| The source of power for commercial vehicle cabs to achieve lifting and turning is the high-pressure oil generated in the manual pump cavity,the processing quality of the sealed spherical surface which located in the inner hole of the manual pump is a prerequisite to determine whether high-pressure oil can be generated.The traditional method of sealing the spherical surface is to manually operate the hand press,which has the problems of low production efficiency,poor product quality stability,and low pass rate.In order to effectively solve these shortcomings,a special equipment for the automatic processing of the inner hole spherical surface of J6 manual pump was contrived in this thesis.According to the technical requirements provided by the company and the traditional processing methods,the whole equipment is divided into six sub-organizations:automatic loading mechanism,automatic feeding mechanism,play steel ball and suck steel ball suction mechanism,scrap steel ball collection mechanism,pump body positioning and clamping mechanism,main frame.The scheme of each sub-organization is designed firstly,and then uses the three-dimensional design software to carry out the detailed and feasible structural design of each sub-organization.Finally,according to the processing process,the sub-organizations are reasonably and compactly arranged on the main frame to complete the structural design of the whole machine.In order to verify the rationality of the structure design of the whole machine at the theoretical level,ADAMS is used to perform kinematics simulation on the automatic loading mechanism to ensure that the part moves smoothly without interference firstly.Then the play steel ball and suck steel ball suction mechanism and the pump body positioning and clamping mechanism are performed by ANSYS Workbench software to guarantee the designed structure satisfies the intensity and stiffness demands.Meanwhile,the modal simulation of the main frame is carried out by using this software to ensure that the main frame will not resonate with the external excitation.In accordance with the control needs of the enterprise,the pneumatic-electric hybrid system is designed to realize the control system design of equipment.The design idea of the pneumatic system is to design the schematic diagram of the pneumatic system by using the pneumatic driving theory and the function of each element.Besides,the design idea of the electronic system can be divided into three steps:?1?draw up the design scheme of the electric control system on the basis of equipment demands and adopt the upper and lower master-slave structure control?upper computer:the HMI human-machine interface,lower computer:the PLC?.?2?design the main circuit diagram,complete the PLC peripheral wiring diagram and PLC control program.?3?accomplish the programming and design of the visual interface.After designing the control system delicately,we make the whole equipment meet the visual and intelligent production requirements.Based on the results of the mechanical mechanism design and control system design,we commissioned the assembled machine.Moreover,the performance of the equipment is evaluated by performing quality inspection on the products processed.According to the experimental results,the maximum truncated circle diameter of the sealed spherical surface of 50 products that have been continuously processed all exceeds 5/6 of the diameter of the steel ball,and the surface roughness Ra values do not exceed 0.4?m.Based on these two evaluation indicators,the process performance index Ppk values are higher than the company's standard?1.67?.This equipment increases the sealing pass rate of the sealing surface of the manual pump inner hole from 83%to 98%.By comparing the production efficiency of automatic equipment processing and manual processing,we can see that when processing the same number of products,the processing efficiency of automatic equipment is at least one time higher than that of manual processing. |
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