汽车线束上线预装系统设计与研究
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摘要
汽车线束犹如人体的中枢神经系统,在整个汽车中的作用是不言而喻的,其制作过程一定要符合其特定的工艺流程。随着对汽车的安全性,舒适性,经济性和排放性要求的不断提高,汽车线束变的越来越复杂,但车身给予的空间却越来越小。因此如何提高汽车线束的综合设计性能,以及汽车线束制造厂家如何做好线束后期设计和制造显得尤为重要。对线束工艺进行系统性的研究和改进,可以在形成规模效益和有效提高利润率等方面起到重要的作用。线束装配是劳动力密集型工作,很多作业由手工完成。特别是对于比较复杂的汽车线束,为避免装配错误,提高生产效率,在设计线束的生产工艺时,通常将线束分解为若干个小单元,然后按照一定的作业顺序将其重新组装在一起。
上海莱尼目前所使用的预装结构,均是手动式的,需由人工来完成电线的升降。
为了提高产品的产能和质量,降低产品成本,满足市场的需求,必须寻求一种适应大批量生产的自动化预装结构。自动化的预装结构在欧洲线束行业已经取得了进一步的提高,而国内在这方面的应用较少:但是,随着我国现代工业化水平的不断提高,自动化的预装系统必然得到越来越广泛的应用。
本文以上海莱尼的预装系统为研究对象,着眼于提高产品质量,生产效率等,设计一套自动化上线的预装系统,切实解决该公司在提高企业竞争力上遇到的困难。本文主要进行了以下研究工作:
论文首先结合线束生产中的各个因素,分析了预装的要求,以提高预装上线的效率为目的,综合设计了上线系统的结构。
其次按照预装工位特点和要求,选择了相应的电机,同步带和带轮,滚珠丝杠螺旋传动等机构,并设计了双剪式升降结构。
然后分析了双剪式升降结构的力学特性,研究了该结构的节点内力分布和整体变形分布在载荷作用下的特性。双剪式升降结构的等效抗弯刚度是结构展开角的函数,与结构中剪式单元数量和结构的长度无关。展开角相同时,不同长度(单元数不同或杆件长度不同)的升降结构具有相同的等效抗弯刚度。等效轴向刚度是结构长度和展开角的函数展开角相同时,等效轴向刚度与结构长度的平方成反比。
最后用Pro/E软件对组成零件进行实体三维建模,建模过程中采用了易于掌握的自底而上的装配方法,即首先建立好各个零件的三维实体模型,然后将这些零件进行装配。
Automotive wire harness, just like the nerve center system of a person, which plays a key role in a car, its manufacture must conform to specific processes. With the development of safety, comfort, economy and emission performance, automotive wiring harness become more and more complex, while the space left get smaller and smaller. It's very important how to improve the design and manufacture of comprehensive wiring harness. Therefore, the systematic research and improvement on manufacturing processes can play an important role in economies of scale and increasing profit margin and so on. Assembling wiring harness is labor-intensive work, many processes are manual. Especially for much more complex car wiring harness, in order to avoid assembly errors and increase manufacturing efficiency, wiring harnesses are always divided into a few of small units when design the process, and then assemble them together in specific order.
Shanghai Leoni Electrical System currently adopts pre-block method; the lift and drop of wires are done by hand.
To meet market requirement, increase output with high quality and decrease cost,a new type of automatically pre-block method is desired to adapt to mass production, which is making progress in Europe wire harness industry, so far much less in China, but it will be adopted more and more popularly with the advancement of our Chinese industrialization.
This thesis regard the pre-block system of LESS as the research object, focus on improving products quality, manufacturing efficiency, design an automated wire-lifting pre-block system, and earnestly resolve difficulties the company encountered in improving the competitiveness.
This thesis covers research as below:
Firstly, this paper analyze the requests of pre-block together with every factor of wire harness manufacturing for increasing the process efficiency, and then design the structure of this wiring lifting system.
Secondly, according to the feature and requirement of pre-block station, choosecorresponding motor, synchronous wheel, ball bearing and guide screw etc, and design scissors-type lifting and dropping structure.
Thirdly, analyze the mechanical properties of the lifting and dropping mechanism, research the force distribution inside nodes of scissors-type folding structure and the characteristics of overall deformation distribution under load. The equivalent bending rigidity of scissors-type folding structure is a function of spread angle of the structure, and is nothing to do with the length of the structure and the amount of scissors-type units. The folding structure has the same equivalent bending rigidity provided with same spread angle even though with different length and different amount of units. The equivalent axial rigidity of the structure is a function of the length and spread angle, which is reversely proportional to the square of thestructure length, when at same spread angle.
Finally, use Pro/E software to create three-dimensional entity model for components, a kind of from bottom to top assembling method easily to master is adopted, in other words, to create three-dimensional entity model first and then to assemble them together.
上海莱尼目前所使用的预装结构,均是手动式的,需由人工来完成电线的升降。
为了提高产品的产能和质量,降低产品成本,满足市场的需求,必须寻求一种适应大批量生产的自动化预装结构。自动化的预装结构在欧洲线束行业已经取得了进一步的提高,而国内在这方面的应用较少:但是,随着我国现代工业化水平的不断提高,自动化的预装系统必然得到越来越广泛的应用。
本文以上海莱尼的预装系统为研究对象,着眼于提高产品质量,生产效率等,设计一套自动化上线的预装系统,切实解决该公司在提高企业竞争力上遇到的困难。本文主要进行了以下研究工作:
论文首先结合线束生产中的各个因素,分析了预装的要求,以提高预装上线的效率为目的,综合设计了上线系统的结构。
其次按照预装工位特点和要求,选择了相应的电机,同步带和带轮,滚珠丝杠螺旋传动等机构,并设计了双剪式升降结构。
然后分析了双剪式升降结构的力学特性,研究了该结构的节点内力分布和整体变形分布在载荷作用下的特性。双剪式升降结构的等效抗弯刚度是结构展开角的函数,与结构中剪式单元数量和结构的长度无关。展开角相同时,不同长度(单元数不同或杆件长度不同)的升降结构具有相同的等效抗弯刚度。等效轴向刚度是结构长度和展开角的函数展开角相同时,等效轴向刚度与结构长度的平方成反比。
最后用Pro/E软件对组成零件进行实体三维建模,建模过程中采用了易于掌握的自底而上的装配方法,即首先建立好各个零件的三维实体模型,然后将这些零件进行装配。
Automotive wire harness, just like the nerve center system of a person, which plays a key role in a car, its manufacture must conform to specific processes. With the development of safety, comfort, economy and emission performance, automotive wiring harness become more and more complex, while the space left get smaller and smaller. It's very important how to improve the design and manufacture of comprehensive wiring harness. Therefore, the systematic research and improvement on manufacturing processes can play an important role in economies of scale and increasing profit margin and so on. Assembling wiring harness is labor-intensive work, many processes are manual. Especially for much more complex car wiring harness, in order to avoid assembly errors and increase manufacturing efficiency, wiring harnesses are always divided into a few of small units when design the process, and then assemble them together in specific order.
Shanghai Leoni Electrical System currently adopts pre-block method; the lift and drop of wires are done by hand.
To meet market requirement, increase output with high quality and decrease cost,a new type of automatically pre-block method is desired to adapt to mass production, which is making progress in Europe wire harness industry, so far much less in China, but it will be adopted more and more popularly with the advancement of our Chinese industrialization.
This thesis regard the pre-block system of LESS as the research object, focus on improving products quality, manufacturing efficiency, design an automated wire-lifting pre-block system, and earnestly resolve difficulties the company encountered in improving the competitiveness.
This thesis covers research as below:
Firstly, this paper analyze the requests of pre-block together with every factor of wire harness manufacturing for increasing the process efficiency, and then design the structure of this wiring lifting system.
Secondly, according to the feature and requirement of pre-block station, choosecorresponding motor, synchronous wheel, ball bearing and guide screw etc, and design scissors-type lifting and dropping structure.
Thirdly, analyze the mechanical properties of the lifting and dropping mechanism, research the force distribution inside nodes of scissors-type folding structure and the characteristics of overall deformation distribution under load. The equivalent bending rigidity of scissors-type folding structure is a function of spread angle of the structure, and is nothing to do with the length of the structure and the amount of scissors-type units. The folding structure has the same equivalent bending rigidity provided with same spread angle even though with different length and different amount of units. The equivalent axial rigidity of the structure is a function of the length and spread angle, which is reversely proportional to the square of thestructure length, when at same spread angle.
Finally, use Pro/E software to create three-dimensional entity model for components, a kind of from bottom to top assembling method easily to master is adopted, in other words, to create three-dimensional entity model first and then to assemble them together.
引文
[1]丁智平,气液动剪叉式升降平台运动受力分析及应用,株洲工学院学报VOL.13 NO.6 1999
[2]田地银 田云,关于滚珠丝杠副的选择,电子工艺技术,VOL.18,NO.1 1993
[3]李鸿,滚珠丝杠副的简便设计计算方法,大连机床厂,
[4]刘燕萍,升降机构可靠保证浅谈[J].山西机械 2003(03)
[5]汪祥国,国旗手动升降机构设计[J].机械工程师,2001(03)
[6]Physik F.Optimization of production planning problems a Case Study for Assembly Lines.Intemational Journal of Modern Physics C,2000(5):949-972
[7]詹友刚.Pro/E中文野火版教程,清华大学出版社,2004.1-46
[8]郭吉安,信息检索,重庆大学出版社,2001
[9]李光耀,李慎国,我国汽车用电线束现状及发展趋势,汽车与市场,2006,Vol.19(40)
[10]西北工业大学机械原理及机械零件教研室编著,濮良贵,纪名刚主编,机械设计,2001年修订本(第七版),高等教育出版社,2001
[11]廖林清,王化培,石晓辉,杨翔宇,曹建国,邓国红编著,机械设计方法学,2003年修订本(第二版),重庆大学出版社,2003
[12]Devdas Shetty,Richard,A.Kolk著,张树生等译,机电一体化系统设计,机械工业出版社,2006.1
[13]二代龙震工作室编著,Pro/ENGINEER Wildfire 3.0基础设计,电子工业出版社,2006
[14]林清安编著,Pro/ENGINEER野火3.0中文版动态机构设计与仿真,电子工业出版社,2007
[15]刘会英,杨志强编著机械原理,机械工业出版社,2003
[16]李海萍主编,机械设计基础,机械工业出版社,2005
[17]石泽华,于雪松,李越秀,滚珠丝杠副在舞台升降机构中的应用,起重运输机械,2002(12)
[18]W.Shan,Computer analysis of foldable structures,Computers & Structures,1992,Vol.42(6):903-912
[19]方文中主编,同步带传动,1993
[20]丁智平,气液动剪叉式升降平台运动受力分析及应用,株洲工学院学报,1999,vol.13(6):49-52
[21]李俐,基于Bennett 4R linkage的折叠结构,[硕士论文],浙江大学,2005
[22]Travis Langbecker,Kinematic analysis of deployable scissors structures,Int.J Space Structures,1999,Vol.14(1):1-15
[23]T.Langbecker,F.Albermani,Kinematic and non-linear analysis of foldable barrel vaults,Engineering Structure,2001,vol.23:158-171
[24]J.P.Valcarcel,F.Escrig,Recent Advances in the analysis of expandable structures,Int.Conf.on Mobile AND Papidly Assembled Structures,Southampton,1996,45-54
[25]钱志伟,程万海,刘锡良,折叠结构的受力分析,建筑结构学报,1996,vol.17(2):48-57
[26]陈向阳,关富玲,折叠结构几何非线性分析,计算力学学报,2000,vol.17(4):435-440
[27]陈向阳,关富玲,陈务军,折叠结构主从自山度分析,工程力学,1999,vol.16(5):83-88
[28]刘榴,500轧钢摆动升降台的结构改进和计算,上海冶金设计,1999,vol.(3):13-20
[29]方文中,同步带传动,1990
[30]刘颖,采用有限元软件对医用加速器治疗床双剪式升降机构的纵向刚度分析初探,医疗装备,2003,vol.16(9):153-156
[31]刘颖,医用直线加速器治疗床升降机构的运动分析,机械设计,2006,vol.23(9):300-302
[32]王海琴,基于Pro-E软件CAD功能的齿轮设计及其机构仿真,科技资讯,2005,vol.(23):97
[33]GB11616-89,同步带尺寸
[34]JB/T9229-1-1999,剪叉式升降平台
[35]JB/5320-2000,剪叉式升降平台-安全规程
[36][日]曲泽真渊,电动机的选择和使用方法,1986
[37]饶振纲,滚珠丝杠副及自锁装置,1990
[38]朱龙根,机械设计,机械工业出版社,2006.3,21-328
[39]刘文芝,武建新,SE雁秋,等.基于Pro/Engineer的三维实体造型[J].计算及辅助设计与制造,2002(1):19-23
[40]和青芳,徐征.Pro/Engineer Wildfire产品设计与机构动力学分析[M].北京:机械工业出版社,2004
[41]郭玉,李富柱,薛武.基于Pro/Engineer软件的装载机工作装置虚拟样 机与仿真分析[J].工程机械,2005.(3):31-34.
[42]祝凌云,李斌.PRO/ENGINEER运动仿真和有限元分析[M].北京:人民邮电出版社,2004.
[2]田地银 田云,关于滚珠丝杠副的选择,电子工艺技术,VOL.18,NO.1 1993
[3]李鸿,滚珠丝杠副的简便设计计算方法,大连机床厂,
[4]刘燕萍,升降机构可靠保证浅谈[J].山西机械 2003(03)
[5]汪祥国,国旗手动升降机构设计[J].机械工程师,2001(03)
[6]Physik F.Optimization of production planning problems a Case Study for Assembly Lines.Intemational Journal of Modern Physics C,2000(5):949-972
[7]詹友刚.Pro/E中文野火版教程,清华大学出版社,2004.1-46
[8]郭吉安,信息检索,重庆大学出版社,2001
[9]李光耀,李慎国,我国汽车用电线束现状及发展趋势,汽车与市场,2006,Vol.19(40)
[10]西北工业大学机械原理及机械零件教研室编著,濮良贵,纪名刚主编,机械设计,2001年修订本(第七版),高等教育出版社,2001
[11]廖林清,王化培,石晓辉,杨翔宇,曹建国,邓国红编著,机械设计方法学,2003年修订本(第二版),重庆大学出版社,2003
[12]Devdas Shetty,Richard,A.Kolk著,张树生等译,机电一体化系统设计,机械工业出版社,2006.1
[13]二代龙震工作室编著,Pro/ENGINEER Wildfire 3.0基础设计,电子工业出版社,2006
[14]林清安编著,Pro/ENGINEER野火3.0中文版动态机构设计与仿真,电子工业出版社,2007
[15]刘会英,杨志强编著机械原理,机械工业出版社,2003
[16]李海萍主编,机械设计基础,机械工业出版社,2005
[17]石泽华,于雪松,李越秀,滚珠丝杠副在舞台升降机构中的应用,起重运输机械,2002(12)
[18]W.Shan,Computer analysis of foldable structures,Computers & Structures,1992,Vol.42(6):903-912
[19]方文中主编,同步带传动,1993
[20]丁智平,气液动剪叉式升降平台运动受力分析及应用,株洲工学院学报,1999,vol.13(6):49-52
[21]李俐,基于Bennett 4R linkage的折叠结构,[硕士论文],浙江大学,2005
[22]Travis Langbecker,Kinematic analysis of deployable scissors structures,Int.J Space Structures,1999,Vol.14(1):1-15
[23]T.Langbecker,F.Albermani,Kinematic and non-linear analysis of foldable barrel vaults,Engineering Structure,2001,vol.23:158-171
[24]J.P.Valcarcel,F.Escrig,Recent Advances in the analysis of expandable structures,Int.Conf.on Mobile AND Papidly Assembled Structures,Southampton,1996,45-54
[25]钱志伟,程万海,刘锡良,折叠结构的受力分析,建筑结构学报,1996,vol.17(2):48-57
[26]陈向阳,关富玲,折叠结构几何非线性分析,计算力学学报,2000,vol.17(4):435-440
[27]陈向阳,关富玲,陈务军,折叠结构主从自山度分析,工程力学,1999,vol.16(5):83-88
[28]刘榴,500轧钢摆动升降台的结构改进和计算,上海冶金设计,1999,vol.(3):13-20
[29]方文中,同步带传动,1990
[30]刘颖,采用有限元软件对医用加速器治疗床双剪式升降机构的纵向刚度分析初探,医疗装备,2003,vol.16(9):153-156
[31]刘颖,医用直线加速器治疗床升降机构的运动分析,机械设计,2006,vol.23(9):300-302
[32]王海琴,基于Pro-E软件CAD功能的齿轮设计及其机构仿真,科技资讯,2005,vol.(23):97
[33]GB11616-89,同步带尺寸
[34]JB/T9229-1-1999,剪叉式升降平台
[35]JB/5320-2000,剪叉式升降平台-安全规程
[36][日]曲泽真渊,电动机的选择和使用方法,1986
[37]饶振纲,滚珠丝杠副及自锁装置,1990
[38]朱龙根,机械设计,机械工业出版社,2006.3,21-328
[39]刘文芝,武建新,SE雁秋,等.基于Pro/Engineer的三维实体造型[J].计算及辅助设计与制造,2002(1):19-23
[40]和青芳,徐征.Pro/Engineer Wildfire产品设计与机构动力学分析[M].北京:机械工业出版社,2004
[41]郭玉,李富柱,薛武.基于Pro/Engineer软件的装载机工作装置虚拟样 机与仿真分析[J].工程机械,2005.(3):31-34.
[42]祝凌云,李斌.PRO/ENGINEER运动仿真和有限元分析[M].北京:人民邮电出版社,2004.