Gearbox assembly machining device and machining method

Abstract

The invention belongs to the technical field of gearbox assembly machining, and particularly relates to a gearbox assembly machining device and method.The gearbox assembly machining device comprises a machining machine tool, the machining machine tool comprises a gear clamp, the gear clamp is used for casting an automobile gearbox gear and comprises a base, a stud and a clamping disc, the stud is fixedly installed on the base, and the clamping disc is fixedly installed on the base; the automobile transmission gear is made of low-carbon alloy carburizing steel, and the low-carbon alloy carburizing steel is based on steel and is prepared by adding nonferrous metals through a carburizing heat treatment process. A counter bore is formed in the middle of the clamping disc, sliding grooves are formed in the left side and the right side of the upper portion of the clamping disc, sliding blocks are slidably connected into the sliding grooves, and clamping rings are arranged at the upper ends of the sliding blocks. The gear hole machining precision is poor, and teeth of the gear are damaged in the hole machining process, so that the machining quality is affected.

Description

Technical Field

[0001] This invention belongs to the technical field of gearbox assembly processing, specifically relating to a gearbox assembly processing device and processing method. Background Technology

[0002] The gearbox assembly is the core power transmission device of automobiles / construction machinery. It is an integrated assembly of components such as housing, shaft system (input / output shaft), gear set, synchronizer, shifting mechanism, lubrication / sealing system and sensors. Its core function is to achieve deceleration and torque increase, speed increase and torque decrease or reverse gear by switching gear mesh ratios, adapting to different working conditions such as vehicle starting, acceleration, and climbing. The machining of gear sets requires the machining of gear holes to ensure the gears can be mounted on the shaft during subsequent assembly. Gearbox gears are typically made of low-carbon alloy carburized steel, with non-ferrous metals added to the steel base to increase strength. However, this addition results in a smoother surface. Existing gear fixtures require manual positioning for hole machining, leading to poor positioning accuracy and low fixing strength. This results in low machining precision, low processing quality, and a tendency for slippage between the gear and the fixture. Furthermore, the fixing strength of the gear cannot be precisely controlled during machining, leading to both poor fixing strength and gear loosening, as well as damage to the gear teeth, affecting the overall quality. This phenomenon has become a problem urgently needing to be solved by those in the field. Summary of the Invention

[0003] The purpose of this invention is to provide a gearbox assembly processing apparatus and processing method to solve the problems mentioned in the background art.

[0004] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a gearbox assembly processing device and processing method, comprising a machine tool, the machine tool including a gear fixture, the gear fixture being used for casting automotive gearbox gears, and including a base, a stud, and a clamping plate, the stud being fixedly installed on the base, the automotive gearbox gear being made of low-carbon alloy carburized steel, the low-carbon alloy carburized steel being steel-based, and non-ferrous metals being added through a carburizing heat treatment process; the clamping plate having a countersunk hole in the middle, and sliding grooves on both the upper left and right sides, with sliders slidably connected in each of the sliding grooves, the upper part of the sliders... Each end is provided with a clamping ring, and the inner side of the clamping ring is integrally formed with a toothed block. The clamping ring includes a front clamp and a rear clamp, which fit together and have a sliding hole at the fitting point. A sliding rod is slidably connected in the sliding hole. A through hole is provided between the front clamp and the rear clamp, and a limit shaft is inserted in the through hole. The limit shaft fits together with the inner side of the slider. The outer side of the slider is trapezoidal. A sleeve block is rotatably connected to the bottom of the stud. A support ring is integrally formed on the outer side of the sleeve block. Two push rods are connected above the support ring. The upper end of the push rod is spherical and contacts the trapezoidal part of the slider. The clamping disc is threadedly connected to the stud.

[0005] The present invention further illustrates that both the front clip and the rear clip are magnetic, and their magnetic poles are opposite.

[0006] The present invention further illustrates that a spring is provided between the upper surface of the sleeve block and the lower surface of the clamping disc, and the spring is sleeved on the outside of the stud.

[0007] The invention further explains that the outer side of the clamping ring is also trapezoidal and fits with the trapezoidal part of the slider, thereby forming a complete inclined surface. The front and rear sides of the trapezoidal part of the slider and the clamping ring are also inclined. When the upper spherical part of the top rod moves to the clamping ring position, it simultaneously contacts the trapezoidal part of the slider and the clamping ring and the inclined surfaces on the front and rear sides of the trapezoidal part, that is, it opens the front clamp and the rear clamp.

[0008] The present invention further illustrates that an annular groove is provided above the support ring, and limit blocks are provided on both the left and right sides of the annular groove. A boss is provided at the lower end of the top rod, and the boss and the limit blocks are engaged with each other.

[0009] The present invention further illustrates that the outer sides of both the boss and the limiting block are arc-shaped; the bottom of the sleeve block is integrally formed with a toothed disc, which is connected to an external drive motor through gear transmission.

[0010] The present invention further describes the processing method as follows: Step S1, core component processing, including housing processing, gear processing, shaft processing, and synchronizer component processing; Step S2, assembly, including housing pre-assembly, shift mechanism assembly, and auxiliary system assembly, wherein the housing pre-assembly sequence is as follows: installing bearings, oil seals, press-fitting input shaft and output shaft assembly, and adjusting shaft clearance; the shift mechanism assembly sequence is as follows: installing shift fork, shift shaft, positioning spring, adjusting shift stroke, and fixing housing end cover; the auxiliary system assembly sequence is as follows: installing oil pump, oil pan, adding transmission fluid, and connecting sensors; Step S3, testing and debugging, including static testing, dynamic testing, and factory inspection, wherein the static testing sequence is as follows: gear meshing clearance measurement, shift flexibility testing, and airtightness testing; the dynamic testing sequence is as follows: bench simulation operation, noise, vibration, oil temperature change detection, and shift smoothness verification; the factory inspection sequence is as follows: appearance cleanliness inspection, nameplate marking, and qualified product packaging.

[0011] The present invention further explains that the housing machining, gear machining, shaft machining and synchronizer component machining in step S1 are all performed using a machining tool. In particular, the machining of holes in gear machining is fixed by a gear fixture.

[0012] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: The gear clamp used in the present invention can simultaneously fix the gear, which can fix the gear and ensure the gear positioning. The positioning is accurate, thereby improving the subsequent processing quality and ensuring accurate positioning for hole processing. It is also simple to operate and applicable to all types of gears. One gear clamp can be used for all types of gears, which relatively reduces the manufacturing cost of the clamp and has a wide range of applications. At the same time, when processing holes, rotating the clamping plate and using threaded transmission provides high stability. The reinforcement strength of the gear is adjustable, which can fix the gear while avoiding excessive reinforcement strength. The reinforcement strength is steadily increased to prevent damage to the gear teeth and ensure the processing quality of the gear. Furthermore, it is convenient to tighten and loosen the gear, thereby relatively improving the processing efficiency. As the clamping disc continues to rotate, the push rod contacts the inclined surfaces on both sides of the front and rear clamps, opening them apart and separating the gear blocks. The gear blocks fit tightly against the inner wall of the gear teeth, thereby improving the fixing strength and preventing the gears from loosening during processing, which could lead to tool breakage. This also protects the gears. Furthermore, since different gear models have different tooth sizes, opening the front and rear clamps allows the gear blocks to be adapted to different gear models. Attached Figure Description

[0013] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a cross-sectional view of the gear clamp of the present invention; Figure 3 This is an exploded view of the gear clamp of the present invention; Figure 4 This is an exploded view of the slider, clamping ring, and push rod of the present invention; Figure 5 This is a schematic diagram of the mounting position of the top rod of the present invention; Figure 6 This is a schematic diagram showing the positional change between the boss and the limiting block after the external drive motor of the present invention is running; In the diagram: 1. Base; 2. Stud; 3. Clamping plate; 31. Slider; 32. Front clamp; 33. Rear clamp; 34. Slide rod; 35. Limiting shaft; 4. Sleeve block; 41. Support ring; 411. Limiting block; 42. Top rod; 421. Boss; 43. Gear plate; 5. Spring. Detailed Implementation

[0014] The following detailed, non-limiting description of the technical solution of the present invention, in conjunction with preferred embodiments and accompanying drawings, is provided. Obviously, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0015] Please see Figures 1-6 The present invention provides a technical solution: a gearbox assembly processing device and processing method, including a processing machine tool, the processing machine tool including a gear fixture, the gear fixture being used for casting automotive gearbox gears, and including a base 1, a stud 2 and a clamping plate 3, the stud 2 being fixedly installed on the base 1, the automotive gearbox gear being made of low carbon alloy carburized steel, the low carbon alloy carburized steel being steel-based, and being made by adding non-ferrous metals through a carburizing heat treatment process; The clamping plate 3 has a countersunk hole in the middle and sliding grooves on the upper left and right sides. Slider 31 is slidably connected in the sliding grooves. Each slider 31 has a clamping ring at its upper end. The inner side of the clamping ring has a toothed block integrally formed. The clamping ring includes a front clamp 32 and a rear clamp 33. The front clamp 32 and the rear clamp 33 fit together and a sliding hole is provided at the fitting point. A sliding rod 34 is slidably connected in the sliding hole. A through hole is provided between the front clamp 32 and the rear clamp 33, and a limiting shaft 35 is inserted in the through hole. The limiting shaft 35 fits together with the inner side of the slider 31. The outer side of the slider 31 is trapezoidal. The bottom of the stud 2 is rotatably connected to the sleeve block 4. The outer side of the sleeve block 4 is integrally formed with a support ring 41. Two push rods 42 are connected above the support ring 41. The upper end of the push rod 42 is spherical and contacts the trapezoidal part of the slider 31. The clamping plate 3 is threadedly connected to the stud 2. In automotive gearbox gears combining non-ferrous metals and steel, after the gear teeth are machined, the operator places the gear to be machined on the clamping plate 3, then rotates the clamping plate 3 so that it moves downward on the stud 2 via a threaded connection. At this time, the push rod 42 moves relative to the clamping plate 3, and the push rod 42 contacts the trapezoidal part of the slider 31 and squeezes it, causing the slider 31 to move inward. The slider 31 drives the front clamp 32 and the rear clamp 33 to move inward synchronously through the limiting shaft 35, so that the tooth block is embedded in the gear teeth. The clamping rings on the left and right sides fix the gear synchronously. Since the gear is made of non-ferrous metals, it is relatively smooth. Using a gear jig can fix the gear and ensure the positioning of the gear. The positioning is accurate, thereby improving the subsequent processing quality, ensuring the accurate positioning of the hole processing, and the operation is simple. It can be applied to all types of gears. One gear jig can be used for all types of gears, which reduces the manufacturing cost of the jig and has a wide range of applications. Meanwhile, during hole machining, rotating the clamping disc 3 and using threaded transmission provides high stability. The reinforcement strength of the gear is adjustable, which can both fix the gear and avoid excessive reinforcement strength. The reinforcement strength is steadily increased, preventing damage to the gear teeth and ensuring the machining quality of the gear. Furthermore, it is very convenient to tighten and loosen the gear, thereby relatively improving the machining efficiency.

[0016] Both the front clip 32 and the rear clip 33 are magnetic, and their magnetic poles are opposite. When the tooth block is engaged with the teeth of the gear, the magnetism of the front clamp 32 and the rear clamp 33 causes them to generate magnetic attraction to ensure synchronous movement.

[0017] A spring 5 is provided between the upper surface of the sleeve block 4 and the lower surface of the clamping plate 3, and the spring 5 is sleeved on the outside of the stud 2. When the clamping disc 3 moves downward, the spring 5 is compressed and deformed, generating a reaction force, which makes the threaded part of the clamping disc 3 fit tightly with the threaded part of the stud 2, improving the stability during the processing, preventing excessive force during gear processing from causing the clamping disc 3 to rotate, and improving the processing quality.

[0018] The outer side of the clamping ring is also trapezoidal and fits with the trapezoidal part of the slider 31, thus forming a complete inclined surface. The front and rear sides of the trapezoidal part of the slider 31 and the clamping ring are also inclined. When the upper spherical part of the push rod 42 moves to the clamping ring position, it simultaneously contacts the slider 31 and the trapezoidal part of the clamping ring and the inclined surfaces on the front and rear sides of the trapezoidal part, that is, it opens the front clamping 32 and the rear clamping 33. As the clamping disc 3 continues to rotate, the push rod 42 contacts the front and rear inclined surfaces of the front clamp 32 and the rear clamp 33, opening the front clamp 32 and the rear clamp 33 so that the tooth block is separated. The tooth block fits tightly with the inner wall of the gear tooth, thereby improving the fixing strength, preventing the gear from loosening during the processing and causing the tool to break, and also protecting the gear. Furthermore, for different gear models, the tooth size is different. By opening the front clamp 32 and the rear clamp 33, the tooth block can be opened to adapt to each gear model.

[0019] A ring groove is provided above the support ring 41, and limit blocks 411 are provided on both the left and right sides of the ring groove. A boss 421 is provided at the lower end of the top rod 42, and the boss 421 and the limit block 411 are engaged with each other.

[0020] Both the outer sides of the boss 421 and the limiting block 411 are arc-shaped; The bottom of the sleeve 4 is integrally formed with a toothed disc 43, which is connected to an external drive motor through gear transmission; When the clamping disc 3 is rotated, the slider 31 drives the limiting block 411 to rotate through the push rod 42. The limiting block 411 drives the support ring 41 to rotate through the boss 421. The support ring 41 drives the sleeve block 4 to rotate and position on the stud 2 to improve the smoothness of fastening the gear. The push rod 42 is supported to ensure the fastening strength. When the upper end of the push rod 42 moves between the front clamp 32 and the rear clamp 33, the tightening strength of the gear needs to be further increased. At this time, the operator drives the external drive motor to run, so that it drives the gear disk 43 to rotate through gear transmission. The gear disk 43 drives the sleeve block 4 to rotate. The sleeve block 4 drives the boss 421 to rotate in the opposite direction through the support ring 41. The boss 421 disengages from the limiting block 411. Then, with rotation, the left boss 421 contacts the right limiting block 411, and the right boss 421 contacts the left limiting block 411. The arc-shaped parts of the two contact each other and squeeze each other, so that the boss 421 rubs against the limiting block 411. The push rod 42 is slightly lifted by the limiting block 411, which causes it to move upward slightly, increasing the compressive strength of the clamping ring and thus increasing the reinforcement strength of the gear teeth by the tooth block. The fixing strength is further improved. After the left boss 421 disengages from the right limiting block 411, the push rod 42 loses its support and resets, thereby reducing the fixing strength and resetting again. This intermittent operation of relatively strengthening the fastening strength and then relatively reducing the fastening strength further strengthens the fixing strength during the processing and avoids continuous high-strength fastening, which could damage the gear teeth caused by the tooth block. This maximizes the protection of the gear processing quality.

[0021] Processing methods include: Step S1: Machining of core components, including housing machining, gear machining, shaft machining, and synchronizer component machining; Step S2, assembly assembly, includes housing pre-assembly, shift mechanism assembly and auxiliary system assembly. The housing pre-assembly sequence is as follows: install bearings, oil seals, press-fit input shaft and output shaft assembly, adjust shaft clearance. The shift mechanism assembly sequence is as follows: install shift fork, shift shaft, positioning spring, adjust shift stroke, fix housing end cover. The auxiliary system assembly sequence is as follows: install oil pump, oil pan, add transmission fluid, connect sensor. Step S3, Inspection and Debugging, includes static inspection, dynamic testing and factory inspection. The static inspection sequence is as follows: gear meshing clearance measurement, shifting flexibility test and air tightness test. The dynamic testing sequence is as follows: bench simulation operation, noise, vibration and oil temperature change detection and shifting smoothness verification. The factory inspection sequence is as follows: appearance cleanliness inspection, nameplate marking and qualified product packaging.

[0022] In step S1, the machining of the housing, gears, shafts, and synchronizer components are all performed using machine tools. In gear machining, the holes are fixed using gear fixtures. The gear clamp described above is used to clamp gears and perform hole machining. It can accommodate gears of all different sizes, significantly reducing costs. It also provides high fixing strength and good stability for gears, while simultaneously improving production efficiency. The gear clamp has a simple structure, low manufacturing cost, and wide range of applications.

[0023] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0024] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features, and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A gearbox assembly processing apparatus, comprising a machine tool, characterized in that: The processing machine tool includes a gear fixture, which is used for casting automotive gearbox gears and includes a base (1), a stud (2) and a clamping plate (3). The stud (2) is fixedly installed on the base (1). The automotive gearbox gear is made of low-carbon alloy carburized steel. The low-carbon alloy carburized steel is based on steel and is made by adding non-ferrous metals through a carburizing heat treatment process. The clamping plate (3) has a countersunk hole in the middle and sliding grooves on the upper left and right sides. A slider (31) is slidably connected in each of the sliding grooves. A clamping ring is provided at the upper end of each slider (31). A toothed block is integrally formed on the inner side of the clamping ring. The clamping ring includes a front clamp (32) and a rear clamp (33). The front clamp (32) and the rear clamp (33) fit together and a sliding hole is provided at the fitting point. A sliding rod (34) is slidably connected in the sliding hole. A through hole is provided between the front clamp (32) and the rear clamp (33), and a limiting shaft (35) is inserted in the through hole. The limiting shaft (35) fits together with the inner side of the slider (31). The outer side of the slider (31) is trapezoidal, and the bottom of the stud (2) is rotatably connected to the sleeve (4). The outer side of the sleeve (4) is integrally formed with a support ring (41). Two top rods (42) are connected above the support ring (41). The upper end of the top rod (42) is spherical and contacts the trapezoidal part of the slider (31). The clamping plate (3) is threadedly connected to the stud (2).

2. The gearbox assembly processing apparatus according to claim 1, characterized in that: Both the front clip (32) and the rear clip (33) are magnetic, and their magnetic poles are opposite.

3. The gearbox assembly processing apparatus according to claim 2, characterized in that: A spring (5) is provided between the upper surface of the sleeve block (4) and the lower surface of the clamping plate (3), and the spring (5) is sleeved on the outside of the stud (2).

4. The gearbox assembly processing apparatus according to claim 3, characterized in that: The outer side of the clamping ring is also trapezoidal and fits with the trapezoidal part of the slider (31) to form a complete inclined surface. The front and rear sides of the trapezoidal part of the slider (31) and the clamping ring are also inclined. When the upper spherical part of the top rod (42) moves to the clamping ring position, it simultaneously contacts the slider (31) and the trapezoidal part of the clamping ring and the inclined surfaces on the front and rear sides of the trapezoidal part, that is, it opens the front clamp (32) and the rear clamp (33).

5. The gearbox assembly processing apparatus according to claim 4, characterized in that: The support ring (41) has an annular groove on its upper part, and limit blocks (411) are provided on both the left and right sides of the annular groove. The bottom end of the top rod (42) is provided with a boss (421), and the boss (421) and the limit block (411) are engaged with each other.

6. The gearbox assembly processing apparatus according to claim 5, characterized in that: The outer sides of both the boss (421) and the limiting block (411) are arc-shaped; The bottom of the sleeve (4) is integrally formed with a toothed disc (43), which is connected to an external drive motor through gear transmission.

7. A processing method for a gearbox assembly processing apparatus, wherein the gearbox assembly processing apparatus according to claim 6 is characterized in that: The processing method includes: Step S1: Machining of core components, including housing machining, gear machining, shaft machining, and synchronizer component machining; Step S2, assembly, including housing pre-assembly, shift mechanism assembly and auxiliary system assembly; Step S3, testing and debugging, including static testing, dynamic testing and factory inspection.

8. The processing method of the gearbox assembly processing device according to claim 7, characterized in that: The machining of the housing, gears, shafts, and synchronizer components in step S1 are all performed using machine tools. In gear machining, the holes are fixed using gear fixtures.

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