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無錫太湖學院
畢業(yè)設計（論文）
題目： 汽車變速箱軸承專用
壓裝裝置設計
信機 系 機電一體化 專業(yè)
學 號： 0923198
學生姓名： 黃雨末
指導教師： 范圣耀 （職稱：副教授 ）
（職稱： ）
2013年5月25日
III
編號
無錫太湖學院
畢業(yè)設計（論文）
相關資料
題目： 汽車變速器軸承的專用壓裝
裝置設計
信機 系 機械工程及自動化專業(yè)
學 號： 0923198
學生姓名： 黃雨末
指導教師： 范圣耀 （職稱：副教授）
（職稱： ）
2013年5月25日
目 錄
一、畢業(yè)設計（論文）開題報告
二、畢業(yè)設計（論文）外文資料翻譯及原文
三、學生“畢業(yè)論文（論文）計劃、進度、檢查及落實表”
四、實習鑒定表
無錫太湖學院
畢業(yè)設計（論文）
開題報告
題目： 汽車變速器軸承的專用
壓裝裝置設計
信機 系 機電一體化 專業(yè)
學 號： 0923198
學生姓名： 黃雨末
指導教師： 范圣耀（職稱：副教授 ）
（職稱： ）
2012年11月25日
課題來源
本課題來源于儀佳設備維修有限公司。本次設計的汽車變速器軸承的專用壓機主要用于汽車4S店維修汽車變速器,對軸承拆卸后的重新壓裝。
軸承是變速箱的重要部件之一，為了使軸套與軸之間嚴格定位，滾動軸承與軸及軸承座孔間需要采用過盈配合，而過盈安裝及其預緊力，不僅對軸承的定位、旋轉精度及軸承的游隙有影響，還對滾動軸承的接觸角、軸承剛度、軸承內部的載荷分布及摩擦力等產生影響，所以軸承壓裝過程直接影響變速箱的使用壽命。為了達到使軸承在變速箱內發(fā)揮到極佳的狀態(tài)的目的，需設計一變速箱軸承的專用壓裝裝置，即設計一能在無縫鋼管兩端均勻壓入二軸套，且要保證二軸套的相對位置的壓裝裝置，軸套壓到底后，還需要在相應位置鉆攻螺孔，壓裝裝置的設計主要是為了保證軸承能夠正確的安裝，從而使車輛正常工作，使車輛性能發(fā)揮到極致。此課題就是由此而來。
科學依據（包括課題的科學意義；國內外研究概況、水平和發(fā)展趨勢；應用前景等）
設計汽車變速器軸承的專用壓機的意義在于，通過此裝置，對4S維修部拆卸下來的軸承進行重新壓裝，其達到了人為手動操作無法達到的高強度、高精度的要求，還可以大大提高一次服務所耗費的時間，達到效率最高。
軸承在過去通常使用手工砸壓的壓裝方式，如今已經遠遠無法滿足現在企業(yè)的批量生產要求，然而壓力機壓裝受力過程較復雜，無法準確測量甚至無法測量壓裝過程中和壓裝完成后軸和軸承的應力分布，如果壓裝力不足，會導致零件壓裝不到位。從而需要對其退卸后重新壓裝，這樣一來，不僅影響了生產效率，還會使軸徑及軸承受損，造成生產資源的浪費，增加生產成本。壓裝機車輛軸承的發(fā)展，也經歷了不少更新換代。在過去的數十年里，我們國家最常見的就是移動小車式的轉向架軸承壓裝機，其優(yōu)點突出，移動方便，操作過程簡單，但移動小車式壓裝機的弊端也很明顯，工作精度差，失敗率高，而且工人勞動強度大的缺陷使其隨著車輛和軸承的不斷發(fā)展，軸承和軸承的配合精度要求越來越高，逐漸被時代所淘汰，取而代之的則是固定式壓裝機。發(fā)展至今日，固定式壓裝機功能已經十分強大，隨后圓錐滾動軸承壓裝機又漸漸被成為適應社會發(fā)展要求的新一代壓裝機，它不僅大大提高了壓裝質量，也減少了工作量。
中國軸承工業(yè)的發(fā)展歷程，大致可以分為三個階段：
奠基階段：1949年瓦房店軸承廠恢復生產，成為中國第一家獨立生產軸承的企業(yè)。抗美援朝期間其遷址哈爾濱并投入生產，而后傷害等市的生產基地也初步形成。至此，我國軸承工業(yè)瓦房店、哈爾濱、洛陽、上海四個主要生產基地初步形成，為軸承制造業(yè)奠定了基礎。
體系形成階段：此階段處于國家“一·五”至“五·五”五個五年計劃發(fā)展時期，給軸承工業(yè)帶來了新的機遇。此時期，軸承制造業(yè)為重點主機配套的新產品發(fā)展較快，已開始生產汽車萬向節(jié)滾針軸承、磁電機軸承、機床主軸軸承和精密軸承，并試制了鐵路機車、軋鋼機、重型機械、石油工業(yè)和航空發(fā)電機、坦克等主機所需要的部分配套軸承。
高質快速發(fā)展階段：1978年中共十一屆三中全會的召開揭開了中國歷史嶄新的一頁，波瀾壯闊的改革大潮在祖國大地洶涌澎湃。軸承行業(yè)不斷推進改革，擴大開放，加速發(fā)展，實現生產力大解放，使綜合技術經濟實力明顯增強，掀起了軸承工業(yè)發(fā)展史上的第三次浪潮。
國外軸承的發(fā)展主要在于7個方面：
（1）主要技術與經濟指標：盡管軸承只作為各個主機中的支承元件，但因為其品種繁多、加工精密、尺寸大，其工業(yè)只能是機械工業(yè)中的一種特殊的獨立產業(yè)。
（2）軸承的整體技術水平，在近30年來得到了令人咋舌的進步。高精度、高轉速、高可靠性、長壽命、免維護保養(yǎng)以及標準化、單元化、通用化已成為了軸承的基本技術指標。
（3）設計理念：傳統(tǒng)的軸承設計及其應用的理論和方法，多采用靜力學和擬靜力學的設計方法。但是近50年來，軸承設計理念有很大的突破，有限差分法、有限元法、動力學、擬動力學、彈性流體動力潤滑理論等的出現有效的促進了軸承產品設計和應用技術的研究和發(fā)展。
（4）通用軸承的結構改進：產量大并且用途廣的通用軸承產品的結構一直以提高軸承載荷、延長使用壽命、增加強度和剛性、減少摩擦磨損、減小噪音、減小尺寸、降低重量、采用新材料及避免維修保養(yǎng)為研究重心。
（5）軸承產品技術：主要有五個顯著特征：堅持產品的“三化”方向，以最少的品種來滿足不同產業(yè)的多樣化需求，并有利于產品規(guī)?；a；產品向輕量化、功能組件化、單元化、智能化方向發(fā)展、致力于滿足主機產品的更新換代要求；產品向高速度、高精度、高可靠性、低摩擦、低振動、低噪聲方向發(fā)展；采用和發(fā)展了計算機輔助設計、計算機輔助制造及計算機集成制造系統(tǒng)；在軸承產品上應用了現在高薪技術。
（6）材料應用技術：1905年德國使用SAE52100高碳鉻鋼制造滾動軸承后，到1920年被廣泛用于滾動軸承制造，五十年代末真空脫氣鋼問世，八十年達推廣了真空脫氣鋼和鋼包精煉，使軸承鋼的純度大幅提高。
（7）加工、測試、專業(yè)化和自動化水平：在工業(yè)發(fā)達的國家，對批量大的標準軸承，通常采用高效、高精度的自動化設備進行加工制造，對批量更大的則組織自動生產線、自動化車間甚至自動化工廠進行生產。
研究內容
① 了解軸承壓機的工作原理，國內外的研究發(fā)展現狀；
② 完成軸承壓機的總體方案設計；
③ 完成有關零部件的選型計算、結構強度校核及壓機結構設計；
④ 熟練掌握有關計算機繪圖軟件，并繪制裝配圖和零件圖紙；
⑤ 完成設計說明書的撰寫，并翻譯外文資料1篇。
擬采取的研究方法、技術路線、實驗方案及可行性分析
確定該專機的設計方案時，不難發(fā)現其組成部分最重要的是一種能夠往復運動的機構。最常用的有：齒輪-齒條機構加滾動或滑動導軌；絲杠螺母機構（滑動或滾珠絲桿螺母副）；氣動或液壓傳動裝置等。由動力機構通過傳動機構將動力傳送至執(zhí)行機構，最終完成往復運動。采用皮帶輪的好處在于柔性傳動，過載時皮帶會打滑，可起到輔助的保護作用，但絕不能當作主要的安全保護措施進行設計和使用。
兩套之間的相對位置可通過定位實現。通過套上的凸臺和的孔及的端面進行定位，的孔插入菱形銷, 的凸臺插入定位沉孔,用這種類似一面兩銷的六點完全定位方式保證其相對位置，其中一只套定位在壓頭上，另一只則定位在固定支座上。
根據三年多所學的專業(yè)知識及通過參閱機械設計手冊、夾具設計手冊及相關圖冊資料，綜合考慮專用壓裝裝置的制造成本和周期，本人擬采用的總體方案是：利用電機-減速機提供動力，通過皮帶輪帶動絲杠轉動，進而帶動裝有螺母的壓頭移動，將旋轉運動轉化為直線壓入運動。
該設計方案經慎重考慮，多次試驗，多次論證，應該是切實可行的。
研究計劃及預期成果
研究計劃：
2012年11月12日-2013年1月20日：按照任務書要求查閱論文相關參考資料，填寫畢業(yè)設計開題報告書。
2013年1月21日-2013年3月15日：填寫畢業(yè)實習報告,學習并翻譯一篇與畢業(yè)設計相關的英文材料。
2013年3月16日-2013年3月22日：軸承壓機結構初步設計。
2013年3月23日-2013年4月20日：繪制裝配圖校核后并進行修改。
2013年4月21日-2013年5月 3 日：繪制相關零件圖。
2013年5月 4 日-2013年5月10日：畢業(yè)論文撰寫。
2013年5月 6日-2013年 5月20日：畢業(yè)論文修改工作。
成果：
設計的軸承壓機應可解決人工裝配時勞動強度大、效率低、定位精度低的問題，而且滿足了大批量生產要求。
特色或創(chuàng)新之處
（1）能解決精度低、勞動強度大的問題，還大大提高了效率。
（2）整體結構簡單，小巧，外觀整潔，穩(wěn)重。
已具備的條件和尚需解決的問題
已具備的條件：設計過程中所需要的各種軟硬件資源和相關產品實物照片。
尚需解決的問題：相關文獻資料的缺乏，對一些結構設計部分的具體設計指導，以及三維軟件的高級運用技巧。
指導教師意見
指導教師（簽名）： 年 月 日
教研室（學科組、研究所）意見
系主任（簽名）： 年 月 日
系意見
主管領導簽名：
年 月 日
英文原文
Hydraulic System
Hydraulic presser drive and air pressure drive hydraulic fluid as the transmission is made according to the 17th century, Pascal's principle of hydrostatic pressure to drive the development of an emerging technology, the United Kingdom in 1795 ? Braman Joseph (Joseph Braman ,1749-1814), in London water as a medium to form hydraulic press used in industry, the birth of the world's first hydraulic press. Media work in 1905 will be replaced by oil-water and further improved.
Hydraulic transmission There are many outstanding advantages, it is widely used, such as general industr- ial use of plastics processing machinery, the pressure of machinery, machine tools, etc.; operating machinery engineering machinery, construction machinery, agricultural machinery, automobiles, etc.; iron and steel indu- stry metallurgical machinery, lifting equipment, such as roller adjustment device; civil water projects with flo- od control and dam gate devices, bed lifts installations, bridges and other manipulation of institutions; speed turbine power plant installations, nuclear power plants, etc.; ship from the deck heavy machinery (winch), the bow doors, bulkhead valve, stern thruster, etc.; special antenna technology giant with control devices, measu- rement buoys, movements such as rotating stage; military-industrial control devices used in artillery, ship anti- rolling devices, aircraft simulation, aircraft retractable landing gear and rudder control devices and other devi- ces.
A complete hydraulic system consists of five parts, namely, power components, the implementation of co- mponents, control components, auxiliary components and hydraulic oil.
The role of dynamic components of the original motive fluid into mechanical energy to the pressure that the hydraulic system of pumps, it is to power the entire hydraulic system. The structure of the form of hydra- ulic pump gears are generally pump, vane pump and piston pump.
Implementation of components (such as hydraulic cylinders and hydraulic motors) which is the pressure of the liquid can be converted to mechanical energy to drive the load for a straight line reciprocating movement or rotational movement.
Control components (that is, the various hydraulic valves) in the hydraulic system to control and regulate the pressure of liquid, flow rate and direction. According to the different control functions, hydraulic pressure control valve can be divided into valves, flow control valves and directional control valve. Pressure control valves are divided into benefits flow valve (safety valve), pressure relief valve, sequence valve, pressure relays, etc.; flow control valves including throttle, adjusting the valves, flow diversion valve sets, etc.; directional control valve includes a one-way valve , one-way fluid control valve, shuttle valve, valve and so on. Under the control of different ways, can be divided into the hydraulic valve control switch valve, control valve and set the value of the ratio control valve.
Auxiliary components, including fuel tanks, oil filters, tubing and pipe joints, seals, pressure gauge, oil level, such as oil dollars.
Hydraulic oil in the hydraulic system is the work of the energy transfer medium, there are a variety of mineral oil, emulsion oil hydraulic molding Hop categories.
The role of the hydraulic system is to help humanity work. Mainly by the implementation of components to rotate or pressure into a reciprocating motion.
Hydraulic system and hydraulic power control signal is composed of two parts, the signal control of some parts of the hydraulic power used to drive the control valve movement.
Part of the hydraulic power means that the circuit diagram used to show the different functions of the interrelationship between components. Containing the source of hydraulic pump, hydraulic motor and auxiliary components; hydraulic control part contains a variety of control valves, used to control the flow of oil, pressure and direction; operative or hydraulic cylinder with hydraulic motors, according to the actual requirements of their choice.
In the analysis and design of the actual task, the general block diagram shows the actual operation of equi - pment. Hollow arrow indicates the signal flow, while the solid arrows that energy flow.
Basic hydraulic circuit of the action sequence - Control components (two four-way valve) and the spring to reset for the implementation of components (double-acting hydraulic cylinder), as well as the extending and retracting the relief valve opened and closed . For the implementation of components and control components, presentations are based on the corresponding circuit diagram symbols, it also introduced ready made circuit diagram symbols.
Working principle of the system, you can turn on all circuits to code. If the first implementation of components numbered 0, the control components associated with the identifier is 1. Out with the implementation of components corresponding to the identifier for the even components, then retracting and implementation of components corresponding to the identifier for the odd components. Hydraulic circuit carried out not only to deal with numbers, but also to deal with the actual device ID, in order to detect system failures.
DIN ISO1219-2 standard definition of the number of component composition, which includes the following four parts: device ID, circuit ID, component ID and component ID. The entire system if only one device, device number may be omitted.
Practice, another way is to code all of the hydraulic system components for numbers at this time, components and component code should be consistent with the list of numbers. This method is particularly applicable to complex hydraulic control system, each control loop are the corresponding number with the system
With mechanical transmission, electrical transmission compared to the hydraulic drive has the following advantages:
1, a variety of hydraulic components, can easily and flexibly to layout.
2, light weight, small size, small inertia, fast response.
3, to facilitate manipulation of control, enabling a wide range of stepless speed regulation (speed range of 2000:1).
4, to achieve overload protection automatically.
5, the general use of mineral oil as a working medium, the relative motion can be self-lubricating surface, long service life;
6, it is easy to achieve linear motion /
7, it is easy to achieve the automation of machines, when the joint control of the use of electro-hydraulic, not only can achieve a higher degree of process automation, and remote control can be achieved.
The shortcomings of the hydraulic system:
1, as a result of the resistance to fluid flow and leakage of the larger, so less efficient. If not handled properly, leakage is not only contaminated sites, but also may cause fire and explosion.
2, vulnerable performance as a result of the impact of temperature change, it would be inappropriate in the high or low temperature conditions.
3, the manufacture of precision hydraulic components require a higher, more expensive and hence the price.
4, due to the leakage of liquid medium and the compressibility and can not be strictly the transmission ratio.
5, hydraulic transmission is not easy to find out the reasons for failure; the use and maintenance requirements for a higher level of technology.
In the hydraulic system and its system, the sealing device to prevent leakage of the work of media within and outside the dust and the intrusion of foreign bodies. Seals played the role of components, namely seals. Medium will result in leakage of waste, pollution and environmental machinery and even give rise to malfunctioning machinery and equipment for personal accident. Leakage within the hydraulic system will cause a sharp drop in volumetric efficiency, amounting to less than the required pressure, can not even work. Micro-invasive system of dust particles, can cause or exacerbate friction hydraulic component wear, and further lead to leakage.
Therefore, seals and sealing device is an important hydraulic equipment components. The reliability of its work and life, is a measure of the hydraulic system an important indicator of good or bad. In addition to the closed space, are the use of seals, so that two adjacent coupling surface of the gap between the need to control the liquid can be sealed following the smallest gap. In the contact seal, pressed into self-seal-style and self-styled self-tight seal (ie, sealed lips) two.
The three hydraulic system diseases
1, as a result of heat transmission medium (hydraulic oil) in the flow velocity in various parts of the existence of different, resulting in the existence of a liquid within the internal friction of liquids and pipelines at the sam- e time there is friction between the inner wall, which are a result of hydraulic the reasons for the oil tempera- ture. Temperature will lead to increased internal and external leakage, reducing its mechanical efficiency. At the same time as a result of high temperature, hydraulic oil expansion will occur, resulting in increased com- pression, so that action can not be very good control of transmission. Solution: heat is the inherent characte -ristics of the hydraulic system, not only to minimize eradication. Use a good quality hydraulic oil, hydraulic piping arrangement should be avoided as far as possible the emergence of bend, the use of high-quality pipe and fittings, hydraulic valves, etc.
2, the vibration of the vibration of the hydraulic system is also one of its malaise. As a result of hydraulic oil in the pipeline flow of high-speed impact and the control valve to open the closure of the impact of the process are the reasons for the vibration system. Strong vibration control action will cause the system to error, the system will also be some of the more sophisticated equipment error, resulting in system failures. Solutions: hydraulic pipe should be fixed to avoid sharp bends. To avoid frequent changes in flow direction, can not avoid damping measures should be doing a good job. The entire hydraulic system should have a good damping measures, while avoiding the external local oscillator on the system.
3, the leakage of the hydraulic system leak into inside and outside the leakage leakage. Leakage refers to the process with the leak occurred in the system, such as hydraulic piston-cylinder on both sides of the leakage, the control valve spool and valve body, such as between the leakage. Although no internal leakage of hydra- ulic fluid loss, but due to leakage, the control of the established movements may be affected until the cause system failures. Outside means the occurrence of leakage in the system and the leakage between the external environment. Direct leakage of hydraulic oil into the environment, in addition to the system will affect the working environment, not enough pressure will cause the system to trigger a fault. Leakage into the enviro- nment of the hydraulic oil was also the danger of fire. Solution: the use of better quality seals to improve the machining accuracy of equipment.
Another: the hydraulic system for the three diseases, it was summed up: "fever, with a father拉稀" (This is the summary of the northeast people). Hydraulic system for the lifts, excavators, pumping station, dynamic, crane, and so on large-scale industry, construction, factories, enterprises, as well as elevators, lifting platforms, Deng Axle industry and so on.
Hydraulic components will be high-performance, high-quality, high reliability, the system sets the direction of development; to the low power, low noise, vibration, without leakage, as well as pollution control, water-based media applications to adapt to environmental requirements, such as the direction of development; the development of highly integrated high power density, intelligence, mechatronics and micro-light mini-hydraulic components; active use of new techniques, new materials and electronics, sensing and other high-tech.
Hydraulic coupling to high-speed high-power and integrated development of hydraulic transmission equ- ipment, development of water hydraulic coupling medium speed and the field of automotive applications to develop hydraulic reducer, improve product reliability and working hours MTBF; hydraulic torque converter to the development of high-power products, parts and components to improve the manufacturing process tech -nology to improve reliability, promote computer-aided technology, the development of hydraulic torque con- verter and power shift transmission technology supporting the use of ; Clutch fluid viscosity should increase the quality of products, the formation of bulk to the high-power and high-speed direction.
Pneumatic Industry:
Products to small size, light weight, low power consumption, integrated portfolio of development, the implementation of the various types of components, compact structure, high positioning accuracy of the direction of development; pneumatic components and electronic technology, to the intelligent direction of development; component performance to high-speed, high-frequency, high-response, high-life, high temp- erature, high voltage direction, commonly used oil-free lubrication, application of new technology, new technology and new materials.
(1)used high-pressure hydraulic components and the pressure of continuous work to reach 40Mpa, the maximum pressure to achieve instant 48Mpa;
(2) diversification of regulation and control;
(3) to further improve the regulation performance, increase the efficiency of the powertrain;
(4) development and mechanical, hydraulic, power transmission of the composite portfolio adjustment gear;
(5) development of energy saving, energy efficient system function;
(6) to further reduce the noise;
(7) Application of Hydraulic Cartridge Valves thread technology, compact structure, to reduce the oil spill
Water-based hydraulic systems
Water-based hydraulic systems traditionally have been used in hot-metal areas of steel mills. The obvious advantage of water systems in these industries is their fire resistance. Water-based hydraulic systems also have obvious cost advantages over oil-based fluid. First, non-toxic, biodegradable synthetic additives for water cost $5 to $6 per gallon. One gallon of concentrate can make 20 gallons of a 5% solution, so the cost of water-based hydraulic fluid actually can be less than 30 cents per gallon.
Considering the costs associated with preventing and cleaning up environmental contamination, water-based hydraulic systems hold the potential for tremendous cost savings at the plant level. Oil that has leaked already becomes a very important problem. It must be collected, properly contained. Water containing synthetic additives, however, can by dumped into plant effluent systems.
Cost savings at the plant level don't stop at the lower cost of the fluid and its disposal. Because water-based hydraulic fluid consists of 10 parts water and one part synthetic additive, 5 gallons of additive mixes with water to make 100 gallons of water-based fluid. A 50gallon container is certainly easier to handle than two 55-gallon drums, so warehousing is simpler, cleaner, and less cluttered. Transportation costs also are lower.5 o: p# a6 |% N! e! ]
Other potential plant-wide savings include improved safety for workers because the water-based fluid is non-toxic as well as non-flammable. These attributes can reduce plant insurance rates. Spills cost less to clean up becaus