Research On Key Technology And Overall Plan Of Automatic Production Line For Car Transmission Gears

The car transmission gears are the key part of the car transmission system,and its production technology and equipment level are representative in the Automobile manufacturing field.Compared with manual production line,the machining of gearbox gears on automatic production line is not only high production efficiency,stable and reliable quality,precise production control,high automatization,but also can save land area,reduce pollution and energy consumption,reduce labor intensity and so on.In recent years,the domestic automobile gear manufacturers have put forward the more urgent market demand for the automatic production line of the automobile gear processing,but the automatic production line is mainly dependent on importing from the developed countries.In this paper,domestic car automatic production lines are studied and developed under the support of the National Science and Technology Major Project “Automatic Production Line for Machining Car Transmission Gears”(Grant No.2011ZX04001-041).The main research contents are as follows:Firstly,the general solution of automatic production line for car transmission gears is studied.Including the establishment of the car gearbox gear processing automatic production line of the quality,efficiency,cost,environmental energy efficiency,services,such as the overall target system;According to the structure of different types of gears to draw up the corresponding process plan;Based on the theory of modularization,the overall integrated scheme and key technical scheme of the automatic production line The automatic logistics system and the whole protection of the production line are designed,and the overall solution of the automatic production line of car transmission gears is formed.Secondly,the key technology and process parameters optimization of high speed dry-cut hobbing machine for automatic production line of car transmission gear are studied.It includes a series of key enabling technologies,such as hobbing cutter,direct drive spindle,machine tool layout,machine tool protection and dry-cutting process parameter optimization,which are oriented to dry hobbing.A new optimization model of high speed dry hobbing process parameters for gears is proposed,in order to realize the application of the model in the automatic production line,a modified model of high speed dry-cut hobbing process parameters in Machine Adaptive optimization is established.Based on Siemens 840 D CNC system,the optimization support system of high speed dry-cut hobbing process parameters was developed.Thirdly,the control and management technology of the automatic production line for car transmission gear is studied.This paper constructs a multi-objective system of monitoring system,monitoring variable system and monitoring information system from the level of general machining automatic production line,establishes a multi-objective monitoring and integration model,and realizes the mapping from uncertain monitoring variable system to deterministic monitoring target system.Thus it provides a theoretical basis for the research and development of the automatic production line monitoring system,and develops the management and monitoring system of the gear processing automatic production line based on the model.Fourth,this paper analyzes and studies the reliability of the automatic production line for car transmission gears.In the Em-plant simulation environment,the I line simulation model of gear machining automatic production line of car gearbox is established,and the mean fault interval(MTBF)and average repair time(MTTR)of the automatic production line for gear processing of car gearbox are simulated,and the failure of machine tool,machining time,The influence of the buffer capacity and other factors on the reliability index MTBF and MTTR of the production line;Through the running Process reliability test statistic data,the reliability of the automatic production line is validated.Based on the above research results,the project group successfully developed the automatic production line for car transmission gear,and passed the acceptance of the national science and technology major special implementation management Office organization.The developed automatic production lines have been successfully applied and actual operation in Chongqing LanDai Powertrain Co.,Ltd.The application indicates good prospects.