An automated assembly line and method for initial assembly of a differential

Abstract

The application discloses an automatic assembly production line and method for initial assembly of a differential. The automatic assembly production line comprises a housing splitting device for splitting a differential housing into a first half housing and a second half housing; a half shaft gear assembly device for assembling two groups of half shaft gears into the first half housing and the second half housing respectively; a conveyor provided with a positioning seat and used to move the positioning seat between the housing splitting device and the half shaft gear assembly device, the positioning seat being provided with a first supporting structure and a second supporting structure; and a mechanical arm provided with a gripper assembly, the mechanical arm being used to sequentially clamp the first half housing and the second half housing obtained after splitting by the gripper assembly and place the two half housings on the first supporting structure and the second supporting structure respectively. The automatic splitting operation of the differential housing and the automatic assembly operation of the half shaft gears relative to the two half housings can be respectively realized by the housing splitting device and the half shaft gear assembly device, so that the assembly efficiency is significantly improved.

Description

Technical Field

[0001] This application relates to the field of differential manufacturing technology, specifically to an automated assembly line and automated assembly method for the initial assembly of differentials. Background Technology

[0002] The differential is a core component of an automotive transmission system, used in the electric drive assemblies of new energy vehicles. The assembly quality of the differential directly affects the vehicle's driving performance and safety. In the differential manufacturing process, the initial assembly stage typically involves disassembling the one-piece differential housing into two halves, and then installing axle gears and shims into each half. Currently, the initial assembly stage presents several problems: First, the housing disassembly operation largely relies on manual labor or semi-automatic equipment for bolt removal and hammering, making it difficult to achieve continuous and efficient automated production lines. The axle gear installation process is cumbersome, involving the handling of gears and shims. This results in low assembly efficiency. Second, the current semi-automatic equipment has an unreasonable structural design, generally only capable of automating the tightening of nuts, with a low degree of automation. Furthermore, nuts and bolts often fall off after loosening, increasing the burden of manual cleaning and sorting later, and potentially causing parts loss or even equipment jamming. In addition, current semi-automatic equipment has poor versatility, as it is designed only for a specific model of differential. When the specifications and model of the differential to be produced change, the original tooling structure cannot be applied because the distribution of flange holes, screw position, and inner diameter of half-shaft gears change. Summary of the Invention

[0003] This application aims to address one of the technical problems in related technologies to a certain extent. To this end, this application provides an automated assembly line and automated assembly method for the initial assembly of differentials.

[0004] To achieve the above objectives, this application adopts the following technical solution: an automated assembly line for the initial assembly of differentials, comprising:

[0005] A housing splitting device for splitting the differential housing into a first half-shell and a second half-shell;

[0006] A half-shaft gear assembly device, which is used to install two sets of half-shaft gears into the first half-shell and the second half-shell respectively;

[0007] A conveyor is provided with a positioning seat and is used to drive the positioning seat to move between a shell splitting device and a half-shaft gear assembly device. The positioning seat is provided with a first support structure for supporting and positioning a first half-shell and a second support structure for supporting and positioning a second half-shell.

[0008] A robotic arm is provided with a gripper assembly. The robotic arm is used to sequentially grip the first half shell and the second half shell obtained after disassembly through the gripper assembly, and place the first half shell and the second half shell on the first support structure and the second support structure respectively.

[0009] The shell disassembly device includes:

[0010] The first turntable has four support positions for supporting the differential housing, and the four support positions switch positions sequentially between the loading position, the screwing position, the pushing position and the unloading position under the rotation of the first turntable.

[0011] A screwing device comprising multiple sets of nut screwing assemblies and used to screw a locking nut on a differential housing via the nut screwing assemblies;

[0012] A pushing device, comprising a lifting and moving jacking mechanism for jacking a locking screw on the differential housing via the jacking mechanism;

[0013] A collection device comprising a first collection mechanism for collecting lock nuts and a second collection mechanism for collecting lock screws.

[0014] The application of this application has the following beneficial effects: By setting up a housing splitting device and a half-shaft gear assembly device to realize the automated splitting operation of the differential housing and the automated assembly operation of the half-shaft gear relative to the two half-housing halves, the assembly efficiency can be significantly improved. Through the cooperation of a robotic arm and a conveyor, the first half-housing halves and the second half-housing halves can be transferred between the housing splitting device and the half-shaft gear assembly device in one go. The first half-housing halves and the second half-housing halves are transferred synchronously on the positioning seat, which facilitates the subsequent synchronous installation of the half-shaft gear.

[0015] Optionally, the screwing device further includes a first lifting drive mechanism, a lifting frame that is driven by the first lifting drive mechanism to move up and down, a rotation drive mechanism disposed on the lifting frame, and a rotating frame that is driven by the rotation drive mechanism to rotate, with multiple sets of the nut screwing assemblies distributed circumferentially on the rotating frame.

[0016] The nut tightening assembly includes a mounting bracket, a pneumatic impact wrench, a housing locking mechanism, and a nut clamping mechanism, all of which are mounted on the mounting bracket.

[0017] The pneumatic impact wrench is used to tighten the lock nut, the housing locking mechanism is used to position the differential housing circumferentially, and the nut clamping mechanism is used to clamp and position the lock nut after it is separated from the lock screw.

[0018] Optionally, the screwing device further includes a first linear driver disposed on the rotating frame. The number of first linear drivers is the same as the number of nut screwing assemblies and corresponds one-to-one. The output end of the first linear driver is connected to the mounting frame and is used to drive the nut screwing assembly to move radially as a whole.

[0019] Optionally, the first collecting mechanism includes a first horizontal driving mechanism, a support frame that is driven by the first horizontal driving mechanism and can move horizontally, a drive motor disposed on the support frame, and a receiving tray. The drive motor is connected to the receiving tray and is used to drive the receiving tray to swing relative to the support frame.

[0020] Optionally, the pushing device further includes a second lifting drive mechanism, a second horizontal drive mechanism, and a translation frame that is driven by the second horizontal drive mechanism and can move in the horizontal direction. The pushing mechanism is provided in multiple sets and is adapted to different models of differential housings. The multiple sets of pushing mechanisms are flexibly and vertically arranged on the translation frame.

[0021] The jacking mechanism includes a connecting member and a plurality of jacking heads disposed on the connecting member. The second lifting drive mechanism is connected to the connecting member and is used to drive the jacking mechanism to move up and down, so as to push the locking screw out of the differential housing through the jacking heads.

[0022] Optionally, the second collection mechanism includes a collection cylinder disposed on the first turntable and a collection box located below the first turntable. The collection cylinder passes through the first turntable and is aligned with the locking screw of the differential housing. The collection box has a collection opening that extends along the screw position to the push position.

[0023] Optionally, the gripper assembly includes a rotating mechanism and a two-finger gripper that is rotatable by the rotating mechanism. The robotic arm grips the first half-shell and the second half-shell sequentially through the two-finger gripper, and the robotic arm drives the first half-shell to switch postures through the rotating mechanism.

[0024] Optionally, the half-shaft gear assembly equipment includes:

[0025] The first feeding assembly is used to store the half-shaft gear and to transfer the half-shaft gear to the first predetermined position;

[0026] The second feeding assembly is used to store the gasket and to transfer the gasket to the second predetermined position;

[0027] The first gripper is used to grip the half-shaft gear from a first predetermined position;

[0028] The second gripper is used to grip the gasket from a second predetermined position;

[0029] The third lifting drive mechanism is used to drive the first gripper and the second gripper to move up and down.

[0030] The third horizontal drive mechanism is used to drive the first and second grippers to move horizontally.

[0031] Optionally, the half-shaft gear assembly equipment further includes a connecting frame, two sets of rotary motors disposed on the connecting frame, and a connecting plate disposed on the output end of the rotary motors. The first gripper is provided in two parts, and the two first grippers are respectively disposed at both ends of the connecting plate corresponding to one set of rotary motors. The second gripper is provided in two parts, and the two second grippers are respectively disposed at both ends of the connecting plate corresponding to the other set of rotary motors.

[0032] Optionally, the first feeding component includes:

[0033] The second turntable has multiple feeding shafts spaced apart along its circumference. The feeding shafts are used to pass through and stack half-shaft gears, and the feeding shafts can rotate to align with the first predetermined position under the rotation of the second turntable.

[0034] The lifting assembly includes a fourth lifting drive mechanism and a lifting plate that is driven by the fourth lifting drive mechanism to move up and down. The lifting plate is used to abut against the half-shaft gear located at the bottom and drive all the half-shaft gears on a feeding shaft to lift, so that the half-shaft gear located at the top is raised to a first predetermined position.

[0035] Among them, the half-shaft gears on the multiple feeding shafts are configured to be adapted to different models of differential housings.

[0036] Optionally, the second feeding assembly includes a storage cylinder and a distributing mechanism located below the storage cylinder. The distributing mechanism includes a second linear driver and a distributing plate that is driven by the second linear driver and can move horizontally. The distributing plate is provided with a dropping groove, and the depth of the dropping groove is configured to be equal to the thickness of the gasket.

[0037] The second feeding assembly is provided in multiple sets and is configured to adapt to different models of differential housings.

[0038] This application also adopts the following technical solution: an automated assembly method for the initial assembly of a differential, wherein the automated assembly method is implemented using an automated assembly production line as described in any of the above technical solutions, and the automated assembly method includes:

[0039] The robotic arm is controlled to grab the differential housing to be disassembled and place it on the support station located at the loading position on the first turntable;

[0040] Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the screw position;

[0041] The nut tightening assembly is controlled to unscrew the locking nut on the differential housing, and the locking nut is collected by the first collecting mechanism.

[0042] Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the push position;

[0043] The pushing mechanism pushes the locking screw on the differential housing, and the second collecting mechanism collects the locking screw.

[0044] Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the unloading position;

[0045] The robotic arm is controlled to remove the first half-shell and the second half-shell from the unloading position and place the first half-shell and the second half-shell on the first support structure and the second support structure, respectively.

[0046] The conveyor is controlled to transfer the first half-shell and the second half-shell located on the first support structure and the second support structure to the half-shaft gear assembly equipment.

[0047] The control device for the half-shaft gear assembly installs two sets of half-shaft gears into the first half-shell and the second half-shell respectively.

[0048] The reasoning process for the beneficial effects of the automated assembly method used in this application is similar to that for the aforementioned automated assembly production line, and will not be repeated here.

[0049] These features and advantages of this application will be disclosed in detail in the following specific embodiments and accompanying drawings. Preferred embodiments or means of this application will be illustrated in detail with reference to the accompanying drawings, but are not intended to limit the technical solutions of this application. Furthermore, each of these features, elements, and components appearing in the following text and drawings is a plurality, and different symbols or numbers are used for convenience of representation, but all represent components with the same or similar structure or function. Attached Figure Description

[0050] The following description, in conjunction with the accompanying drawings, further illustrates this application:

[0051] Figure 1 A schematic diagram of the housing disassembly device in an automated assembly line for the initial assembly of a differential, provided as an embodiment of this application;

[0052] Figure 2 This is a structural diagram of a half-shaft gear assembly equipment in an automated assembly line.

[0053] Figure 3 This is a schematic diagram of a conveyor in an automated assembly line.

[0054] Figure 4 This is a schematic diagram of the screwing device in the shell disassembly equipment;

[0055] Figure 5 This is an exploded view of the screwing device;

[0056] Figure 6 This is a schematic diagram of the nut tightening assembly;

[0057] Figure 7 This is a schematic diagram of the material pushing device in the shell splitting equipment.

[0058] Figure 8 This is a schematic diagram of the first collecting mechanism;

[0059] Figure 9 This is a schematic diagram of the structure of the first turntable and the second collecting mechanism;

[0060] Figure 10 for Figure 1 Enlarged diagram of part A

[0061] Figure 11 for Figure 2 Enlarged schematic diagram of part B;

[0062] Figure 12 for Figure 2 An enlarged schematic diagram of section C;

[0063] Figure 13 A structural schematic diagram of the half-shaft gear assembly equipment from another perspective;

[0064] Figure 14 This is a partial schematic diagram of the second feeding component in the half-shaft gear assembly equipment.

[0065] Among them, 1. First turntable; 10. Support station; 2. Tightening device; 20. Nut tightening assembly; 200. Mounting bracket; 201. Pneumatic impact wrench; 202. Housing locking mechanism; 203. Nut clamping mechanism; 21. First lifting drive mechanism; 22. Lifting frame; 23. Rotation drive mechanism; 230. First motor; 231. Transmission gear ring; 24. Rotation frame; 25. First linear driver; 3. Pushing device; 30. Pushing mechanism; 300. Connecting component; 301. Pushing head; 31. Second lifting drive mechanism; 32. Second horizontal drive mechanism; 33. Translation frame; 4. Collection device; 40. First collection mechanism; 400. First horizontal drive mechanism; 401. Support frame; 402. Drive motor; 403. Receiving tray; 41. Second collection mechanism; 41 0. Collection cylinder; 411. Collection box; 5. Conveyor; 50. Positioning seat; 51. First support structure; 52. Second support structure; 6. Feeding assembly; 60. First feeding assembly; 600. Second turntable; 601. Discharge shaft; 602. Fourth lifting drive mechanism; 603. Lifting plate; 61. Second feeding assembly; 610. Storage cylinder; 611. Second linear drive; 612. Distributor plate; 7. Transfer assembly; 70. First gripper; 71. Second gripper; 73. Connecting frame; 74. Rotary motor; 75. Connecting plate; 8. Drive assembly; 80. Third lifting drive mechanism; 81. Third horizontal drive mechanism; 9. Differential gear component; 90. First half-shell; 91. Second half-shell; 92. Locking screw; 93. Locking nut; 94. Half-shaft gear; 95. Washer. Detailed Implementation

[0066] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described are intended to explain this application and should not be construed as limiting it.

[0067] The terms "an embodiment," "example," or "example" used in this specification refer to a particular feature, structure, or characteristic described in connection with the embodiment itself that may be included in at least one embodiment disclosed in this application. The phrase "in an embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment.

[0068] In the description of this application, it should be understood that the terms "upper," "lower," "front," "rear," "vertical," "horizontal," "top," "bottom," "inner," and "outer," 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 application and simplifying the description, 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 on this application. In the description of this application, "a plurality of" means two or more, unless otherwise precisely specified.

[0069] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "connected," "linked," and "connected" should be interpreted broadly. For example, they can refer to a fixed connection, a connection through an intermediary, the internal connection of two elements, or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0070] This embodiment provides an automated assembly line for the initial assembly of differentials, such as... Figure 1 , Figure 2 and Figure 3 As shown, the automated assembly line includes a housing splitting device, a half-shaft gear assembly device, a conveyor 5, and a robotic arm (not shown in the figure). The housing splitting device splits the differential housing into a first half-shell 90 and a second half-shell 91. The half-shaft gear assembly device assembles two sets of half-shaft gears 94 into the first half-shell 90 and the second half-shell 91, respectively. The conveyor 5 is equipped with a positioning seat 50, which moves between the housing splitting device and the half-shaft gear assembly device. The positioning seat 50 has a first support structure 51 for supporting and positioning the first half-shell 90 and a second support structure 52 for supporting and positioning the second half-shell 91. The robotic arm is equipped with a gripper assembly, which sequentially grips the split first half-shell 90 and the second half-shell 91, placing them onto the first support structure 51 and the second support structure 52, respectively.

[0071] Combination Figure 3 and Figure 11As shown, the initial assembly of the differential in this embodiment mainly involves the assembly of the following differential component 9, which mainly includes a differential housing (including a first half-shell 90 and a second half-shell 91), a locking screw 92, a locking nut 93, a half-shaft gear 94, and a washer 95. By setting up a housing splitting device and a half-shaft gear assembly device to realize the automated splitting operation of the differential housing and the automated assembly operation of the half-shaft gear 94 relative to the two half-shells, the assembly efficiency can be significantly improved. With the cooperation of the robotic arm and the conveyor 5, the first half-shell 90 and the second half-shell 91 can be transferred between the housing splitting device and the half-shaft gear assembly device in one go. The first half-shell 90 and the second half-shell 91 are synchronously transferred on the positioning seat 50, which facilitates the subsequent synchronous installation of the half-shaft gear 94.

[0072] Combination Figure 1 , Figure 4 , Figure 5 and Figure 7 As shown, specifically in this embodiment, the housing disassembly device includes a first turntable 1, a screwing device 2, a pushing device 3, and a collecting device 4. The first turntable 1 has four support stations 10 for supporting the differential housing, and these four support stations 10 sequentially switch between loading, screwing, pushing, and unloading positions under the rotation of the first turntable 1. It is easy to understand that a servo motor (not shown in the figure) is located below the first turntable 1 to drive its rotation; this will not be elaborated further. The screwing device 2 includes multiple sets of nut screwing assemblies 20 for screwing the locking nuts 93 on the differential housing. The pushing device 3 includes a lifting and lowering pushing mechanism 30 for pushing the locking screws 92 on the differential housing. It is easy to understand that the loading position, screwing position, pushing position, and unloading position are not physical structures, but rather spatial locations. The screwing position and pushing position refer to the work positions suitable for the screwing device 2 and the pushing device 3 to perform assembly operations on the differential housing, respectively. The loading position and unloading position refer to the work positions that facilitate the robotic arm to pick up and place the differential housing relative to the first turntable 1. The robotic arm clamps a differential housing to be disassembled and places it at the support work position 10 located at the loading position. The robotic arm then sequentially removes the disassembled first half-shell 90 and second half-shell 91 from the support work position 10 located at the unloading position.

[0073] The above structural design allows for a more compact layout of the housing disassembly equipment, facilitating the robotic arm's work area to cover both the loading and unloading positions. Furthermore, the disassembly process of the differential housing is broken down into four steps: loading, loosening the locking nut 93, pushing the locking screw 92 to drop it, and unloading. This design ensures that the time required for each step is relatively consistent, allowing for better control of the assembly cycle and preventing excessive time consumption at a single step from affecting the overall disassembly time.

[0074] The collection device 4 in this embodiment includes a first collection mechanism 40 and a second collection mechanism 41. The first collection mechanism 40 is used to collect the locking nut 93, and the second collection mechanism 41 is used to collect the locking screw 92. By setting up the collection device 4, the locking nut 93 and locking screw 92 that have been unscrewed from the differential housing can be prevented from falling off randomly.

[0075] Combination Figure 4 , Figure 5 and Figure 6 As shown, the screwing device 2 in this embodiment further includes a first lifting drive mechanism 21, a lifting frame 22 that is driven by the first lifting drive mechanism 21 to move up and down, a rotation drive mechanism 23 disposed on the lifting frame 22, and a rotating frame 24 that is driven by the rotation drive mechanism 23 to rotate. Multiple sets of nut screwing assemblies 20 are distributed circumferentially on the rotating frame 24. The first lifting drive mechanism 21 can drive the lifting frame 22 and the rotation drive mechanism 23, rotating frame 24 and nut screwing assemblies 20 disposed on the lifting frame 22 to move up and down synchronously. Thus, the lifting action can avoid the differential housing from rotating the first turntable 1, and the lowering action can lower the nut screwing assembly 20 to contact the locking nut 93 on the differential housing for screwing operation.

[0076] The housing disassembly device also includes a frame. The first lifting drive mechanism 21 is specifically a lead screw motor designed on the frame. The rotary drive mechanism 23 includes a first motor 230 and a transmission gear ring 231. The first motor 230 is fixedly mounted on the lifting frame 22. The bottom of the lifting frame 22 is provided with a connecting structure and a limiting structure. The transmission gear ring 231 is circumferentially rotatably mounted on the connecting structure, and the limiting structure axially restricts the transmission gear ring 231 from being positioned relative to the other side. The connecting structure is an annular body formed on the lifting frame 22, and the limiting structure is a detachable annular plate structure connected to the bottom of the connecting structure. Simultaneously, the transmission gear ring 231 is rotatably connected to the connecting structure via bearings. Thus, the first motor 230 can drive the transmission gear ring 231 to rotate via a drive gear located on its output shaft. The transmission gear ring 231 can then drive the rotary frame 24 and the nut tightening assembly 20 located on the rotary frame 24 to rotate.

[0077] The ability to control the nut tightening assembly 20 to rotate circumferentially has two advantages: it reduces the number of nut tightening assemblies 20 required, facilitating adaptation to different specifications and models of differential housings. Firstly, some differential housings have a large number of locking screws 92, or, although the number of locking screws 92 is small, there may be two or more locking screws 92 in close proximity in certain locations. If the nut tightening assembly 20 is installed for each locking screw 92 in a one-to-one correspondence, adjacent nut tightening assemblies 20 may interfere with each other spatially. In this case, controlling the rotation of the nut tightening assembly 20 ensures that a relatively small number of nut tightening assemblies 20 can tighten and loosen a relatively large number of locking screws 92. Secondly, the positions of the locking screws 92 on different specifications and models of differential housings may differ; controlling the rotation of the nut tightening assembly 20 allows for corresponding adaptation.

[0078] The nut tightening assembly 20 in this embodiment includes a mounting bracket 200, a pneumatic impact wrench 201, a housing locking mechanism 202, and a nut clamping mechanism 203. The pneumatic impact wrench 201, housing locking mechanism 202, and nut clamping mechanism 203 are all mounted on the mounting bracket 200. Specifically, the pneumatic impact wrench 201 is used to tighten the locking nut 93, the housing locking mechanism 202 is used to position the differential housing circumferentially, and the nut clamping mechanism 203 is used to clamp and position the locking nut 93 after it separates from the locking screw 92. The pneumatic impact wrench 201 can be directly purchased from the market; its specific structure and working principle will not be described here. The pneumatic impact wrench 201 enables automatic alignment and engagement with the locking nut 93, as well as automatic loosening, while ensuring that the locking screw 92 does not rotate during the loosening of the locking nut 93. The screw locking mechanism includes a telescopic cylinder and an abutment block located at the output end of the telescopic cylinder. The telescopic cylinder drives the abutment block to move towards the differential housing, causing the abutment block to abut against the differential housing. The cooperation of the abutment blocks in the multiple sets of nut tightening assemblies 20 ensures the stability of the differential during the tightening of the locking nut 93. The nut clamping mechanism 203 prevents the locking nut 93 from falling uncontrollably after being loosened. The nut clamping mechanism 203 is a jaw mechanism, which can be purchased directly from the market; its specific structure and working principle will not be described here. The two jaws in the nut clamping mechanism 203 are located on both sides of the corresponding pneumatic impact wrench 201. After loosening the locking nut 93, it can be clamped and fixed by the nut clamping mechanism 203. In subsequent operations, the locking nut 93 can be controllably placed in the first collecting mechanism 40.

[0079] As mentioned earlier, the tightening device 2 in this embodiment can be adapted to differential housings of different sizes. When the position of the locking screw 92 on the differential housing changes not only circumferentially but also radially, the position of the nut tightening assembly 20 needs to be adjusted accordingly. Therefore, the tightening device 2 in this embodiment also includes a first linear actuator 25 disposed on the rotating frame 24. The number of first linear actuators 25 is the same as the number of nut tightening assemblies 20 and corresponds one-to-one. The output end of the first linear actuator 25 is connected to the mounting frame 200 and is used to drive the nut tightening assembly 20 to move radially as a whole. Thus, by pre-setting a control program, when disassembling differential housings of different sizes, the first linear actuator 25 can drive the nut tightening assembly 20 to the corresponding position, aligning the pneumatic impact wrench 201 in the nut tightening assembly 20 with the locking nut 93. Figure 4 , Figure 5 and Figure 6 As shown, a slide rail structure is fixedly installed on the rotating frame 24. The first linear driver 25 is a slide cylinder fixedly installed on the mounting frame 200. The slide cylinder can drive the mounting frame 200 and the pneumatic impact wrench 201, housing locking mechanism 202 and nut clamping mechanism 203 installed on the mounting frame 200 to move synchronously.

[0080] Combination Figure 4 and Figure 8 As shown, the first collecting mechanism 40 in this embodiment includes a first horizontal driving mechanism 400, a support frame 401 that is driven by the first horizontal driving mechanism 400 and can move horizontally, a drive motor 402 disposed on the support frame 401, and a receiving tray 403. The drive motor 402 is connected to the receiving tray 403 and is used to drive the receiving tray 403 to swing relative to the support frame 401. With the above structural design, the receiving tray 403 can be driven to move horizontally by the first horizontal driving mechanism 400. The receiving tray 403 can switch positions relative to the nut tightening assembly 20 by moving horizontally, so that it can avoid the nut tightening assembly 20 when the nut tightening operation is required. After the nut tightening operation is completed, the receiving tray 403 moves to below the nut tightening assembly 20 by translation, and then the nut clamping mechanism 203 is controlled to release the locking nut 93, so that the locking nut 93 falls into the receiving tray 403 in a controlled manner. In addition, the receiving tray 403 can be driven to swing by the drive motor 402. The receiving tray 403 can controllably unload the collected locking nuts 93 to a designated position through the swinging action, so as to realize automated unloading.

[0081] Combination Figure 1 and Figure 7As shown, the pushing device 3 in this embodiment also includes a second lifting drive mechanism 31, a second horizontal drive mechanism 32, and a translation frame 33 that is driven by the second horizontal drive mechanism 32 and can move horizontally. Multiple sets of pushing mechanisms 30 are provided, each adapted to different models of differential housings. These multiple sets of pushing mechanisms 30 are flexibly mounted on the translation frame 33. This structural design allows the pushing device 3 to adapt to different specifications and models of differential housings. In this embodiment, two sets of pushing mechanisms 30 are used as an example. In other optional embodiments, three or more sets of pushing mechanisms 30 can also be provided. After the differential housing rotates to the pushing position following the first turntable 1, the corresponding pushing mechanism 30 can be driven by the second horizontal drive mechanism 32 to translate to the top of the differential housing. Then, the second lifting drive mechanism 31 drives the pushing mechanism 30 to move downwards, using the pushing mechanism 30 to push the locking screw 92 to separate it from the differential housing.

[0082] The jacking mechanism 30 in this embodiment includes a connecting member 300 and a plurality of jacking heads 301 disposed on the connecting member 300. The second lifting drive mechanism 31 is connected to the connecting member 300 and is used to drive the jacking mechanism 30 to move up and down, so as to push the locking screw 92 out of the differential housing through the jacking head 301.

[0083] Specifically, the pushing device 3 in this embodiment also includes a frame, and the second horizontal drive mechanism 32 is an electric slide table mounted on the frame. The second lifting drive mechanism 31 is a cylinder, and the output end of the cylinder is connected to one of the multiple pushing mechanisms 30. The multiple pushing mechanisms 30 are interconnected by a crossbar and can move synchronously or lift.

[0084] Combination Figure 1 , Figure 9 and Figure 10 As shown, the second collecting mechanism 41 in this embodiment includes a collecting cylinder 410 disposed on the first turntable 1 and a collecting box 411 located below the first turntable 1. The collecting cylinder 410 passes through the first turntable 1 and is aligned with the locking screw 92 of the differential housing. The collecting box 411 has a collecting opening that extends from the screw-in position to the pushing position. That is, after being pushed by the pushing mechanism 30, the locking screw 92 can fall directly downwards through the collecting cylinder 410 and into the collecting box 411. The collecting cylinder 410 prevents the locking screw 92 from falling onto the first turntable 1 due to tilting or other reasons. Furthermore, a small number of locking screws 92 may fall from the differential housing due to gravity, vibration, or other reasons after the locking nut 93 is loosened. The collecting opening extending to the screw-in position can collect these locking screws 92.

[0085] In this embodiment, the gripper assembly mounted on the robotic arm includes a rotating mechanism and a two-finger gripper. The rotating mechanism is configured to drive the two-finger gripper to rotate. (Reference) Figure 1 and Figure 3 As shown, the posture of the second half-shell 91 remains unchanged whether it is on the first turntable 1 or on the second support structure 52, while the posture of the first half-shell 90 on the first support structure 51 is flipped relative to its posture on the first turntable 1. Using this structural design, the robotic arm can sequentially grip the first half-shell 90 and the second half-shell 91 using a two-finger gripper, and the robotic arm can switch the posture of the first half-shell 90 via a rotating mechanism. The rotating mechanism is a motor, and the two-finger gripper is a common gripper product; its structure and working principle will not be described in detail here.

[0086] Combination Figure 2 , Figure 3 , Figure 11 and Figure 12 As shown, the half-shaft gear assembly equipment in this embodiment includes a feeding assembly 6, a transfer assembly 7, and a drive assembly 8. The feeding assembly 6 includes a first feeding assembly 60 and a second feeding assembly 61; the transfer assembly 7 includes a first gripper 70 and a second gripper 71; and the drive assembly 8 includes a third lifting drive mechanism 80 and a third horizontal drive mechanism 81.

[0087] In this embodiment, the first feeding assembly 60 is used to store the half-shaft gear 94 and to transfer the half-shaft gear 94 to a first predetermined position. The second feeding assembly 61 is used to store the shim 95 and to transfer the shim 95 to a second predetermined position. The first gripper 70 is used to grip the half-shaft gear 94 from the first predetermined position, and the second gripper 71 is used to grip the shim 95 from the second predetermined position. The third lifting drive mechanism 80 is used to drive the first gripper 70 and the second gripper 71 to move vertically, and the third horizontal drive mechanism 81 is used to drive the first gripper 70 and the second gripper 71 to move horizontally.

[0088] By adopting the above structural design, the first gripper 70 and the second gripper 71 can be driven to translate and lift by the cooperation of the third lifting drive mechanism 80 and the third horizontal drive mechanism 81, quickly moving the first gripper 70 and the second gripper 71 to the designated position. The first gripper 70 and the second gripper 71 can respectively grip the half-shaft gear 94 and the washer 95 at the first predetermined position and the second predetermined position, and then move to the top of the positioning seat 50 to install the half-shaft gear 94 and the washer 95 into the first half-shell 90 and the second half-shell 91, realizing the automated assembly of the half-shaft gear 94 and the washer 95 and improving assembly efficiency.

[0089] In this embodiment, the third lifting drive mechanism 80 and the third horizontal drive mechanism 81 are both common linear drive mechanisms, which can be implemented by a screw drive structure, a gear and rack drive structure or a synchronous belt drive structure in conjunction with a motor, and will not be described in detail here.

[0090] The half-shaft gear assembly equipment in this embodiment also includes a connecting frame 73, two sets of rotary motors 74 disposed on the connecting frame 73, and a connecting plate 75 disposed on the output end of the rotary motors 74. Two first grippers 70 are provided, and the two first grippers 70 are respectively disposed at both ends of the connecting plate 75 corresponding to one set of rotary motors 74. Two second grippers 71 are provided, and the two second grippers 71 are respectively disposed at both ends of the connecting plate 75 corresponding to the other set of rotary motors 74. Using the above structural design, combined with the aforementioned design of "setting a first support structure 51 and a second support structure 52 on the positioning seat 50, and placing the first half-shell 90 and the second half-shell 91 on the first support structure 51 and the second support structure 52 respectively," the half-shaft gear 94 can be simultaneously inserted into the first half-shell 90 and the second half-shell 91 at one time using the two first grippers 70, and the shim 95 can be simultaneously inserted into the first half-shell 90 and the second half-shell 91 at one time using the two second grippers 71, thus improving assembly efficiency. By rotating the connecting plate 75 180° through the rotary motor 74, the two first grippers 70 or the two second grippers 71 can be moved to exchange positions. This allows the two first grippers 70 to sequentially grip the half-shaft gear 94 located at the first predetermined position, and the two second grippers 71 to sequentially grip the shim 95 located at the second predetermined position.

[0091] In this embodiment, both the first gripper 70 and the second gripper 71 are internally expanding grippers. The gripper extends into the inner ring of the half-shaft gear 94 or the washer 95 and then moves outward radially to open, thereby achieving tensioning and positioning of the gripper relative to the half-shaft gear 94 or the washer 95.

[0092] Combination Figure 2 and Figure 13 As shown, the first feeding assembly 60 in this embodiment includes a second turntable 600, a feeding shaft 601, and a lifting assembly. The second turntable 600 has multiple feeding shafts 601 spaced circumferentially. The feeding shafts 601 pass through and stack the half-shaft gears 94, and can rotate to align with a first predetermined position under the rotation of the second turntable 600. The lifting assembly includes a fourth lifting drive mechanism 602 and a lifting plate 603 driven by the fourth lifting drive mechanism 602. The lifting plate 603 abuts against the half-shaft gears 94 at the bottom and lifts all the half-shaft gears 94 on one feeding shaft 601, so that the half-shaft gears 94 at the top are raised to the first predetermined position. That is, the first gripper 70 only needs to move to align with the feeding shaft 601, and then the lifting component will raise the half shaft gear 94 on the feeding shaft 601 to the top position, so that the half shaft gear 94 can be gripped by the first gripper 70.

[0093] It is easy to understand that a servo motor for driving the rotation of the second turntable 600 is set below the second turntable 600, which will not be described in detail here.

[0094] In this embodiment, the half-shaft gears 94 on the multiple feeding shafts 601 are configured to adapt to different models of differential housings, thereby enabling the half-shaft gear assembly equipment to also adapt to different models of differential housings.

[0095] Combination Figure 2 and Figure 14 As shown, the second feeding assembly 61 in this embodiment includes a storage cylinder 610 and a dispensing mechanism located below the storage cylinder 610. The dispensing mechanism includes a second linear actuator 611 and a dispensing plate 612 that is driven by the second linear actuator 611 and can move horizontally. The dispensing plate 612 is provided with a dropping groove, the depth of which is configured to be equal to the thickness of the pad 95. When the dropping groove on the dispensing plate 612 is aligned with the storage cylinder 610, the pad 95 at the bottom of the storage cylinder 610 will fall into the dropping groove under the action of gravity. Since the depth of the dropping groove is configured to be equal to the thickness of the pad 95, only one pad 95 can fall into the dropping groove at a time. By driving the dispensing plate 612 to translate through the second linear actuator 611, one pad 95 can be moved to a second predetermined position, making it convenient for the second gripper 71 to grip the pad 95.

[0096] Similarly, in this embodiment, the second feeding component 61 is provided in multiple sets and is configured to adapt to different models of differential housings, thereby enabling the half-shaft gear assembly equipment to also adapt to different models of differential housings.

[0097] like Figure 3 As shown, the conveyor 5 in this embodiment can be directly purchased from the market, and can be a belt conveyor 5, a roller conveyor 5, a chain conveyor 5, etc. Its structure and working principle will not be described in detail here. The first support structure 51 and the second support structure 52 set on the positioning seat 50, and the support station 10 set on the first turntable 1, all include a main positioning column with steps and auxiliary support columns set around the main positioning column. The main positioning column extends into the first half-shell 90 or the second half-shell 91, and supports the first half-shell 90 or the second half-shell 91 through the steps on the main positioning column. This restricts the horizontal movement of the first half-shell 90 or the second half-shell 91, while simultaneously forming a main support for the first half-shell 90 or the second half-shell 91. The auxiliary support columns support the outer ring of the first half-shell 90 or the second half-shell 91, playing an auxiliary support role and improving the stability of the first half-shell 90 and the second half-shell 91.

[0098] The automated assembly method for initial assembly of the differential housing using the automated assembly line provided in this embodiment includes the following steps:

[0099] Control the robotic arm to grab the differential housing to be disassembled and place it on the first turntable 1 at the support station 10 located at the loading position;

[0100] Control the first turntable 1 to rotate 90° so that the differential housing to be disassembled reaches the screw position;

[0101] The control nut tightening assembly 20 unscrews the locking nut 93 on the differential housing and collects the locking nut through the first collecting mechanism 40;

[0102] Control the first turntable 1 to rotate 90° so that the differential housing to be disassembled reaches the push position;

[0103] The control jacking mechanism 30 pushes the locking screw 92 on the differential housing, and the second collecting mechanism collects the locking screw.

[0104] Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the unloading position;

[0105] The robotic arm is controlled to remove the first half-shell 90 and the second half-shell 91 from the unloading position and place the first half-shell 90 and the second half-shell 91 on the first support structure 51 and the second support structure 52 respectively.

[0106] The control conveyor 5 transfers the first half-shell 90 and the second half-shell 91 located on the first support structure 51 and the second support structure 52 to the half-shaft gear assembly equipment.

[0107] The control half-shaft gear assembly equipment loads two sets of half-shaft gears 94 into the first half-shell 90 and the second half-shell 91, respectively.

[0108] The specific details are as follows:

[0109] After the automated assembly line starts, the robotic arm first uses a gripper assembly to pick up the differential housing to be disassembled from the material storage area and places it on the support station 10 at the loading position on the first turntable 1. Then, the first turntable 1 is rotated 90°, and the first linear driver 25 in the tightening device 2 adjusts the radial position of multiple sets of nut tightening assemblies 20 according to a preset program, ensuring that the pneumatic impact wrench 201 is accurately aligned with the locking nut 93 on the differential housing. Next, the nut tightening assembly 20 is lowered to engage the pneumatic impact wrench 201 with the locking nut 93, and the housing locking mechanism 202 extends to press against the differential housing. Then, the pneumatic impact wrench 201 is activated to loosen the locking nut 93. The loosened locking nut 93 is temporarily clamped and positioned by the nut clamping mechanism 203. The control nut tightening assembly 20 is raised to avoid obstruction, and then the receiving tray 403 of the first collecting mechanism 40 is moved horizontally to below the nut tightening assembly 20. The control nut clamping mechanism 203 is released, allowing the locking nut 93 to fall into the receiving tray 403, completing the controlled collection of the locking nut 93. The control first turntable 1 continues to rotate, causing the differential housing to reach the pushing position. The second horizontal drive mechanism 32 drives the corresponding push mechanism 30 to move horizontally above the differential housing. Then, the second lifting drive mechanism 31 drives the push head 301 to press down, pushing the loosened locking screw 92 downward. The locking screw 92 passes through the collecting cylinder 410 on the first turntable 1 and falls into the collecting box 411 below, realizing the separate collection of the locking screw 92, thereby completing the automated disassembly of the differential housing, obtaining the separated first half-shell 90 and second half-shell 91.

[0110] After disassembly, the first turntable 1 is controlled to rotate the differential housing to the unloading position. Then, the robotic arm controls the two-finger gripper to first grasp the first half-shell 90 and drives the first half-shell 90 to flip through the rotation mechanism, and then places the first half-shell 90 on the first support structure 51. Then, the second half-shell 91 is grasped and placed directly on the second support structure 52. Afterwards, the conveyor 5 drives the positioning seat 50 to move to the location of the half-shaft gear assembly equipment.

[0111] At the axle gear assembly equipment, the second turntable 600 of the first feeding assembly 60 has rotated the unloading shaft 601, which carries the matching axle gear 94, to align with the first predetermined position. The lifting plate 603 is controlled to lift the axle gear 94, bringing the topmost axle gear 94 to the first predetermined position. Simultaneously, the separating plate 612 of the second feeding assembly 61, through reciprocating motion, separates the gaskets 95 one by one from the storage cylinder 610 and conveys them to the second predetermined position. The first gripper 70 and the second gripper 71 are controlled to respectively grasp the axle gear 94 and the gasket 95. Through the cooperation of the third horizontal drive mechanism 81 and the third lifting drive mechanism 80, the first gripper 70 and the second gripper 71 are driven to reach above the positioning seat 50, respectively, and the axle gear 94 and the gasket 95 are installed into the first half-shell 90 and the second half-shell 91. Then, driven by the conveyor 5, they proceed to the next process. Thus, the automated assembly line completes the initial assembly of the differential housing.

[0112] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Those skilled in the art will understand that this application includes, but is not limited to, the contents described in the accompanying drawings and the specific embodiments above. Any modifications that do not depart from the functional and structural principles of this application will be included within the scope of the claims.

Claims

1. An automated assembly line for the initial assembly of differentials, characterized in that, include: A housing splitting device for splitting the differential housing into a first half-shell and a second half-shell; A half-shaft gear assembly device, which is used to install two sets of half-shaft gears into the first half-shell and the second half-shell respectively; A conveyor is provided with a positioning seat and is used to drive the positioning seat to move between a shell splitting device and a half-shaft gear assembly device. The positioning seat is provided with a first support structure for supporting and positioning a first half-shell and a second support structure for supporting and positioning a second half-shell. A robotic arm is provided with a gripper assembly. The robotic arm is used to sequentially grip the first half shell and the second half shell obtained after disassembly through the gripper assembly, and place the first half shell and the second half shell on the first support structure and the second support structure respectively. The shell disassembly device includes: The first turntable has four support positions for supporting the differential housing, and the four support positions switch positions sequentially between the loading position, the screwing position, the pushing position and the unloading position under the rotation of the first turntable. A screwing device comprising multiple sets of nut screwing assemblies and used to screw a locking nut on a differential housing via the nut screwing assemblies; A pushing device, comprising a lifting and moving jacking mechanism for jacking a locking screw on the differential housing via the jacking mechanism; A collection device comprising a first collection mechanism for collecting lock nuts and a second collection mechanism for collecting lock screws.

2. The automated assembly line for the initial assembly of differentials as described in claim 1, characterized in that, The screwing device further includes a first lifting drive mechanism, a lifting frame that is driven by the first lifting drive mechanism to move up and down, a rotation drive mechanism disposed on the lifting frame, and a rotating frame that is driven by the rotation drive mechanism to rotate. Multiple sets of the nut screwing components are distributed circumferentially on the rotating frame. The nut tightening assembly includes a mounting bracket, a pneumatic impact wrench, a housing locking mechanism, and a nut clamping mechanism, all of which are mounted on the mounting bracket. The pneumatic impact wrench is used to tighten the lock nut, the housing locking mechanism is used to position the differential housing circumferentially, and the nut clamping mechanism is used to clamp and position the lock nut after it is separated from the lock screw.

3. The automated assembly line for the initial assembly of the differential as described in claim 2, characterized in that, The screwing device further includes a first linear driver disposed on the rotating frame. The number of first linear drivers is the same as the number of nut screwing assemblies and corresponds one-to-one. The output end of the first linear driver is connected to the mounting frame and is used to drive the nut screwing assembly to move radially as a whole.

4. The automated assembly line for the initial assembly of the differential as described in claim 3, characterized in that, The first collection mechanism includes a first horizontal drive mechanism, a support frame that is driven by the first horizontal drive mechanism and can move horizontally, a drive motor disposed on the support frame, and a receiving tray. The drive motor is connected to the receiving tray and is used to drive the receiving tray to swing relative to the support frame.

5. The automated assembly line for the initial assembly of the differential as described in claim 1, characterized in that, The pushing device also includes a second lifting drive mechanism, a second horizontal drive mechanism, and a translation frame that is driven by the second horizontal drive mechanism and can move in the horizontal direction. The pushing mechanism is provided in multiple sets and is adapted to different models of differential housings. The multiple sets of pushing mechanisms are flexibly and vertically arranged on the translation frame. The jacking mechanism includes a connecting member and a plurality of jacking heads disposed on the connecting member. The second lifting drive mechanism is connected to the connecting member and is used to drive the jacking mechanism to move up and down, so as to push the locking screw out of the differential housing through the jacking heads.

6. The automated assembly line for the initial assembly of the differential as described in claim 1, characterized in that, The second collection mechanism includes a collection cylinder disposed on the first turntable and a collection box located below the first turntable. The collection cylinder passes through the first turntable and is aligned with the locking screw of the differential housing. The collection box has a collection opening that extends along the screw position to the push position.

7. The automated assembly line for the initial assembly of differentials as described in any one of claims 1 to 6, characterized in that, The gripper assembly includes a rotating mechanism and a two-finger gripper that is rotatable by the rotating mechanism. The robotic arm grips the first half-shell and the second half-shell sequentially through the two-finger gripper, and the robotic arm drives the first half-shell to switch postures through the rotating mechanism.

8. The automated assembly line for the initial assembly of the differential as described in any one of claims 1 to 6, characterized in that, The half-shaft gear assembly equipment includes: The first feeding assembly is used to store the half-shaft gear and to transfer the half-shaft gear to the first predetermined position; The second feeding assembly is used to store the gasket and to transfer the gasket to the second predetermined position; The first gripper is used to grip the half-shaft gear from a first predetermined position; The second gripper is used to grip the gasket from a second predetermined position; The third lifting drive mechanism is used to drive the first gripper and the second gripper to move up and down. The third horizontal drive mechanism is used to drive the first and second grippers to move horizontally.

9. The automated assembly line for the initial assembly of the differential as described in claim 8, characterized in that, The half-shaft gear assembly equipment also includes a connecting frame, two sets of rotary motors disposed on the connecting frame, and a connecting plate disposed on the output end of the rotary motors. The first gripper is provided in two parts, and the two first grippers are respectively disposed at both ends of the connecting plate corresponding to one set of rotary motors. The second gripper is provided in two parts, and the two second grippers are respectively disposed at both ends of the connecting plate corresponding to the other set of rotary motors.

10. The automated assembly line for the initial assembly of the differential as described in claim 8, characterized in that, The first feeding component includes: The second turntable has multiple feeding shafts spaced apart along its circumference. The feeding shafts are used to pass through and stack half-shaft gears, and the feeding shafts can rotate to align with the first predetermined position under the rotation of the second turntable. The lifting assembly includes a fourth lifting drive mechanism and a lifting plate that is driven by the fourth lifting drive mechanism to move up and down. The lifting plate is used to abut against the half-shaft gear located at the bottom and drive all the half-shaft gears on a feeding shaft to lift, so that the half-shaft gear located at the top is raised to a first predetermined position. Among them, the half-shaft gears on the multiple feeding shafts are configured to be adapted to different models of differential housings.

11. The automated assembly line for the initial assembly of the differential as described in claim 8, characterized in that, The second feeding assembly includes a storage cylinder and a distributing mechanism located below the storage cylinder. The distributing mechanism includes a second linear driver and a distributing plate that is driven by the second linear driver and can move horizontally. The distributing plate is provided with a dropping groove, and the depth of the dropping groove is configured to be equal to the thickness of the gasket. The second feeding assembly is provided in multiple sets and is configured to adapt to different models of differential housings.

12. An automated assembly method for the initial assembly of a differential, characterized in that, The automated assembly method is implemented using an automated assembly production line as described in any one of claims 1 to 11, and the automated assembly method includes: The robotic arm is controlled to grab the differential housing to be disassembled and place it on the support station located at the loading position on the first turntable; Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the screw position; The nut tightening assembly is controlled to unscrew the locking nut on the differential housing, and the locking nut is collected by the first collecting mechanism. Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the push position; The pushing mechanism pushes the locking screw on the differential housing, and the second collecting mechanism collects the locking screw. Control the first turntable to rotate 90° so that the differential housing to be disassembled reaches the unloading position; The robotic arm is controlled to remove the first half-shell and the second half-shell from the unloading position and place the first half-shell and the second half-shell on the first support structure and the second support structure, respectively. The conveyor is controlled to transfer the first half-shell and the second half-shell located on the first support structure and the second support structure to the half-shaft gear assembly equipment. The control device for the half-shaft gear assembly installs two sets of half-shaft gears into the first half-shell and the second half-shell respectively.

Images