倾斜缸成套装备的设计及其应用研究

Design and practical application of equipmentfor assembling tilt hydraulic cylinder

针对倾斜缸手工装配造成的装配质量稳定性差、效率低等问题,设计开发了一种全自动的倾斜缸成套装备。首先,分析了常规倾斜缸的装配结构,并设计了倾斜缸成套装备的整体工艺及结构方案;然后,通过采用设计失效模式、影响分析和过程失效模式及影响分析工具,研究分析了倾斜缸成套装备的失效模式;其次,采用PLC作为控制核心,设计开发了倾斜缸成套装备控制系统,并依次完成了硬件电路、伺服控制子系统、控制系统程序流程等的设计,以及控制系统上位机的软件开发;最后,将所开发的倾斜缸全自动化装配成套设备应用于倾斜缸产品实际装配生产现场,以验证设计开发的成套装备的实际工作性能。研究结果表明:采用该设计开发的倾斜缸成套装备后,倾斜缸的装配效率可提高30%,装配工人数量可减少50%,装配合格率可提高95%以上;同时可有效地提高倾斜缸装配质量的稳定性。

Aiming at the problem of poor assembly quality stability and low efficiency which caused by manual assembly operation of tilt hydraulic cylinder,a full-automatic equipment for assembling tilt hydraulic cylinder was designed.Firstly,the assembly structure of tilt hydraulic cylinder was analyzed,and then the overall process and structure scheme of the full-automatic equipment were studied and designed,then the failure mode of the full-automatic equipment was studied by design failure mode effects analysis(DFMEA),process failure modes and effects analysis(PFMEA)tools.The control system of the full-automatic equipment was designed with PLC as control core,which included the hardware circuit design,the servo control subsystem design,the control system program flow design and the upper-computer software design.Finally,the fully automatic assembly equipment of tilt cylinder was applied to the actual assembly production site of tilt cylinder to verify the actual working performance of the equipment.The results indicate that the full-automatic equipment can improve the assembly efficiency by 30%,reduce the number of assembly workers by 50%,increase the pass rate of assembly to more than 95%,and effectively improve the stability of assembly.