the limiting block. The guide rod connects the limiting block and the stop block. The spring is sleeved on the guide rod, with its two ends abutting against the stop block and the inner wall of the first positioning shaft section, respectively, providing an outward elastic force to the stop block.

[0010] The first positioning shaft section has an opening on its outer periphery for the abutment to extend out, and the inner wall of the gear mounting hole has a keyway adapted to the abutment. When the electromagnet module is de-energized, the spring pushes the abutment radially outward into the keyway to tighten and clamp the gear. The clamping assembly controlled by the electromagnet module achieves rapid and automated tooling clamping and release of the gear, with fast response speed, high integration, and suitability for automated production.

[0011] In a preferred embodiment of a gear processing device for new energy vehicles, the surface of the abutment block has a friction layer. This friction layer increases the friction between the abutment block and the gear keyway contact surface, making the clamping more secure and reliable.

[0012] In a preferred embodiment of a gear processing device for new energy vehicles, the lower chamfering seat is provided with a suction channel. One end of the suction channel leads to the bottom of the lower receiving groove, and the other end is provided with a suction interface for connecting to an external suction system. This allows for the timely removal of metal chips and dust generated during the chamfering process and falling into the lower receiving groove, maintaining the cleanliness of the processing area.

[0013] In a preferred embodiment of a gear processing device for new energy vehicles, both the upper and lower chamfering seats are detachably equipped with baffles to prevent metal chips generated during chamfering from flying out. The baffles effectively block high-speed flying metal chips during chamfering, ensuring the cleanliness of the base surface.

[0014] As a preferred embodiment of a gear processing device for new energy vehicles, the shield is made of soft rubber material, which has a good blocking effect and will not cause hard impact damage to the gears or equipment in the event of accidental contact.

[0015] In a preferred embodiment of a gear processing device for new energy vehicles, the end of the first positioning shaft segment is provided with a second positioning shaft segment with a diameter smaller than its own; the lower positioning seat is provided with an upwardly protruding third positioning shaft segment, and the top of the third positioning shaft segment is provided with a positioning groove that mates with the second positioning shaft segment. This design achieves precise alignment of the upper and lower positioning shaft segments.

[0016] A preferred embodiment of a gear processing device for new energy vehicles further includes a feeding mechanism, a conveying mechanism, and a unloading mechanism. The feeding mechanism, used for conveying gears, includes a conveyor belt, a stop bar at the end of the conveyor belt, and stop plates on both sides of the conveyor belt. The conveying mechanism includes a mounting frame, a two-axis moving module mounted on the mounting frame, and a mounting plate driven by the two-axis moving module; the upper chamfering assembly is mounted on the mounting plate. The unloading mechanism is located downstream of the chamfering mechanism and is used to receive the chamfered gears.

[0017] As a preferred embodiment of a gear processing device for new energy vehicles, the feeding mechanism further includes a limiting component, which includes a limiting cylinder and a limiting rack driven by the limiting cylinder. The limiting rack is configured to mesh with the gear being conveyed to limit its rotation.

[0018] In a preferred embodiment of a gear processing device for new energy vehicles, the mounting plate is equipped with two sets of upper chamfering components. One set of upper chamfering components is used to transport the gear from the feeding mechanism to the lower chamfering component for chamfering, while the other set is used to transport the chamfered gear from the lower chamfering component to the unloading mechanism. By setting up two sets of upper chamfering components, parallel operation of processing and loading / unloading is achieved. When one set of upper chamfering components is performing loading and chamfering, the other set of mechanisms can simultaneously perform unloading, improving production efficiency.

[0019] Compared with the prior art, this application has the following beneficial technical effects: by setting up upper and lower chamfer seats that are opposite each other, and integrating the upper and lower grinding surfaces respectively, the one-time synchronous chamfering of the upper and lower end face tooth edges of the gear is realized, which greatly improves the processing efficiency and consistency and avoids the errors caused by secondary clamping. Attached Figure Description

[0020] Figure 1 This is a three-dimensional view of a gear processing device.

[0021] Figure 2This is a front view of the gear machining device.

[0022] Figure 3 This is a top view of the gear machining device.

[0023] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0024] Figure 5 This is a structural diagram of the upper chamfer component.

[0025] Figure 6 This is a structural diagram of the lower chamfer assembly.

[0026] Figure 7 A partial cross-section of the chamfering mechanism during chamfering. Figure 1 .

[0027] Figure 8 A partial cross-section of the chamfering mechanism during chamfering. Figure 2 .

[0028] The following is an explanation of the reference numerals in the attached figures:

[0029] 1. Abutment;

[0030] 2. Chamfering mechanism; 20. Upper chamfering assembly; 21. Upper chamfering seat; 210. Upper receiving groove; 211. Upper polished surface; 22. Upper positioning seat; 220. First positioning shaft section; 221. Second positioning shaft section; 23. Drive unit; 24. Clamping assembly; 240. Electromagnet module; 241. Limit block; 242. Abutment block; 243. Guide rod; 244. Spring; 25. Lower chamfering assembly; 26. Lower chamfering seat; 260. Lower receiving groove; 261. Lower polished surface; 262. Suction channel; 263. Suction interface; 27. Lower positioning seat; 270. Third positioning shaft section; 271. Positioning groove; 28. Baffle;

[0031] 3. Handling mechanism; 30. Mounting bracket; 31. Two-axis moving module; 32. Mounting plate;

[0032] 4. Feeding mechanism; 40. Conveyor belt; 41. Material stop bar; 42. Material stop plate; 43. Limiting assembly; 431. Limiting cylinder; 432. Limiting rack;

[0033] 5. Material feeding mechanism;

[0034] 6. Gear; 61. Assembly hole; 62. Keyway. Detailed Implementation

[0035] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0036] In the following embodiments, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0037] In the description of this invention, it should be understood that terms such as center, longitudinal, transverse, length, width, thickness, upper, lower, front, rear, left, right, vertical, horizontal, top, bottom, inner, outer, clockwise, counterclockwise, etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing and simplifying the description of this invention; therefore, they should not be construed as limiting this invention. Furthermore, terms such as first, second, etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features shown. In the description of this invention, unless otherwise expressly specified and limited, terms such as installation, connection, linking, etc., should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0038] This invention provides a gear processing device for new energy vehicles, with reference to... Figures 1 to 8 The device includes a base 1, and a chamfering mechanism 2, a feeding mechanism 4, a conveying mechanism 3 and a unloading mechanism 5 integrated on the base 1, which together constitute a complete gear 6 processing system.

[0039] The feeding mechanism 4 is responsible for conveying the gear 6 to be processed. It includes a conveyor belt 40, a baffle strip 41 at the end of the conveyor belt 40, and baffle plates 42 distributed on both sides of the conveyor belt 40. The cooperation of these structures guides and limits the conveying process of the gear 6. The chamfering mechanism 2, as the core processing unit, adopts a split design of upper and lower chamfering components 25. The upper chamfering component 20 integrates the dual functions of clamping and conveying and upper end face chamfering, including an upper chamfering seat 21, an upper positioning seat 22, a drive unit 23, and a clamping component 24. The lower chamfering component 25 is fixedly set on the base 1 and is responsible for the chamfering and positioning of the lower end face of the gear 6. It includes a lower chamfering seat 26 and a lower positioning seat 27. The conveying mechanism 3 undertakes the task of transferring the gear 6 between various workstations. It includes a mounting frame 30, a two-axis moving module 31 set on the mounting frame 30, and a mounting plate 32 driven by the two-axis moving module 31. The upper chamfering component 20 is mounted on the mounting plate 32. The blanking mechanism 5 is located downstream of the chamfering mechanism 2 and is used to receive and guide the finished gear 6.

[0040] like Figures 5 to 8As shown, in the specific implementation of the upper chamfering assembly 20, the upper chamfering seat 21 is fixedly installed on the mounting plate 32 of the conveying mechanism 3. The upper chamfering seat 21 is provided with an upper receiving groove 210, and the connection between its bottom wall and side wall forms an upper grinding surface 211, which is used to chamfer the tooth edge of the upper end face of the gear 6. The upper positioning seat 22 is rotatably mounted in the upper chamfering seat 21 through a bearing structure, and its lower end extends to form a first positioning shaft section 220. This shaft section is located in the upper receiving groove 210 and is used to insert into the mounting hole 61 at the center of the gear 6. The drive unit 23 is connected to the upper positioning seat 22 for transmission, providing power for the rotation of the gear 6. The clamping assembly 24 is disposed inside the first positioning shaft section 220 and includes an electromagnet module 240 fixed inside the shaft section, a limiting block 241 and a stop block 242 that are slidably disposed in the radial direction, a guide rod 243 that connects the limiting block 241 and the stop block 242, and a spring 244 that is sleeved on the guide rod 243 and provides continuous outward elastic force.

[0041] The clamping assembly 24 is configured as follows: When the electromagnet module 240 is de-energized, the spring 244 pushes the abutment block 242 radially outward. If the first positioning shaft section 220 has already been inserted into the gear 6 assembly hole 61 and the abutment block 242 is aligned with the keyway 62 inside the hole, the abutment block 242 automatically engages with the keyway 62 to achieve radial tension. When it is necessary to release the gear 6, the electromagnet module 240 is energized to generate magnetic force, attracting the limiting block 241 to move inward. Through the guide rod 243, the abutment block 242 retracts against the force of the spring 244, thereby releasing the clamp. To further enhance the transmission reliability, a friction layer can be provided on the working surface of the abutment block 242 to significantly improve the friction between it and the keyway 62.

[0042] In the embodiment of the lower chamfering assembly 25, the lower chamfering seat 26 is fixed to the base 1 and aligned with the upper chamfering seat 21. It is provided with a lower receiving groove 260, and the connection between the bottom wall and side wall of the lower receiving groove 260 forms a lower grinding surface 261 for chamfering the tooth edge of the lower end face of the gear 6. The lower positioning seat 27 is rotatably mounted in the lower chamfering seat 26 via bearings, and during processing, it works in conjunction with the first positioning shaft section 220 to complete the radial positioning of the gear 6. To ensure the alignment accuracy of the upper and lower assemblies, a second positioning shaft section 221 with a smaller diameter is provided at the end of the first positioning shaft section 220. Simultaneously, a third positioning shaft section 270 with a positioning groove 271 is provided on the lower positioning seat 27. The third positioning shaft section 270 is used to mate with the mounting hole 61 of the gear 6. The positioning groove 271 and the second positioning shaft section 221 cooperate to achieve precise alignment between the upper positioning seat 22 and the lower positioning seat 27.

[0043] To ensure a clean processing environment and operational safety, this device features a suction channel 262 inside the lower chamfering seat 26. One end of this channel leads to the bottom of the receiving groove, and the other end connects to the interface of an external suction system, allowing for timely removal of deposited metal shavings. Simultaneously, removable baffles 28 are fitted to both the upper and lower chamfering seats 26 to effectively prevent metal shavings from splashing during processing. The baffles 28 are preferably made of soft rubber, ensuring both protection and preventing damage in the event of accidental collisions with the gear 6.

[0044] refer to Figure 4 In the optimized implementation of the feeding mechanism 4, a limiting component 43, consisting of a limiting cylinder 431 and a limiting rack 432, is added. This component, through the meshing of the limiting rack 432 with the conveying gear 6, achieves limiting constraint on the circumferential rotation of the gear 6, providing a positioning basis for subsequent clamping operations.

[0045] To achieve efficient and continuous production, two independent upper chamfering components 20 are arranged in parallel on the mounting plate 32 of the conveying mechanism 3. The first group is responsible for picking up materials from the feeding mechanism 4 and transferring them to the lower chamfering component 25 for processing, while the second group is responsible for transferring the processed gears 6 from the lower chamfering component 25 to the unloading mechanism 5. This dual-station configuration enables the parallel operation of the processing and loading / unloading processes, significantly improving the overall production efficiency of the equipment.

[0046] The working principle of this invention is as follows: The feeding mechanism 4 first transports the gear 6 to be processed to the designated station. At this time, the limiting component 43 is activated, and the circumferential angle is fixed by the limiting rack 432 meshing with the gear 6. Then, the conveying mechanism 3 drives the first set of upper chamfering components 20 to move directly above the gear 6, and the clamping component 24 begins to perform clamping actions in sequence: the electromagnet module 240 is energized to generate magnetic force, causing the abutment 242 to retract into the first positioning shaft section 220; then the first positioning shaft section 220 is inserted into the mounting hole 61 of the gear 6. After the positioning is completed, the electromagnet module 240 is de-energized, and the driving unit 23 drives the first positioning shaft section 220 to rotate until the spring 244 pushes the abutment 242 to extend radially and accurately engage with the keyway 62 of the gear 6, thus completing the reliable clamping of the workpiece.

[0047] After clamping, the conveying mechanism 3 moves the first set of upper chamfering components 20, along with the clamped gear 6, to the processing station. Alignment is achieved through the cooperation of the second positioning shaft section 221 and the positioning groove 271, ensuring that the upper end face of the gear 6 contacts the upper grinding surface 211 and the lower end face contacts the lower grinding surface 261. The drive unit 23 starts, driving the gear 6 to rotate at high speed, ensuring continuous contact between the upper and lower end face tooth edges and the upper and lower grinding surfaces 261, achieving simultaneous double-sided chamfering. During this process, the suction system continuously operates to promptly remove metal debris generated during processing.

[0048] After the processing step is completed, the electromagnet module 240 of the first set of upper chamfering components 20 is energized again, causing the stop block 242 to retract and release the gear 6. The conveying mechanism 3 drives the mounting plate 32 to move, causing the second set of upper chamfering components 20 to descend to the processing station, clamp the chamfered gear 6 and transfer it to the unloading mechanism 5, while the first set of upper chamfering components 20 returns to the feeding station to start the next round of material handling.

[0049] The scope of protection of this invention includes, but is not limited to, the above embodiments. The scope of protection of this invention is defined by the claims. Any substitutions, modifications, or improvements to this technology that are easily conceived by those skilled in the art fall within the scope of protection of this invention.

Claims

1. A gear processing device for new energy vehicles, comprising a base (1), wherein a chamfering mechanism (2) is mounted on the base (1), characterized in that, The chamfering mechanism (2) includes an upper chamfering component (20) and a lower chamfering component (25); The upper chamfer assembly (20) includes: The upper chamfering seat (21) is provided with an upper receiving groove (210). The connection between the bottom wall and the side wall of the upper receiving groove (210) forms an upper grinding surface (211) for chamfering the tooth edge of the upper end face of the gear (6). The upper positioning seat (22) is rotatably mounted on the upper chamfer seat (21). The upper positioning seat (22) is provided with a first positioning shaft section (220). The first positioning shaft section (220) extends into the upper receiving groove (210) and is used to pass through the mounting hole (61) in the middle of the gear (6). A clamping assembly (24) is disposed on the first positioning shaft section (220) for clamping the gear (6) by tightening the mounting hole (61); The drive unit (23) is connected to the upper positioning seat (22) and is used to drive the upper positioning seat (22) and the clamped gear (6) to rotate together; The lower chamfer assembly (25) includes: The lower chamfering seat (26) is arranged opposite to the upper chamfering seat (21). The lower chamfering seat (26) is provided with a lower receiving groove (260). The connection between the bottom wall and the side wall of the lower receiving groove (260) forms a lower grinding surface (261) for chamfering the tooth edge of the lower end face of the gear (6). The lower positioning seat (27) is rotatably mounted on the lower chamfer seat (26) and located in the lower receiving groove (260), and is used to radially position the gear (6) together with the first positioning shaft section (220) when the gear (6) falls. The feeding mechanism (4) is used to convey the gear (6), including a conveyor belt (40), a baffle strip (41) disposed at the end of the conveyor belt (40) and baffle plates (42) disposed on both sides of the conveyor belt (40). The conveying mechanism (3) includes a mounting frame (30), a two-axis moving module (31) disposed on the mounting frame (30), and a mounting plate (32) driven by the two-axis moving module (31), wherein the upper chamfering component (20) is mounted on the mounting plate (32); The material feeding mechanism (5) is located downstream of the chamfering mechanism (2) and is used to receive the chamfered gear (6). The clamping assembly (24) includes an electromagnet module (240), a limiting block (241), a stop block (242), a guide rod (243), and a spring (244). The electromagnet module (240) is located inside the first positioning shaft section (220). The limiting block (241) is slidably arranged along the radial direction of the first positioning shaft section (220) and is opposite to the electromagnet module (240). The electromagnet module (240) is configured to attract the limiting block when energized. (241); The abutment (242) is slidably disposed radially along the first positioning shaft segment (220) and located outside the limiting block (241); The guide rod (243) connects the limiting block (241) and the abutment (242); The spring (244) is sleeved on the guide rod (243), and its two ends abut against the abutment (242) and the inner wall of the first positioning shaft segment (220) respectively, providing an outward elastic force to the abutment (242); The first positioning shaft section (220) has an opening on its outer periphery for the abutment block (242) to extend out, and the inner wall of the mounting hole (61) of the gear (6) has a keyway (62) that matches the abutment block (242). When the electromagnet module (240) is de-energized, the spring (244) pushes the abutment block (242) to extend radially outward into the keyway (62) to tighten and clamp the gear (6). The feeding mechanism (4) further includes a limiting component (43), which includes a limiting cylinder (431) and a limiting rack (432) driven by the limiting cylinder (431). The limiting rack (432) is configured to mesh with the gear (6) in the conveying process to limit its rotation. Two sets of upper chamfering components (20) are installed on the mounting plate (32). One set of upper chamfering components (20) is used to transport the gear (6) from the feeding mechanism (4) to the lower chamfering component (25) and perform chamfering. The other set of upper chamfering components (20) is used to transport the chamfered gear (6) from the lower chamfering component (25) to the unloading mechanism (5).

2. The gear processing device for new energy vehicles according to claim 1, characterized in that, The surface of the abutment (242) has a friction layer.

3. The gear processing device for new energy vehicles according to claim 1, characterized in that, The lower chamfered seat (26) is provided with a suction channel (262), one end of which leads to the bottom of the lower receiving groove (260), and the other end is provided with a suction interface (263) for connecting to an external suction system.

4. The gear processing device for new energy vehicles according to claim 1, characterized in that, Both the upper chamfering seat (21) and the lower chamfering seat (26) are detachably equipped with baffles (28) to prevent metal chips generated during chamfering from flying out.

5. A gear processing device for new energy vehicles according to claim 4, characterized in that, The shield (28) is made of soft rubber.

6. The new energy vehicle gear processing device according to claim 1, characterized in that, The end of the first positioning shaft segment (220) is provided with a second positioning shaft segment (221) with a diameter smaller than itself; the lower positioning seat (27) is provided with an upwardly protruding third positioning shaft segment (270), and the top of the third positioning shaft segment (270) is provided with a positioning groove (271) that cooperates with the second positioning shaft segment (221).

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