A light-weight new energy heavy-load vehicle decelerator shell and a numerical control milling processing clamp thereof

Abstract

The present application provides a kind of light weight new energy heavy load vehicle speed reducer shell and its numerical control milling fixture, including base, base top is equipped with platform, platform one side is equipped with spindle box, spindle box top is equipped with adjusting head, adjusting head can flexibly switch height and angle to make milling cutter head milling, first displacement component drives movable plate to adjust relative position, second displacement component drives placement plate to adjust relative position;Placement plate is equipped with positioning component, side wall clamping assembly, top pressing assembly and adjusting abutment assembly;Speed reducer shell is divided into upper shell and lower shell, inner wall is treated with thin wall and is equipped with reinforcing rib, edge is equipped with thickened edge strip, inside is equipped with detachable partition and filling block, realize light weight and structural strength, for thin-walled shell milling deformation problem, design special fixture, cooperate rough milling unloading force, auxiliary support, stress release process of precision milling forming, inhibit thin-walled flutter and deformation, realize high-precision processing.

Description

Technical Field

[0001] This invention relates to the field of speed reducers, specifically to a lightweight speed reducer housing for new energy heavy-duty vehicles and its CNC milling fixture. Background Technology

[0002] In heavy-duty applications such as new energy engineering vehicles, mining trucks, and port tractors, the electric drive reducer, as a core component for power transmission, not only needs to accommodate and support the high-torque gear shaft system, but also needs to withstand the severe impact loads caused by frequent vehicle starts and stops, heavy-load uphill climbing, and harsh road conditions. To meet the requirements of vehicle lightweighting and improve driving range, the reducer housing generally adopts a thin-walled design; at the same time, to facilitate the assembly and maintenance of the gear shaft system, the housing adopts a separate upper and lower housing structure, which is processed independently in stages and then assembled. However, while the thin-walled treatment brings weight reduction benefits, it also significantly weakens the structural rigidity of the housing itself, making it exhibit obvious weak rigidity characteristics during CNC milling and prone to processing deformation.

[0003] A Chinese patent publication (CN206084472U) discloses a milling and clamping device for the bottom surface of a two-stage reducer housing. The device includes a support, a base plate mounted on the support, a positioning mechanism for positioning the reducer housing, and a clamping mechanism mounted on the base plate for pressing the reducer housing. The positioning mechanism includes several support plates mounted on the base plate, with the top surface of each support plate serving as a plane for contacting the reducer housing. This utility model's milling and clamping device for the bottom surface of a two-stage reducer housing is simple in structure and easy to operate. By setting up the positioning and clamping mechanisms, it achieves precise clamping of the reducer housing, improves the machining accuracy of the bearing cover mating surface, and also improves clamping efficiency and clamping reliability. The machining efficiency is relatively high, and employees processing this product can operate it without training.

[0004] While the aforementioned existing technologies simplify the clamping operation to some extent, they do not provide an effective solution to the machining deformation problem of lightweight thin-walled housings. Traditional split housings, to ensure load-bearing rigidity, often have thicker walls and higher weight, which is detrimental to the vehicle's range. Furthermore, in the pursuit of lightweight design, thinning the housing walls can lead to uneven rigidity distribution after milling. If the universal support plate and clamping mechanism described in the aforementioned patent are used for clamping, the simple planar support surface and single clamping force easily cause localized indentation or overall prismatic deformation in the thin-walled area, making it difficult to guarantee machining accuracy and failing to meet the process requirements of high-precision reducer housings.

[0005] To address these issues, a lightweight reducer housing for new energy heavy-duty vehicles and its CNC milling fixture are proposed. Summary of the Invention

[0006] In order to overcome the problem that the machining accuracy is difficult to guarantee during actual milling due to the lightweight design of the reducer housing in the existing technology, the present invention provides a lightweight reducer housing for new energy heavy-duty vehicles and its CNC milling fixture.

[0007] This invention is achieved using the following technical solution: A lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture include a base, a platform at the top of the base, a spindle box on one side of the platform, an adjusting head at the top of the spindle box, and a milling cutter at the bottom of the adjusting head. The adjusting head can flexibly switch the height and angle to allow the milling cutter to perform milling. A first displacement component is provided on one side of the platform, a movable plate is connected to the first displacement component, a second displacement component is provided on the movable plate, and a placement plate is connected to the second displacement component. The first displacement component drives the movable plate to adjust the relative position, and the second displacement component drives the placement plate to adjust the relative position. A positioning component is provided at the top center of the placement plate, a side wall clamping assembly for fixing the reducer housing is provided at the top of the placement plate, a top clamping assembly for pressing the reducer housing is provided at the top of the placement plate, and an abutment assembly for auxiliary positioning is provided at the top of the placement plate.

[0008] As a preferred embodiment of the present invention, the first displacement component includes an adjusting handle and an adjusting rod. The adjusting rod is located at the top of the base, the adjusting handle is disposed at the end of the adjusting rod, and a movable block is movably connected to the adjusting rod. The movable block is slidably connected to the adjusting rod, and the top end of the movable block is fixedly connected to the movable plate. Rotating the adjusting handle drives the adjusting rod to rotate, thereby driving the movable block to slide along the axial direction of the adjusting rod. The second displacement component includes a servo motor, which is located at one end of the movable plate. The output end of the servo motor is equipped with a lead screw, and a moving block is threaded onto the lead screw. The top of the moving block is fixedly connected to the placement plate. The servo motor drives the lead screw to rotate, thereby causing the moving block and the placement plate to move along the lead screw axis. The movable plate is symmetrically equipped with slide rails on both sides, and sliders are slidably connected to the slide rails. The sliders are fixedly connected to the movable plate.

[0009] As a preferred embodiment of the present invention, the positioning component includes a docking platform, with docking keys symmetrically arranged at the top of the docking platform and locking pins arranged around the top of the docking platform.

[0010] As a preferred embodiment of the present invention, the side wall clamping assembly is symmetrically arranged in multiple sets, each set of side wall clamping assembly includes a first cylinder, the first cylinder is installed on one side of the placement plate, the output end of the first cylinder is provided with a first extension rod, the end of the first extension rod is provided with a side plate, and a docking handle is detachably provided on the outer side of the side plate.

[0011] As a preferred embodiment of the present invention, the top pressing assembly is provided in multiple sets, each set of top pressing assembly includes a second cylinder, the second cylinder is installed above the placement plate, the output end of the second cylinder is provided with a second extension rod, and the end of the second extension rod is provided with a pressure plate.

[0012] As a preferred embodiment of the present invention, multiple sets of abutting components are symmetrically arranged. The abutting components can be adjusted at an adjustable angle for clamping. Each abutting component includes a mounting base, which is fixed to the top of the placement plate. A movable seat is hinged to the mounting base, which can rotate around the hinge point. An angle seat is hinged to the movable seat, which can adjust the tilt angle around the hinge point. A third cylinder is provided at the top of the angle seat, a third extension rod is provided at the output end of the third cylinder, a connecting plate is provided at the end of the third extension rod, and an abutment is detachably provided on the outside of the connecting plate.

[0013] As a preferred embodiment of the present invention, the mounting base is provided with a handle for fixing the rotation angle, and the angle seat is provided with a pin for fixing the tilt angle.

[0014] A lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture processing method are disclosed. The reducer housing is divided into an upper housing and a lower housing. The upper housing and the lower housing are processed independently in stages. Edge strips are provided around the edges of the upper housing and the lower housing. A shank hole is provided in the center of the side wall of the edge strip. A pin hole is provided at the edge of the end face of the edge strip. Locking key holes are symmetrically provided on the bottom surface of the upper housing and the lower housing. The upper shell, after being milled, has an upper mating cover at its bottom and the lower shell, after being milled, has a lower mating cover at its top. The inner walls of the upper and lower shells are thinned and reinforced with ribs. The processing method of the shell includes the following steps: S1. Placement of components: The upper and lower housings are milled separately, and the milled surfaces are deburred and cleaned. The lower housing is placed on the mating table and fits together. The mating key is inserted into the keyhole, and the locking pin is inserted into the pin hole. The initial orientation positioning is completed. S2, Side Locking: The first cylinder drives the first extension rod to extend, causing the side plate and docking handle to move towards the center side, so that the docking handle abuts against the handle hole, and the lower housing edge position is locked. S3. Top clamping: The second cylinder drives the second extension rod to retract, which moves the pressure plate downward. The pressure plate clamps the top of the upper housing, completing the vertical fixation. S4. Rough Milling: Rotate the adjusting rod to drive the movable block to slide along the adjusting rod axis to the specified machining position. The servo motor drives the lead screw to rotate, thereby driving the moving block and the placement plate to move along the lead screw axis to below the milling head. Start the milling head to perform rough milling on the mating surface of the lower housing. S5, Fine Milling: After rough milling, the milling cutter head retracts and switches to the fine milling cutter to fine mill the mating surface. Before fine milling, the top clamping component applies appropriate force relief, the side wall clamping component keeps the bottom surface positioning constraint unchanged throughout the entire process, the movable seat rotates around the hinge point, the angle seat adjusts the tilt angle around the hinge point, the third cylinder drives the third extension rod to extend, and drives the abutment to fit against the side of the housing for auxiliary support. The milling cutter head performs precision cutting on the mating surface. S6. Unloading: After the cutting is completed, the milling cutter head retracts and resets. At this time, the servo motor drives the lead screw to rotate, so that the placement plate moves to the unloading station. The abutment component, the clamping component and the side wall clamping component are removed in sequence. The processed lower shell is taken out and the processing is completed. S7. Then repeat steps S1 to S6 on the upper shell to complete the overall machining.

[0015] The upper and lower mating covers are provided with corresponding insertion holes, and positioning pins are provided in the insertion holes for fastening. After the upper and lower housings are assembled, they form a sealed cavity, and a transmission mechanism is installed in the cavity. The upper housing has upper toothed openings on both sides, and the lower housing has lower toothed openings on both sides. The upper housing and the lower housing have main toothed openings on one side, and bearings are installed inside the main toothed openings.

[0016] The upper and lower shells are detachably equipped with a partition. The inner walls of the upper and lower shells are provided with fastening grooves on both sides, and the partition is provided with a buckle on the outside. The buckle and the fastening groove cooperate to realize the quick installation of the partition. The inner bottom walls of the upper and lower shells are provided with thin-walled openings, and the bottom of the partition is provided with a filling block that matches the thin-walled opening.

[0017] Compared with the prior art, the advantages of this invention are: 1. This invention incorporates cross-reinforcing ribs on the inner wall of the shell and adds edge strip reinforcement structures at the edges, effectively dispersing load stress and preventing stress concentration. This reduces the shell's weight while maintaining its strength. Furthermore, it employs a detachable internal partition, allowing for quick installation via snap-fit ​​and slot-fitting. Filler blocks are used to fill the bottom wall opening, eliminating insufficient rigidity caused by excessive cavity size and avoiding material redundancy. This design enables the shell to achieve significant wall thickness reduction for lightweighting while maintaining excellent torsional rigidity and dimensional stability, solving the industry pain point of balancing lightweighting and structural strength.

[0018] 2. This invention employs a combined fixture solution of bottom-surface contact positioning, side flexible locking, and top adaptive clamping. The bottom surface is positioned without interference using a mating key, locking pin, and keyhole, avoiding clamping stress caused by uneven reference surfaces. The side wall clamping assembly is driven by a first cylinder to extend the mating shank into the edge strip hole, utilizing the thickened edge area to bear the force and avoiding sensitive thin-walled areas. The top clamping assembly contacts the non-machined surface at the top of the housing with its pressure plate surface, increasing the force-bearing area and ensuring Z-axis fixation while preventing excessive local compressive stress that could cause workpiece indentation or overall rhomboid distortion.

[0019] 3. This invention incorporates an adjustable-angle abutment component as an auxiliary support. During the finish milling stage, when the sidewall clamping component is appropriately unloaded, the third cylinder drives the abutment to actively support the housing from the side. The movable seat is rotatable, and the angled seat is tiltable, adapting to different profile curvatures and tilt angles of the housing sidewalls. This achieves a follow-up effect where the support point follows the cutting point of the tool, minimizing the suspended span in thin-walled areas, greatly enhancing the rigidity of the process system, effectively suppressing tool deflection and regenerative chatter, and significantly improving the flatness and surface roughness quality of the mating surfaces.

[0020] 4. This invention employs a composite machining strategy of rough milling, stress relief, support, and finish milling. After rough milling, the side wall clamping assembly and the top clamping assembly are appropriately relieved of stress, actively releasing cutting and clamping stresses, allowing the housing to elastically spring back into position. Subsequently, finish milling is performed under rigid support on the back of the abutment assembly, avoiding dimensional deviations caused by finish machining under deformed conditions, eliminating the influence of residual stress on the final accuracy, and ensuring that key dimensions such as bearing hole coaxiality and mating surface flatness meet the standards.

[0021] 5. This invention constructs a two-dimensional adjustment platform through the cooperation of a horizontal adjustment rod and a vertical servo screw. During machining, the relative position of the housing and the milling cutter head is precisely adjusted. After machining, the servo motor quickly drives the placement plate to the unloading station. The detachable docking handle and pressure plate facilitate replacement and maintenance, and are compatible with different housing models. This solves the inefficiency problems caused by frequent model changes and manual datum adjustments in traditional machining, making it suitable for large-scale, high-precision automated production of new energy vehicle parts. Attached Figure Description

[0022] Figure 1 This is an overall assembly structure diagram of the present invention; Figure 2 This is an exploded view of the invention; Figure 3 This is a structural diagram of the positioning component, side wall clamping assembly, and top pressing assembly on the placement plate of the present invention; Figure 4 This is a structural diagram of the movable block and slider of the present invention; Figure 5 This is a cross-sectional view of the abutment component of the present invention; Figure 6This is an assembly structure diagram of the upper housing and the lower housing of the present invention; Figure 7 This is an exploded view of the upper and lower shells of the present invention; Figure 8 This is a first-view structural diagram of the lower housing of the present invention; Figure 9 This is a second-view sectional view of the bottom of the lower housing of the present invention; Figure 10 This is a diagram of the partition structure of the present invention; In the diagram: 1. Base; 11. Platform; 12. Adjusting rod; 121. Adjusting handle; 13. Movable block; 14. Spindle box; 15. Adjusting head; 16. Milling cutter head; 2. Movable plate; 20. Placement plate; 21. Servo motor; 210. Lead screw; 22. Slide rail; 220. Slider; 23. Moving block; 3. Dating table; 31. Dating key; 32. Locking pin; 4. First cylinder; 41. First extension rod; 42. Side plate; 43. Dating handle; 5. Second cylinder; 51. Second extension rod; 52. Pressure plate; 6. Mounting seat; 61. Movable seat; 610. Clamping handle; 611. 62. Snap pin; 63. Angle seat; 64. Third cylinder; 65. Third extension rod; 66. Connecting plate; 651. Abutment joint; 7. Upper housing; 71. Inspection cover; 72. Upper mating cover; 73. Upper side toothed opening; 8. Lower housing; 80. Reinforcing rib; 81. Partition; 810. Snap fastener; 8100. Snap groove; 812. Filler block; 8120. Thin-walled opening; 82. Lower mating cover; 821. Insertion hole; 822. Positioning pin; 83. Lower side toothed opening; 88. Main toothed opening; 881. Bearing; 9. Edge strip; 91. Pin hole; 92. Locking key hole; 93. Handle hole; 900. Transmission mechanism. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and 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. Example

[0024] Please see Figure 1 - Figure 10 A lightweight reducer housing for new energy heavy-duty vehicles and its CNC milling fixture, including a base 1, specifically referring to... Figure 1 and Figure 2The base 1 forms the foundation of the milling machine, supporting the entire machine and providing stable support. A platform 11 is located at the top of the base 1. A spindle box 14 is located on one side of the platform 11. The spindle box 14 integrates a motor and a speed transmission mechanism 900, forming the power and control unit for milling operations. An adjusting head 15 is located at the top of the spindle box 14, and is connected to the spindle box 14 for driving and adjusting the rotation and feed of the milling cutter head 16 to perform milling operations on the workpiece. The milling cutter head 16 is clamped at the bottom of the adjusting head 15 and moves synchronously with the adjustment head 15. The adjusting head 15 can flexibly switch height and angle, thereby enabling the milling cutter head 16 to adapt to different machining positions and postures, meeting the process requirements of complex shell surfaces and multi-angle milling.

[0025] A first displacement component is provided on one side of the platform 11, and a movable plate 2 is connected to the first displacement component. The first displacement component is used to drive the movable plate 2 to adjust its relative position laterally, thereby precisely adjusting the relative position between the housing and the milling cutter head 16 to meet the alignment requirements of milling. A second displacement component is provided on the movable plate 2, and a placement plate 20 is connected to the second displacement component. The second displacement component is used to drive the placement plate 20 to adjust its relative position longitudinally, and after processing, it drives the placement plate 20 to move to the unloading station to complete the automatic loading, unloading and transfer of workpieces, thereby improving processing efficiency and automation.

[0026] To ensure lightweight design and weight reduction of the housing, new challenges have been introduced to CNC milling. In the manufacturing process of reducer housings for existing heavy-duty new energy engineering vehicles, high-strength aluminum alloy materials are commonly used and the housing is thinned to achieve overall vehicle lightweighting, reduce energy consumption, and improve range. However, while thinning the wall brings weight reduction benefits, it also significantly weakens the structural rigidity of the housing itself, making it exhibit obvious weak rigidity characteristics during CNC milling. When using traditional general-purpose tooling to clamp the housing, if the clamping force is too small, the housing will deflect and chatter under the action of cutting force; if the clamping force is too large, local indentation is easily generated in the thin-walled area.

[0027] Specific reference Figure 3A positioning component is located at the center of the top of the placement plate 20. This component engages with the bottom surface of the reducer housing to achieve initial workpiece positioning and datum establishment. The positioning component includes a mating surface 3, which forms the basic positioning surface for workpiece placement, supporting and conforming to the bottom surface of the reducer housing to ensure stable placement. Symmetrically arranged at the top of the mating surface 3 are mating keys 31, which protrude upwards and mate with locking holes 92 on the bottom surface of the housing. These keys restrict the horizontal translational and rotational freedom of the housing, achieving precise angular positioning. Locking pins 32 are arranged around the top of the mating surface 3, engaging with pin holes 91 on the edge of the housing to further restrict positional deviation. Together with the mating keys 31, they form a multi-point positioning constraint on the bottom surface, ensuring datum stability of the housing during processing. A side-wall clamping assembly is located at the top of the placement plate 20. This assembly applies clamping force from the side of the housing to horizontally fix the reducer housing and prevent lateral displacement of the workpiece during processing. The top of the placement plate 20 is also equipped with a top clamping component, which is used to apply downward pressure from the top of the housing to press the reducer housing against the positioning component, ensuring that the workpiece is firmly fixed in the vertical direction. The top of the placement plate 20 is also equipped with an abutment component, which is used to provide auxiliary support and abutment from the side wall of the housing during milling, enhancing the local rigidity of the thin-walled area and suppressing cutting vibration and deformation.

[0028] Specific reference Figure 6 and Figure 7 The reducer housing is divided into two parts: an upper housing 7 and a lower housing 8. The upper housing 7 and the lower housing 8 each constitute half of the reducer assembly's cavity structure. During assembly, the upper housing 7 and the lower housing 8 are joined together to form a complete internal gear housing space. In this invention, the upper housing 7 and the lower housing 8 are milled in stages. That is, one half of the housing is first positioned, clamped, and milled to achieve high-precision forming of the mating surface, bearing 881 hole, and mounting features of this half of the housing. Then, the other half of the housing is placed on the same fixture or corresponding station, and the positioning, clamping, and milling processes are repeated.

[0029] In this embodiment, specific reference is made. Figure 1 and Figure 2The first and second moving components are described in detail. The first moving component includes an adjusting handle 121 and an adjusting rod 12. The adjusting rod 12 is horizontally positioned on the top of the base 1, and the adjusting handle 121 is fixedly mounted on one end of the adjusting rod 12 for the operator to adjust the relative position. A movable block 13 is movably connected to the adjusting rod 12, forming a helical transmission engagement with the adjusting rod 12. The top end of the movable block 13 is fixedly connected to the movable plate 2. Rotating the adjusting handle 121 causes the adjusting rod 12 to rotate around its axis, thereby converting the rotational motion into a sliding displacement of the movable block 13 along the axial direction of the adjusting rod 12, thus driving the movable plate 2 and the components above it to achieve lateral position adjustment.

[0030] Specific reference Figure 2 The second displacement component includes a servo motor 21, which is fixedly mounted on one end of the movable plate 2. The output end of the servo motor 21 is connected to a lead screw 210, which is arranged horizontally along the longitudinal direction. A moving block 23 is threaded onto the lead screw 210, and the top of the moving block 23 is fixedly connected to the placement plate 20. The servo motor 21 drives the lead screw 210 to rotate in the forward or reverse direction, causing the moving block 23 to move axially along the lead screw 210, thereby adjusting the longitudinal position of the placement plate 20 and the housing workpiece above it, thus precisely controlling the relative position of the workpiece and the milling cutter head 16 in the front-back direction.

[0031] Specific reference Figure 2 and Figure 4 The movable plate 2 has symmetrically arranged slide rails 22 on both sides. The slide rails 22 are fixedly laid on the surface of the movable plate 2 along the longitudinal direction. The sliders 220 are slidably connected to the slide rails 22 and are fixedly connected to the placement plate 20. The slide rails 22 and the sliders 220 constitute a linear guide mechanism, which is used to provide smooth sliding support and guiding constraint when the placement plate 20 moves with the lead screw 210.

[0032] In this embodiment, specific reference is made. Figure 2 and Figure 3The side wall clamping assembly is described in detail. Multiple sets of side wall clamping assemblies are symmetrically arranged, preferably four sets, distributed around the perimeter of the placement plate 20. These assemblies are used to clamp and fix the reducer housing from multiple directions around its perimeter. Each pair of side wall clamping assemblies constitutes a clamping unit. These two sets of side wall clamping assemblies can be spaced apart or symmetrically arranged along the centerline of the placement plate 20 to accommodate housing workpieces of different shapes and sizes. Each side wall clamping assembly includes a first cylinder 4, which is fixedly installed on one side of the placement plate 20. The output end of the first cylinder 4 is provided with a first extension rod 41, which can extend and retract horizontally. A side plate 42 is provided at the end of the first extension rod 41, which transmits clamping force. A docking handle 43 is detachably provided on the outer side of the side plate 42, protruding towards the housing side and used to embed into the handle hole 93 of the housing edge strip 9, thereby achieving rigid contact and horizontal positioning of the side wall.

[0033] In this embodiment, specific reference is made. Figure 2 and Figure 3 Specifically, the top clamping assembly is used to restrict the vertical freedom of the reducer housing from above. By applying downward pressure, it firmly presses the housing onto the positioning component, preventing vertical displacement or warping of the workpiece during processing. Multiple sets of top clamping assemblies are provided, preferably three sets. These three sets are spaced apart at the top of the placement plate 20, avoiding the machining path of the milling cutter head 16. Each set of top clamping assemblies includes a second cylinder 5, which is fixedly installed above the placement plate 20. The output end of the second cylinder 5 is provided with a second extension rod 51, which can extend and retract vertically. A pressure plate 52 is provided at the end of the second extension rod 51. As the second extension rod 51 descends, the pressure plate 52 abuts against the edge of the top surface of the housing, applying clamping force through surface contact. This ensures the Z-axis fixation effect while preventing workpiece indentation or deformation due to localized stress concentration.

[0034] In this embodiment, specific reference is made. Figure 3 and Figure 4The abutment assembly is described in detail below. Multiple sets of abutment assemblies are symmetrically arranged, preferably two sets. These two sets of abutment assemblies are symmetrically arranged and clamp the thin-walled areas on both sides of the housing. The abutment assemblies can be engaged after rough milling to provide auxiliary support and clamping action from the housing sidewalls, suppressing chatter in the thin-walled areas during finish milling. The abutment assembly includes a mounting base 6, which is fixedly mounted on the top of the placement plate 20. A movable seat 61 is hinged to the mounting base 6. The movable seat 61 can rotate around its hinge axis with the mounting base 6, thereby adjusting the horizontal rotation angle of the abutment direction to accommodate reducer housings of different widths or profiles. An angle seat 62 is hinged to the movable seat 61. The angle seat 62 can adjust its tilt angle around its hinge point with the movable seat 61, thereby changing the contact posture of the abutment joint 651 relative to the housing sidewall, adapting to housing sides of different heights and tilt angles.

[0035] A third cylinder 63 is provided at the top of the angle seat 62. A third extension rod 64 is provided at the output end of the third cylinder 63. The third extension rod 64 can extend and retract in a set direction. A connecting plate 65 is provided at the end of the third extension rod 64. An abutment 651 is detachably provided on the outer side of the connecting plate 65. The abutment 651 is used to fit tightly against the side wall of the housing to form rigid support on the opposite side of the tool cutting point. A handle 610 is provided on the mounting base 6 for fixing the rotation angle of the movable seat 61. The handle 610 can lock the movable seat 61 after the angle is adjusted to prevent deflection during processing. A locking pin 611 is provided on the angle seat 62 for fixing the tilt angle. The locking pin 611 can lock the angle seat 62 after the tilt angle is adjusted to ensure stable support posture. During the rough milling stage, the abutment component can remain in a retracted state without participating in clamping to avoid over-positioning. After the rough milling is completed and the force is appropriately released, the posture of the movable seat 61 and the angle seat 62 is adjusted so that the abutment 651 fits against the side wall of the housing. Then, the locking handle 610 and the locking pin 611 are locked and driven by the third cylinder 63 to abut, thereby forming a stable and reliable follow-up auxiliary support during the finish milling stage.

[0036] A lightweight reducer housing for new energy heavy-duty vehicles and a CNC milling fixture for machining the reducer housing, specifically referring to... Figure 6 , Figure 7 as well as Figure 8 The reducer housing is divided into two parts: an upper housing 7 and a lower housing 8. Both the upper housing 7 and the lower housing 8 are made of aluminum alloy and feature a thin-walled design to reduce overall weight. Edge strips 9 are provided around the perimeter of both the upper housing 7 and the lower housing 8. These edge strips extend integrally along the outer circumference of the housing mating surface, and their cross-sectional dimensions are locally thicker than the thin-walled areas of the inner wall of the housing. This enhances the structural rigidity around the housing mating surface and provides a load-bearing carrier for clamping and positioning.

[0037] A shank hole 93 is provided at the center of the side wall of the edge strip 9. The shank hole 93 is opened through the side wall of the edge strip 9 along the circumference of the housing and is used to cooperate with the docking shank 43 in the clamping assembly of the side wall of the clamp. When the first cylinder 4 drives the docking shank 43 to extend into the shank hole 93, a horizontal clamping force and positioning constraint can be applied to the housing to lock the edge position of the housing.

[0038] A pin hole 91 is provided at the edge of the end face of the edge strip 9. The pin hole 91 is opened on the machined bottom surface of the edge strip 9 and is used to cooperate with the locking pin 32 in the fixture positioning component. When the housing is placed on the docking table 3, the locking pin 32 is engaged in the pin hole 91, thereby restricting the translation and rotation of the housing in the horizontal plane. Together with the docking key 31, it forms a multi-point positioning constraint on the bottom surface.

[0039] Both the upper housing 7 and the lower housing 8 have symmetrical key holes 92 on their bottom surfaces. The key holes 92 are opened on the machined bottom surface of the housing and are used to match the mating key 31 on the mating table 3. When the housing is placed on the mating table 3, the mating key 31 is inserted into the key hole 92 to restrict the angular freedom of the housing and ensure the stable establishment of the housing machining reference.

[0040] The processing method for the shell includes the following steps: S1. Placement of components: The upper housing 7 and the lower housing 8 are milled respectively. The milled surfaces are deburred and cleaned. The lower housing 8 is placed on the docking table 3 and fits together. The docking key 31 is inserted into the keyhole 92, and the locking pin 32 is inserted into the pinhole 91. The initial orientation positioning is completed. S2, Side locking: The first cylinder 4 drives the first extension rod 41 to extend, which drives the side plate 42 and the docking handle 43 to move towards the center side, so that the docking handle 43 abuts against the handle hole 93, and the edge of the lower housing 8 is locked. S3, Top clamping: The second cylinder 5 drives the second extension rod 51 to retract, which drives the pressure plate 52 to move downward. The pressure plate 52 clamps the top of the upper housing 7, completing the vertical fixation. S4. Rough milling: Rotate the adjusting rod 12 to drive the movable block 13 to slide along the axis of the adjusting rod 12 to the specified processing position. The servo motor 21 drives the lead screw 210 to rotate, thereby driving the moving block 23 and the placement plate 20 to move along the axis of the lead screw 210 to below the milling head 16. Start the milling head 16 to perform rough milling on the mating surface of the lower housing 8. S5, Fine Milling: After rough milling, the milling head 16 retracts and switches to the fine milling tool to perform fine milling on the mating surface. Before fine milling, the top clamping component performs moderate force relief, and the side wall clamping component keeps the bottom positioning constraint unchanged throughout the entire process. The movable seat 61 rotates around the hinge point, and the angle seat 62 adjusts the tilt angle around the hinge point. The third cylinder 63 drives the third extension rod 64 to extend, which drives the abutment 651 to fit against the side of the housing for auxiliary support. The milling head 16 performs precision cutting on the mating surface. After rough milling, the tool retracts, the clamping system releases residual stress in stages, the side auxiliary support is activated to strengthen rigidity, and the fine milling tool is replaced to complete the fine machining of the mating surface. S6. Unloading: After the cutting is completed, the milling cutter head 16 retracts and resets. At this time, the servo motor 21 drives the lead screw 210 to rotate, so that the placement plate 20 moves to the unloading station. The abutment component, the clamping component and the side wall clamping component are removed in sequence, and the processed lower housing 8 is taken out. The processing is completed.

[0041] S7. Then repeat steps S1 to S6 on the upper shell 7 to complete the overall machining.

[0042] The upper housing 7, after milling, has an upper mating cover 72 at its bottom end. The upper mating cover 72 constitutes the main structure of the mating surface of the upper housing 7 and is used for mating with the lower housing 8. The lower housing 8, after milling, has a lower mating cover 82 at its top end. The lower mating cover 82 constitutes the main structure of the mating surface of the lower housing 8 and is used for mating with the upper housing 7. When assembling the finished upper housing 7 and lower housing 8, corresponding positions of the upper mating cover 72 and lower mating cover 82 are provided with insertion holes 821. The insertion holes 821 are opened through the mating covers for the insertion of positioning pins 822. The positioning pins 822 are provided in the insertion holes 821, and the positioning pins 822 are interference-fitted or transition-fitted with the insertion holes 821 to accurately align and fasten the upper housing 7 and lower housing 8 during the assembly stage, preventing misalignment during assembly.

[0043] After the upper housing 7 and the lower housing 8 are assembled, a sealed cavity is formed, as detailed in the following reference. Figure 6 The sealed cavity is used to house the gear set and transmission components. A transmission mechanism 900 is installed inside the cavity. The transmission mechanism 900 includes a gear shaft system and a bearing 881 assembly, which is used to reduce and transmit torque in a sealed environment.

[0044] The upper housing 7 has upper toothed openings 73 on both sides, and the lower housing 8 has corresponding lower toothed openings 83 on both sides. After the housings are assembled, the upper toothed openings 73 and lower toothed openings 83 are joined together to form a complete side shaft hole for mounting and supporting the drive shaft. The upper housing 7 and the lower housing 8 have a main toothed opening 88 on one side. After assembly, the main toothed opening 88 forms the main shaft mounting hole of the reducer. A bearing 881 is installed inside the main toothed opening 88 for mounting the output shaft.

[0045] Specific reference Figure 10The inner walls of both the upper shell 7 and the lower shell 8 are thinned to reduce the overall weight of the shell. At the same time, the inner walls of the upper shell 7 and the lower shell 8 are provided with reinforcing ribs 80. The reinforcing ribs 80 are distributed in a cross or grid pattern and are integrally formed on the inner wall surface of the shell to compensate for the rigidity loss caused by the thinning of the wall thickness. While maintaining the lightweight, the shell's torsional resistance and dimensional stability are enhanced.

[0046] In this embodiment, specific reference is made. Figure 10 The upper housing 7 and the lower housing 8 are detachably equipped with a partition 81. The partition 81 is used to divide the internal cavity of the housing into different functional areas to facilitate the distribution of lubricating oil, the isolation of gear sets, or the arrangement of controller components. The inner walls of the upper housing 7 and the lower housing 8 are provided with latching grooves 8100 on both sides. The latching grooves 8100 are recessed into the inner wall surface of the housing and are used to engage with the latches 810 on the outer side of the partition 81. The latches 810 are provided on the outer side of the partition 81, protruding from the outer surface of the partition 81. The shape of the latches 810 and the latching grooves 8100 are adapted to each other. When the partition 81 is placed inside the housing, the latches 810 are embedded in the latching grooves 8100 to form a snap-fit ​​engagement, realizing the quick installation and removal of the partition 81 without the need for additional fasteners, resulting in high assembly efficiency and reliable connection.

[0047] The inner bottom walls of the upper shell 7 and the lower shell 8 are provided with thin-walled openings 8120, as detailed below. Figure 9 and 10 The thin-walled opening 8120 is an opening or recessed area formed after the bottom wall of the shell is partially thinned, which is used to further reduce the weight of the shell. The bottom of the partition 81 is provided with a filler block 812. The shape and position of the filler block 812 are adapted to the thin-walled opening 8120. When the partition 81 is installed inside the shell, the filler block 812 is embedded in the thin-walled opening 8120, forming a back support and structural reinforcement for the thin-walled area. This not only eliminates the suspended span at the thin-walled opening 8120, but also avoids the lack of local rigidity caused by large-area thinning, thereby maintaining the overall strength and dimensional stability of the shell while ensuring lightweight.

[0048] The upper shell 7 and the lower shell 8 are processed independently in stages using the same set of fixtures. That is, the same positioning components, side wall clamping components, top pressing components and abutment components are used to perform the same positioning, clamping, rough milling, unloading, finish milling and unloading process on the two shell halves in turn. Only the shell placement posture and the orientation of the mating cover are adjusted according to the structural differences between the upper and lower shell halves. There is no need to change the fixture or switch the reference, thus effectively avoiding the reference conversion error caused by the box assembly process, and ensuring the flatness consistency and fitting accuracy of the mating surfaces of the upper and lower shell halves.

[0049] The abutment assembly is used for sidewall rigid reinforcement during the finish milling stage. During the rough milling stage, the abutment assembly remains retracted and does not participate in clamping to avoid introducing additional clamping stress before the housing has released the residual stress from rough machining, and to prevent over-positioning leading to superposition of elastic deformation. After the rough milling is completed and the sidewall clamping assembly and the top clamping assembly are appropriately unloaded, the housing slightly springs back to its original position within the elastic range. At this time, the posture of the movable seat 61 and the angle seat 62 is adjusted so that the abutment 651 fits against the sidewall of the housing and locks the shank 610 and the pin 611. The abutment is driven by the third cylinder 63, thereby forming a stable and reliable rigid support on the back side during the finish milling stage, ensuring that the finish milling is carried out in a near-free workpiece posture.

[0050] The assembly of the partition 81 with the housing is carried out after all milling is completed and inspected. Specifically, the partition 81 is first inserted into the housing using the engagement of the snap-fit ​​810 and the snap-fit ​​groove 8100. This prevents the partition 81 from occupying tool space or deforming due to heat during milling, which could affect machining accuracy. After the partition 81 is installed, its bottom filler block 812 embeds into the thin-walled opening 8120 to form a back support. This, together with the reinforcing ribs 80 inside the housing, constitutes a multi-dimensional rigid reinforcement structure, ensuring the housing is lightweight while maintaining overall strength and dimensional stability.

[0051] The locating pin 822 is inserted into the insertion hole 821 with an interference fit or transition fit during the assembly of the upper and lower housings 8. This ensures the precise alignment and fastening of the upper mating cover 72 and the lower mating cover 82, preventing misalignment from causing excessive coaxiality of the bearing 881 hole. The sealed cavity formed after the upper housing 7 and the lower housing 8 are assembled is further secured by bolt pairs or other fasteners after assembly to ensure reliable operation of the transmission mechanism 900 in a sealed environment.

[0052] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture, comprising a base (1), a platform (11) at the top of the base (1), a spindle box (14) on one side of the platform (11), an adjusting head (15) at the top of the spindle box (14), and a milling cutter head (16) at the bottom of the adjusting head (15), characterized in that: The adjusting head (15) can flexibly switch the height and angle to enable the milling cutter head (16) to perform milling. The platform (11) is provided with a first displacement component on one side. A movable plate (2) is connected to the first displacement component. A second displacement component is provided on the movable plate (2). A placement plate (20) is connected to the second displacement component. The first displacement component drives the movable plate (2) to adjust the relative position. The second displacement component drives the placement plate (20) to adjust the relative position. A positioning component is provided at the center of the top of the placement plate (20). A side wall clamping assembly for fixing the reducer housing is provided at the top of the placement plate (20). A top clamping assembly for pressing the reducer housing is provided at the top of the placement plate (20). An abutment assembly for auxiliary positioning is provided at the top of the placement plate (20).

2. The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 1, characterized in that: The first displacement component includes an adjusting handle (121) and an adjusting rod (12). The adjusting rod (12) is located on the top of the base (1), and the adjusting handle (121) is located at the end of the adjusting rod (12). A movable block (13) is movably connected to the adjusting rod (12). The movable block (13) is slidably connected to the adjusting rod (12). The top of the movable block (13) is fixedly connected to the movable plate (2). Rotating the adjusting handle (121) drives the adjusting rod (12) to rotate, thereby driving the movable block (13) to slide along the axial direction of the adjusting rod (12). The second displacement component includes a servo motor (21), which is located at one end of the movable plate (2). The output end of the servo motor (21) is provided with a lead screw (210), and a moving block (23) is threadedly connected to the lead screw (210). The top of the moving block (23) is fixedly connected to the placement plate (20). The servo motor (21) drives the lead screw (210) to rotate, thereby driving the moving block (23) and the placement plate (20) to move along the axial direction of the lead screw (210). The movable plate (2) is symmetrically provided with slide rails (22) on both sides, and a slider (220) is slidably connected on the slide rails (22). The slider (220) is fixedly connected to the movable plate (2).

3. The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 2, characterized in that: The positioning component includes a docking platform (3), with docking keys (31) symmetrically provided at the top of the docking platform (3), and locking pins (32) provided around the top of the docking platform (3).

4. The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 3, characterized in that: The side wall clamping assemblies are symmetrically arranged in multiple sets. Each set of side wall clamping assemblies includes a first cylinder (4). The first cylinder (4) is installed on one side of the placement plate (20). The output end of the first cylinder (4) is provided with a first extension rod (41). The end of the first extension rod (41) is provided with a side plate (42). A docking handle (43) is detachably provided on the outside of the side plate (42).

5. The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 4, characterized in that: The top pressing assembly is provided in multiple sets. Each set of top pressing assembly includes a second cylinder (5). The second cylinder (5) is installed above the placement plate (20). The output end of the second cylinder (5) is provided with a second extension rod (51). The end of the second extension rod (51) is provided with a pressure plate (52).

6. The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 5, characterized in that: The abutting components are symmetrically arranged in multiple sets. The abutting components can be adjusted at an adjustable angle for clamping. The abutting components include a mounting base (6), which is fixed to the top of the placement plate (20). A movable seat (61) is hinged on the mounting base (6). The movable seat (61) can rotate around the hinge point. An angle seat (62) is hinged on the movable seat (61). The angle seat (62) can adjust the tilt angle around the hinge point. The top of the angle seat (62) is provided with a third cylinder (63), the output end of the third cylinder (63) is provided with a third extension rod (64), the end of the third extension rod (64) is provided with a connecting plate (65), and the outside of the connecting plate (65) is detachably provided with an abutment (651).

7. The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 6, characterized in that: The mounting base (6) is provided with a handle (610) for fixing the rotation angle, and the angle seat (62) is provided with a pin (611) for fixing the tilt angle.

8. A method for machining a lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture, characterized in that, The lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture described in claim 6 are used in the following: The reducer housing is divided into two parts: an upper housing (7) and a lower housing (8). The upper housing (7) and the lower housing (8) are processed independently in stages. Edge strips (9) are provided around the edges of the upper housing (7) and the lower housing (8). A shank hole (93) is provided in the center of the side wall of the edge strip (9). A pin hole (91) is provided at the edge of the end face of the edge strip (9). Locking key holes (92) are symmetrically provided on the bottom surfaces of the upper housing (7) and the lower housing (8). The upper shell (7) after milling is provided with an upper mating cover (72) at the bottom and the lower shell (8) after milling is provided with a lower mating cover (82) at the top. The inner walls of the upper shell (7) and the lower shell (8) are thinned and reinforced with ribs (80). The processing method for the shell includes the following steps: S1. Placement of components: The upper housing (7) and the lower housing (8) are milled respectively. The milled surfaces are deburred and cleaned. The lower housing (8) is placed on the docking table (3) and fits together. The docking key (31) is inserted into the keyhole (92), and the locking pin (32) is inserted into the pin hole (91). The initial orientation positioning is completed. S2, Side locking: The first cylinder (4) drives the first extension rod (41) to extend, causing the side plate (42) and the docking handle (43) to move towards the center side, so that the docking handle (43) abuts against the handle hole (93), and the edge position of the lower housing (8) is locked. S3, Top clamping: The second cylinder (5) drives the second extension rod (51) to retract, which drives the pressure plate (52) to move downward. The pressure plate (52) clamps the top of the upper housing (7) to complete the vertical fixation. S4. Rough milling: Rotate the adjusting rod (12) to drive the movable block (13) to slide along the axis of the adjusting rod (12) to the specified machining position. The servo motor (21) drives the lead screw (210) to rotate, thereby driving the moving block (23) and the placement plate (20) to move along the axis of the lead screw (210) to below the milling head (16). Start the milling head (16) to perform rough milling on the mating surface of the lower housing (8). S5, fine milling: The milling head (16) retracts after rough milling and switches to the fine milling tool to perform fine milling on the mating surface. Before fine milling, the top clamping component performs moderate force relief, the side wall clamping component keeps the bottom positioning constraint unchanged throughout the process, the movable seat (61) rotates around the hinge point, the angle seat (62) adjusts the tilt angle around the hinge point, the third cylinder (63) drives the third extension rod (64) to extend, and drives the abutment (651) to fit against the side of the housing for auxiliary support. The milling head (16) performs precision cutting on the mating surface. S6, Unloading: After the cutting is completed, the milling cutter head (16) retracts and resets. At this time, the servo motor (21) drives the lead screw (210) to rotate, so that the placement plate (20) moves to the unloading station. The abutment component, the clamping component and the side wall clamping component are removed in sequence, and the processed lower shell (8) is taken out. The processing is completed. S7. Then repeat steps S1 to S6 on the upper shell (7) to complete the overall processing.

9. A method for machining a lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 8, characterized in that: The upper docking cover (72) and the lower docking cover (82) are provided with corresponding insertion holes (821), and the insertion holes (821) are provided with positioning pins (822) for fastening. After the upper housing (7) and the lower housing (8) are assembled, a sealed cavity is formed, and a transmission mechanism (900) is installed in the cavity. The upper housing (7) has upper toothed openings (73) on both sides, and the lower housing (8) has lower toothed openings (83) on both sides. The upper housing (7) and the lower housing (8) have main toothed openings (88) on one side, and a bearing (881) is provided in the main toothed openings (88).

10. A method for machining a lightweight new energy heavy-duty vehicle reducer housing and its CNC milling fixture according to claim 9, characterized in that: The upper shell (7) and the lower shell (8) are detachably provided with a partition (81). The inner walls of the upper shell (7) and the lower shell (8) are provided with fastening grooves (8100) on both sides. The partition (81) is provided with a buckle (810) on the outside. The buckle (810) and the fastening groove (8100) cooperate to realize the quick installation of the partition (81). The inner bottom walls of the upper shell (7) and the lower shell (8) are provided with thin-walled openings (8120), and the bottom of the partition (81) is provided with a filling block (812) that is compatible with the thin-walled openings (8120).

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