A fastening device and method for compressor split cylinder heads and cylinder blocks

Abstract

The application provides a fastening device and method for a compressor split cylinder head and cylinder base, comprising a tool support, a rotary drive mechanism, a cylinder head pushing mechanism, a fastening mechanism, a position sensor and a controller, the tool support is used for positioning a pump body, the rotary drive mechanism is used for driving the crankshaft of the pump body to rotate so that the piston moves to the top dead center position, the cylinder head pushing mechanism is used for pushing the cylinder head to the crankshaft hole direction by a certain distance to adjust the piston extension value, and the fastening mechanism is used for tightening the connecting bolt between the cylinder head and the cylinder base; the position sensor is used for detecting whether the piston reaches the top dead center position, and the rotary drive mechanism, the cylinder head pushing mechanism, the fastening mechanism and the position sensor are all signal connected with the controller; the application realizes automatic fastening of the split cylinder head and the cylinder base on the assembly production line, can control the piston extension value within the set range, thereby reducing the gasket group, simplifying the assembly process and improving the product quality consistency.

Description

Technical Field

[0001] This invention relates to the field of compressor manufacturing technology, specifically to a fastening device and method for a split cylinder head and cylinder seat in a compressor. Background Technology

[0002] Existing reciprocating piston compressors typically consist of components such as a cylinder block, crankshaft, piston, and connecting rod. During production, these components are first assembled into a pump body, and then the motor is installed. The clearance of the cylinder has a significant impact on the compressor's performance during operation. The clearance is the distance between the piston end face and the cylinder end face when the piston reaches top dead center. The larger the clearance, the greater the negative impact on the compressor's performance. To minimize the clearance volume, a gasket of appropriate thickness is usually installed at the cylinder head. Existing cylinder blocks are generally integrally cast structures, and the cumulative machining errors of each part will eventually affect the piston extension value. Therefore, during actual assembly, the piston extension value of each pump body needs to be measured, and a suitable gasket needs to be selected based on the measured value. Currently, the gasket thickness range on the production line is quite large, with 20-30 groups of valve plate gaskets. Workers often select the wrong group during assembly, which is detrimental to improving product quality consistency.

[0003] To effectively control piston extension, some compressor manufacturers have developed a structure that separates the cylinder head from the cylinder seat. The cylinder head and cylinder seat are fixed together by bolts, allowing for flexible adjustment of the distance between the cylinder surface and the center of the crankshaft bore within a certain range. However, in mass production, there is no automated fastening device suitable for this structure. Therefore, in order to improve product quality consistency, it is essential to develop a fastening device for the separate cylinder head and cylinder seat structure to meet the needs of mass production of this structure. Summary of the Invention

[0004] The purpose of this invention is to solve the problems existing in the prior art and to provide a fastening device for a compressor with a separate cylinder head and cylinder seat.

[0005] The specific solution of the present invention is: a fastening device for a compressor with a separate cylinder head and cylinder seat, comprising a tooling bracket, a rotary drive mechanism, a cylinder head pushing mechanism, a fastening mechanism, a position sensor, and a controller. The tooling bracket is used to position and place the pump body. The rotary drive mechanism is used to drive the crankshaft of the pump body to rotate, causing the piston to move to the top dead center position. The cylinder head pushing mechanism is used to push the cylinder head a certain distance towards the crankshaft hole to adjust the piston extension value. The fastening mechanism is used to tighten the connecting bolts between the cylinder head and the cylinder seat. The position sensor is used to detect whether the piston has reached the top dead center position. The rotary drive mechanism, the cylinder head pushing mechanism, the fastening mechanism, and the position sensor are all signal-connected to the controller.

[0006] Furthermore, the rotary drive mechanism includes a servo motor, the output end of which is equipped with a split clamp for clamping the crankshaft, and the servo motor drives the crankshaft to rotate through the clamp.

[0007] Furthermore, the position sensor is positioned above the pump body and aligned with the crankshaft balance block of the pump body. When the process notch of the balance block aligns with the position sensor, it indicates that the piston has reached the top dead center position.

[0008] Furthermore, the cylinder head pushing mechanism includes a servo electric cylinder, the output end of which is equipped with a U-shaped pad. The opening of the U-shaped pad faces the cylinder head and the opening width is greater than the piston diameter. A displacement sensor is installed inside the opening of the U-shaped pad, and the probe of the displacement sensor is aligned with the end face of the piston for real-time detection of the piston extension value.

[0009] Furthermore, the fastening mechanism includes an electric shaft, the output end of which is equipped with a sleeve that matches the bolt, and the electric shaft is used to control the bolt fastening torque.

[0010] Furthermore, the tooling bracket includes a base plate, on which several pillars are provided. A positioning plate is mounted on the top of all the pillars. The top surface of the positioning plate is provided with a positioning pin that matches the position of the cylinder seat support. Both the positioning plate and the base plate have through holes in their centers, which are used to allow the lower end of the crankshaft to pass through.

[0011] The present invention also provides a method for fastening a split cylinder head and cylinder seat of a compressor, using the above-mentioned fastening device, specifically including the following steps: S1. The tooling bracket carrying the pump body is transferred through the assembly line. When the tooling bracket reaches the fastening station, it is intercepted and stopped. S2. The rotary drive mechanism extends from bottom to top into the tooling bracket, driving the crankshaft to rotate. When the position sensor detects the process gap of the balance block, it feeds back to the rotary drive mechanism to stop automatically. S3. The cylinder head pushing mechanism moves by pushing the cylinder head towards the crankshaft hole using a U-shaped pad. During the pushing process, the displacement sensor detects in real time. When the detected value reaches the preset value, the cylinder head pushing mechanism automatically stops. S4. The fastening mechanism operates to tighten the connecting bolts between the cylinder head and the cylinder seat.

[0012] Furthermore, the fastening station is equipped with a lifting stop and a photoelectric sensor. The lifting stop is used to intercept the tooling bracket, and the photoelectric sensor is used to detect whether there is a tooling bracket supporting the pump body at the fastening station. Both the photoelectric sensor and the lifting stop are connected to the controller signal.

[0013] Compared with the prior art, the present invention has the following advantages: it realizes the automated fastening of the separate cylinder head and cylinder seat structure, thereby meeting the needs of mass production; it can stably control the piston extension value of each compressor, greatly reducing the number of gasket thickness groups, improving assembly efficiency, and improving product quality stability. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural schematic diagram of the present invention; Figure 2 This is a perspective view of the invention from another angle; Figure 3 This is a top view of the present invention; Figure 4 yes Figure 3 AA view; Figure 5 This is a schematic diagram of the structure of the separate cylinder head and cylinder seat of the present invention; In the diagram: 1. Tooling bracket; 101. Base plate; 102. Support column; 103. Positioning plate; 2. Cylinder seat; 201. Threaded hole; 3. Crankshaft balance block; 301. Process notch; 4. Position sensor; 5. Cylinder head; 501. Bolt hole; 6. Sleeve; 7. U-shaped pad; 8. Servo electric cylinder; 9. Displacement sensor; 10. Clamp; 11. Servo motor. Detailed Implementation

[0015] See Figure 1-5 This embodiment provides a fastening device for a compressor with a separate cylinder head 5 and cylinder seat 2, including a tooling bracket 1, a rotary drive mechanism, a cylinder head pushing mechanism, a fastening mechanism, a position sensor 4, and a controller. The tooling bracket 1 is used to position and place the pump body. The rotary drive mechanism is used to drive the crankshaft of the pump body to rotate, so that the piston moves to the top dead center position. The cylinder head pushing mechanism is used to push the cylinder head 5 a certain distance towards the crankshaft hole to adjust the piston extension value. The fastening mechanism is used to tighten the connecting bolts between the cylinder head 5 and the cylinder seat 2. The position sensor 4 is used to detect whether the piston has reached the top dead center position. The rotary drive mechanism, cylinder head pushing mechanism, fastening mechanism, and position sensor 4 are all signal-connected to the controller.

[0016] Furthermore, the rotary drive mechanism includes a servo motor 11, the output end of which is equipped with a segmented clamp 10. The segmented clamp 10 is used to clamp the crankshaft, and the servo motor 11 drives the crankshaft to rotate through the clamp 10. The segmented clamp 10 is composed of multiple circumferentially distributed clamping arms. When the clamp 10 is in motion, it clamps the lower end of the crankshaft from the outside to the inside, and then drives the clamp 10 to rotate through the servo motor 11, thereby driving the crankshaft to rotate.

[0017] Furthermore, the position sensor 4 is positioned above the pump body, aligned with the crankshaft balance block 3 of the pump body. When the process notch 301 of the balance block aligns with the position sensor 4, it indicates that the piston has reached the top dead center position. In this embodiment, the position sensor 4 is a photoelectric sensor, aligned with the process notch 301 of the crankshaft balance block 3 when the piston is at the top dead center position. The rotary drive mechanism drives the crankshaft to rotate at a relatively slow speed. When the process notch 301 of the balance block rotates to the detection point position of the photoelectric sensor, a signal is sent to the controller. The controller sends a command to control the servo motor 11 to stop immediately and remain at that position. At this time, the piston is at the top dead center position.

[0018] Furthermore, the cylinder head pushing mechanism includes a servo electric cylinder 8, the output end of which is equipped with a U-shaped pad 7. The opening of the U-shaped pad 7 faces the cylinder head 5 and the opening width is greater than the piston diameter. A displacement sensor 9 is installed inside the opening of the U-shaped pad 7. The probe of the displacement sensor 9 is aligned with the end face of the piston for real-time detection of the piston extension value.

[0019] In this embodiment, a crossbar is provided in the middle of the opening of the U-shaped pad 7. The two ends of the crossbar are fixedly connected to the U-shaped pad 7. The displacement sensor 9 is fixedly installed in the middle of the crossbar. The displacement sensor 9 is a contact sensor, and its end is provided with a spring-loaded probe. The probe is arranged along the axial direction of the piston and perpendicular to the piston end face.

[0020] Furthermore, the fastening mechanism includes an electric shaft, the output end of which is equipped with a sleeve 6 that matches the bolt. The electric shaft is used to control the bolt tightening torque to ensure that the bolt tightening torque reaches the set process parameters, thereby ensuring that the cylinder head 5 and the cylinder seat 2 will not loosen or slip.

[0021] Furthermore, the tooling bracket 1 includes a base plate 101, on which a plurality of support columns 102 are provided. All the support columns 102 are mounted on a common positioning plate 103 at their top ends. The top surface of the positioning plate 103 is provided with a positioning pin that matches the position of the cylinder seat 2 support leg. The center of the positioning plate 103 and the base plate 101 are provided with through holes, through which the lower end of the crankshaft and the clamp 10 pass.

[0022] The present invention also provides a method for fastening the separate cylinder head 5 and cylinder seat 2 of a compressor, using the above-mentioned fastening device, specifically including the following steps: S1. The tooling bracket 1 carrying the pump body flows through the assembly line. When the tooling bracket 1 runs to the fastening station, it is intercepted and stopped. At the position where the tooling bracket 1 stops, the clamp 10 of the rotary drive mechanism is exactly coaxial with the crankshaft, and the U-shaped pad 7 is directly opposite the end face of the cylinder head 5. The piston is in the middle of the opening of the U-shaped pad 7. S2. The rotary drive mechanism extends from bottom to top into the tooling bracket 1, driving the crankshaft to rotate. When the position sensor 4 detects the process gap 301 of the balance block, it feeds back to the rotary drive mechanism to stop automatically. S3. The cylinder head pushing mechanism moves by pushing the cylinder head 5 towards the crankshaft hole through the U-shaped pad 7. The displacement sensor 9 detects in real time during the pushing process. When the detected value reaches the preset value, the cylinder head pushing mechanism is automatically stopped. S4. The fastening mechanism operates to tighten the connecting bolts between the cylinder head 5 and the cylinder seat 2.

[0023] Furthermore, the fastening station is equipped with a lifting stop and a photoelectric sensor. The lifting stop is used to intercept the tooling bracket 1, and the photoelectric sensor is used to detect whether there is a tooling bracket 1 carrying the pump body at the fastening station. Both the photoelectric sensor and the lifting stop are connected to the controller signal.

[0024] The working principle of this invention is as follows: When the tooling bracket 1 carrying the pump body moves to the fastening position and stops moving, the rotation drive mechanism first drives the crankshaft to rotate slowly. When the position sensor 4 detects the notch of the crankshaft balance block 3, it indicates that the piston has reached the top dead center position. Because when the piston is at the top dead center position, the process notch 301 of the crankshaft balance block 3 will also reach the fixed position. At this time, the rotation drive mechanism stops immediately, so that the piston stays at the top dead center position. Then the cylinder head pushing mechanism moves, pushing the cylinder head 5 towards the crankshaft hole through the U-shaped pad 7. During the pushing process, the displacement sensor 9 first contacts the piston end face. As the cylinder head 5 moves, the probe of the displacement sensor 9 is continuously compressed by the piston, generating a displacement distance signal. When the cylinder head 5 moves to a certain position, the distance of the piston extending out of the cylinder surface enters the preset standard range of piston extension value. At this time, the cylinder head pushing mechanism stops immediately, and then the fastening mechanism moves to tighten the bolts between the cylinder head 5 and the cylinder seat 2, thereby fixing the piston extension value at the top dead center position of the pump body, which facilitates subsequent assembly process control parameters and helps improve product consistency.

[0025] A bolt hole 501 is provided on each side of the cylinder head 5, and two threaded holes 201 are provided on the cylinder seat 2 accordingly. The bolt hole 501 is slightly larger than the threaded hole 201. When adjusting the piston extension value, the cylinder head 5 is allowed to make a small displacement relative to the cylinder seat 2. After the bolt is tightened, the cylinder head 5 and the cylinder seat 2 can no longer move relative to each other. This invention controls the piston extension value within the set range by controlling the distance of the cylinder head 5 to move online, thereby reducing the number of valve plate gasket groups from 20-30 groups to 1-3 groups, basically eliminating the possibility of workers selecting the wrong gasket, thereby achieving the goal of improving the stability of product quality.

Claims

1. A fastening device for a split cylinder head and cylinder seat in a compressor, characterized in that: The system includes a tooling bracket, a rotary drive mechanism, a cylinder head pushing mechanism, a fastening mechanism, a position sensor, and a controller. The tooling bracket is used to position and place the pump body. The rotary drive mechanism is used to drive the crankshaft of the pump body to rotate, causing the piston to move to the top dead center position. The cylinder head pushing mechanism is used to push the cylinder head a certain distance towards the crankshaft hole to adjust the piston extension value. The fastening mechanism is used to tighten the connecting bolts between the cylinder head and the cylinder seat. The position sensor is used to detect whether the piston has reached the top dead center position. The rotary drive mechanism, cylinder head pushing mechanism, fastening mechanism, and position sensor are all connected to the controller for signal transmission.

2. The fastening device for a split cylinder head and cylinder seat of a compressor according to claim 1, characterized in that: The rotary drive mechanism includes a servo motor, the output end of which is equipped with a split clamp. The split clamp is used to clamp the crankshaft, and the servo motor drives the crankshaft to rotate through the clamp.

3. A fastening device for a compressor split cylinder head and cylinder seat according to claim 1, characterized in that: The position sensor is positioned above the pump body and aligned with the crankshaft balance block of the pump body. When the process notch of the balance block aligns with the position sensor, it indicates that the piston has reached the top dead center position.

4. A fastening device for a split cylinder head and cylinder seat of a compressor according to claim 1, characterized in that: The cylinder head pushing mechanism includes a servo electric cylinder. The output end of the servo electric cylinder is equipped with a U-shaped pad. The opening of the U-shaped pad faces the cylinder head and the opening width is greater than the piston diameter. A displacement sensor is installed inside the opening of the U-shaped pad. The probe of the displacement sensor is aligned with the end face of the piston to detect the piston extension value in real time.

5. A fastening device for a compressor split cylinder head and cylinder seat according to claim 1, characterized in that: The fastening mechanism includes an electric shaft, the output end of which is equipped with a sleeve that matches the bolt. The electric shaft is used to control the bolt tightening torque.

6. A fastening device for a compressor split cylinder head and cylinder seat according to claim 1, characterized in that: The tooling bracket includes a base plate with several support columns. All the support columns are mounted on a positioning plate at their top. The top surface of the positioning plate is provided with a positioning pin that matches the position of the cylinder seat support. The positioning plate and the base plate are both provided with a through hole in their center, which is used to allow the lower end of the crankshaft to pass through.

7. A method for fastening a split cylinder head and cylinder seat in a compressor, characterized in that: The fastening device according to any one of claims 1-6 specifically includes the following steps: S1. The tooling bracket carrying the pump body is transferred through the assembly line. When the tooling bracket reaches the fastening station, it is intercepted and stopped. S2. The rotary drive mechanism extends from bottom to top into the tooling bracket, driving the crankshaft to rotate. When the position sensor detects the process gap of the balance block, it feeds back to the rotary drive mechanism to stop automatically. S3. The cylinder head pushing mechanism moves by pushing the cylinder head towards the crankshaft hole using a U-shaped pad. During the pushing process, the displacement sensor detects in real time. When the detected value reaches the preset value, the cylinder head pushing mechanism automatically stops. S4. The fastening mechanism operates to tighten the connecting bolts between the cylinder head and the cylinder seat.

8. The fastening method for a split cylinder head and cylinder seat of a compressor according to claim 7, characterized in that: The fastening station is equipped with a lifting stop and a photoelectric sensor. The lifting stop is used to intercept the tooling bracket, and the photoelectric sensor is used to detect whether there is a tooling bracket supporting the pump body at the fastening station. Both the photoelectric sensor and the lifting stop are connected to the controller signal.

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