Double-Station Wheel Hub Drilling for Precision and Shorter Cycle Time
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Solution Overview
Problem
The existing three-step machining process for cast aluminum alloy wheel hubs is inefficient due to lengthy drilling operations, especially when dealing with wheels having many bolt holes, as it requires a four-axis machining center with a long X-axis stroke, leading to low precision and increased overall machining time.
Innovation Solution
A wheel hub special drilling device with a double-station design, featuring a main shaft transmission mechanism, clamping device, and driving system that allows one station to machine while the other performs auxiliary operations like clamping, utilizing a cylinder-driven positioning system to switch between machining and clamping positions, reducing auxiliary time and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-station four-axis machining center is used for drilling machining, then the machining precision can be maintained, but the drilling machining time becomes excessively long, exceeding the machining time of the first and second steps
Solution Approach 1:
The single-station machining center is segmented into two independent working stations: a machining station for drilling operations and a clamping station for workpiece clamping and positioning. This allows parallel execution of machining and clamping operations, effectively halving the auxiliary time while maintaining machining precision through dedicated station functionality
Solution Approach 2:
The double-station design enables continuous productive action by allowing the machining station to perform drilling operations while the clamping station simultaneously prepares the next workpiece for machining. This eliminates idle time and ensures that both stations are continuously contributing to production output
2Productivity
If a four-axis machining center with double-station is used, then the productivity is improved, but the feeding axis X-axis stroke becomes too long, resulting in relatively low precision
Solution Approach 1:
Instead of extending the X-axis stroke to accommodate both machining and clamping functions, the patent transitions to a vertical Z-axis arrangement where the clamping station is positioned below the machining station. This dimensional change allows both stations to be compactly arranged within a small horizontal footprint while maintaining high positioning precision through the vertical transmission mechanism
Solution Approach 2:
A transmission mechanism base serves as an intermediary structure that integrates both the machining station and clamping station within a compact footprint. This base provides precise positioning and movement control for both stations without requiring long X-axis strokes, thereby maintaining high positioning precision while achieving double-station productivity
3Device complexity
If auxiliary operations are performed sequentially at the same station, then the device complexity is reduced, but the auxiliary time increases, lowering overall efficiency
Solution Approach 1:
The auxiliary operations are segmented and assigned to separate stations: the clamping station handles workpiece clamping, positioning, and preparation, while the machining station handles drilling operations. This functional segmentation allows auxiliary operations to proceed in parallel with machining operations, reducing total auxiliary time without significantly increasing device complexity
Solution Approach 2:
The clamping station is designed with multi-functionality, performing clamping, positioning, and workpiece preparation operations in one location. This universal design consolidates auxiliary functions without requiring additional complex mechanisms, as the same clamping device structure serves multiple purposes across different operational phases
Data Source
AI summary
A wheel hub special drilling device comprises a main shaft transmission device, which has a transmission mechanism base and a transmission mechanism mounted on the transmission mechanism base, wherein the transmission mechanism comprises an X-axis transmission mechanism, a Y-axis transmission mechanism and a Z-axis transmission mechanism which are used for respectively moving a main shaft in three vertical axial directions; a main shaft, which is mounted on the vertical Z-axis transmission mechanism; a drilling tool, which is mounted on the main shaft and is rotationally driven by the main shaft; a clamp device, which is used for clamping and fixing a wheel hub to be processed.