裝配圖單線畫線機(jī),裝配,單線,畫線 畫線機(jī)是用滾輪等再日用陶瓷、玻璃制品的圓形或橢圓形器皿上，畫一條或多條彩色、彩帶的機(jī)械?？梢苑譃閱紊珯C(jī)畫線機(jī)和多色畫線機(jī)。本次設(shè)計(jì)主要是研究設(shè)計(jì)單色畫線機(jī)，即單線畫線機(jī)。 陶瓷是無(wú)機(jī)材料之母，從家庭至宇宙對(duì)陶瓷的渴求量愈來(lái)愈大，其許多優(yōu)越、潛在特性不斷被發(fā)現(xiàn)，近20年來(lái)各國(guó)非常重視陶瓷的研究、開(kāi)發(fā)與應(yīng)用，各國(guó)將先后進(jìn)入陶瓷世界。 陶瓷一般指陶器和瓷器的合稱，“陶”為燒成之意，“瓷”是指硬而之謎的器物。陶瓷是我國(guó)歷史悠久的古老文化之一，也是文明的象征。我國(guó)陶瓷的出現(xiàn)可上溯到距今一萬(wàn)年左右，距今3000年前的殷周時(shí)代，有了以高嶺土為原料的白陶，已懂得用釉的方法。原始瓷器是以鐵為著色劑的青釉器，是青瓷的前身。晉朝出現(xiàn)“瓷”字，說(shuō)明當(dāng)時(shí)人們已認(rèn)識(shí)到陶和瓷的區(qū)別。 陶瓷是一種與我們?nèi)粘Ｉ钜约霸诟鞣N工程項(xiàng)目能夠經(jīng)常接觸到的材料。隨著技術(shù)經(jīng)濟(jì)的發(fā)展，在某些科學(xué)領(lǐng)域陶瓷已形成其他材料無(wú)法比擬的優(yōu)點(diǎn)。例如，工程陶瓷，由工程陶瓷的制成的零件具有耐磨、耐熱、耐摩擦、熱膨脹系數(shù)小等一系列優(yōu)點(diǎn)，是當(dāng)今世界高技術(shù)含量的產(chǎn)品。在國(guó)外已越來(lái)越多地應(yīng)用工程陶瓷取代金屬零件，使產(chǎn)品地壽命、穩(wěn)定性等大大提高。在如，低溫?zé)Y(jié)陶瓷（LTCC）大家一定還都記得在手機(jī)行業(yè)剛剛起步時(shí)的代表作——大哥大，它又笨又重，攜帶不方便，而現(xiàn)在的手機(jī)就越來(lái)越袖珍了，這里的關(guān)鍵就是LTCC技術(shù)的發(fā)展。;LTCC技術(shù)是把很多東西整合在一起，其全稱為“低溫共燒陶瓷”技術(shù)，，簡(jiǎn)單地說(shuō)，就是一種整合、小型化地技術(shù)將各種被動(dòng)組件整合在一起，縮小到陶瓷式電路板上，如果沒(méi)有它，手機(jī)是無(wú)法達(dá)到輕薄短小地效果地?？傊?，陶瓷已經(jīng)成為與我們密不可分地伙伴了。 我國(guó)陶瓷生產(chǎn)歷史悠久，日用陶瓷一直暢銷國(guó)內(nèi)外。在我們的生活中，能夠給人們留下直觀印象的是日用陶瓷。這里不乏一些工藝美術(shù)品。因此，對(duì)于陶瓷制品，我們不僅要求其本身質(zhì)量要好、使用方便，同時(shí)還要對(duì)其表面進(jìn)行一定程度的美化處理，繪制出各種線條精美的圖案，增加美感及藝術(shù)感。然而，傳統(tǒng)的陶瓷畫線主要是由手工完成的，畫出的線條寬窄不一，嚴(yán)重影響產(chǎn)品的質(zhì)量，與其是在畫寬度3mm以上的線條時(shí)，用手工的方法根本無(wú)法實(shí)現(xiàn)，因此生產(chǎn)陶瓷的廠家不得不將線條印成畫紙，將畫紙貼在陶瓷制品上進(jìn)行彩烤，而這又大大提高了成本。陶瓷生產(chǎn)廠家一直都無(wú)法解決這一問(wèn)題。隨著機(jī)械化、自動(dòng)化技術(shù)的不斷發(fā)展，研制新型高效的畫線機(jī)以代替手工作業(yè)已成為迫切需要。目前，世界各國(guó)對(duì)裝飾機(jī)械的研制十分迅速，不斷推陳出新。其中以畫線機(jī)和印花機(jī)發(fā)展最為迅速。我國(guó)在這方面發(fā)展比較晚，目前用于生產(chǎn)陶瓷機(jī)械數(shù)量較小，品種較單一，因此有必要投入人力物力財(cái)力設(shè)計(jì)新產(chǎn)品，引進(jìn)設(shè)備，消化技術(shù)。 1.3 工作內(nèi)容和要求 1.3.1 畫線機(jī)總體參數(shù)的確定 主要技術(shù)指標(biāo)及重要技術(shù)參數(shù) ①主要技術(shù)指標(biāo) 畫線色種: 單色 公稱生產(chǎn)能力：6-12件/分 彩色寬度： 0.25-6mm 制品最大直徑：406mm 制品最大高度：230mm 總功率消耗： 3.5kw 整機(jī)重要： 約100kg 外型尺寸： 約1.4m×0.8m×1.6m ②重要技術(shù)參數(shù) 電動(dòng)機(jī)的變速范圍：1000-3000rpm 最短畫線時(shí)間： ＝1.22s 最長(zhǎng)畫線時(shí)間： ＝4.14s 畫線輔助時(shí)間： t＝3s 1.3.2 單線畫線機(jī)的機(jī)構(gòu)設(shè)計(jì) 單線自動(dòng)畫線機(jī)主要由主機(jī)架、工作臺(tái)、施彩器組件、真空泵、氣動(dòng)系統(tǒng)、電器部分組成.其主要功能包括：驅(qū)動(dòng)功能、畫線功能、自動(dòng)裝卸功能、輔助功能、測(cè)控功能、安全保護(hù)功能。功能分解如下圖： 單 線 畫 線 機(jī) 驅(qū)動(dòng) 施彩頭電機(jī)驅(qū)動(dòng) 吸盤主電機(jī)驅(qū)動(dòng) 單線畫線機(jī) 前伸 后仰 吸 盤 吸氣 放氣 輔 助 支撐 導(dǎo)向 測(cè)控—單線畫線機(jī)畫線 安全保護(hù) 漏電保護(hù) 過(guò)載保護(hù) 圖1 單線畫線機(jī)的功能結(jié)構(gòu)圖 依據(jù)這些功能，系統(tǒng)組成為：動(dòng)力系統(tǒng)、傳動(dòng)系統(tǒng)、執(zhí)行系統(tǒng)、輔助系統(tǒng)、測(cè)控系統(tǒng)、安全保護(hù)系統(tǒng)。各主要系統(tǒng)概述如下： 動(dòng)力系統(tǒng)：為操作部件提供動(dòng)力，如機(jī)械手的仰俯、旋轉(zhuǎn)、單線機(jī)的移動(dòng)畫線。本設(shè)計(jì)中動(dòng)力裝置為電動(dòng)機(jī)和氣壓系統(tǒng)。 傳動(dòng)系統(tǒng)：是將動(dòng)力機(jī)的運(yùn)動(dòng)和動(dòng)力傳遞給執(zhí)行機(jī)構(gòu)或執(zhí)行構(gòu)件的中間裝置。主要有帶傳動(dòng)、齒輪傳動(dòng)、蝸輪蝸桿傳動(dòng)等。在本設(shè)計(jì)中，由電動(dòng)機(jī)到施釉輪之間的傳動(dòng)是通過(guò)帶傳動(dòng)來(lái)完成的。 執(zhí)行機(jī)構(gòu)：能直接完成預(yù)期工作任務(wù)的機(jī)構(gòu)和部件，為完成對(duì)陶瓷制品的畫線功能所需的執(zhí)行機(jī)構(gòu)的部件主要是機(jī)械手、施釉輪及帶釉輪。 測(cè)控系統(tǒng)：是控制畫線機(jī)各執(zhí)行機(jī)構(gòu)按規(guī)定程序和要求，以一定順序和規(guī)律運(yùn)動(dòng)完成畫線機(jī)，具體測(cè)控有機(jī)械手旋轉(zhuǎn)角度、升降角度、單線機(jī)的位移量、放氣時(shí)間等。 輔助系統(tǒng)：為完成畫線功能，以上各功能還需要一些輔助系統(tǒng)支持，如支承、下料、送料等輔助系統(tǒng)。 為了保證準(zhǔn)確可靠地實(shí)現(xiàn)畫線機(jī)地畫線功能，實(shí)現(xiàn)畫線自動(dòng)化，需滿足以下條件： ① 機(jī)構(gòu)地布局應(yīng)合理，相互之間保證不干涉，不阻擋。 ② 總體布局應(yīng)使工人操作安全方便，節(jié)省空間。 ③ 吸盤吸、放氣時(shí)要考慮工人操作時(shí)間地合理性。 ④ 機(jī)器的電動(dòng)、氣動(dòng)部分都需外殼罩住，已加工與未加工的工件放置要整齊，物料陪送線路要清晰、合理。 ⑤ 本機(jī)分四部分安裝，各部分安裝好后再連接在一起構(gòu)成一個(gè)整體，這樣能夠提高效率，保證質(zhì)量且運(yùn)輸時(shí)也方便。 1.3.3 相關(guān)部件、零件設(shè)計(jì) 單線畫線機(jī)主要有施彩器傳動(dòng)系統(tǒng)、氣動(dòng)系統(tǒng)、真空系統(tǒng)、電器系統(tǒng)四部分.其中零件要首先選擇標(biāo)準(zhǔn)件,若標(biāo)準(zhǔn)件中沒(méi)有合適的零件可自行進(jìn)行設(shè)計(jì).在本機(jī)的設(shè)計(jì)中,我們需要設(shè)計(jì)選擇電機(jī)、傳動(dòng)系統(tǒng)、減速器、阻尼裝置等. 表1 形態(tài)學(xué)矩陣 分功能 解 法 1 2 3 4 5 6 A動(dòng)力源 B位移傳動(dòng) C位移 D取物傳動(dòng) E取物 電動(dòng)機(jī) 齒輪傳動(dòng) 軌道及車 輪 拉桿 挖斗 汽油機(jī) 蝸輪蝸桿 傳動(dòng) 輪胎 繩傳動(dòng) 抓斗 柴油機(jī) 帶傳動(dòng) 履帶 汽缸傳動(dòng) 鉗式斗 蒸氣透平 鏈傳動(dòng) 氣墊 液壓缸傳 動(dòng) 機(jī)械手 液動(dòng)機(jī) 液力耦合器 氣動(dòng)馬達(dá) 1.3.3.1 電動(dòng)機(jī)的選擇 電動(dòng)機(jī)施機(jī)械系統(tǒng)中最常用的動(dòng)力機(jī),與其他動(dòng)力機(jī)相比,它具有較高的驅(qū)動(dòng)效率,且其種類和型號(hào)較多,與工作機(jī)械連接方便,具有良好的調(diào)速、啟動(dòng)、制動(dòng)和反向控制性能.易于實(shí)現(xiàn)遠(yuǎn)距離、自動(dòng)控制,工作時(shí)無(wú)環(huán)境污染,可滿足大多數(shù)機(jī)械的工作要求. 1.3.3.2 氣動(dòng)系統(tǒng)的選擇 特點(diǎn): ① 元件結(jié)構(gòu)簡(jiǎn)單、緊湊、易于制造,且不污染環(huán)境.可集中供氣和遠(yuǎn)距離輸送,便于管理. ② 易于實(shí)現(xiàn)快速的直線往復(fù)運(yùn)動(dòng),擺動(dòng)的高速轉(zhuǎn)動(dòng).輸出力和運(yùn)動(dòng)速度調(diào)節(jié)很方便,且能實(shí)現(xiàn)過(guò)載自動(dòng)保護(hù). ③ 工作環(huán)境適應(yīng)性較強(qiáng). ④ 由于壓縮空氣的工作壓力不高,一般在0.4-0.6MPa,故輸出力和力矩不高,且傳動(dòng)效率也較低,一般用于輸出力不大的傳動(dòng)裝置.采用擴(kuò)力機(jī)械或氣液增壓裝置,可提高輸出力. ⑤ 由于空氣有壓縮性,故運(yùn)動(dòng)速度的穩(wěn)定性較差,較難實(shí)現(xiàn)精密控制.采用氣液聯(lián)動(dòng)方式,可提高運(yùn)動(dòng)速度的穩(wěn)定性. ⑥ 由于氣信號(hào)的傳遞速度比電信號(hào)慢得多,故不宜用于遙控及復(fù)雜得控制系統(tǒng). 組成: 起源部分、執(zhí)行部分、控制部分、輔助部分. 1.3.3.3減速器的選擇 本機(jī)可選擇常用的阿基米德圓柱蝸桿減速器,這種減速器適用于蝸桿轉(zhuǎn)速不超過(guò)1500r/min,環(huán)境溫度為-40-+40°C的場(chǎng)合,可以正反兩向運(yùn)轉(zhuǎn).在選用減速器時(shí),首先根據(jù)工作要求確定傳動(dòng)比i,再按蝸輪軸的計(jì)算轉(zhuǎn)矩查蝸輪軸額定轉(zhuǎn)矩表,確定減速器的中心距.然后按機(jī)器布置,潤(rùn)滑等要求選擇減速器的裝配形式.必要時(shí)要進(jìn)行散熱計(jì)算. 1.4 課題的重點(diǎn)和難點(diǎn) 1.4.1 單線畫線機(jī)設(shè)計(jì)重點(diǎn) 單線自動(dòng)畫線機(jī)的用途是在陶瓷制品上畫出裝飾線條或圖案，以達(dá)到美化陶瓷質(zhì)樸那的目的。這種機(jī)械代替了手工畫線工作，提高了勞動(dòng)生產(chǎn)率以及精度，可以畫出粗細(xì)均勻的線條，克服了手工作業(yè)的缺點(diǎn)與不足，滿足了廣大消費(fèi)者的審美要求并提高了勞動(dòng)生產(chǎn)率。我國(guó)地域遼闊，該機(jī)不受地形氣候等外界因素影響和限制，并且易于維修，工作可靠，適用于相關(guān)陶瓷生產(chǎn)部門。 經(jīng)各種常用系統(tǒng)的計(jì)算比較得出，當(dāng)施釉輪與被加工陶瓷盤間實(shí)現(xiàn)純滾動(dòng)，且滾動(dòng)畫線速度在0.4m/s時(shí),畫線效果最佳，故單線畫線機(jī)的一切設(shè)計(jì)要以此為宗旨。 通過(guò)帶傳動(dòng)的裝置，電動(dòng)機(jī)將動(dòng)力傳遞給了施釉輪與帶釉輪，兩輪開(kāi)始旋轉(zhuǎn)，此時(shí)主從摩擦輪接觸，帶動(dòng)陶瓷旋轉(zhuǎn)，設(shè)計(jì)合理的技術(shù)參數(shù)，可實(shí)現(xiàn)上述的畫線速度要求，畫線機(jī)開(kāi)始畫線。在每個(gè)陶瓷畫線的開(kāi)始與結(jié)束，為了便與裝卸陶瓷，支承施釉頭組件的桿件必須能夠?qū)崿F(xiàn)擺動(dòng)，以使施釉頭組件準(zhǔn)確靠近、離開(kāi)瓷器。經(jīng)多方面的比較，我們最終選擇氣動(dòng)系統(tǒng)實(shí)現(xiàn)這一環(huán)節(jié)。另外，在被加工定位的這一環(huán)節(jié)也有講究。由于陶瓷制品易碎這一特點(diǎn)，使得我們必須摒棄普通機(jī)床夾具而選擇其它的定位夾緊方法。基于盤狀陶瓷表面光潔的特點(diǎn)，我們想到了可以利用真空吸附夾緊方式定位，及手部為真空吸盤。 1.4.2單線畫線機(jī)的設(shè)計(jì)難點(diǎn) 對(duì)于單線自動(dòng)畫線機(jī)，最重要的是能夠畫出均勻清晰的線條，以滿足廣大消費(fèi)者的審美要求，因此對(duì)各機(jī)構(gòu)的運(yùn)動(dòng)精度和定位精度要求較高。畫線機(jī)的運(yùn)動(dòng)精度和定位精度主要包括以下幾個(gè)方面： ①施彩頭組件擺動(dòng)的運(yùn)動(dòng)與機(jī)械手的運(yùn)動(dòng)需協(xié)調(diào)一致，即與裝、卸料工作要配合。 ②為了保證施釉輪與制品之間的接觸精度，單線機(jī)的前進(jìn)與后退要有較高的定位精度。 ③機(jī)械手的旋轉(zhuǎn)角度是否精確，關(guān)系到安放工件時(shí)的中心線能否與吸盤中心重合。 由于這些精度將直接關(guān)系到產(chǎn)品質(zhì)量，建議采取開(kāi)環(huán)伺服系統(tǒng)進(jìn)行控制。 1.5 單線畫線機(jī)的機(jī)械系統(tǒng)的方案設(shè)計(jì) 機(jī)械系統(tǒng)的方案設(shè)計(jì)，是機(jī)械設(shè)計(jì)中極其重要的一環(huán)。正確、合理的機(jī)械系統(tǒng)的方案，對(duì)于提高機(jī)械的性能、質(zhì)量、市場(chǎng)競(jìng)爭(zhēng)力和經(jīng)濟(jì)效益等都是至關(guān)重要的。 單線畫線機(jī) 制成品M’ 陶瓷器件M 指令S 信息顯示S’ 能量E 輸出E’ 圖2 單線畫線機(jī)黑箱圖 1.5.1 執(zhí)行系統(tǒng)的方案設(shè)計(jì) 包括執(zhí)行系統(tǒng)的功能原理設(shè)計(jì)，執(zhí)行系統(tǒng)的運(yùn)動(dòng)規(guī)律設(shè)計(jì)，執(zhí)行系統(tǒng)的形式設(shè)計(jì)，執(zhí)行系統(tǒng)的協(xié)調(diào)設(shè)計(jì)以及執(zhí)行系統(tǒng)的方案評(píng)價(jià)。 1.5.2 傳動(dòng)系統(tǒng)的方案設(shè)計(jì) 包括選擇合理的傳動(dòng)裝置的類型、確定傳動(dòng)路線的方案以及合理分配傳動(dòng)系統(tǒng)。 1.5.3 原動(dòng)機(jī)類型的選擇 包括原動(dòng)機(jī)的類型、轉(zhuǎn)速、以及原動(dòng)機(jī)容量的選擇。 1.5.4 操縱控制系統(tǒng)的選擇 包括機(jī)電控制系統(tǒng)、機(jī)液控制系統(tǒng)、電業(yè)控制系統(tǒng)、液壓控制系統(tǒng)、氣動(dòng)系統(tǒng)、電氣控制系統(tǒng)以及微機(jī)控制系統(tǒng)。 1.6 國(guó)內(nèi)外同類產(chǎn)品的對(duì)比 國(guó)外很多國(guó)家重視裝飾機(jī)械的研制與開(kāi)發(fā)，特別時(shí)在畫線機(jī)、印花機(jī)方面的發(fā)展時(shí)十分迅速的，與國(guó)外產(chǎn)品比起來(lái)，該產(chǎn)品的生產(chǎn)效率低且柔性化程度不高；但在國(guó)內(nèi)，由于這一方面起步較晚，發(fā)展較慢，所以該產(chǎn)品已經(jīng)達(dá)到了一個(gè)新的水平。 1.7關(guān)于用戶的需求和企業(yè)發(fā)展計(jì)劃的介紹 對(duì)于用戶來(lái)說(shuō)，他們希望用更好的陶瓷制品，外表美觀大方，且物美價(jià)廉，這就是用戶所追求的方向。因此，企業(yè)的發(fā)展應(yīng)以此為導(dǎo)向，來(lái)滿足用戶的需求。這樣的企業(yè)才能有所創(chuàng)造，有所發(fā)展。 1.8 可能用到的知識(shí)和技能 理論知識(shí)：機(jī)械原理、機(jī)械設(shè)計(jì)、材料力學(xué)、機(jī)械制造技術(shù)等 應(yīng)用軟件：AutoCAD、CATIA、ADAMS、Office word等。 1.9 需要自學(xué)的知識(shí)和技能 由于在本科的學(xué)習(xí)階段，我們主要學(xué)習(xí)了一些專業(yè)理論知識(shí)而過(guò)少解除各科知識(shí)在實(shí)際當(dāng)中的應(yīng)用。因此，在設(shè)計(jì)過(guò)程中，我們應(yīng)注重在實(shí)際應(yīng)用方面豐富自己的頭腦。針對(duì)這次的畢業(yè)設(shè)計(jì)，我應(yīng)多多學(xué)習(xí)關(guān)于陶瓷加工機(jī)械方面的知識(shí)，爭(zhēng)取創(chuàng)造條件實(shí)際觀察陶瓷的單線畫線機(jī)的工作過(guò)程，了解其原理。另外，在三維造型方面，目前市面流行的工程軟件很多，除了CATIA，我們還可以考慮用其他的軟件。若有條件，我會(huì)考慮學(xué)習(xí)另外的軟件來(lái)進(jìn)行三維造型。 2 工作計(jì)劃 表2 進(jìn)度計(jì)劃表 2006.2-2006.3 調(diào)研、譯文、參考文獻(xiàn) 2006.4.1-2006.4.15 總體布置、草圖、開(kāi)題報(bào)告 2006.4.15-2006.5.1 總體設(shè)計(jì)、總裝圖 2006.5.1-2006.5.15 部件設(shè)計(jì)、相關(guān)計(jì)算 2006.5.15-2006.6.1 零件、部件、設(shè)計(jì)、論文 2006.6.1-2006.6.20 修改、完善、圖紙論文、答辯 摘要 本次設(shè)計(jì)的是單色自動(dòng)畫線機(jī)，其主要功能是在一個(gè)瓷器上畫出一條粗細(xì)均勻的線。 本文主要討論了設(shè)計(jì)的必要性，通過(guò)系統(tǒng)功能分解、功能合成、方案設(shè)計(jì)提出新方案。這一點(diǎn)對(duì)產(chǎn)品的成敗起決定性作用。計(jì)算和安排一些與設(shè)計(jì)有關(guān)的重要數(shù)據(jù)的設(shè)計(jì)計(jì)算書(shū)、分析典型零部件的結(jié)構(gòu)工藝性、闡明如何操作的說(shuō)明書(shū)、設(shè)計(jì)總結(jié)等等。 1、 設(shè)計(jì)計(jì)算說(shuō)明 1.1該機(jī)主要有施彩輪傳動(dòng)系統(tǒng)、氣動(dòng)系統(tǒng)、真空系統(tǒng)、電器系統(tǒng)四部分組成 1.2施彩輪傳動(dòng)系統(tǒng)中施彩輪轉(zhuǎn)速得確定施根據(jù)以下試驗(yàn)確定的： 速度(m/s) 0.1 0.2 0.3 0.4 0.5 0.6 畫線效果 滴釉 苦釉 粗細(xì)不均 符合要求 缺釉 毛刺 由表可知，畫線輪的最佳轉(zhuǎn)速為0.4m/s。 1.2.1施彩輪電機(jī)功率及吸盤電機(jī)功率的確定 施彩輪與被畫陶瓷器件的摩擦力矩為： 將P＝40，＝5，R＝0.03，f＝0.9代入上式（此數(shù)據(jù)為試驗(yàn)所得）， M＝1.215（公斤米） 由 式中為電機(jī)所用總功率 n為電機(jī)減速輸出轉(zhuǎn)速 h為傳動(dòng)效率 由以上可得主機(jī)電機(jī)功率為0.17KW。 1.3氣缸的選擇： 由于瓷器在燒成過(guò)程中不可避免產(chǎn)成變形現(xiàn)象，因而畫線輪要用適當(dāng)壓力對(duì)瓷器實(shí)行壓緊。這一壓力在每平方厘米一公斤為好，總壓力為40公斤，畫出線條符合質(zhì)量要求。而行程長(zhǎng)度為20mm為最佳，因而我們?nèi)?zhǔn)力為40mm，行程為20mm的氣缸作為縱向氣缸。為了適應(yīng)于陶瓷制品周邊的變形或者不規(guī)則形狀的畫線施彩輪靠輪必須始終給瓷器周邊以壓應(yīng)力，因而試驗(yàn)證明，橫向氣缸壓力應(yīng)與縱向汽缸相等。為適應(yīng)于魚(yú)盤等不規(guī)則瓷器的畫線工作，氣缸行程選擇80mm為宜。 1.4該機(jī)真空度及抽氣速率的決定 以日用陶瓷中的16寸盤（本機(jī)所畫最大口徑的畫線盤）為例： 1.5帶動(dòng)摩擦輪的電動(dòng)機(jī)的選擇 畫線輪與瓷器之間應(yīng)保證0.4m/s速度的純滾動(dòng)，擬定主、從摩擦輪的轉(zhuǎn)速為： 由電動(dòng)機(jī)到摩擦輪之間設(shè)置一級(jí)蝸桿減速器，其傳動(dòng)比為62，則電動(dòng)機(jī)的轉(zhuǎn)速范圍為： （18.8——63.7）×62=1160——4000rpm,據(jù)此選擇直流電動(dòng)機(jī)如如下： 型號(hào)： G4524 額定功率： 60KW 額定轉(zhuǎn)速： 4000rpm 額定電流： 2.5A 額定轉(zhuǎn)矩： 1.7KNm 1.6主傳動(dòng)路線： 住傳動(dòng)路線即由主電動(dòng)機(jī)傳到主動(dòng)摩擦輪的路線。由于帶傳動(dòng)具有緩沖減震的作用，所以由主電動(dòng)機(jī)帶動(dòng)一級(jí)皮帶傳動(dòng)。因?yàn)橹绷麟妱?dòng)機(jī)轉(zhuǎn)速一般較高，在帶傳動(dòng)以后選擇了一個(gè)標(biāo)準(zhǔn)蝸桿減速器，其輸出通過(guò)一個(gè)彈性套柱銷聯(lián)軸器傳到主動(dòng)摩擦輪上，再經(jīng)從動(dòng)摩擦輪帶動(dòng)吸盤進(jìn)行旋轉(zhuǎn)畫線工作。 1.7實(shí)現(xiàn)瓷器自轉(zhuǎn)的傳動(dòng)路線： 摩擦輪電動(dòng)機(jī)直接連接在一個(gè)蝸輪蝸桿減速器上。其輸入軸豎直，輸出軸水平放置且直接連接到主動(dòng)摩擦輪，當(dāng)從動(dòng)摩擦輪與主動(dòng)摩擦輪接觸時(shí)，動(dòng)力便傳到從動(dòng)摩擦輪繼而帶動(dòng)吸盤旋轉(zhuǎn)。 1.8主動(dòng)蝸輪蝸桿減速器的選擇： 根據(jù)功率、傳動(dòng)比及安裝要求，選擇主減速器為WS150蝸桿減速器。傳動(dòng)比約為40，單向工作，JC=15%。 1.9為實(shí)現(xiàn)畫線的全自動(dòng)控制，對(duì)電器的基本說(shuō)明 首先為了實(shí)現(xiàn)陶瓷品種的變化，為使陶瓷的畫線速度保持0.4m/s吸盤主電機(jī)應(yīng)采用直流電機(jī)，采用控制電樞可調(diào)整流裝置，其基本控制如下： 2畫線機(jī)畫線質(zhì)量總結(jié) 以下因素對(duì)畫線質(zhì)量有明顯影響： 2.1畫線輪中心與此其重心在同一平面是取得最佳畫線效果的主要因素之一，如圖1.1，如果畫線輪偏上或偏下（相對(duì)瓷器中心比較）都會(huì)給瓷器帶上毛刺的線，影響產(chǎn)品質(zhì)量。如圖1.2、圖1.3。 2.2畫線輪偏擺對(duì)畫線的影響 畫線輪由于安裝加工等引起的偏擺將使畫出線條成曲線狀， 如圖1.4 2.3顏料的混合和黏度對(duì)畫線的影響 畫線用顏料的黏度將給所畫線條帶來(lái)影響，如果黏度過(guò)大則所畫線條較標(biāo)準(zhǔn)寬度寬，如果黏庫(kù)過(guò)小則出現(xiàn)滴油現(xiàn)象，試驗(yàn)表明最好是兩份介質(zhì)和一份燃料構(gòu)成。 3目前存在的問(wèn)題 ①畫線機(jī)體積大； ②各調(diào)整螺栓不夠方便； ③整機(jī)藝術(shù)造型不夠理想。 導(dǎo)軌的設(shè)計(jì) 1概述 1.1導(dǎo)軌的作用 導(dǎo)軌主要用來(lái)支承和引導(dǎo)運(yùn)動(dòng)部件沿一定的軌跡運(yùn)動(dòng)并支承受運(yùn)動(dòng)部件的重量和工作載荷。兩個(gè)作相對(duì)運(yùn)動(dòng)的部件構(gòu)成一對(duì)導(dǎo)軌副，其中不動(dòng)的配合面成為固定導(dǎo)軌或靜導(dǎo)軌，運(yùn)動(dòng)的配合面稱為運(yùn)動(dòng)導(dǎo)軌過(guò)動(dòng)導(dǎo)軌。在運(yùn)動(dòng)導(dǎo)軌和固定之間；一般只允許有一個(gè)自由度。 1.2導(dǎo)軌應(yīng)滿足的要求 1.2.1導(dǎo)向精度 ①幾何精度 ②接觸精度 1.2.2精度保持性 1.2.3移動(dòng)靈敏度 1.2.4低速運(yùn)動(dòng)的平穩(wěn)性 1.2.5抗振性和穩(wěn)定性 1.2.6剛度 1.2.7結(jié)構(gòu)工藝性 1.2.8對(duì)溫度變化的適應(yīng)能力 常用滑動(dòng)導(dǎo)軌的類型、特點(diǎn)和應(yīng)用 類型 工作原理和摩擦性 導(dǎo)向精度 靈敏度和定位精度 低速運(yùn)動(dòng)平穩(wěn)性 精度保持性 抗振形和穩(wěn)定性 應(yīng)用 特點(diǎn) 滑動(dòng)導(dǎo)軌 普通滑動(dòng)導(dǎo)軌 整體式 導(dǎo)軌副工作面是混合摩擦狀態(tài)，靜動(dòng)摩擦系數(shù)相差較大，低速時(shí)摩擦系數(shù)隨速度增加而減小 采用精銑、磨削或刮削可達(dá)到較高的幾何精度 較差、不采用減磨措施時(shí)，定位精度為0～0.02mm 低速時(shí)（1～60mm/min） 易產(chǎn)生爬行 導(dǎo)軌表面淬火可將耐磨性提高1～2倍 好 廣泛應(yīng)用于普通精度的機(jī)械 結(jié)構(gòu)簡(jiǎn)單，制造容易，維護(hù)簡(jiǎn)便，成本低 鑲裝式 采用鑲銅、有色金屬或塑料板，改變導(dǎo)軌機(jī)體的摩擦特性，增加耐磨性 一般比整體式的好 一般 比整體式好 貼 ︵ 涂 ︶ 塑式 由工程塑料做成動(dòng)高貴表面，與金屬制靜導(dǎo)軌的摩擦系數(shù)較小，只隨著速度增加而略有增大，但承載能力較差 用聚四氟乙烯軟帶時(shí)，定位精度可達(dá)0.002mm 無(wú)爬行 好 廣泛用于粳米和重型機(jī)械，也常用于舊機(jī)器導(dǎo)軌的大修 結(jié)構(gòu)簡(jiǎn)單，制造容易，維修簡(jiǎn)便，制造成本較低，靜導(dǎo)軌常用鑲鋼式 靜壓導(dǎo)軌 液體 壓力油通過(guò)節(jié)流器進(jìn)入導(dǎo)軌承載面，在任何速度下均為液體摩擦狀態(tài)；油膜承載能力大 油膜有均化誤差的作用，精度可達(dá) 0.001～0.006mm /1000mm 微量位移定位精度為0.002mm摩擦系數(shù)很小，約為混合摩擦得1% 低速運(yùn)動(dòng)時(shí)無(wú)爬行，定位精確，速度均勻 導(dǎo)軌無(wú)磨損，精度保持性好 油膜有吸振能力 用于重型、大型和精密機(jī)械如數(shù)控機(jī)床 制造復(fù)雜，調(diào)整較難，需要一套較復(fù)雜的供油系統(tǒng) 氣體 用壓縮空氣經(jīng)節(jié)流器進(jìn)入導(dǎo)軌面內(nèi)腔，形成厚約0.02～0.025mm厚的氣墊，比液體靜壓導(dǎo)軌摩擦系數(shù)下，承載能力低 空氣介質(zhì)有很好的冷卻作用，減小導(dǎo)軌熱變形，導(dǎo)向精度可達(dá)0.00025mm /300mm 很高，定位精度可達(dá)0.125mm重復(fù)精度0.025 很好，低速無(wú)爬行 導(dǎo)軌副無(wú)金屬接觸，還可以用空氣起凈化作用 可以采用花崗巖作機(jī)座，隔振性很好，由于氣隙很小，在很小振幅下已產(chǎn)生接觸，阻尼性強(qiáng) 多用于數(shù)控機(jī)床三坐標(biāo)測(cè)量機(jī)等 需要一套供氣系統(tǒng)，承載能力低，空氣不需回收，不污染環(huán)境，結(jié)構(gòu)比液壓體靜壓導(dǎo)軌簡(jiǎn)單 動(dòng)壓導(dǎo)軌 液體 利用導(dǎo)軌面間的相對(duì)運(yùn)動(dòng)形成壓力油楔，將動(dòng)導(dǎo)軌浮起，形成液體摩擦 有“浮升”現(xiàn)象，導(dǎo)向精度一般 一般 不能用于低速 起動(dòng)和停止時(shí)速度低，不能建立動(dòng)壓，有磨損 油膜有吸振能力 只適用于高速運(yùn)動(dòng)的主運(yùn)動(dòng)導(dǎo)軌，如立式車床的圓周運(yùn)動(dòng)導(dǎo)軌 2滑動(dòng)導(dǎo)軌結(jié)構(gòu)設(shè)計(jì) 2.1滑動(dòng)導(dǎo)軌的截面形狀設(shè)計(jì) 2.1.1直線滑動(dòng)導(dǎo)軌的截面形狀設(shè)計(jì) 直線運(yùn)動(dòng)導(dǎo)軌的截面，應(yīng)保證運(yùn)動(dòng)部件只能沿直線方向運(yùn)動(dòng)，限制運(yùn)動(dòng)部件的轉(zhuǎn)動(dòng)和橫向移動(dòng)。當(dāng)移動(dòng)部件的尺寸較小，為細(xì)長(zhǎng)條狀或行程較小時(shí)，可將導(dǎo)軌做成封閉性。選擇截面形狀時(shí)要注意： ①導(dǎo)軌磨損量隨表面比壓增加而增加，設(shè)計(jì)時(shí)應(yīng)盡可能使導(dǎo)軌面垂直于外力的方向。 ②導(dǎo)軌磨損后對(duì)導(dǎo)向精度的影響要小。 2.2滑動(dòng)導(dǎo)軌的間隙調(diào)整裝置 為保證導(dǎo)軌的正常運(yùn)動(dòng)，運(yùn)動(dòng)件和支承件之間應(yīng)保持適當(dāng)?shù)拈g隙，間隙過(guò)小會(huì)增加摩擦力，操作費(fèi)力還會(huì)加快磨損，間隙過(guò)大會(huì)使精度降低，甚至?xí)a(chǎn)生振動(dòng)。因此，除在裝配過(guò)程中應(yīng)仔細(xì)地調(diào)整導(dǎo)軌的間隙外，在使用一段時(shí)間后因默存還需要重調(diào)。 調(diào)整的方法： ①采用磨、刮相應(yīng)地結(jié)合面或加墊片的方法，以獲取合適的間隙。 ②用鑲條和壓板來(lái)調(diào)整導(dǎo)軌的間隙。 2.2.1鑲條和壓板的結(jié)構(gòu)型式 用鑲條來(lái)調(diào)整矩形和燕尾形導(dǎo)軌的間隙時(shí)，把鑲條布置在受力較小的一側(cè)。 壓板用于調(diào)整輔助導(dǎo)軌的間隙，并承受傾覆力矩。 2.2.2導(dǎo)軌加緊裝置 有些導(dǎo)軌（如非水平放置的導(dǎo)軌）在移動(dòng)到預(yù)定位置后，要求將它的位置固定，為此采用專用的鎖（夾）緊裝置。常用的鎖緊方式有機(jī)械鎖緊和液壓鎖緊。 2.3滑動(dòng)導(dǎo)軌的材料和熱處理 2.3.1對(duì)導(dǎo)軌材料的要求 導(dǎo)軌材料應(yīng)具有以下性能： ①良好的耐磨性 在導(dǎo)軌不封閉，動(dòng)導(dǎo)軌頻繁停歇和反向，潤(rùn)滑不良的情況下，導(dǎo)軌面的磨損較快而且不均勻。在潤(rùn)滑劑潔凈，不發(fā)生擦傷的條件下，處于混合摩擦區(qū)段的滑動(dòng)導(dǎo)軌表面出現(xiàn)的磨損可以認(rèn)為是正常磨損，滑動(dòng)導(dǎo)軌材料匹配及其相對(duì)壽命值見(jiàn)表 導(dǎo)軌材料匹配（動(dòng)導(dǎo)軌/靜導(dǎo)軌） 相對(duì)壽命 鑄鐵/鑄鐵（均為普通鑄鐵） 鑄鐵/淬硬鑄鐵 鑄鐵/淬硬鋼 淬硬鑄鐵/淬硬鑄鐵 鑄鐵/鍍鉻或噴涂鉬鑄鐵 1 2~3 〉5~10 4~5 3~4 ②良好的摩擦特性 在設(shè)計(jì)滑動(dòng)導(dǎo)軌時(shí)，為避免在低速運(yùn)動(dòng)時(shí)出現(xiàn)爬行，除合理選用潤(rùn)滑劑及加強(qiáng)船東系統(tǒng)得剛度以外，要求導(dǎo)軌副的靜摩擦和動(dòng)摩擦系數(shù)差以及滑動(dòng)速度對(duì)動(dòng)摩擦系數(shù)的影響都要小。 ③良好的尺寸穩(wěn)定性 導(dǎo)軌在加工和使用過(guò)程中，殘余應(yīng)力引起的變形，溫度和溫度的變化，都會(huì)影響稽核尺寸的穩(wěn)定性。對(duì)于塑料導(dǎo)軌除了材料的線脹系數(shù)大，導(dǎo)熱性差，易吸濕外，還存在冷流性和常溫蠕變性大的問(wèn)題。 ④工藝性好，成本低。 2.3.2常用的滑動(dòng)導(dǎo)軌材料 鑄鐵是應(yīng)用最廣泛的滑動(dòng)導(dǎo)軌材料，它具有良好的耐磨性和抗振性。鑄鐵導(dǎo)軌常與支承部件或支座制成一體。 為增強(qiáng)導(dǎo)軌的抗磨損能力，可將鑄鐵導(dǎo)軌表面淬火，鍍鉻式噴涂相等。 對(duì)于灰鑄鐵HT200或HT300，若采用高頻淬火，淬火前的硬度不應(yīng)低于180HBS，淬火后可取48~55HRC，硬化層厚度1.5~2.5mm，其相對(duì)壽命可提高1~2倍，這種方法工藝設(shè)備簡(jiǎn)單，操作方便，淬火變形小。 對(duì)于鍍鉻鑄鐵（或鋼）/鑄鐵導(dǎo)軌副，其鍍層厚度0.025~0.05mm,硬度為68~72HRC，耐磨性提高2~3倍。 常用鑲裝材料有鋼、有色金屬、合金鑄鐵及工程塑料等。鋼材；又可分為冷軋彈簧鋼帶，經(jīng)高頻淬火的中碳結(jié)構(gòu)鋼、滲碳鋼、氮化鋼、軸承鋼或特殊的工具鋼等。常用的工程塑料有酚醛夾布塑料，聚酰胺（尼龍）和聚四氟乙烯，改性聚甲醛等。 2.4滑動(dòng)導(dǎo)軌的技術(shù)要求 2.4.1表面粗糙度 ①刮研導(dǎo)軌 刮研導(dǎo)軌可以達(dá)到最高的精度，同時(shí)還具有接觸好，變形小，表面可以存油的優(yōu)點(diǎn)。它的缺點(diǎn)是勞動(dòng)強(qiáng)度大，生產(chǎn)率低，刮研導(dǎo)軌主要用于高精度機(jī)床和精密機(jī)械，在缺乏磨削設(shè)備時(shí)，也可用于精密機(jī)床和普通精度機(jī)床。 ②磨削導(dǎo)軌 磨削導(dǎo)軌可以達(dá)到較高的精度和表面粗糙度，生產(chǎn)率高，而且是加工淬硬導(dǎo)軌的唯一方法。 2.4.2幾何精度 ①單條的V形導(dǎo)軌，其幾何精度包括：導(dǎo)軌在垂直面內(nèi)的直線度，導(dǎo)軌在水平面內(nèi)的直線度，打soguibiaomiande扭曲。 單條的平導(dǎo)軌，其幾何精度包括：導(dǎo)軌在縱向的直線度，導(dǎo)軌工作表面的平面度。 ②與同一運(yùn)動(dòng)部件配合的兩條或兩條以上導(dǎo)軌（即導(dǎo)軌的組合），除注明各單導(dǎo)軌的精度外，還應(yīng)注明各導(dǎo)軌之間的平行度，有時(shí)還要注明各導(dǎo)軌之間的平面度（扭曲）。 ③幾個(gè)運(yùn)動(dòng)部件的各導(dǎo)軌組合之間，應(yīng)注明其相互位置精度要求，如平行度或垂直度。 在規(guī)定上述各項(xiàng)精度時(shí)，有時(shí)還要注明其誤差的方向性，例如“只許凸起”、“只許凹下”，“只許向下偏”等。 使用說(shuō)明書(shū) 一、技術(shù)特征 1、用途： 本機(jī)主要用于日用陶瓷盤類制品單線畫線。 2、參數(shù)： 產(chǎn)品規(guī)格：盤類最大直徑——406mm; 生產(chǎn)能力：8——12件/分； 總動(dòng)力消耗：3KW； 最大描線彩帶寬度：6mm; 外型尺寸：1300×1000×1000（高×寬×厚）； 整機(jī)重量：500kg。 二、基本結(jié)構(gòu) 本機(jī)主要有主機(jī)架、工作臺(tái)、施彩輪組件、真空泵、氣動(dòng)系統(tǒng)、電氣部分組成。 三、安裝 將該機(jī)小心的立放在水平地面上，調(diào)整四螺栓，使其保持水平，然后清除防銹物。將壓縮機(jī)放在室外的專門小屋里，將出氣管與主機(jī)進(jìn)氣管接通。用氣管接連真空泵與主機(jī)吸盤，用螺栓壓在機(jī)殼上銅線使其接地，接地銅棒不得低于一米，應(yīng)保證安全。然后用380v電源及零件接到主機(jī)接線柱上。再接上壓縮機(jī)及真空泵電源，接線應(yīng)嚴(yán)格按照電工安全操作規(guī)程進(jìn)行，保證接線牢固、可靠、安全。 四、調(diào)整 將真空泵加足潤(rùn)滑油，再將主機(jī)上的油霧氣及活動(dòng)部位加油，檢查電器等是否安全可靠后，開(kāi)動(dòng)真空泵，空壓機(jī)，觀察其轉(zhuǎn)向是否正確，如不正確應(yīng)立即糾正，然后打開(kāi)氣閥觀察其動(dòng)作的可靠性。 把所需畫線瓷件，如8寸盤等放到吸盤上吸住后，開(kāi)啟氣缸控制按鈕，這時(shí)橫向氣缸將施彩輪推到盤邊，連個(gè)定位滾靠到盤邊，縱向氣缸將畫線輪推靠盤上所要畫線的位置進(jìn)行畫線，線畫至兩三圈后，縱向氣缸將施彩輪頭拉下，橫向氣缸將施彩機(jī)架立回原位，完成畫線過(guò)程。 畫線時(shí)如果發(fā)現(xiàn)線條有一定缺陷，應(yīng)考慮以下調(diào)整措施： ①畫線輪與盤所畫線位置的線速度是否保持一致，用速度表測(cè)量畫線輪速度，然后測(cè)量速度，再測(cè)量盤所畫線位置速度是否如同畫線輪一樣線速度。 ②調(diào)整顏色黏度，直至達(dá)到理想線條。 ③調(diào)整時(shí)間繼電器適當(dāng)增減畫線圈數(shù)。 ④調(diào)整畫線輪傳動(dòng)電機(jī)的速度，達(dá)到理想為止。 ⑤對(duì)于生產(chǎn)能力在5寸以下的盤類每分鐘8-12件為好，5寸以上盤類一般在每分鐘6-10件為好。 畫線輪用完后，連同釉盒應(yīng)一同卸下清洗干凈，并放到煤油中浸泡到下次使用為止。 五、日常操作及維護(hù) 1、本機(jī)開(kāi)動(dòng)前應(yīng)檢查電器的安全性，是否有可靠的接地措施。傳動(dòng)部件，真空泵，空氣壓縮機(jī)及動(dòng)作磨損部位是否已加足潤(rùn)滑油，所有調(diào)整部位是否緊固好。 2、所有潤(rùn)滑部位應(yīng)每班注油一次。 3、施彩頭，畫線輪、刮油器應(yīng)每班清洗干凈，如果不用，應(yīng)放到煤油里浸泡。 4、所有部位應(yīng)保持清潔。長(zhǎng)期停用應(yīng)防止銹蝕。 標(biāo)準(zhǔn)化審查報(bào)告： 1、畫線機(jī)應(yīng)具備有關(guān)技術(shù)未見(jiàn)所規(guī)定的結(jié)構(gòu)和使用性能，滿足 用戶的要求。 2、畫線機(jī)各部位應(yīng)靈活可靠。 3、畫線機(jī)各氣動(dòng)密封可靠，在規(guī)定的進(jìn)氣壓力范圍內(nèi)，各氣缸不得有漏氣現(xiàn)象。 4、畫線機(jī)畫線輪在正常運(yùn)轉(zhuǎn)情況下，其外圓跳動(dòng)不得超過(guò)0.10mm，其兩側(cè)跳動(dòng)不得超過(guò)0.15毫米。 5、畫線機(jī)真空系統(tǒng)應(yīng)可靠，陶瓷制品被吸住后不得有松動(dòng)現(xiàn)象，去除真空后，制品應(yīng)立即去下。 6、畫線機(jī)外購(gòu)件應(yīng)符合現(xiàn)行有關(guān)標(biāo)準(zhǔn)的要求，并具有合格證明書(shū)。 7、畫線機(jī)影響人身安全的部位應(yīng)設(shè)置相應(yīng)得保安設(shè)備。 8、畫線機(jī)電器應(yīng)安全可靠，畫線機(jī)外殼硬又可靠的接地措施。 9、畫線機(jī)工作時(shí)不應(yīng)有不正常聲響，噪聲聲壓級(jí)不得超過(guò)80dB(A)。 10、畫線機(jī)在正常運(yùn)轉(zhuǎn)情況下中修前運(yùn)轉(zhuǎn)時(shí)間不得少于2000小時(shí)，大修前運(yùn)轉(zhuǎn)時(shí)間不得少于4000小時(shí)，使用壽命不得少于十年。 11、畫線機(jī)的鑄鋁件，應(yīng)符合GB1173的規(guī)定。 12、機(jī)械加工件應(yīng)符合GB342.5-6標(biāo)準(zhǔn)的規(guī)定。 13、畫線機(jī)施彩頭及擺動(dòng)支架等鑄件上的澆口、冒口、飛邊、多肉、結(jié)疤、粘沙、結(jié)沙等應(yīng)清除平整。 14、畫線機(jī)表面不應(yīng)有圖樣未規(guī)定的凸凹和粗糙不平等缺陷，外漏加工表面不允許有磕碰，擦痕等損傷。 15、畫線機(jī)油漆應(yīng)符合QB842.7標(biāo)準(zhǔn)的規(guī)定。 帶傳動(dòng)的設(shè)計(jì)計(jì)算 1、確定設(shè)計(jì)功率 2、選擇帶型 根據(jù)及小帶輪轉(zhuǎn)速（取為2000rmp）,選擇Z型V帶。 3、確定帶輪基準(zhǔn)直徑 取主動(dòng)輪基準(zhǔn)直徑并驗(yàn)算帶速 4、確定中心矩和帶長(zhǎng) 5、驗(yàn)算小帶輪包角 6、確定帶的根數(shù)Z 7、確定初拉力 8、計(jì)算壓軸力Q 復(fù)位彈簧優(yōu)化設(shè)計(jì) 1、一直條件： 安裝高度安裝載荷最大工作載荷工作行程h=30.25mm，彈簧的工作頻率彈簧絲用油淬回火的50鋼絲，進(jìn)行噴丸處理；工作溫度為20°C。 要求彈簧中徑為15mm<<20mm,彈簧總?cè)?shù)為4<<50支撐圈數(shù)=1.75；旋繞比C>6;安全系數(shù)為1.2；設(shè)計(jì)一個(gè)具有重量最輕的彈簧結(jié)構(gòu)方案。 2、性能參數(shù) 初選彈簧鋼絲直徑3mm＜d≤8mm,對(duì)應(yīng)得抗拉強(qiáng)度可知其脈動(dòng)循環(huán)疲勞極限為 取可靠度為90%，則查得可靠性系數(shù)。溫度修正系數(shù)： 。 再考慮噴丸處理，按提高疲勞強(qiáng)度10%計(jì)算，得實(shí)際應(yīng)用脈動(dòng)循環(huán)疲勞極限為： 彈簧平均載荷和載荷幅為 要求彈簧具有的剛度為 彈簧的最大形變?yōu)? 3、設(shè)計(jì)變量 取彈簧鋼絲直徑、彈簧中徑和彈簧總?cè)?shù)為設(shè)計(jì)變量，即 并作為連續(xù)變量考慮。 目標(biāo)函數(shù)為彈簧的重量： 4、約束條件 根據(jù)對(duì)彈簧功能和結(jié)構(gòu)的要求，可列出下列約束方程： ①由公式得疲勞強(qiáng)度的約束 ②根據(jù)旋繞比的要求，得約束 ③根據(jù)對(duì)彈簧中徑尺寸的要求，得約束 ④根據(jù)穩(wěn)定性條件，得約束 ⑤為保證彈簧具有足夠的剛度，要求彈簧的剛度與設(shè)計(jì)要求的剛度誤差小于1/100，由此得約束 ADAMS 1.1虛擬樣機(jī)技術(shù)的研究范圍 機(jī)械工程中的虛擬樣機(jī)技術(shù)有被稱為機(jī)械系統(tǒng)動(dòng)態(tài)仿真技術(shù)，是國(guó)際上20世紀(jì)80年代隨著計(jì)算機(jī)技術(shù)的發(fā)展而迅速發(fā)展起來(lái)的一項(xiàng)計(jì)算機(jī)輔助工程（CAE）技術(shù)。工程師在計(jì)算機(jī)上建立樣機(jī)模型，為模型進(jìn)行各種動(dòng)態(tài)性能分析，然后蓋緊樣機(jī)設(shè)計(jì)方案，用數(shù)字化形式代替?zhèn)鹘y(tǒng)的實(shí)物樣機(jī)試驗(yàn)。運(yùn)用虛擬樣機(jī)技術(shù)，可以大大簡(jiǎn)化機(jī)械產(chǎn)品的設(shè)計(jì)開(kāi)發(fā)過(guò)程，大幅度縮短產(chǎn)品的開(kāi)發(fā)周期，大量減少產(chǎn)品開(kāi)發(fā)費(fèi)用和成本，明顯提高產(chǎn)品質(zhì)量，提高產(chǎn)品的系統(tǒng)及性能，獲得最優(yōu)化的創(chuàng)新的設(shè)計(jì)產(chǎn)品。因此，該技術(shù)一出現(xiàn)，立即受到了工業(yè)發(fā)達(dá)國(guó)家、有關(guān)科研機(jī)構(gòu)和大學(xué)、公司的極大重視，許多著名制造廠商紛紛將虛擬樣機(jī)技術(shù)引入各自的產(chǎn)品開(kāi)發(fā)中，取得了很好的經(jīng)濟(jì)效益。 虛擬樣機(jī)技術(shù)的研究范圍主要是機(jī)械系統(tǒng)運(yùn)動(dòng)學(xué)和動(dòng)力學(xué)分析，其核心是利用計(jì)算機(jī)輔助分析技術(shù)進(jìn)行機(jī)械系統(tǒng)得運(yùn)動(dòng)學(xué)和動(dòng)力學(xué)分析，以確定系及其各構(gòu)件在任意時(shí)刻的位置、速度、和加速度，同時(shí)，通過(guò)求解袋鼠方程組去頂一起系統(tǒng)計(jì)其各構(gòu)件運(yùn)動(dòng)所需的作用力及其反作用力。 機(jī)械系統(tǒng)動(dòng)力學(xué)自動(dòng)分析軟件ADAMS（Autoumatic Dynamic Analysis Mechanical Systems）是美國(guó)MDI公司（Mechanical Dynamics Inc）開(kāi)發(fā)的非常著名的虛擬樣機(jī)分析軟件。 參考文獻(xiàn) ［1］瓷器、精瓷與彩瓷 劉達(dá)權(quán) 北京：輕工業(yè)出版社，1984 ［2］新型陶瓷 邱關(guān)明 北京：兵器工業(yè)出版社，1993.3 ［3］設(shè)計(jì)材料與加工工藝 張錫 北京：化學(xué)工業(yè)出版社，2004.8 ［4］陶瓷造型基礎(chǔ) 楊永善 北京：輕工業(yè)出版社，1985 ［5］日用陶瓷工業(yè)學(xué) 李家駒 武漢：武漢工業(yè)大學(xué)出版社，1992 ［6］高性能陶瓷論文集 郭景坤 北京：人民交通出版社，1998.5 ［7］機(jī)械系統(tǒng)設(shè)計(jì) 朱龍根 北京：機(jī)械工業(yè)出版社，2001.8 ［8］非標(biāo)準(zhǔn)設(shè)備機(jī)械手冊(cè) 張展 北京：兵器工業(yè)出版社 ［9］中國(guó)機(jī)電產(chǎn)品大辭典 北京：機(jī)械工業(yè)出版社 ［10］現(xiàn)代綜合機(jī)械設(shè)計(jì)手冊(cè)（下） 北京出版社 ［11］機(jī)械設(shè)計(jì) 譚慶昌，趙洪志 吉林科學(xué)技術(shù)出版社 ［12］材料力學(xué) 聶毓琴，孟廣偉 吉林科學(xué)技術(shù)出版社 ［13］機(jī)械制造技術(shù)基礎(chǔ) 于駿一，張福潤(rùn) 機(jī)械工業(yè)出版社 ［14］機(jī)械原理 秦榮榮，崔可維 吉林科學(xué)技術(shù)出版社 400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2002-01-1691 Developing Next Generation Axle Fluids: Part I – Test Methodology to Measure Durability and Temperature Reduction Properties of Axle Gear Oils Edward S. Akucewich, James N. Vinci, Farrukh S. Qureshi and Robert W. Cain The Lubrizol Corporation International Spring Fuels & Lubricants Meeting & Exhibition Reno, Nevada May 6-9, 2002 The appearance of this ISSN code at the bottom of this page indicates SAE’s consent that copies of the paper may be made for personal or internal use of specific clients. This consent is given on the condition, however, that the copier pay a per article copy fee through the Copyright Clearance Center, Inc. Operations Center, 222 Rosewood Drive, Danvers, MA 01923 for copying beyond that permitted by Sections 107 or 108 of the U.S. Copyright Law. This consent does not extend to other kinds of copying such as copying for general distribution, for advertising or promotional purposes, for creating new collective works, or for resale. Quantity reprint rates can be obtained from the Customer Sales and Satisfaction Department. To request permission to reprint a technical paper or permission to use copyrighted SAE publications in other works, contact the SAE Publications Group. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher. ISSN 0148-7191 Copyright ? 2002 Society of Automotive Engineers, Inc. Positions and opinions advanced in this paper are those of the author(s) and not necessarily those of SAE. The author is solely responsible for the content of the paper. A process is available by which discussions will be printed with the paper if it is published in SAE Transactions. For permission to publish this paper in full or in part, contact the SAE Publications Group. Persons wishing to submit papers to be considered for presentation or publication through SAE should send the manuscript or a 300 word abstract of a proposed manuscript to: Secretary, Engineering Meetings Board, SAE. Printed in USA All SAE papers, standards, and selected books are abstracted and indexed in the Global Mobility Database ABSTRACT Light trucks and sport utility vehicles (SUVs) have become extremely popular in the United States in recent years, but this shift to larger passenger vehicles has placed new demands upon the gear lubricant. The key challenge facing vehicle manufacturers in North America is meeting government-mandated fuel economy requirements while maintaining durability. Gear oils must provide long-term durability and operating temperature control in order to increase equipment life under severe conditions while maintaining fuel efficiency. This paper describes the development of a full-scale light duty axle test that simulates a variety of different driving conditions that can be used to measure temperature reduction properties of gear oil formulations. The work presented here outlines a test methodology that allows gear oil formulations to be compared with each other while accounting for axle changes due to wear and conditioning during testing. Results are shown from a variety of different axle configurations and loading conditions. This test method shows the importance of accounting for changes in the axle when comparing test results whenever severe conditions are experienced. INTRODUCTION Within the last few years, there has been a renewed desire to make fuel economy improvements in North America’s light trucks and sport utility vehicles (SUV’s). Vehicle manufacturers have set aggressive fuel efficiency improvement objectives for these vehicles. Because of this, gear lubricants have been targeted to contribute fuel economy improvements over the current products used in these applications. This is not as easy as it may seem. In addition to acceptable fuel economy, gear lubricants are required to protect axle components under a variety of stressed conditions. These include high speed scuffing, low speed, high torque wear, corrosion and oxidation. In light truck and racing applications, gear oils must provide long-term durability and operating temperature control under extreme conditions, such as trailer towing or extended high speed applications. Higher operating temperatures for prolonged periods can adversely affect metallurgical properties and reduce fluid film thickness, both of which can lead to premature equipment failures. In our view, operating temperature is an important indicator of durability. While fuel economy is now the driving force in next generation lubricant development, it is clearly recognized that any improvements in fuel economy must not be at the expense of axle durability or performance. Fuel economy improvements can be measured via the U.S. EPA 55/45 driving cycles(1). Automotive manufacturers use this test to certify a vehicle’s fuel economy. This test can also be used to show fuel economy improvements in gear oil lubricants. Many manufacturers feel that stabilized operating temperature under the proper controlled conditions is an important indicator of the durability performance of a lubricant under severe conditions. In the case of operating temperature assessment, there exists no standard test method or methodology. Typically, when applied in a laboratory test stand a single axle is broken-in and then used repeatedly to evaluate many lubricants. Under severe conditions, the stabilized operating temperatures for a given reference oil decreases each time it is run in an axle. As the number of test runs on an axle increases the stabilized operating temperature of the reference oil is lower. This poses a problem when evaluating candidate lubricants. With a changing target, how can a lubricant be accurately evaluated? This paper describes a laboratory test method that accounts for test-to-test changes in the axle and gives the lubricant formulator an accurate way of comparing test results. In addition, common pitfalls of this method and operating guidelines will be described. 2002-01-1691 Developing Next Generation Axle Fluids: Part I – Test Methodology to Measure Durability and Temperature Reduction Properties of Axle Gear Oils Edward S. Akucewich, James N. Vinci, Farrukh S. Qureshi and Robert W. Cain The Lubrizol Corporation Copyright ? 2002 Society of Automotive Engineers, Inc. 2 The remainder of this paper is divided into four parts. First, the test stand used to develop and utilize the test procedure is described. Second, the test methodology is discussed in detail. The third section focuses on presenting test results that demonstrate the usefulness of the test methodology. Finally, the last section summarizes the paper’s findings and offers some conclusions. PART 1 - AXLE TEST STAND CONFIGURATION This full-scale axle dynamometer test stand was designed and set up to simulate a variety of operating conditions. A schematic of the test stand is shown in Figure 1. This figure illustrates the axle rig and its major components. Figure 2 shows a picture of the test stand. Figure 1: Schematic of Axle Test Stand Input torque Output Torque Meter (2) Output Torque Meter (1) Box shroud + fan (optional) ENGINE: V8 GASOLINE DynamometerDynamometer Speed Increaser Speed Increaser 3 Figure 2: Photograph of Test Stand STAND CONFIGURATION - Power is supplied to the axle by a gasoline fueled 7.4 liter V8 engine through a heavy duty 4-speed automatic transmission that can be automatically shifted by the data acquisition and control (DAC) system. The axle used for lubricant evaluation is rigidly mounted to the stand. The power driven through the axle is absorbed by two air gap eddy current dynamometers. A speed increaser is placed between the axle wheel end and the dynamometer to boost output speed to the dynamometer for low speed applications. The stand used is flexible and with a quick change of torque meters and/or axle fixtures is able to accommodate a wide range of axle sizes, from small passenger vehicle axles to large on highway truck axles. TORQUE METERS - A single in-line torque meter integral to the drive shaft measures the input pinion torque to the axle. Two in-line torque meters measure the output torque from the axle to the dynamometers. One output torque meter has been placed between each axle wheel end and speed increaser. In addition, the torque meters used are the enhanced accuracy, DC operated models. This was done to increase and maintain a high degree of accuracy and repeatability. These torque meters are periodically dead weight calibrated to insure accurate torque measurements. AXLE COOLING AND TEMPERATURE MONITORING - Behind the axle a fan is positioned to provide airflow across the axle. This was done to simulate the actual airflow cooling experienced in field tests. The fan speed, size and position were selected to produce temperatures in the axle which match field test data for the axle being tested. In addition, two water spray nozzles are positioned around the axle. These spray nozzles are used for two purposes. First, they are used to control the lubricant temperature during axle break-in. Second, they provide protection against high axle lubricant temperatures. Depending upon the lubricant under evaluation, this test procedure has the potential of experiencing very high axle lubricant 4 temperatures. To protect the axle, high temperature limits have been put in place for each test stage. Another major concern is the measurement of the ambient air and axle lubricant temperatures. Thus, care was taken to properly position the thermocouples. The axle lubricant temperature is measured by a thermocouple positioned directly next to the axle ring gear. The thermocouple is held in place by a specially modified axle cover. The ambient air temperature is measured by placing a thermocouple in the air stream produced by the fan. Both thermocouples are periodically calibrated to insure accurate temperature measurements. DATA ACQUISITION AND CONTROL SYSTEM - A DSP Redline ADAPT / MRTP system is used to control the operation of the stand and to acquire data throughout the test. In addition to the ambient and lubricant temperatures, this system monitors and records additional temperatures (engine oil, transmission oil, dyno, gear box, fuel, and coolant), torques (input and two outputs), speeds (engine, pinion, axle shafts, and dynos) and axle efficiency (ratio of output torque to input torque) throughout the test. Data is logged periodically. This system controls the operation of the stand with five control loops. ? Two control loops are used to maintain the desired pinion speed. This is done by modulating each dynamometer current to achieve a desired pinion rpm. ? The load on the pinion is maintained by adjusting the engine throttle. ? A fourth control loop is used to control the axle lubricant temperature during axle break in and to prevent high temperatures from damaging the axle during lubricant evaluations. ? Finally, a fifth control loop is used to insure that the automatic transmission is running each test stage in the appropriate gear. It is important that the automatic transmission is operating in the proper gear. Some of the test stages during this test run at relatively high loads. Premature failure will occur if the transmission does not operate in the appropriate gear for a given test stage. PART 2 - TEST METHOD In general, the evaluation of the lubricant’s durability was assessed by determining its stabilized operating temperature and axle efficiency at a number of discrete speed / torque conditions. The test procedure used is described below. REFERENCE OILS - Reference oils are critical to this test methodology. For the development of this test procedure and evaluation of lubricants, two reference oils were used. The fluids used as reference oils are as follows: Good Reference: Synthetic SAE 75W-140 Poor Reference: Synthetic SAE 75W-90 The good reference has been shown to provide outstanding performance in a wide variety of severe service applications. This fluid provided excellent temperature reduction in a controlled severe duty field test. This reference oil is used to break-in the axle and is periodically tested on a given axle to track any changes that might occur in stabilized operating temperatures. The poor reference was also field tested and did not provide the same level of durability or temperature reduction in severe conditions as the good reference. Testing has shown however that this lubricant provides measurable fuel economy benefits. This reference oil is used to verify that the test procedure can distinguish between oils that provide different levels of performance in the field. AXLE BREAK-IN - Before an axle can be used for lubricant evaluation, a break-in procedure is run. This procedure consists of a series of controlled load and speed conditions. The axle lubricant temperature is controlled throughout the break-in procedure where it is not allowed to exceed 250°F (121°C). The good reference oil is used for the break-in procedure. Running an adequate break-in is critical in preparing the axle for accurate lubricant evaluations. Once broken in an axle can run multiple candidate lubricant evaluations. TEST STAGES - Following the break-in procedure, candidate lubricants are evaluated by determining the stabilized operating temperature and efficiency at five combinations of speed and loads (stages) to approximate different severe operating conditions. Table 1 outlines the test conditions used. 5 Table 1 Durability and Operating Temperature Test Conditions STAGE GENERAL CONDITION CORRELATION I High torque / low speed Heavy Load - Start-Up II Moderate torque / high speed High Speed - Flat Surface III Moderate torque / moderate-high speed Heavy Load - Flat Surface IV Moderate-high torque / moderate speed Heavy Load - Moderate Grade V High Torque / low-moderate speed Heavy Load - Steep Grade Each of the load stages is run until a stabilized lubricant temperature is achieved. This typically takes 1.5 to 2.5 hours. Once a stabilized temperature is reached, the next test stage is started. This cycle is repeated until all test stages have been evaluated. At the completion of each test stage, the ambient air temperature, stabilized lubricant temperature and stabilized axle efficiency is recorded(2). AMBIENT AIR TEMPERATURE ADJUSTMENTS - It has been observed that changes in ambient air temperature affect the stabilized operating temperature of the axle lubricant. Since this test method was run in a laboratory where the ambient air temperature may vary, changes in ambient air temperatures must be accounted for. Adjusting the axle lubricant temperature to account for ambient air temperature changes is done by normalizing the axle lubricant temperature relative to an ambient air temperature of 80°F with the following equation: Tcorrected = Taxle + (80°F – Tambient) Where, Tcorrected = lubricant temperature (°F) corrected for the ambient air temperature. Taxle = measured lubricant temperature (°F). Tambient = measured ambient air temperature (°F). Before applying any of the methodology described below, the axle lubricant temperature is adjusted to account for ambient air temperature differences. REFERENCE TEMPERATURE CHANGES - As the number of tests run on an axle increases, the stabilized operating temperature for a given load condition of any single oil is lower. This fact poses a problem when evaluating a candidate lubricant. To solve this problem in the past, reference oil is tested periodically and the candidate result is compared to the last reference test result. However, if the reference test temperature gets lower after each test run, comparing the candidate to the last reference result will make the candidate seem better than it actually is relative to the reference. Figure 3 shows the change in stabilized operating temperatures for stage V conditions on a test axle when the good reference oil is tested. The stabilized operating temperature goes down as the number of test runs on the axle increases. For this test procedure, this trend occurs on all 5 test stages. 6 Figure 3: Stabilized Operating Temperature For the Good Reference Oil Over the Life of a Test Axle Under Stage V Conditions REFERENCE TARGET TEMPERATURE - To make a fair comparison between a reference and a candidate, the reference oil’s stabilized operating temperature used for comparison should be adjusted for the number of runs made on the axle. This adjustment must be done for each test stage and lubricant evaluated on an axle. The adjusted reference oil temperature or “reference target temperature” can then be compared to the candidate oil’s stabilized operating temperature for the load stage in question. Based on the reference test data, an equation for each test stage can be generated taking into account the reduction in the reference stabilized operating temperature as the number of test runs increases on an axle. This must be done for each axle tested. Once generated, candidate results can be accurately compared to reference oil performance. Figure 4 shows a curve fitted to the stabilized operating temperatures of the good reference oil for Stage V test conditions. Stabilized Axle Temperature Good Reference Oil Stage V Conditions 180 200 220 240 260 280 Increased Axle Runs Corrected Temperature (Deg F) 7 Figure 4: Curve Fitted To Stabilized Operating Temperature Results for Good Reference Oil on a Test Axle Under Stage V Conditions From the equation developed in Figure 4, a reference target temperature can be calculated for each test run on the axle for each test stage. Candidate test results can now be accurately compared to reference test results. In addition, this method allows the formulator to more accurately compare results that were tested on different axles since your comparison is relative to the reference oil. AXLE EFFICIENCY CHANGES - Just as with the stabilized temperature, a similar effect occurs with the axle efficiency measurements on test axles. The axle efficiency gradually increases as the number of tests on an axle increases. Figure 5 shows the changes in the axle efficiency and the reference target efficiency equation developed from the test results. Stabilized Axle Temperature Good Reference Oil Stage V Conditions y = 0.0172x2 - 1.4508x + 237.02 R2 = 0.9302 200 210 220 230 240 250 260 Increased Axle Runs Corrected Temperature (Deg F) 8 Figure 5: Stabilized Axle Efficiency Values For the Good Reference Oil Over Life of a Test Axle Under Stage II Conditions It has been our experience with this test procedure that the stabilized axle efficiency for any test stage is inversely proportional to the stabilized operating temperature. The higher the efficiency, the lower the operating temperature. Thus our primary focus in the paper is on the operating temperatures and not the axle efficiencies. The test methodology described in this paper can be applied to both. ASSESSMENT OF TEST REPEATABILITY - Test repeatability can be estimated from the reference test results on each axle. This is done by comparing the differences between the actual stabilized operating temperature and the calculated reference target temperature for each reference test in an axle for a given test stage. For example, the test repeatability was calculated to be 5.9°F for Stage V conditions shown in Figure 4. Our experience has been that repeatability estimates range from 0.5 to 8.0° F depending upon the test stage run, axle used and lubricants tested.(3, 4) The test repeatability on any given axle is greatly affected by the quality of the candidate oils tested. Running a poor quality oil affects the results of the tests that run on the axle after it finishes. This introduces additional variability in the test stand. Thus it is important to run go