After the gear box is processed, it is cleaned with a washing machine. The tray of the washing machine can place three gear boxes and automatically enter and exit through the track. The tray can be rotated inside the machine, and the nozzles on both sides and the top can simultaneously spray the cleaning agent to clean the gear box. After washing, blow dry air to dry. The cleaned gear box removes residual iron and oil from the processing, ensuring the adhesion and corrosion resistance of the topcoat.
For the integral gearbox, the press-fit process is as follows: (1) Lift the large gear into the erected gearbox and carefully level the gearbox. Screw the lifting bolt into the screw hole of the sealing cover of the gear box, and hang the gear box together with the large gear to the tooling and straighten it. (2) Wipe the surface of the axle gear mount and evenly coat a layer of white lead oil lubricant. Hang the axle vertically into the large gear hole with a spreader. (3) Move the centering device at the top of the hydraulic machine to the center, the table rises, and the center hole of the axle contacts the cone surface of the centering device, so that the axle is centered vertically. A mirror is placed next to the centering device for easy viewing. (4) Remove the centering device and raise the table so that the upper end surface of the axle is in contact with the top beam. Increase the pressure and press the large gear onto the axle until the lower end of the axle is in contact with the tooling. The recorder also draws a pressure curve on the chart, and the tonnage is not less than the specified value. (5) Check the bearing mounting end face and the downward facing side of the gear with a lever dial gauge to check whether the gear is perpendicular to the axle. Use a caliper to check if the gear is at the correct position from the end face of the axle.
The gearbox assembly gearbox assembly is primarily done on a rotary table. The workbench has 4 stations, 1 is a large bearing compression station, equipped with a small vertical press; the other is a large bearing axial clearance detection station, with a hanger at the top; the other 2 It is an assembly station. This layout not only facilitates the assembly of the integral gearbox, but also enables the assembly of the gearbox to achieve flow-through operations and improve production efficiency. The assembly process of the split gear box is as follows: a layer of lubricant is evenly coated on the inner surface of the bearing housing, and the selected outer ring of the bearing is sequentially pressed into the bearing housing, and the parts are closely attached. Lift the axles of the gears onto the swivel assembly table. The inner ring of the bearing is heated to 120 ° C by an induction heater, and then the inner ring of the bearing, the retaining ring and the bearing seat with the outer ring are sequentially placed on the axle. Use a small press to press the phase 2 times in a phase difference of 180° to make the bearing close. After the bearing is completely cooled, the axial clearance of the large bearing is measured (Fig. 2). Two lifting bolts are symmetrically mounted on the bearing housing, and two magnetic dial gauges are symmetrically attracted on the gear, and the head is in contact with the bearing housing. Rotate the 30° bearing block to the left and right, and read the average of the stable readings of the two thousand parts. Then the axle is lifted slightly and an average value is detected. The difference between the two is the axial clearance of the large bearing. If the axial clearance of the large bearing does not meet the requirements, the bearing housing can be pushed out by bolts, and the retaining ring of the outer ring of the bearing is replaced to adjust the clearance. The oil block and the collector ring are heated and assembled on the axle, and the parts are closely attached. Install the sealing cover. Press the outer ring of the small bearing into the bearing housing and apply the lubricant to the bonding surface. The small bearing is heated to 110 ° C with an induction heater and mounted on the pinion shaft. Install the gearbox upper and lower casings on the bearing housing, apply the sealant to the joint surface and the joint surface, and bolt the upper and lower casings and fasten them. Since the aluminum alloy gear box has a small allowable stress and the thread shape is easily damaged, a wire sleeve is embedded in the threaded hole, but this increases the resistance of the bolt. To reduce installation resistance, the bolt surface is sprayed with a layer of black molybdenum disulfide lubricant prior to assembly.
Temperature detectors and thermocouples can be used for temperature sensing. After the run-in test, the following checks are required. Before the test, the white developer was pre-sprayed at the joint surface of the weld bead, labyrinth, bearing cap and gear box, bolts, etc., and the oil was leaked according to the discoloration condition. Check if the iron on the filler port is attracted to iron. Before the test, apply a layer of purple pigment on one of the tooth surfaces of the large and small gears; after the test, open the observation hole and check whether the traces of the gears left on the paint are abnormal. After the running test is completed for 12 hours, when the temperature of the driving device returns to normal, check whether the axial clearance of the small bearing changes. Coupling assembly Toyo Electric's drive unit has two types of couplings, one is a conventional toothed coupling; the other is a TD flexible plate coupling. The TD coupling achieves radial offset and torque transfer of the coupling by elastic deformation of the flexplate. Reduced maintenance work due to the elimination of lubricants. The flexible board must have sufficient strength and flexibility, so special steel is needed, and the manufacturing process is difficult.
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