| When automotive synchronizer gear hub matched with gear sleeve, gear sleeve setscould not be set into gear hub, the smoothness or tilt degree was unqualified, which was themain forms of matching failure. At present, the direct matching method was widely used toassemble gear hub and sleeve, and this method lead to lots of matching failure for withoutoptimization matching, which increased the number and workload of twice matching, andreduced assembly efficiency. So it was necessary to develop optimization matching method.However research showed that there was not synchronizer gear hub gear sleeve optimizationmatching and automatic assembly technology at present. Therefore, this paper studied thecomputer aided matching and automatic assembly technology and system for synchronizergear hub gear sleeve.By analyzing the matching failure forms and associated factors of gear hub and sleeve,we found out that the main factors affecting the success or failure was backlash of gear huband sleeve Ligand. The backlash depended on processing errors of gear hub and sleeve, andthe mathematical model of theory backlash and effect backlash was derived by the M, thecriteria based on theory backlash and effect backlash was established which suitable forcomputer aided matching, and designed computer aided matching algorithm optimizationaiming at the maximum number; compiled the corresponding computer aided optimalmatching program based on the Matlab environment. By setting the gear hub gear sleevenumber, comparative experiments of three matching methods were tested, the results showedthat: when assembled gear hub and sleeve by computer aided optimization matching methodbased on theoretical backlash optional criteria, the rate of gear hub and sleeve matching wasabout65%, which was higher rate30%at least than direct matching method, and the methodcould effectively reduce the gear hub and sleeve matching failure number and ensure that allthe matching sets of gear sleeve could assemble into gear hub. So the optimization matchingmethod could be used to realize the automatic assembly of gear hub and sleeve.On the basis of computer aided optimizing matching method, designed a synchronizer gear hub gear set of automatic assembly system. By gear hub gear sleeve manual assembly process analysis, and based on theory Backlash selection criteria for computer aided selection, designed the overall scheme of the gear hub gear set of automatic assembly system;designed thegear hub gear sleeve automatic assembly systems and mechanical systems of the body structure by Solidworks in detail;designed the corresponding automatic control system based on thePLC and touch screen.The mechanical system is mainly composed of a gear hub and gear slee ve feeder machine, grab the moving assembly line robot, assembly work station and the hub gear teeth are sheathed ligand conveyor belt and so on. The design of automatic control systemmainly includes the system work flow and process sequence design, the PLC selection of input and output module, I/O distribution and design of the system hardware and software.Thus achieving the function of computer-aided optimization matching and automatic assembly for gear gub and gear sleeve and forming the corresponding automatic assembly systems for gear hub gear sleeve.In order to improve the synchronizer assembly quality and efficiency, reduce labor intensity,the system together with the production chain of upstream hub and tooth set of processing parameters measurement system developed by the research team and the downstream automatic detection system of the self-sliding performance and tilting amount, automatic assembly machine system such as slide pin cotter, etc make up the automobile synchronizer automatic assembly line. |
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