Assembly process and device for a speed reducer

Abstract

The present application relates to the technical field of speed reducer assembly, in particular to a kind of speed reducer's assembly process and device, one of which includes the intelligent sorting system of small parts, assembly part tray, component conveying system, transfer device and assembly workstation, the component conveying system is ball conveying line, the ball conveying line is connected in head-to-tail, and the head-to-tail of it is provided with partition, transfer feeding station and transfer discharge station are respectively arranged on the ball conveying line of the two sides of partition, the transfer device is arranged in the side of transfer feeding station and transfer discharge station, and the assembly part tray is transferred to ball conveying line from intelligent sorting system by transfer device.The present application adds intelligent sorting system, component conveying system and transfer device, and by this design, manual receipt of small parts is not needed, and assembly efficiency is greatly improved.

Description

Technical Field

[0001] This invention relates to the field of speed reducer assembly technology, and more specifically to a speed reducer assembly process and apparatus. Background Technology

[0002] Currently, the assembly of speed reducers by workers lacks standardized assembly procedures, resulting in significant uncertainty in the quality of the assembled reducers. Quality relies entirely on the worker's experience and intuition, especially in gear assembly. To increase assembly speed, workers often only briefly inspect the gear surface, which introduces considerable uncertainty when assembling smaller gears. This can easily lead to the assembly of damaged gears into the speed reducer. Furthermore, workers often collect too many or too few small parts during assembly material requisition. Therefore, designing a speed reducer assembly process and device to address these issues is of paramount importance. Summary of the Invention

[0003] To address the aforementioned problems, this invention presents an assembly process and apparatus for a speed reducer, which incorporates an intelligent sorting system, a parts conveying system, and a transfer device. This design eliminates the need for manual handling of small parts, significantly improving material handling efficiency and preventing over- or under-hand handling, thereby enhancing practicality.

[0004] To solve the above-mentioned technical problems, the present invention provides an assembly device for a speed reducer, including an intelligent sorting system for small parts, an assembly pallet, a parts conveying system, a transfer device, and an assembly workbench. The parts conveying system is a ball bearing conveyor line, which is connected end to end with a partition between the ends. A transfer loading station and a transfer unloading station are respectively located on the ball bearing conveyor line on both sides of the partition. The transfer device is located on one side of the transfer loading station and the transfer unloading station. Small parts are loaded into the assembly pallet via the intelligent sorting system. The assembly pallet is equipped with several placement... The system includes a sorting area, two T-shaped supports for handling, and a chip-embedded identification plate. The assembly pallets are transferred from the intelligent sorting system to the ball conveyor line via a transfer device. The ball conveyor line has several assembly loading and unloading stations, each with an assembly workbench on one side. On each assembly workbench, there are assembly stations and assembly part picking stations on the left and right sides, respectively. A picking robot arm is installed at each assembly part picking station. One end of the assembly station on the assembly workbench is connected to a gear detection workbench, which is equipped with a gear detection device.

[0005] Furthermore, the intelligent sorting system includes a pallet roller loading conveyor and a pallet roller unloading conveyor arranged side by side, a storage rack located on one side of the pallet roller loading conveyor, a parts conveyor, and a parts gripping robotic arm. One end of the pallet roller loading conveyor and the pallet roller unloading conveyor extends into the transfer device. Several assembly loading stations are arranged sequentially from front to back on the pallet roller loading conveyor. Each assembly loading station has a storage rack on one side. Three parts conveyors are arranged sequentially from front to back on the storage rack. Several parts storage racks are arranged sequentially from left to right on the parts conveyors. Assembled parts are taken out from the parts storage racks by the parts gripping robotic arm and placed on the assembly pallet.

[0006] Furthermore, the gripping robotic arm comprises a component gripper, a lifting electric cylinder, a first telescopic electric cylinder, a first telescopic support plate, a lead screw translation mechanism, and a position adjustment plate. The component gripper is connected to the bottom of the first telescopic support plate via the lifting electric cylinder. The top of the first telescopic support plate is provided with an inverted first trapezoidal slide rail. The bottom of the position adjustment plate has a first groove relative to the position of the first trapezoidal slide rail. The first telescopic support plate is connected to the bottom of the position adjustment plate through the cooperation of the first trapezoidal slide rail and the first groove, and is driven by the first telescopic electric cylinder to move to the right of the component conveyor. The position adjustment plate moves left and right above the top of the end and above the corresponding assembly loading station. The bottom of the position adjustment plate is provided with a second sliding groove that matches the second guide rail on the top of the first upper support plate. The second guide rail is in the shape of an inverted trapezoid. The position adjustment plate is connected to the first upper support plate through a screw translation mechanism and moves back and forth along the second guide rail under the drive of the screw translation mechanism. The first upper support plate is horizontally fixed on the top of the storage rack. The right end of the component conveyor is located directly below the outer side of the right end of the first upper support plate. The right end of the position adjustment plate extends to directly above the right end of the component conveyor.

[0007] Furthermore, the transfer device includes a transfer box, a first transfer plate, a second transfer plate, a translational electric cylinder, and a first pallet gripper structure. The transfer box has a first inlet and a first outlet on one side facing the pallet roller feeding conveyor line and the pallet roller unloading conveyor line, respectively. The pallet roller feeding conveyor line and the pallet roller unloading conveyor line extend into the transfer box along the first inlet and the first outlet, respectively. On the other side of the transfer box, opposite the first inlet and the first outlet, a second outlet and a second inlet are respectively provided. The translational electric cylinder is installed on the top of the transfer box. The output shaft end of the translational electric cylinder is connected to the first transfer plate via a transmission component. The top of the transfer box has a through groove for the transmission component to extend into. The transmission component extends along the through groove... The first and second transfer plates are horizontally positioned. One end of the pallet roller feeding conveyor extends along the first inlet to directly below one end of the first transfer plate, and the other end of the first transfer plate extends along the second outlet to directly above the transfer feeding station. The first transfer plate can move left and right within the second outlet under the drive of the translation electric cylinder. One end of the pallet roller unloading conveyor extends along the first outlet to directly below one end of the second transfer plate in the transfer box, and the other end of the second transfer plate extends along the second inlet to directly above the transfer unloading station. The bottom of the first and second transfer plates is connected to a set of first pallet gripper structures through a front and rear translation mechanism.

[0008] Furthermore, the material handling robotic arm includes a second telescopic electric cylinder, a second telescopic support plate, a second lifting electric cylinder, and a second pallet gripper structure. The second pallet gripper structure is connected to the bottom of the second telescopic support plate via the second lifting electric cylinder. A second slide rail is provided on the top of the second telescopic support plate. The second slide rail is in the shape of an inverted trapezoid. A second upper support plate is horizontally fixed above the assembly material handling station via a column. A third slide groove is provided at the bottom of the second upper support plate relative to the position of the second slide rail. The second telescopic support plate is connected to the bottom of the second upper support plate through the cooperation of the second slide rail and the third slide groove. Driven by the second telescopic electric cylinder, it moves horizontally above the assembly material handling station and above the corresponding assembly loading and unloading station. An alarm reminder light is installed on the top of the second upper support plate.

[0009] Furthermore, the gear inspection device includes a gear placement fixture, a U-shaped support plate horizontally fixed above the front end of the gear inspection workbench via a column, an industrial camera, and a magnifying display. The industrial camera is installed directly below the U-shaped support plate, and a camera lighting fixture is also provided at the bottom of the U-shaped support plate on one side of the industrial camera. The magnifying display is vertically installed at the top of the rear end of the U-shaped support plate and electrically connected to the industrial camera. Two parallel third slide rails are fixed at the top of the rear end of the gear inspection workbench. The gear placement fixture is slidably connected to the third slide rails by a slider at the bottom, and the front end of the third slide rails extends directly below the U-shaped support plate.

[0010] Furthermore, the gear placement fixture includes a fixture base plate, two fourth slide rails parallel to each other arranged on the fixture base plate, auxiliary support rollers, a spacing adjustment mechanism, a support base, a support outer cylinder, a three-section support shaft, and a handwheel. The two fourth slide rails are placed one in front of the other. Two auxiliary support rollers are provided, namely a first auxiliary support roller and a second auxiliary support roller, which are horizontally placed one in front of the other. The two ends of the first auxiliary support roller are connected to the two fourth slide rails via a first sliding block and a second sliding block, respectively. The first auxiliary support roller is rotatably connected to the first and second sliding blocks. The two ends of the second auxiliary support roller are connected to the two fourth slide rails via a third sliding block and a fourth sliding block, respectively. The second auxiliary support roller is rotatably connected to the third and fourth sliding blocks. The spacing adjustment mechanism is located at the top right end of the fixture base plate and is divided into... The support base is fixedly installed on the top of the left end of the tooling base plate, and a guide hole matching the outer cylinder is opened between the left and right ends of the support base. The outer cylinder passes through the guide hole and can move left and right along the guide hole. The support base is connected to a tightening bolt through a threaded hole on the top. The tightening bolt extends into the guide hole along the threaded hole to tighten and lock the outer cylinder. The three-section support shaft is composed of a rotating connection part, a first placement part, a second placement part, and a third placement part connected from left to right. The first placement part, the second placement part, and the third placement part are all provided with a gear lateral restraint structure. The rotating connection part is rotatably connected to the outer cylinder, and one end of it passes through the outer cylinder and is connected to a handwheel. Two push-pull handles are also provided on the top of the rear end of the tooling base plate.

[0011] Furthermore, the spacing adjustment mechanism includes a knob, an adjusting gear, a first rack, and a second rack. The knob is installed on the upper end of the rotating shaft, which is vertically rotatably connected to the top of the tooling base plate. The adjusting gear is mounted on the rotating shaft and rotates with it. The first rack and the second rack are respectively located on both sides of the adjusting gear and mesh with it. The rear end of the first rack is connected to the second sliding block, and the front end of the second rack is connected to the fourth sliding block.

[0012] Furthermore, a small piston air compressor is also provided on the top of the convex-shaped support plate, and the small piston air compressor is connected to the jet cleaning air gun through a hose.

[0013] The present invention also provides an assembly process for a speed reducer, specifically including the following steps: S1: Material Retrieval: First, small parts are intelligently retrieved through an intelligent sorting system. At the same time, the reducer housing, input shaft, output shaft, and gears are manually retrieved and transported to the assembly station. S2: Cleaning and Inspection: The inner and outer surfaces of the gearbox housing, input shaft, output shaft, and gears are cleaned by blowing air gun. After cleaning, the gears are inspected using a gear placement fixture, an industrial camera, and a magnifying monitor. S3: Assembly of housing and bearings: After inspection and verification, transport the lower housing of the reducer to the assembly station of the assembly workbench for fixing. After leveling with a level, use the heating method or cold installation method to install the bearing into the shaft and housing hole, ensuring that it is close to the shaft shoulder. S4: Gear shaft assembly: Assemble the gears onto the input shaft and output shaft in sequence, first assembling the larger gear and ensuring it is close to the shaft shoulder; S5: Gear shaft assembly into the housing: Smoothly lift the assembled gear shaft into the lower housing, check and adjust the gear backlash and bearing clearance; S6: Gear grinding: Apply a colorant to the drive wheel, then manually rotate the wheel and inspect by observing the contact marks; S7: Box assembly and sealing: After confirming that there are no foreign objects inside the box, apply sealant to the split surface, install the tapered pin for positioning, and tighten the connecting bolts in multiple steps according to the diagonal sequence and the specified torque; S8: Install external accessories: Inject lubricating oil / grease, and press in using the screw hole at the shaft end when assembling couplings or pulleys; S9: Testing and Inspection: First, perform a pneumatic pressure test on the assembled reducer. The pressure remains constant at 0.2MPa for 30 seconds. Then, perform no-load and load tests. Run at low speed for 30 minutes. After checking for any abnormalities, gradually increase the speed and perform 4 hours of temperature rise monitoring and 8 hours of load testing. Check for vibration and noise during the tests.

[0014] With the above structure, the present invention has the following beneficial effects: This invention adds an intelligent sorting system, a parts conveying system, and a transfer device. This design eliminates the need for manual handling of small parts, which not only greatly improves material handling efficiency but also avoids over-handling and under-handling, thus enhancing practicality.

[0015] This invention achieves quantitative assembly standards by controlling the shoulder clearance to be less than 0.02mm, checking for non-insertion with a 0.03-0.05mm feeler gauge, and observing contact marks to ensure that the length is greater than or equal to 85% and the height is greater than or equal to 60%, rather than relying on experience. This avoids the uncertainty caused by relying on workers' manual assembly and ensures that the transmission efficiency and operating noise of each reducer meet the design specifications when it leaves the factory.

[0016] 3. By adopting this process, the present invention can ensure the quality of the gear reducer after assembly, enabling it to have a high load-bearing capacity. The strict clearance control and gear grinding test of the present invention can maximize the contact area of ​​the gear under load, effectively avoid local overload and tooth breakage of the gear, and significantly improve the impact resistance. Attached Figure Description

[0017] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0018] Figure 1 This is a top view of the assembly device in this invention.

[0019] Figure 2 for Figure 1 A magnified view of A in the middle.

[0020] Figure 3 for Figure 1 A magnified view of B in the middle.

[0021] Figure 4 This is a partial structural diagram of an intelligent sorting system.

[0022] Figure 5 This is a structural diagram of the transfer device.

[0023] Figure 6 This is a top view of the assembly workbench and gear inspection workbench.

[0024] Figure 7 This is a structural diagram of the material handling robotic arm.

[0025] Figure 8 This diagram illustrates the gripping principle of the first and second pallet gripper structures working in conjunction with the T-shaped bracket.

[0026] Figure 9 A top view of the fixture for placing the gear.

[0027] In the diagram: 1 is the ball bearing conveyor line, 2 is the pallet roller loading conveyor line, 3 is the pallet roller unloading conveyor line, 4 is the transfer box, 5 is the gear inspection workbench, 6 is the assembly workbench, 7 is the assembly pallet, 8 is the identification label plate, 9 is the T-shaped bracket, 10 is the mounting bracket, 11 is the second identification label plate detection sensor, 12 is the third telescopic electric cylinder, 13 is the first baffle, 14 is the second baffle, 15 is the first identification label plate detection sensor, 16 is the partition plate, 17 is the first transfer plate, 18 is the second transfer plate, 19 is the translation electric cylinder, 20 is the storage rack, 21 is the parts conveyor, 22 is the first upper support plate, 23 is the first telescopic electric cylinder, 24 is the first telescopic support plate, 25 is the first trapezoidal slide rail, 26 is the position adjustment plate, 27 is the lead screw translation mechanism, 28 is the second guide rail, 29 is the convex support plate, 30 is the first auxiliary support roller, and 31 is the magnifying display. 32 is the third slide rail, 33 is the small piston air compressor, 34 is the tooling base plate, 35 is the support base, 36 is the support outer cylinder, 37 is the handwheel, 38 is the tightening bolt, 39 is the three-section support shaft, 40 is the third sliding block, 41 is the first sliding block, 42 ​​is the second sliding block, 43 is the fourth sliding block, 44 is the push-pull handle, 45 is the first rack, 46 is the second rack, 47 is the adjusting gear, and 48 is the second upper... Support plate, 49 is the second telescopic electric cylinder, 50 is the alarm reminder light, 51 is the second telescopic support plate, 52 is the second slide rail, 53 is the second lifting electric cylinder, 54 is the gripper drive electric cylinder, 55 is the pallet gripper, 56 is the gripper mounting plate, 57 is the fourth slide rail, 58 is the second auxiliary support roller, I is the transfer loading station, II is the transfer unloading station, III is the assembly loading and unloading station, IV is the assembly part picking station, V is the assembly part picking station, and VI is the assembly station. Detailed Implementation

[0028] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] In the description of this invention, it should be noted that certain terms indicating orientation or positional relationships are used only for the convenience of describing this invention and simplifying the description, and are not intended to 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 limiting this invention.

[0030] In the description of this invention, it should be noted that the term "connection" should be interpreted broadly. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0031] The present invention will be further described in detail below through specific embodiments.

[0032] like Figure 1 and Figure 2The illustrated assembly device for a speed reducer includes an intelligent sorting system for small parts, an assembly pallet 7, a parts conveying system, a transfer device, and an assembly workbench 6. The parts conveying system is a ball bearing conveyor line 1, connected end-to-end, with a partition plate 16 between the ends. A transfer loading station II and a transfer unloading station III are respectively located on the ball bearing conveyor line 1 on both sides of the partition plate. The transfer device is located on one side of each of the transfer loading station II and transfer unloading station III. Small parts are loaded into the assembly pallet 7 via the intelligent sorting system. The assembly pallet 7 has several placement areas, two T-shaped supports 9 for handling, and an identification tag with a chip. The assembly pallet 7 is transferred from the intelligent sorting system to the ball conveyor line 1 via a transfer device. The ball conveyor line 1 is equipped with several assembly loading and unloading stations IV. Each assembly loading and unloading station IV has an assembly workbench 6 on one side. The assembly workbench 6 has an assembly station VI and an assembly part picking station V on the left and right sides, respectively. The assembly part picking station V is equipped with a picking robot arm. One end of the assembly station VI on the assembly workbench is connected to the gear detection workbench 5. The gear detection workbench 5 is equipped with a gear detection device. A touch screen is installed on the outer wall of the transfer device. The touch screen is electrically connected to the main controller built into the transfer device. During operation, assembly personnel first input the model of the reducer to be assembled into the touch screen. Then, they manually collect large parts and transport them to assembly station VI. Upon receiving the signal, the main controller automatically sorts the required small parts into assembly pallets 7 via the intelligent sorting system. The assembly pallets 7 containing small parts are then transported to the ball conveyor line 1 via a transfer device, and then conveyed to the corresponding assembly loading / unloading station IV. Upon receiving the signal, the picking robot arm transports the assembly pallets 7 containing small parts to the assembly picking station V. At this point, the small parts are manually removed one by one from the assembly pallets 7. Empty assembly pallets 7 are then placed back into the ball conveyor line 1 via the picking robot arm and transferred back to the intelligent sorting system for recycling via a transfer device. After all parts have been collected, the collected gears are first inspected by a gear inspection device. If the inspection is successful, they are assembled one by one. After assembly, airtightness, no-load, and load tests are performed sequentially. If all tests are successful, the gears are stored in the warehouse. This invention adds an intelligent sorting system, a parts conveying system, and a transfer device. This design eliminates the need for manual handling of small parts, which not only greatly improves material handling efficiency but also avoids over-handling and under-handling, thus enhancing practicality.

[0033] like Figure 2Each assembly loading / unloading station IV shown is equipped with two first identification plate detection sensors 15 on the side away from the assembly workbench. The two first identification plate detection sensors are arranged in sequence and electrically connected to the first limiting mechanism through the main controller. The first limiting mechanism includes a mounting frame 10 installed on the ball conveyor line 1 on the other side of the assembly loading / unloading station IV, two third telescopic electric cylinders 12, and two first baffles 13 connected to the two first telescopic electric cylinders respectively. Two third telescopic electric cylinders 12 are fixed on the mounting frame one in front and one behind. Each of the two third telescopic electric cylinders is connected to a first baffle 13. Under the action of the two third telescopic electric cylinders, the two first baffles 13 extend into the ball conveyor line 1 to block the assembly pallet. After the first identification sign detection sensor located at the rear detects the corresponding identification sign, the third telescopic electric cylinder located at the front is activated to block the corresponding assembly pallet 7 using the first baffle connected to it. When the first identification sign detection sensor located at the front also detects the corresponding identification sign, the third telescopic electric cylinder located at the rear is activated to block the assembly pallet 7 behind it using the first baffle connected to it, so as to prevent it from affecting the gripping of the picking robot arm.

[0034] like Figure 1 and Figure 4 The intelligent sorting system shown includes a pallet roller loading conveyor line 2 and a pallet roller unloading conveyor line 3 arranged side by side, a storage rack 20 located on one side of the pallet roller loading conveyor line 2, a parts conveyor 21, and a parts gripping robotic arm. One end of the pallet roller loading conveyor line 2 and the pallet roller unloading conveyor line 3 extends into a transfer device. Several assembly loading stations I are arranged sequentially from front to back on the pallet roller loading conveyor line 2. Each assembly loading station I has a storage rack 20 on one side. Three parts conveyors 21 are arranged sequentially from front to back on the storage racks 20. Several parts storage racks are arranged sequentially from left to right on the parts conveyors. Assembled parts are taken out from the parts storage racks by the parts gripping robotic arm and placed on the assembly pallet 7. After receiving the model number of the reducer to be assembled, the main controller controls the palletizing and handling robotic arm to place the empty assembly pallet 7 onto the pallet roller conveyor line 2. When the assembly pallet 7 moves to the side of the corresponding storage rack 20, the component gripping robotic arm will take the component from the storage rack and place it on the assembly pallet 7. This invention can automatically complete the material requisition of small parts for the reducer, greatly improving the assembly efficiency.

[0035] like Figure 4The bottom of the pallet roller feeding conveyor line 2 and the pallet roller unloading conveyor line 3 is evenly arranged with several conveying rollers for transporting the assembly pallets 7. Several rubber guide rollers are provided on both sides of the pallet roller feeding conveyor line 2 and the pallet roller unloading conveyor line 3. The guide rollers on both sides are arranged opposite each other, and the distance between the two opposite guide rollers matches the width of the assembly pallet 7.

[0036] like Figure 3 Two second identification plate detection sensors 11 are installed on the pallet roller conveyor line 2 on one side of each assembly loading station I shown. The two second identification plate detection sensors are arranged in sequence and electrically connected to the second limiting mechanism through the main controller. The second limiting mechanism includes two fourth telescopic electric cylinders installed at the bottom of the assembly loading station I and two second baffles 14 connected to the two fourth telescopic electric cylinders respectively. The two fourth telescopic electric cylinders are arranged one in front of the other, and each of the two fourth telescopic electric cylinders is connected to a second baffle 14. Under the action of the two fourth telescopic electric cylinders, the two second baffles 14 extend into the pallet roller conveyor line 2 to block the assembly pallet. After the second identification sign detection sensor located on the rear side detects the corresponding identification sign, the fourth telescopic electric cylinder located on the front side is activated to block the corresponding assembly pallet 7 using the second baffle connected to it. When the second identification sign detection sensor located on the front side also detects the corresponding identification sign, the fourth telescopic electric cylinder located on the rear side is activated to block the assembly pallet 7 behind it using the second baffle connected to it, so as to prevent it from affecting the material release of the parts gripping robot arm.

[0037] like Figure 4The gripping robotic arm shown consists of a component gripper, a lifting electric cylinder, a first telescopic electric cylinder 23, a first telescopic support plate 24, a lead screw translation mechanism 27, and a position adjustment plate 26. The component gripper is connected to the bottom of the first telescopic support plate 24 via the lifting electric cylinder. The top of the first telescopic support plate 24 is provided with an inverted first trapezoidal slide rail 25. The bottom of the position adjustment plate has a first groove relative to the position of the first trapezoidal slide rail 25. The first telescopic support plate 24 is connected to the bottom of the position adjustment plate through the cooperation of the first trapezoidal slide rail and the first groove, and is driven by the first telescopic electric cylinder 23 to the right end of the component conveyor. The position adjustment plate moves left and right above the corresponding component loading station I. The bottom of the position adjustment plate has a second sliding groove that matches the second guide rail 28 on the top of the first upper support plate 22. The second guide rail 28 is an inverted trapezoid. The position adjustment plate is connected to the first upper support plate 22 via a screw translation mechanism 27 and moves back and forth along the second guide rail under the drive of the screw translation mechanism. The first upper support plate 22 is horizontally fixed to the top of the storage rack 20. The right end of the component conveyor 21 is located directly below the outer right end of the first upper support plate, and the right end of the position adjustment plate extends directly above the right end of the component conveyor 21. This invention allows different specifications of the same type of component to be placed on three component conveyors on the same storage rack. During operation, the screw translation mechanism allows selection of the corresponding specification of component from the three component conveyors, increasing practicality.

[0038] like Figure 4The transfer device shown includes a transfer box 4, a first transfer plate 17, a second transfer plate 18, a translational electric cylinder 19, and a first pallet gripper structure. The transfer box 4 has a first inlet and a first outlet on one side facing the pallet roller feeding conveyor line 2 and the pallet roller unloading conveyor line 3, respectively. The pallet roller feeding conveyor line 2 and the pallet roller unloading conveyor line 3 extend into the transfer box 4 along the first inlet and the first outlet, respectively. On the other side of the transfer box 4, directly opposite the first inlet and the first outlet, a second outlet and a second inlet are respectively provided. The translational electric cylinder 19 is installed on the top of the transfer box 4. The output shaft end of the translational electric cylinder 19 is connected to the first transfer plate 17 via a transmission component. The top of the transfer box 4 has a through groove for the transmission component to extend into the transfer box. Inside the box 4, the first transfer plate 17 and the second transfer plate 18 are horizontally arranged. One end of the pallet roller feeding conveyor line 2 extends along the first feed port to directly below one end of the first transfer plate 17. The other end of the first transfer plate 17 extends along the second discharge port to directly above the transfer feeding station II. The first transfer plate 17 can be moved left and right in the second discharge port under the drive of the translation electric cylinder 19. One end of the pallet roller unloading conveyor line 3 extends along the first discharge port to directly below one end of the second transfer plate 18 inside the transfer box 4. The other end of the second transfer plate 18 extends along the second feed port to directly above the transfer unloading station III. The bottom of the first transfer plate 17 and the second transfer plate 18 are each connected to a set of first pallet gripper structures through the front and rear translation mechanism. The bottom of the aforementioned ball conveyor line is equipped with several ball structures, and rubber conveying rollers are installed on the inner walls of both sides. The width of the assembly pallet matches the conveying width of the ball conveyor line. The transfer and loading station II of the ball conveyor line is flared. The assembly pallet is transported to the transfer and loading station II with the cooperation of the first pallet gripper structure and the T-shaped bracket 9. Then, driven by the translation electric cylinder 19, the assembly pallet is disengaged from the first pallet gripper structure at the point where it contacts the conveying rollers. The assembly pallet continues to be conveyed forward under the action of the conveying rollers on both sides.

[0039] like Figure 6 and Figure 7The shown material handling robotic arm includes a second telescopic electric cylinder 49, a second telescopic support plate 51, a second lifting electric cylinder 53, and a second pallet gripper structure. The second pallet gripper structure is connected to the bottom of the second telescopic support plate 51 via the second lifting electric cylinder 53. A second slide rail 52 is provided on the top of the second telescopic support plate 51. The second slide rail is in the shape of an inverted trapezoid. A second upper support plate 48 is horizontally fixed above the assembly material handling station V via a column. A third slide groove is provided at the bottom of the second upper support plate 48 relative to the position of the second slide rail. The second telescopic support plate 51 is connected to the bottom of the second upper support plate 48 through the cooperation of the second slide rail and the third slide groove. Driven by the second telescopic electric cylinder 49, it moves horizontally above the assembly material handling station V and above the corresponding assembly loading and unloading station IV. An alarm reminder light 50 is installed on the top of the second upper support plate 48. When the two first identification label detection sensors detect the identification label for 5-10 seconds, the second telescopic electric cylinder 49 is activated to move the second pallet gripper structure to the top of the corresponding assembly pallet. At the same time, the alarm reminder light 50 is turned on by the main controller to display red light. Then, through the cooperation of the second telescopic electric cylinder, the second lifting electric cylinder and the second pallet gripper structure, the assembly pallet is moved to the assembly picking station V. When the assembly pallet is put back into the ball conveyor line 1, the main controller will make the alarm reminder light display green light.

[0040] like Figure 7 and Figure 8 The first and second pallet gripper structures shown have the same structural composition, specifically consisting of a gripper mounting plate 56, a gripper drive cylinder 54, and a pallet gripper 55. The gripper mounting plate is connected to a lifting cylinder, and two gripper drive cylinders are mounted on the left and right sides of the gripper mounting plate. The output shaft ends of the two gripper drive cylinders pass through the gripper mounting plate and are each connected to a pallet gripper 55. The pallet gripper 55 opens and closes under the extension and retraction of the output shaft ends of the gripper drive cylinders, thereby cooperating with the T-shaped bracket 9 to grip the assembly pallet 7.

[0041] like Figure 6The gear inspection device shown includes a gear placement fixture, a U-shaped support plate 29 horizontally fixed above the front end of the gear inspection workbench 5 by a column, an industrial camera, and a magnifying display 31. The industrial camera is mounted directly below the U-shaped support plate 29. A camera lighting fixture is also provided at the bottom of the U-shaped support plate 29 on one side of the industrial camera. The magnifying display 31 is vertically mounted on the top of the rear end of the U-shaped support plate 29 and electrically connected to the industrial camera. Two parallel third slide rails 32 are fixed to the top of the rear end of the gear inspection workbench 5. The gear placement fixture is slidably connected to the third slide rails 32 via a slider located at the bottom. The front end of the third slide rail extends directly below the U-shaped support plate 29. During inspection, the gear is first placed on the gear placement fixture, and then the gear placement fixture is pushed directly below the industrial camera. The magnifying display 31 provides magnified observation of the gear's tooth structure. This invention, using this structure, allows for clear observation of the gear's teeth, is not affected by the gear's size, and increases its practicality.

[0042] like Figure 9The gear placement fixture shown includes a fixture base plate 34, two fourth slide rails 57 parallel to each other on the fixture base plate 34, auxiliary support rollers, a spacing adjustment mechanism, a support base 35, a support outer cylinder 36, a three-section support shaft 39, and a handwheel 37. The two fourth slide rails 57 are placed one in front of the other. Two auxiliary support rollers are provided: a first auxiliary support roller 30 and a second auxiliary support roller 58. The first auxiliary support roller 30 and the second auxiliary support roller 58 are placed horizontally, one in front of the other. The two ends of the first auxiliary support roller 30 are connected to the two fourth slide rails 57 via a first sliding block 41 and a second sliding block 42, respectively. The first auxiliary support roller 30 is rotatably connected to the first sliding block 41 and the second sliding block 42. The two ends of the second auxiliary support roller 58 are connected to the two fourth slide rails 57 via a third sliding block 40 and a fourth sliding block 43, respectively. The second auxiliary support roller 58 is rotatably connected to the third sliding block 40 and the fourth sliding block 43, respectively. The spacing adjustment mechanism is provided on the fixture. The top of the right end of the base plate 34 is connected to the second sliding block 42 and the fourth sliding block 43 respectively. The support base 35 is fixedly installed on the top of the left end of the tooling base plate 34. A guide hole matching the support outer cylinder 36 is opened between the left and right ends of the support base 35. The support outer cylinder 36 passes through the guide hole and can move left and right along the guide hole. The support base is connected to a tightening bolt 38 through a threaded through hole opened at the top. The tightening bolt extends into the guide through hole along the threaded through hole to tighten and lock the support outer cylinder. The three-section support shaft 39 is composed of a rotating connection part, a first placement part, a second placement part, and a third placement part connected from left to right. The first placement part, the second placement part, and the third placement part are all provided with a gear lateral restraint structure. The rotating connection part is rotatably connected inside the support outer cylinder 36. One end of the rotating connection part passes through the support outer cylinder 36 and is connected to the handwheel 37. The top of the rear end of the tooling base plate 34 is also provided with two push-pull handles 44. When inspecting the large gear, loosen the tightening bolt and pull the handwheel to the left. Then, adjust the distance between the two auxiliary support rollers using the distance adjustment mechanism according to the actual situation. After adjustment, place the gear on the two auxiliary support rollers. When inspecting the small gear, fit it onto the corresponding placement part according to its size. Then, adjust the position of the outer support cylinder so that the gear is directly below the industrial camera during observation.

[0043] like Figure 9The pitch adjustment mechanism shown includes a knob, an adjusting gear 47, a first rack 45, and a second rack 46. The knob is mounted on the upper end of a rotating shaft, which is vertically rotatably connected to the top of a tooling base plate. The adjusting gear 47 is mounted on the rotating shaft and rotates with it. The first rack 45 and the second rack 46 are respectively located on both sides of the adjusting gear 47 and mesh with it. The rear end of the first rack is connected to a second sliding block 42, and the front end of the second rack is connected to a fourth sliding block 43. This invention adjusts the pitch by rotating the knob, utilizing the meshing of the adjusting gear and the two racks to make the two auxiliary support rollers move in opposite directions.

[0044] like Figure 9 The gear lateral limiting structure shown includes two connecting holes on each of the first placement part, the second placement part, and the third placement part, a spring, and a spherical plug. The spherical plug is connected to the connecting hole by the spring. Under the action of the spring, the spherical plug extends out of the connecting hole to block and limit the gear in the assembly.

[0045] like Figure 6 The top of the convex-shaped support plate 29 shown is also equipped with a small piston air compressor 33, which is connected to a jet-type cleaning air gun via a hose. This invention uses a jet-type cleaning air gun to perform jet-type cleaning on various surfaces of the gears, housing, input shaft, and output shaft of the reducer, thus increasing its practicality.

[0046] The present invention also provides an assembly process for a speed reducer, which specifically includes the following steps: S1: Material Retrieval: First, small parts are intelligently retrieved through an intelligent sorting system. At the same time, the reducer housing, input shaft, output shaft, and gears are manually retrieved and transported to the assembly station. S2: Cleaning and Inspection: The inner and outer surfaces of the gearbox housing, input shaft, output shaft, and gears are cleaned by blowing air gun. After cleaning, the gears are inspected using a gear placement fixture, an industrial camera, and a magnifying monitor. S3: Assembly of housing and bearings: After inspection and verification, transport the lower housing of the reducer to the assembly station of the assembly workbench for fixing. After leveling with a level, use the heating method or cold installation method to install the bearing into the shaft and housing hole, ensuring that it is close to the shaft shoulder and the shaft shoulder gap is <0.02mm. S4: Gear shaft assembly: Assemble the gears onto the input shaft and output shaft in sequence. First, install the large gear and ensure it is close to the shaft shoulder. Use a 0.03-0.05mm feeler gauge to check that it does not fit. S5: Gear shaft assembly into the housing: Smoothly lift the assembled gear shaft into the lower housing, check and adjust the gear backlash and bearing clearance; S6: Gear grinding: Apply colorant to the drive wheel, then manually rotate the wheel and inspect by observing the contact marks. The length should be ≥85% and the height ≥60%. S7: Box assembly and sealing: After confirming that there are no foreign objects inside the box, apply sealant to the split surface, install the tapered pin for positioning, and tighten the connecting bolts in multiple steps according to the diagonal sequence and the specified torque; S8: Install external accessories: Inject lubricating oil / grease, and press in using the screw hole at the shaft end when assembling couplings or pulleys; S9: Testing and Inspection: First, perform a pneumatic pressure test on the assembled reducer. The pressure remains constant at 0.2MPa for 30 seconds. Then, perform no-load and load tests. Run at low speed for 30 minutes. After checking for any abnormalities, gradually increase the speed and perform 4 hours of temperature rise monitoring and 8 hours of load testing. Check for vibration and noise during the tests.

[0047] This invention employs a quantitative assembly standard by controlling the shoulder clearance to be less than 0.02mm, checking for non-penetration with a 0.03-0.05mm feeler gauge, and observing contact marks to ensure the length is greater than or equal to 85% and the height is greater than or equal to 60%, rather than relying on experience. This avoids the uncertainty caused by assembly based on worker feel, ensuring that the transmission efficiency and operating noise of each reducer meet design specifications upon leaving the factory. Furthermore, it ensures the quality of the reducer after assembly, enabling it to withstand high loads. The invention's strict clearance control and gear grinding inspection maximize the contact area of ​​the gears under load, effectively preventing localized overload and tooth breakage, and significantly improving impact resistance.

[0048] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should be considered within the scope of protection of the present invention.

Claims

1. An assembly device for a speed reducer, characterized in that: The system includes an intelligent sorting system for small parts, an assembly pallet (7), a parts conveying system, a transfer device, and an assembly workbench (6). The parts conveying system is a ball conveyor line (1), which is connected end to end with a partition plate (16) between its ends. The transfer loading station (II) and the transfer unloading station (III) are respectively located on the ball conveyor line (1) on both sides of the partition plate. The transfer device is located on one side of the transfer loading station (II) and the transfer unloading station (III). Small parts are loaded into the assembly pallet (7) through the intelligent sorting system. The assembly pallet (7) has several placement areas and two T-shaped supports for handling. 9) and an identification label (8) with a chip, wherein the assembly pallet (7) is transferred from the intelligent sorting system to the ball conveyor line (1) by a transfer device, wherein the ball conveyor line (1) is provided with several assembly loading and unloading stations (Ⅳ), and each assembly loading and unloading station (Ⅳ) is provided with an assembly workbench (6) on one side, wherein the assembly workbench (6) is provided with an assembly station (Ⅵ) and an assembly part picking station (Ⅴ) on the left and right sides respectively, wherein the assembly part picking station (Ⅴ) is equipped with a picking robot arm, wherein one end of the assembly station (Ⅵ) on the assembly workbench is connected to the gear detection workbench (5), wherein the gear detection workbench (5) is provided with a gear detection device; The intelligent sorting system includes a pallet roller loading conveyor (2) and a pallet roller unloading conveyor (3) arranged side by side, a storage rack (20) set on one side of the pallet roller loading conveyor (2), a parts conveyor (21) and a parts gripping robot arm. One end of the pallet roller loading conveyor (2) and the pallet roller unloading conveyor (3) extends into the transfer device. Several assembly loading stations (Ⅰ) are arranged sequentially from front to back on the pallet roller loading conveyor (2). Each assembly loading station (Ⅰ) has a storage rack (20) on one side. Three parts conveyors (21) are arranged sequentially from front to back on the storage rack (20). Several parts storage racks are arranged sequentially from left to right on the parts conveyors. The assembled parts are taken out from the parts storage racks by the parts gripping robot arm and placed on the assembly pallet (7). The gear inspection device includes a gear placement fixture, a U-shaped support plate (29) horizontally fixed above the front end of the gear inspection workbench (5) by a column, an industrial camera, and a magnifying display (31). The industrial camera is installed directly below the U-shaped support plate (29). A camera lighting fixture is also provided at the bottom of the U-shaped support plate (29) on one side of the industrial camera. The magnifying display (31) is vertically installed at the top of the rear end of the U-shaped support plate (29) and electrically connected to the industrial camera. Two parallel third slide rails (32) are fixed at the top of the rear end of the gear inspection workbench (5). The gear placement fixture is slidably connected to the third slide rails (32) by a slider at the bottom. The front end of the third slide rail extends directly below the U-shaped support plate (29).

2. The assembly device for a speed reducer according to claim 1, characterized in that: The gripping robotic arm consists of a component gripper, a lifting electric cylinder, a first telescopic electric cylinder (23), a first telescopic support plate (24), a lead screw translation mechanism (27), and a position adjustment plate (26). The component gripper is connected to the bottom of the first telescopic support plate (24) via the lifting electric cylinder. The top of the first telescopic support plate (24) is provided with an inverted first trapezoidal slide rail (25). The bottom of the position adjustment plate is provided with a first groove relative to the position of the first trapezoidal slide rail (25). The first telescopic support plate (24) is connected to the bottom of the position adjustment plate through the cooperation of the first trapezoidal slide rail and the first groove, and is driven by the first telescopic electric cylinder (23) to the right end of the component conveyor. The position adjustment plate moves left and right above the corresponding assembly loading station (Ⅰ). The bottom of the position adjustment plate is provided with a second sliding groove that matches the second guide rail (28) at the top of the first upper support plate (22). The second guide rail (28) is an inverted trapezoid. The position adjustment plate is connected to the first upper support plate (22) through the screw translation mechanism (27) and moves back and forth along the second guide rail under the drive of the screw translation mechanism. The first upper support plate (22) is horizontally fixed on the top of the storage rack (20). The right end of the component conveyor (21) is located directly below the outside of the right end of the first upper support plate. The right end of the position adjustment plate extends to the right end of the component conveyor (21).

3. The assembly device for a speed reducer according to claim 1, characterized in that: The transfer device includes a transfer box (4), a first transfer plate (17), a second transfer plate (18), a translational electric cylinder (19), and a first pallet gripper structure. The transfer box (4) has a first inlet and a first outlet on one side facing the pallet roller feeding conveyor line (2) and the pallet roller unloading conveyor line (3), respectively. The pallet roller feeding conveyor line (2) and the pallet roller unloading conveyor line (3) extend into the transfer box (4) along the first inlet and the first outlet, respectively. On the other side of the transfer box (4), a second outlet and a second inlet are respectively located opposite the first inlet and the first outlet. The translational electric cylinder (19) is installed on the top of the transfer box (4). The output shaft end of the translational electric cylinder (19) is connected to the first transfer plate (17) through a transmission component. The top of the transfer box (4) has a through groove for the transmission component to extend into. The transmission component extends into the transfer box along the through groove. Inside the box (4) and driven by the translation electric cylinder, it moves along the through groove. The first transfer plate (17) and the second transfer plate (18) are set horizontally. One end of the pallet roller feeding conveyor line (2) extends along the first feed port to the bottom of one end of the first transfer plate (17). The other end of the first transfer plate (17) extends along the second discharge port to the top of the transfer feeding station (Ⅱ). The first transfer plate (17) can move left and right in the second discharge port under the drive of the translation electric cylinder (19). One end of the pallet roller unloading conveyor line (3) extends along the first discharge port to the bottom of one end of the second transfer plate (18) in the transfer box (4). The other end of the second transfer plate (18) extends along the second feed port to the top of the transfer unloading station (Ⅲ). The bottom of the first transfer plate (17) and the second transfer plate (18) are each connected to a set of first pallet gripper structures through the front and rear translation mechanism.

4. The assembly device for a speed reducer according to claim 1, characterized in that: The material handling robotic arm includes a second telescopic electric cylinder (49), a second telescopic support plate (51), a second lifting electric cylinder (53), and a second pallet gripper structure. The second pallet gripper structure is connected to the bottom of the second telescopic support plate (51) via the second lifting electric cylinder (53). A second slide rail (52) is provided on the top of the second telescopic support plate (51). The second slide rail is in the shape of an inverted trapezoid. A second upper support plate (48) is horizontally fixed above the assembly material handling station (V) via a column. A third slide groove is provided at the bottom of the second upper support plate (48) relative to the position of the second slide rail. The second telescopic support plate (51) is connected to the bottom of the second upper support plate (48) through the cooperation of the second slide rail and the third slide groove. Driven by the second telescopic electric cylinder (49), it moves horizontally above the assembly material handling station (V) and above the corresponding assembly loading and unloading station (Ⅳ). An alarm reminder light (50) is installed on the top of the second upper support plate (48).

5. The assembly device for a speed reducer according to claim 1, characterized in that: The gear placement fixture includes a fixture base plate (34), two fourth slide rails (57) arranged parallel to each other on the fixture base plate (34), auxiliary support rollers, a spacing adjustment mechanism, a support base (35), a support outer cylinder (36), a three-section support shaft (39), and a handwheel (37). The two fourth slide rails (57) are placed one in front of the other. There are two auxiliary support rollers, namely a first auxiliary support roller (30) and a second auxiliary support roller (58). The first auxiliary support roller (30) and the second auxiliary support roller (58) are arranged in a front-to-back configuration. The first auxiliary support roller (30) is placed horizontally. Its two ends are connected to two fourth slide rails (57) via a first sliding block (41) and a second sliding block (42), respectively. The first auxiliary support roller (30) is rotatably connected to the first sliding block (41) and the second sliding block (42). The two ends of the second auxiliary support roller (58) are connected to two fourth slide rails (57) via a third sliding block (40) and a fourth sliding block (43), respectively. The second auxiliary support roller (58) is rotatably connected to the third sliding block (40) and the fourth sliding block (43). The spacing adjustment mechanism is located at the top right end of the tooling base plate (34) and is connected to the second sliding block (42) and the fourth sliding block (43) respectively. The support base (35) is fixedly installed at the top left end of the tooling base plate (34). A guide hole matching the support outer cylinder (36) is opened between the left and right ends of the support base (35). The support outer cylinder (36) passes through the guide hole and can move left and right along the guide hole. The support base is connected to a tightening bolt (38) through a threaded through hole at the top. The tightening bolt moves along the threaded through hole. The through hole extends into the guide through hole to tighten and lock the outer cylinder of the support. The three-section support shaft (39) is composed of a rotating connection part, a first placement part, a second placement part and a third placement part connected from left to right. The first placement part, the second placement part and the third placement part are all provided with a gear lateral restraint structure. The rotating connection part is rotatably connected inside the outer cylinder of the support (36). One end of the rotating connection part passes through the outer cylinder of the support (36) and is connected to the handwheel (37). The top of the rear end of the tooling base plate (34) is also provided with two push-pull handles (44).

6. The assembly device for a speed reducer according to claim 5, characterized in that: The spacing adjustment mechanism includes a knob, an adjustment gear (47), a first rack (45), and a second rack (46). The knob is installed on the upper end of the rotating shaft, which is vertically connected to the top of the tooling base plate. The adjustment gear (47) is mounted on the rotating shaft and rotates with it. The first rack (45) and the second rack (46) are respectively arranged on both sides of the adjustment gear (47) and mesh with it. The rear end of the first rack is connected to the second sliding block (42), and the front end of the second rack is connected to the fourth sliding block (43).

7. The assembly device for a speed reducer according to claim 1, characterized in that: The top of the convex support plate (29) is also equipped with a small piston air compressor (33), which is connected to the blow-type cleaning air gun through a hose.

8. An assembly process for an assembly device for a speed reducer according to any one of claims 1-7, characterized in that: Specifically, the following steps are included: S1: Material Retrieval: First, small parts are intelligently retrieved through an intelligent sorting system. At the same time, the reducer housing, input shaft, output shaft, and gears are manually retrieved and transported to the assembly station. S2: Cleaning and Inspection: The inner and outer surfaces of the gearbox housing, input shaft, output shaft, and gears are cleaned by blowing air gun. After cleaning, the gears are inspected using a gear placement fixture, an industrial camera, and a magnifying monitor. S3: Assembly of housing and bearings: After inspection and verification, transport the lower housing of the reducer to the assembly station of the assembly workbench for fixing. After leveling with a level, use the heating method or cold installation method to install the bearing into the shaft and housing hole, ensuring that it is close to the shaft shoulder. S4: Gear shaft assembly: Assemble the gears onto the input shaft and output shaft in sequence, first assembling the larger gear and ensuring it is close to the shaft shoulder; S5: Gear shaft assembly into the housing: Smoothly lift the assembled gear shaft into the lower housing, check and adjust the gear backlash and bearing clearance; S6: Gear grinding: Apply a colorant to the drive wheel, then manually rotate the wheel and inspect by observing the contact marks; S7: Box assembly and sealing: After confirming that there are no foreign objects inside the box, apply sealant to the split surface, install the tapered pin for positioning, and tighten the connecting bolts in multiple steps according to the diagonal sequence and the specified torque; S8: Install external accessories: Inject lubricating oil / grease, and press in using the screw hole at the shaft end when assembling couplings or pulleys; S9: Testing and Inspection: First, perform a pneumatic pressure test on the assembled reducer. The pressure remains constant at 0.2MPa for 30 seconds. Then, perform no-load and load tests. Run at low speed for 30 minutes. After checking for any abnormalities, gradually increase the speed and perform 4 hours of temperature rise monitoring and 8 hours of load testing. Check for vibration and noise during the tests.

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