Assembly mistake-proof testing fixture and forklift gearbox multi-disc clutch

Abstract

The utility model discloses an assembly error-proofing testing fixture and a fork truck gearbox multi-disc clutch, which comprise a main body rod, a plurality of guide teeth are arranged on one side of the main body rod at equal intervals, a guide groove is arranged between every two adjacent guide teeth, a pressure sensor is arranged on the inner wall of each guide groove, a display screen is arranged at the top of the main body rod, and the display screen is connected with the main body rod. Wherein the pressure sensor is electrically connected with the display screen. According to the detection tool integrating physical limiting and electronic feedback, through the fusion design of the guide teeth and the sensor, installation errors generated by the assembly sequence, number and direction between the steel sheets and the friction sheets can be rapidly intercepted, plug-and-play detection is achieved, the rework rate is reduced, and the assembly efficiency is improved; the detection tool designed by the utility model can effectively detect the phenomena of neglected assembly and wrong assembly in the assembly of the multi-disc clutch, and human errors are reduced from the source and the product consistency is ensured by combining the physical structure design of the detection tool with the use of the embedded sensor.

Description

Technical Field

[0001] This utility model relates to the field of assembly error prevention technology, specifically to an assembly error prevention inspection tool and a multi-plate clutch for a forklift gearbox. Background Technology

[0002] The multi-plate clutch of a forklift is a core component of the transmission system, and its assembly accuracy directly affects power transmission, service life, and safety. As industrial vehicles become more efficient and intelligent, traditional manual, visually-based operations are prone to assembly errors, leading to malfunctions and even safety accidents. Therefore, optimizing the assembly process through error-proofing fixtures has become an inevitable choice for improving quality and reducing costs.

[0003] Multi-plate clutches typically consist of alternating friction plates and steel plates. The number of plates is determined by the maximum torque the clutch needs to withstand. The required number of friction pairs must be calculated based on the engine output power and forklift load. The friction plates are designed for bidirectional operation; the number of friction pairs is calculated based on both sides of each clutch plate. Therefore, the correct installation sequence and orientation are crucial for torque transmission and heat dissipation. Incorrect installation can cause the contact surfaces of the friction plates and steel plates to fail to mesh properly, leading to slippage or inability to disengage. This can result in difficulty shifting gears and even damage to the transmission. Consequences of incorrect installation also include performance degradation, such as insufficient torque transmission, weak vehicle acceleration, or inability to move. Furthermore, incorrect installation can lead to abnormal wear and even overheating, damaging the clutch assembly. Additionally, the clutch hydraulic system or electronic control unit may experience abnormal pressure due to incorrect clutch installation, causing malfunctions.

[0004] Currently, conventional forklift clutch assembly relies on manual visual inspection or random sampling with general measuring tools, which has the problem of high omission rate: the alternation sequence and installation direction of friction plates and steel plates are easily confused, and it is difficult to check each piece manually; it is inefficient: repeated disassembly and assembly verification is required, which affects the production line cycle. Utility Model Content

[0005] The technical problem to be solved by this utility model is: how to solve the problem of high missed inspection rate in conventional forklift clutch assembly.

[0006] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0007] An assembly error-proofing fixture includes a main rod, with a plurality of guide teeth evenly spaced on one side of the main rod, and guide grooves between adjacent guide teeth. A pressure sensor is provided on the inner wall of each guide groove, and a display screen is provided on the top of the main rod, wherein the pressure sensor is electrically connected to the display screen.

[0008] This application proposes a fixture that integrates physical limits and electronic feedback. Through the fusion design of guide teeth and sensors, it can quickly intercept installation errors caused by sample assembly sequence, quantity, and orientation, achieving "plug and check," reducing rework rate, and improving assembly efficiency.

[0009] As a further embodiment of this utility model: a dual-color light is installed on the main body rod, and the dual-color light is electrically connected to the display screen.

[0010] As a further embodiment of this utility model: a gauge handle is installed on the top of the main rod, and a dual-color light is installed on the top of the gauge handle.

[0011] As a further embodiment of this utility model: the display screen is equipped with a power supply and a data processing module, and the data processing module is connected to the pressure sensor.

[0012] As a further embodiment of this invention, the front end of the guide tooth is chamfered.

[0013] As a further embodiment of this invention, a chamfer is provided on the innermost side of the guide groove.

[0014] This utility model also discloses a multi-plate clutch for a forklift gearbox, including a clutch hub, a hydraulic piston, several steel plates and friction plates arranged in an alternating manner, a return spring and a drive shaft, and the aforementioned error prevention checker, wherein several friction plates extend into several guide grooves and contact pressure sensors.

[0015] As a further aspect of this invention, the thickness of the guide tooth matches the thickness of the steel sheet.

[0016] As a further aspect of this invention, the thickness of the guide groove is greater than the thickness of the friction plate.

[0017] As a further embodiment of this invention, the number of friction plates is the same as the number of guide grooves.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] 1. This application designs a fixture that integrates physical limiting and electronic feedback. Through the fusion design of guide teeth and sensors, it can quickly intercept installation errors caused by the assembly sequence, quantity and direction between steel plates and friction plates, realize "plug and check", reduce rework rate and improve assembly efficiency;

[0020] 2. The inspection fixture designed in this application can effectively check for omissions and misassemblies in the assembly of multi-plate clutches. Based on the physical structure design of the inspection fixture and the use of embedded sensors, human error is reduced from the source, ensuring product consistency.

[0021] 3. The inspection fixture designed in this application solves the shortcomings of general inspection fixtures, such as poor adaptability, inability to simultaneously verify sequence, quantity and orientation, and the need for multiple operations, achieving "one insertion and removal, multiple verifications" and making the inspection more efficient;

[0022] 4. The inspection fixture designed in this application fully integrates physical limits and electronic feedback, which improves the intelligence level of clutch plate inspection and upgrades the error prevention method from "passive error correction" to "active prevention", thus improving the quality and efficiency of the assembly process.

[0023] 5. This application has a simple structure, is quick to operate, has low usage costs, and is cost-effective. Attached Figure Description

[0024] Figure 1 An exploded view of a multi-plate clutch in a gearbox;

[0025] Figure 2 A partial structural diagram of a multi-plate clutch in a gearbox. Figure 1 ;

[0026] Figure 3 A partial structural diagram of a multi-plate clutch in a gearbox. Figure 2 ;

[0027] Figure 4 This is a schematic diagram of the structure of a multi-plate clutch in a gearbox;

[0028] Figure 5 This is a schematic diagram of the clutch hub in an embodiment of the present invention;

[0029] Figure 6 This is a schematic diagram of the structure of the inspection tool according to an embodiment of the present utility model;

[0030] Figure 7 This is a partial cross-sectional view of the inspection fixture located inside the clutch hub according to an embodiment of the present invention;

[0031] Figure 8 This is a schematic diagram showing the qualified assembly of the inspection tool and friction plate according to an embodiment of the present utility model.

[0032] Figure 9 This is a schematic diagram illustrating the defective assembly of the inspection tool and friction plate in an embodiment of this utility model. Figure 1 ;

[0033] Figure 10 This is a schematic diagram illustrating the defective assembly of the inspection tool and friction plate in an embodiment of this utility model. Figure 2 ;

[0034] Explanation of reference numerals in the attached figures:

[0035] 1. Drive shaft; 2. Return spring; 3. Steel plate; 4. Friction plate; 5. Hydraulic piston; 6. Clutch hub;

[0036] 7. Inspection tool; 71. Dual-color light; 72. Inspection tool handle; 73. Display screen; 74. Main rod; 75. Guide teeth; 76. Pressure sensor. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below in conjunction with the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0038] Example 1

[0039] Reference Figure 6 An assembly error-proofing inspection tool includes a dual-color light 71, an inspection tool handle 72, a display screen 73, a main body rod 74, guide teeth 75, and a pressure sensor 76. Several guide teeth 75 are equally spaced on one side of the main body rod 74, and guide grooves are formed between adjacent guide teeth 75. A pressure sensor 76 is provided on the inner wall of each guide groove.

[0040] Furthermore, a fixture handle 72 is installed on the top of the main body rod 74, a dual-color light 71 is installed on the top of the fixture handle 72, and a display screen 73 is provided on the top of the main body rod 74, wherein the dual-color light 71 and the pressure sensor 76 are electrically connected to the display screen 73.

[0041] Reference Figure 6 The dual-color light 71 can illuminate in two modes: green and red. When the fixture detects that the assembly is correct, the dual-color light illuminates green, allowing the assembler to quickly determine whether the assembly is qualified by observing the green light and the quantity display on the screen. When the fixture detects that the assembly is incorrect, the dual-color light illuminates red, allowing the assembler to quickly determine whether the assembly is unqualified by observing the red light and the quantity display on the screen.

[0042] Reference Figure 6 The display screen 73 is mounted on the top of the main rod 74 and on one side of the fixture handle 72. The display screen 73 integrates a power supply and a data processing module. The data processing module is connected to the pressure sensor 76 and can convert the signal received by the pressure sensor 76 into the digital display and the signal of the dual-color light. The power supply provides power to the display screen 73, the pressure sensor 76 and the dual-color light 71.

[0043] Reference Figure 6 The main rod 74 has an overall arc-shaped structure to accommodate round-shaped samples, such as the assembly of steel sheets and friction plates.

[0044] Reference Figure 6The guide tooth 75 has a chamfer at the front end and the guide groove has a chamfer at the innermost side; this prevents wear on the sample when the guide tooth 75 and the innermost side of the guide groove come into contact with the sample during assembly.

[0045] Reference Figure 6 The pressure sensor 76 is a miniature pressure sensor, which is embedded in the main rod 74 and located at the innermost side of the guide groove. It is triggered when the sample presses against the sensor.

[0046] Example 2

[0047] Reference Figure 1 A multi-plate clutch for a forklift gearbox using a fault-proofing fixture is disclosed. The multi-plate clutch mainly includes an active part, a driven part, a clamping mechanism, and a disengagement mechanism. The active part mainly consists of an active shaft 1 and friction plates 4 (active plates). The friction plates 4 are connected to the active shaft 1 via internal splines and rotate with the input power. The driven part includes steel plates 3 (driven plates), a clutch hub 6, etc. The steel plates 3 are connected to the clutch hub 6 via external splines and transmit power to the transmission system. The clamping mechanism includes a hydraulic piston 5 driven by hydraulic oil, which applies pressure evenly to clamp the friction plates 4 and the steel plates 3. The disengagement mechanism mainly includes a return spring 2, which resets the piston when the hydraulic pressure is released, separating the friction plates 4 and the steel plates 3.

[0048] Reference Figure 2 , Figure 3 and Figure 4 A multi-plate clutch consists of multiple alternating friction plates 4 and steel plates 3. In the clutch disengaged state, under the action of the return spring 2, there is a gap between the friction plates 4 and the steel plates 3, and the rotation of the drive shaft 1 cannot be transmitted to the clutch hub 6 through the clutch. In the clutch engaged state, the hydraulic system injects hydraulic oil into the hydraulic chamber to push the piston to press the clutch plate assembly. Under the action of hydraulic pressure, the friction plates 4 and the steel plates 3 are pressed together, and power is transmitted through friction 4, transmitting the rotation of the drive shaft 1 to the clutch hub 6. The installation sequence and direction of the friction plates 4 and the steel plates 3 determine the power transmission capacity of the entire clutch system, which is crucial for torque transmission and heat dissipation. Multi-plate clutches are existing technology, so their working principle is only roughly described and not elaborated in detail.

[0049] Reference Figure 5 , Figure 6 and Figure 7 After the assembler places multiple alternating friction plates 4 and steel plates 3 into the clutch hub 6, the assembler holds the inspection tool handle 72 and inserts it into the clutch hub 6 from the middle position, aligning it with the clutch plate assembly and pushing it in horizontally. During the pushing process, there are four possible scenarios:

[0050] 1.Reference Figure 8If the installation quantity and sequence are correct, the size of the guide tooth 75 is perfectly matched with the clutch plate assembly (i.e., steel plate 3 and friction plate 4), the gauge can be pushed in smoothly, the friction plate 4 abuts against the rear end of the guide tooth root (i.e., guide groove) along the internal spline, the pressure sensor 76 is triggered by pressure, the dual-color light turns green, and the number of triggers of the pressure sensor 76 will also be displayed on the display, which serves as a counting function. The assembler can quickly judge whether the assembly is qualified by the green light and the number display on the screen.

[0051] 2.Reference Figure 9 If the quantity installed is incorrect but the order is correct, the gauge 7 can still be pushed in smoothly. The friction plate 4 abuts against the rear end of the guide tooth root (i.e., the guide groove) along the internal spline. The pressure sensor 76 is triggered by pressure, and the dual-color light turns green. The number of pressure sensors 76 triggered will also be displayed on the screen, which serves as a counting function. The assembler can quickly determine whether the assembly order is correct but the quantity is missing by using the green light and the number display on the screen.

[0052] 3.Reference Figure 10 If the installation quantity is correct but the sequence is wrong, the gauge cannot be pushed in smoothly because the guide tooth 75 is blocked by the wrong piece group. The pressure sensor 76 at the rear end of the guide tooth root is not triggered by pressure, the dual-color light turns red, and the display 73 module assembly will show a count of zero. The assembler can quickly judge the assembly failure by the red light and the number display on the screen.

[0053] 4. If the installation quantity and sequence are incorrect, the gauge cannot be pushed in smoothly because the guide tooth 75 is blocked by the wrong piece group. The pressure sensor 76 at the rear end of the guide tooth root will not receive pressure and will be triggered. The dual-color light will turn red, and the display module assembly will show a count of zero. The assembler can quickly judge the assembly failure by the red light and the number display on the screen.

[0054] Since any incorrect installation sequence requires the assembler to remove the clutch plate assembly for re-inspection and adjustment, the feedback from the inspection tool is the same for both the third point (correct quantity but incorrect sequence) and the fourth point (incorrect quantity and incorrect sequence): both prompt the assembler to re-inspect the clutch plate assembly status.

[0055] It should be noted that the thickness of the guide tooth 75 matches the thickness of the steel plate 3, and the thickness of the guide groove is greater than the thickness of the friction plate 4, so that the friction plate 4 can enter the guide groove when checking whether the assembly is qualified in the later stage; and the number of friction plates 4 is the same as the number of guide grooves.

[0056] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. An assembly error-proofing inspection tool, characterized in that, The system includes a main rod (74), on one side of the main rod (74) there are several guide teeth (75) at equal intervals, and there are guide grooves between adjacent guide teeth (75). A pressure sensor (76) is provided on the inner wall of each guide groove. A display screen (73) is provided on the top of the main rod (74), wherein the pressure sensor (76) is electrically connected to the display screen (73).

2. The assembly error-proofing inspection fixture according to claim 1, characterized in that: A dual-color light (71) is installed on the main rod (74), and the dual-color light (71) is electrically connected to the display screen (73).

3. The assembly error-proofing inspection fixture according to claim 2, characterized in that: The top of the main rod (74) is equipped with a fixture handle (72), and a dual-color light (71) is installed on the top of the fixture handle (72).

4. The assembly error-proofing inspection fixture according to claim 1, characterized in that: The display screen (73) is equipped with a power supply and a data processing module, and the data processing module is connected to the pressure sensor (76).

5. The assembly error-proofing inspection fixture according to claim 1, characterized in that: The front end of the guide tooth (75) is chamfered.

6. The assembly error-proofing inspection fixture according to claim 1, characterized in that: The innermost side of the guide groove is chamfered.

7. A multi-plate clutch for a forklift gearbox, comprising a clutch hub (6), wherein the clutch hub (6) is provided with a hydraulic piston (5), a plurality of steel plates (3) and friction plates (4) arranged in an alternating manner, a return spring (2) and a drive shaft (1), characterized in that, It also includes the error-proofing fixture as described in any one of claims 1-6, wherein a plurality of friction plates (4) are capable of extending into a plurality of guide grooves and contacting the pressure sensor (76).

8. A multi-plate clutch for a forklift gearbox according to claim 7, characterized in that: The thickness of the guide tooth (75) matches the thickness of the steel sheet (3).

9. A multi-plate clutch for a forklift gearbox according to claim 7, characterized in that: The thickness of the guide groove is greater than the thickness of the friction plate (4).

10. A multi-plate clutch for a forklift gearbox according to claim 7, characterized in that: The number of friction plates (4) is the same as the number of guide grooves.

Images