Diploma in Industrial Automation

Contents

1 Terms of Reference

1.1 Introduction

1.2 Energy and kinematic calculations of the drive

1.3 Gearbox Gear Design Calculation

1.4 Preliminary calculation of shaft diameters

1.5 Calculation of chain transmission

1.6 Coupling selection

2 Sketch Design

2.1 Main parameters of the drive

2.2 Gearbox gears check calculation

2.3 Gear Wheel Design

2.4 Gearbox structural elements

2.5 Lubrication of hooks and bearings

2.6 Transmission Effort

2.7 Check calculation of shafts for bending and torsion

2.8 Selection of rolling bearings

2.9 Calculation of key connections

3 Technical design

3.1 Check of low-speed shaft dangerous section for endurance

3.2 Calculation of reduction gear box attachment bolts to the frame

4 List of sources used

Introduction

The theme of this diploma project is the development of an automated section (AU) for processing parts of the "Front Wheel Drive Shaft 66401802110 type."

The main direction of the development of mechanical engineering is to increase the output of products and increase its quality while reducing labor costs. This is achieved by improving existing and introducing new types of equipment and technological processes, means of their mechanization and automation, as well as improving the organization and management of production.

The level and methods of automation depend on the type of production, its seriality, equipment.

The efficiency of automation through the use of robotics can be achieved only with a comprehensive approach to the creation and implementation of industrial robots and manipulators, processing equipment, controls, auxiliary mechanisms and devices. To carry out a significant amount of organizational and technological measures for the sake of a single introduction of an industrial robot and manipulator is unprofitable. Only the expanded use of industrial robots and manipulators in complex robotic systems will be justified technically, economically and socially. Compared to traditional automation tools, AU provides more flexibility in technical and organizational solutions.

The main prerequisites for the use of AU are:

1. Facilitating the labor of a worker in order to free him from unskilled, monotonous, as well as hard work.

2. Increase of labor productivity due to intensification of technological processes and provision of constant operation mode of equipment in two or three shifts.

3. Create prerequisites for the next high-quality jump in the organization of production and the transition to fully automated flexible production.

AU shall meet the following requirements:

1. Provide technological flexibility and adaptation to changes in production conditions.

2. Connect equipment of different purposes with wide variation of loading and other accessories.

3. Have high performance and reliability.

4. Consider further development and improvement.

Work on the creation and improvement of automation tools should develop in the following areas:

1. Creation of automation tools for equipment produced and currently operating in order to increase its efficiency.

2. Creation of new automated technological complexes, where the issues of improving productivity, reliability, accuracy are linked

performance of works, as well as level of automation of operation with required and

Cost-effective flexibility for rapid readjustment to adapt to changing production conditions.

2 Process part.

2.1. Main directions of part manufacturing process design.

The type of production is large-scale, based on the fact that the enterprise has a narrow range of processed parts, a large volume of their production and continuous production throughout the year.

The equipment in GAZ OJSC has a large number of machines (lathe, drill, extension, honing and tooth-cutting). The time of individual operations is not always multiple, and machine tools have accumulated parts, but there is in-line processing. Machines are located in the line, which provides free removal of the machine from the site, as well as access to them for maintenance. Backup platforms for backup storage of parts are provided near the machines. Arrangement of equipment ensures sequential execution of technological operations.

In foreign countries with developed production of automotive industry, the sits are not of a mass nature, but products are produced in medium or small series, since otherwise it is difficult to maintain a stable position in a rapidly changing market situation. Therefore, the production of modern automobile plants is focused on the operation of readjustable automatic lines and flexible production systems. And accordingly, the processing is organized using typical and group processes.

Various measures are used as measures to increase productivity, facilitate working conditions on metal cutting machines and expand the possibilities of heavy maintenance:

- increase of billets accuracy;

- application of wear-resistant coatings on the cutting tool, which increase their resistance by 210 times or more and allow processing with increased cutting speeds.

- automation of technological processes, namely creation of complex automatic lines, workshops and plants with continuous flow, which completely excludes the use of manual labor.

2.2. Service assignment of the part.

The part "Front axle drive shaft" is part of the "Transfer box" unit of the four-wheel drive truck GAZ66. The part has a number of main surfaces that are designed to fulfill its service purpose. Surface Ø35 with rectilinear splines is designed to be installed on the shaft of the coupling of the cardan shaft flange. The coupling is fixed on the drive shaft by means of nut by thread M22x1,56h. The nut is stopped on a shaft by means of a retaining washer which short mustache is unbent in a groove of a shaft 4х10. Two smooth cylindrical journals Ø35 are designed for installation on the shaft of two ball bearings. Bearings are supports of shaft, their outer rings are pressed into holes in housing of transfer box. Surface Ø70.5 with involute teeth is engaged with gear of intermediate shaft of transfer box.

Part operation diagram in the subassembly:

Torque from the engine is transmitted through the variable gear box through the cardan shaft to the primary shaft of the transfer box. From the primary shaft, the moment through the gear block is first transferred to the intermediate shaft of the transfer box and then through the intermediate shaft gear to the front axle drive shaft. The moment is then transmitted through the flange coupling bolted to the cardan shaft flange to the cardan shaft and directly to the front wheels. When working in a node, the shaft experiences significant torque alternating moments. The part is one of the most important de-tals of the dispenser box, since it works under significant dynamic loads and provides the correct geometry of gear engagement and directly affects the reliability of the dispenser box of the car.

Based on the above, the part is subject to high requirements for strength, wear resistance and quality of the treated surface. To increase wear resistance, the part undergoes chemical-thermal treatment - nitrocementation.

As a conclusion to the R&D, the following conclusions can be drawn:

The studies showed that in the temperature range of 4506000C, the strength properties of the treated material decrease by three times, and the plastic properties increase by six times. Cutting at these temperatures does not affect the structure of the treated material, the physical and mechanical parameters of the part are completely preserved. Studies have shown that the cutting temperature of cold metal at cutting speeds above 40 m/min exceeds 8008500C. When cutting with heat, the temperature of the cutting edge and tool decreases to a temperature of 6507000C due to the absence of heat release in the metal from plastic de-shear formations. The resistance of the cutting tool is determined by known formulas. Wear on the trailing edge of the tool cutter indicates that there is no wear in the temperature range from 5000C to 6000C. At temperatures above 6000C there is a sharp increase in tool wear. This is due to the difficult heat removal from the face of the cutting tool without cooling.