深沟球轴承自动装球机的研制
摘要
针对目前带装球口的深沟球轴承人工装配生产效率低,需求量大的现状,采用经验设计与现代设计相结合的方法,研制一种轴承自动装球机。此装球机应用于轴承内外圈均带有装球口的深沟球轴承的自动装配。利用PLC控制整机进行上料、装球、出料等顺序工作,整个系统可以实现自动运行和故障自诊断等功能。本文的主要工作如下：
(1)根据深沟球轴承自动装球机功能要求,逐个分析各个装置动作过程中预定方案以及可能出现的问题,给出各机构的工作原理图,并最终确定各装置的方案和整个动作过程。
(2)在确定设备总体方案的基础上,对自动装球机主要装置包括自动拨球、送球和装球装置,以及其他辅助装置进行具体结构设计,通过气缸驱动各机构完成相应动作,明确各装置相对位置,给出各装置结构图,详细说明工作原理,并利用ANSYS软件验证自动装球机轴承座和机架的强度和刚度是否满足要求。
(3)基于所设计的机械结构,对设备的电气控制系统进行功能分析,选择适合各装置的气缸类型,确定设备的气压传动系统,利用PLC实现设备的自动控制,做出设备运行流程图,给出自动装球机内外圈一次定位开始和第四次压球程序。
该设备已经应用于生产实际,装球成功率可达98%,平均速度为11s/个,降低了工人的劳动强度,提高了该类轴承的装配效率,增加了设备的自动化程度,实现了手工装配到自动装配的转变。
Directed at inefficiency of manual assembling and large requirement about deep groove ball bearing, automatic assembly machine is developed for deep groove ball bearing by both empirical design and modern design. This machine suits for automatic assembling of deep groove ball bearing with ball gap in both the inner and outer rings. Through control of PLC this machine is able to finish such sequential process as feeding, loading ball and blanking. The whole system takes advantage of automatic operation and self diagnosis of fault. This paper researches mainly includes the following aspects:
(1) According to function requirement of automatic assembly machine of deep groove ball bearing, analyzes proposed scheme and problems that would occur in the action process of each device individually. Working principle diagram of every mechanism are given. The plans and the whole action process of each device are determined ultimately.
(2) On the basis of overall scheme of the equipment, its main devices included automatic dialing, sending and putting balls and other auxiliary devices are designed specifically. Relative position of each device is identified. With regard to structure diagrams, the specific working principle is illustrated in detail. Using ANSYS software to test whether strength and stiffness of bearing block and frame meets requirement.
(3) Based on the design of mechanical structure, the electrical control system of the equipment is analyzed. The suitable types of cylinder for each device are chosen and pneumatic transmission system is confirmed. PLC is used to realize the automatic control of the equipment. Operation flow diagram, beginning program of an inner and outer rings positioning and the fourth pressing ball program of the equipment are presented.
The equipment has been used in actual production. The success rate is98%, and the average speed is every11seconds. It reduces the labor intensity, and improves the bearing assembly efficiency and automation. The equipment makes a transition from manual assembly to automatic assembly.
(1)根据深沟球轴承自动装球机功能要求,逐个分析各个装置动作过程中预定方案以及可能出现的问题,给出各机构的工作原理图,并最终确定各装置的方案和整个动作过程。
(2)在确定设备总体方案的基础上,对自动装球机主要装置包括自动拨球、送球和装球装置,以及其他辅助装置进行具体结构设计,通过气缸驱动各机构完成相应动作,明确各装置相对位置,给出各装置结构图,详细说明工作原理,并利用ANSYS软件验证自动装球机轴承座和机架的强度和刚度是否满足要求。
(3)基于所设计的机械结构,对设备的电气控制系统进行功能分析,选择适合各装置的气缸类型,确定设备的气压传动系统,利用PLC实现设备的自动控制,做出设备运行流程图,给出自动装球机内外圈一次定位开始和第四次压球程序。
该设备已经应用于生产实际,装球成功率可达98%,平均速度为11s/个,降低了工人的劳动强度,提高了该类轴承的装配效率,增加了设备的自动化程度,实现了手工装配到自动装配的转变。
Directed at inefficiency of manual assembling and large requirement about deep groove ball bearing, automatic assembly machine is developed for deep groove ball bearing by both empirical design and modern design. This machine suits for automatic assembling of deep groove ball bearing with ball gap in both the inner and outer rings. Through control of PLC this machine is able to finish such sequential process as feeding, loading ball and blanking. The whole system takes advantage of automatic operation and self diagnosis of fault. This paper researches mainly includes the following aspects:
(1) According to function requirement of automatic assembly machine of deep groove ball bearing, analyzes proposed scheme and problems that would occur in the action process of each device individually. Working principle diagram of every mechanism are given. The plans and the whole action process of each device are determined ultimately.
(2) On the basis of overall scheme of the equipment, its main devices included automatic dialing, sending and putting balls and other auxiliary devices are designed specifically. Relative position of each device is identified. With regard to structure diagrams, the specific working principle is illustrated in detail. Using ANSYS software to test whether strength and stiffness of bearing block and frame meets requirement.
(3) Based on the design of mechanical structure, the electrical control system of the equipment is analyzed. The suitable types of cylinder for each device are chosen and pneumatic transmission system is confirmed. PLC is used to realize the automatic control of the equipment. Operation flow diagram, beginning program of an inner and outer rings positioning and the fourth pressing ball program of the equipment are presented.
The equipment has been used in actual production. The success rate is98%, and the average speed is every11seconds. It reduces the labor intensity, and improves the bearing assembly efficiency and automation. The equipment makes a transition from manual assembly to automatic assembly.
引文
[1]郭淑芳,商建东,张俊江.深沟球轴承自动合套机设计[J].河南科技大学报,2003(1)：37-39.
[2]贾秋生,常宝臣.重载荷轴承309N的设计[J].哈尔滨轴承,2006(1)：13-14.
[3]魏芳.深沟球轴承套圈装球缺口的加工[J].哈尔滨轴承,2011(2)：45-46.
[4]Harris T A. Rolling Bearing Analysis [M]. New York:John Wiley & Sons INC,1991.
[5]Palmgren. A. Ball and Roller Bearing Engineering [M].3rd ed. Burbank, Philadephia, 1959.
[6]F. T. Barwell. Bearing systems [M]. Oxford:Oxford University Press,1979.
[7]路兴邦,袁新,刘莹.国内轴承装配设备的发展状况[J].哈尔滨轴承,2004(4)：38-40.
[8]杨乃燕.大力开展创新科技,提高我国轴承国际竞争能力[J].轴承,2002(1)：2-6.
[9]刘冲.滚动轴承系统应用的现代设计[M].海洋出版社,1993：1-5.
[10]中国轴承工业协会.轴承装配工艺[M].河南人民出版社,2006：3-7.
[11]陆兴邦.国内轴承装配设备的发展状况[J].哈尔滨轴承,2004(4)：31-34.
[12]徐弘毅.重载滚动轴承的仿真与优化设计[D].清华大学学报,2010.
[13]SHIMPO MASATOSHI, ISHIDA KEIICHI, HIRASAWA MASATO, et al. Method for Bearings Measurement of Detected Ships Using Navigational Image Sequence [J]. Journal of Japan Institute of Navigation.2006.115:67-74.
[14]日本轴承行业调研报告.中国汽摩配,2006(8)：42-43.
[15]王锦标.提高轴承自动装配水平初探[J].轴承,1980(3)：2-5.
[16]吴紫城.圆锥滚子半自动装配机[J].轴承,1998(2)：20-24.
[17]金惠庆.短圆柱滚子轴承自动装配机[J].轴承,1980(4)：22-24.
[18]http://ww.mysteel,com.世界轴承发展史,2007.12.18
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[20]杨可桢,程光蕴,李仲生.机械设计基础[M].北京：高等教育出版社,2006.
[21]王之栎,马纲,陈心颐.机械设计[M].北京：北京航空航天大学出版社,2011.
[22]王玉,高桂仙.机械设计基础[M].北京：北京理工大学出版社,2011.
[23]殷玉枫.机械设计课程设计[M].北京：机械工业出版社,2006.
[24]何贞志.圆锥滚子轴承装配高在线自动检测技术研究[D].华中科技大学学报,2011.
[25]成大先主编.机械设计手册.第五卷-5版.北京：化学工业出版社,2008.
[26]沈艳芝.机械设计基础实验教程[M].武汉：华中科技大学出版社,2011.
[27]Antonino Risitano. Mechanical design [M]. Boca Raton, FL:CRC Press,2011.
[28]A. Keith Escoe. Mechanical design of process systems [M]. Houston:Gulf Pub. Co., Book Division,1986.
[29]David G. Ullman. The mechanical design process [M].2nd ed. New York:McGraw-Hill, 1997.
[30]Jack A. Collins. Mechanical design of machine elements and machines [M]. New York: John Wiley,2003.
[31]P. H. Sydenham. Mechanical design of instruments [M]. Research Triangle Park, N. C.:Instrument Society of America and the Institute of Measurement and Control, 1986.
[32]张朝晖ANSYS11.0结构分析工程应用实例解析[M].北京：机械工业出版社,2008.
[33]刘伟,高维成,于广滨ANSYS12.0宝典[M].北京：电子工业出版社,2010.
[34]王金龙,王清明,王伟章ANSYS12.0有限元分析与范例解析[M].北京：机械工业出版社,2010.
[35]张红松,胡仁喜,康士廷ANSYS12.0有限元分析从入门到精通[M].北京：机械工业出版社,2010.
[36]尚晓江,邱峰,赵海峰ANSYS结构有限元高级分析方法与范例应用[M].北京：中国水利水电出版社,2008.
[37]Milwaukee, Wis. Bearing technology:analysis, development, and testing [C]. Warrendale, PA:Society of Automotive Engineers,1985.
[38]魏二有.PLC在全自动轴承装配机中的应用[J].自动化仪表,2006(3)：38-40.
[39]王东鹏,李猛.基于PLC的轴承生产线质量检测系统的研究[J].制造业自动化,2007(11)：59-61.
[40]徐海东.基于PLC的轴承自动装配机电气控制系统设计[J].仪表技术,2011(7)：59-61.
[41]陈淑梅.液压与气压传动[M].北京：机械工业出版社,2007.
[42]曹玉平,阎祥安.气压传动与控制[M].天津：天津大学出版社,2010.
[43]田勇,高长银.液压与气压传动技术及应用[M].北京：电子工业出版社,2011.
[44]Herz H. On the contact of elastic solids [J]. J. Reine and Angew. Math.1881,92.
[45]罗继伟,罗天宇.滚动轴承分析计算与应用[M].北京：机械工业出版社,2009.
[46]李岳生,黄有谦.数值逼近[M].北京：人民教育出版社,1978.
[47]陈立定等主编.电气控制与可编程控制器[M].广州：华南理工大学出版社,2001.
[48]范永胜,王岷.电气控制与PLC应用[M].北京：中国电力出版社,2007.
[49]徐海东.基于PLC的轴承自动装配机电气控制系统设计[J].仪表技术,2011(7)：59-61.
[50]魏二有.全自动分选合套机的程序设计[J].轴承,2006(2)：41-43.
[51]杨明,严思杰,许璐璐.一种轴承套圈漏工序在线自动检测设备的研制[J].机床与液压,2011(11)：81-84.
[52]Frank D. Petruzella. Programmable logic controllers [M].2nd ed. New York: Glencoe/McGraw-Hill,1998.
[53]霍罡.欧姆龙PLC应用系统设计实例精解[M].北京：电子工业出版社,2010.
[2]贾秋生,常宝臣.重载荷轴承309N的设计[J].哈尔滨轴承,2006(1)：13-14.
[3]魏芳.深沟球轴承套圈装球缺口的加工[J].哈尔滨轴承,2011(2)：45-46.
[4]Harris T A. Rolling Bearing Analysis [M]. New York:John Wiley & Sons INC,1991.
[5]Palmgren. A. Ball and Roller Bearing Engineering [M].3rd ed. Burbank, Philadephia, 1959.
[6]F. T. Barwell. Bearing systems [M]. Oxford:Oxford University Press,1979.
[7]路兴邦,袁新,刘莹.国内轴承装配设备的发展状况[J].哈尔滨轴承,2004(4)：38-40.
[8]杨乃燕.大力开展创新科技,提高我国轴承国际竞争能力[J].轴承,2002(1)：2-6.
[9]刘冲.滚动轴承系统应用的现代设计[M].海洋出版社,1993：1-5.
[10]中国轴承工业协会.轴承装配工艺[M].河南人民出版社,2006：3-7.
[11]陆兴邦.国内轴承装配设备的发展状况[J].哈尔滨轴承,2004(4)：31-34.
[12]徐弘毅.重载滚动轴承的仿真与优化设计[D].清华大学学报,2010.
[13]SHIMPO MASATOSHI, ISHIDA KEIICHI, HIRASAWA MASATO, et al. Method for Bearings Measurement of Detected Ships Using Navigational Image Sequence [J]. Journal of Japan Institute of Navigation.2006.115:67-74.
[14]日本轴承行业调研报告.中国汽摩配,2006(8)：42-43.
[15]王锦标.提高轴承自动装配水平初探[J].轴承,1980(3)：2-5.
[16]吴紫城.圆锥滚子半自动装配机[J].轴承,1998(2)：20-24.
[17]金惠庆.短圆柱滚子轴承自动装配机[J].轴承,1980(4)：22-24.
[18]http://ww.mysteel,com.世界轴承发展史,2007.12.18
[19]濮良贵,纪名刚.机械设计[M].北京：高等教育出版社,2006.
[20]杨可桢,程光蕴,李仲生.机械设计基础[M].北京：高等教育出版社,2006.
[21]王之栎,马纲,陈心颐.机械设计[M].北京：北京航空航天大学出版社,2011.
[22]王玉,高桂仙.机械设计基础[M].北京：北京理工大学出版社,2011.
[23]殷玉枫.机械设计课程设计[M].北京：机械工业出版社,2006.
[24]何贞志.圆锥滚子轴承装配高在线自动检测技术研究[D].华中科技大学学报,2011.
[25]成大先主编.机械设计手册.第五卷-5版.北京：化学工业出版社,2008.
[26]沈艳芝.机械设计基础实验教程[M].武汉：华中科技大学出版社,2011.
[27]Antonino Risitano. Mechanical design [M]. Boca Raton, FL:CRC Press,2011.
[28]A. Keith Escoe. Mechanical design of process systems [M]. Houston:Gulf Pub. Co., Book Division,1986.
[29]David G. Ullman. The mechanical design process [M].2nd ed. New York:McGraw-Hill, 1997.
[30]Jack A. Collins. Mechanical design of machine elements and machines [M]. New York: John Wiley,2003.
[31]P. H. Sydenham. Mechanical design of instruments [M]. Research Triangle Park, N. C.:Instrument Society of America and the Institute of Measurement and Control, 1986.
[32]张朝晖ANSYS11.0结构分析工程应用实例解析[M].北京：机械工业出版社,2008.
[33]刘伟,高维成,于广滨ANSYS12.0宝典[M].北京：电子工业出版社,2010.
[34]王金龙,王清明,王伟章ANSYS12.0有限元分析与范例解析[M].北京：机械工业出版社,2010.
[35]张红松,胡仁喜,康士廷ANSYS12.0有限元分析从入门到精通[M].北京：机械工业出版社,2010.
[36]尚晓江,邱峰,赵海峰ANSYS结构有限元高级分析方法与范例应用[M].北京：中国水利水电出版社,2008.
[37]Milwaukee, Wis. Bearing technology:analysis, development, and testing [C]. Warrendale, PA:Society of Automotive Engineers,1985.
[38]魏二有.PLC在全自动轴承装配机中的应用[J].自动化仪表,2006(3)：38-40.
[39]王东鹏,李猛.基于PLC的轴承生产线质量检测系统的研究[J].制造业自动化,2007(11)：59-61.
[40]徐海东.基于PLC的轴承自动装配机电气控制系统设计[J].仪表技术,2011(7)：59-61.
[41]陈淑梅.液压与气压传动[M].北京：机械工业出版社,2007.
[42]曹玉平,阎祥安.气压传动与控制[M].天津：天津大学出版社,2010.
[43]田勇,高长银.液压与气压传动技术及应用[M].北京：电子工业出版社,2011.
[44]Herz H. On the contact of elastic solids [J]. J. Reine and Angew. Math.1881,92.
[45]罗继伟,罗天宇.滚动轴承分析计算与应用[M].北京：机械工业出版社,2009.
[46]李岳生,黄有谦.数值逼近[M].北京：人民教育出版社,1978.
[47]陈立定等主编.电气控制与可编程控制器[M].广州：华南理工大学出版社,2001.
[48]范永胜,王岷.电气控制与PLC应用[M].北京：中国电力出版社,2007.
[49]徐海东.基于PLC的轴承自动装配机电气控制系统设计[J].仪表技术,2011(7)：59-61.
[50]魏二有.全自动分选合套机的程序设计[J].轴承,2006(2)：41-43.
[51]杨明,严思杰,许璐璐.一种轴承套圈漏工序在线自动检测设备的研制[J].机床与液压,2011(11)：81-84.
[52]Frank D. Petruzella. Programmable logic controllers [M].2nd ed. New York: Glencoe/McGraw-Hill,1998.
[53]霍罡.欧姆龙PLC应用系统设计实例精解[M].北京：电子工业出版社,2010.