Semiautomatic Improving On The Hydraulic Machine Of The Gear-shaft Straightening

Gear-shaft is one of the most important parts in the vehicle's speed transmission case, which functioned in the change of speed of vehicles. In avoid of making the gear-shaft diverge its central axes during its mechanic processing, the straightening of gear-shaft is necessary and essential for meeting the high demand of gear-shaft quality. One Gear Company Ltd. is a big company producing transmission case in China. In one year, about two million gear-shafts are produced ready to be straightened by a manual controll YA10-40 hydraulic machine, which needed man to detect, position and modify the divergence of gear-shaft's central axes. Unfortunatecy the quality of gear-shaft is unstable even among gear-shafts in one set of products. The work is labor and time consumed and with low efficiency. No doubt, the machine needed to be improved. Automatic hydraulic machines are applied in the straightening of mechanical parts with axes, which greatly increased the accuracy and efficiency of straightening work. However, because most automatic hydraulic machines straightened the axes based on the optical theory, which inevitably remain some errors when they are used to straighten gear-shaft with complicate shapes. Utilizing automatic straightening machines is not only costly but also no definite to meet the high demand of gear-shaft quality. The company had several manual hydraulic machines and a good large number of technical workers. Therefore, improvement on the present hydraulic machine would not only save investment cost on the purchase of new equipments, but also help the technical workers to increase the precise straightening of gear-shaft. Aiming to the semiautomatic improvement on the manual hydraulic machine, the main content included the development of new techniques to detect the distortion of gear-shaft axes, automatically process the detection data using computer, and optimize the dimensional relationship of affiliated parts to support the precise straightening of gear-shafts. The main results of the study are as follows. 1. Based on the consult of references, the changes of some parameters, such as stress, stain, etc. during the straightening process are discussed and the relationship between them is concluded. 2. The distortion degrees of different type of gear-shaft parts are statistically calculated. the results demonstrated that the positions in axe's shoulder and between two splines are prone to be distorted. The maximum distortion distance is not more than 0.6 mm. Therefore, differential transformer is selected in the study. This conclusion is also a basis of devisiy the support structures. 3. Automatic detection equipment of gear-shaft precision and the detection data processing system are devised based on the displacement transducer. The design made the automatic detection of distortion grade and bend direction comes into true. The detection results could be directly shown on the screen of a PC or printed in a piece of paper. 4. The straightening desk, including the detection system of distortion grade and the driving structure of mechanical parts, is completed. 5. An integrative support system of different kinds of gear-shaft parts is devised on the basis of straightening theory and statistics data.