INTRODUCTION The JMY31.5A hydraulic riveting machine is a riveting machine that replaces the traditional pneumatic riveting machine. It uses hydraulic and electrical control technology, which combines hydraulic, electrical control and mechanical manufacturing.
Compared with the pneumatic riveting machine, the riveting force is large, the riveting work is high, the vibration is small, the noise is low, and the riveting is safe and reliable. The riveting design has a maximum riveting pressure of KN, and can be used for various industries with riveted structures, such as automobiles, ships, boilers, bridges, buildings, etc., with various steel rivets for cold riveting 13mm and hot riveting 23mm.
1 Hydraulic riveting machine structure The hydraulic riveting machine structure is shown in Figure 1. The hydraulic riveting machine consists of ten parts: fuel tank components, electrical control box components, motor components, hydraulic generator components, rivet components, cylinder components, suspension components, moving trolley components and rail components.
1. Fuel tank 2. Electrical box 3. Electric motor 4. Hydraulic generator 5. Riveting pliers 6. Cylinder 7. Oil pipe 8. Suspension device 9. Car 10. Wire 2 Hydraulic riveting machine Main design technical parameters Fuel tank volume: 0.4 Rivet material : 16Mn nominal rivet pressure: kN hydraulic pump pressure: 6.3MPa hydraulic pressure ratio: 1:5 riveting stroke times: 15 ~ 20 times / min system maximum pressure: 31.5MPa rivet maximum diameter: cold rivet 13 ┨ hot riveting 20 ┨ riveting The working process is required to be safe and reliable, and the riveting action can be jogged, single stroke automatic, continuous automatic.
3 hydraulic riveting machine hydraulic system principle Hydraulic riveting machine hydraulic principle shown in Figure 2.
1. Oil pump 3. Pressure gauge switch 5. Working cylinder 7. Pressure relay 9. Pressure gauge switch 11. Pressurized cylinder 13. Solenoid valve 15. Oil filter 17. Fuel tank 2. Electric motor 4. Pressure gauge 6. Pressure relay 8 Pressure gauge 10. Hydraulic control check valve 12. Solenoid valve 14. Relief valve 16. Air filter From the hydraulic schematic, it can be seen that the hydraulic system has the following characteristics: (1) The selection of the more popular price, hydraulic The medium pressure vane pump with small liquid pulsation is a hydraulic power source.
(2) The three-position four-way has a H-type neutral function solenoid valve to realize the reversal of the liquid flow and the unloading of the pump.
(3) The two-position four-way solenoid valve is used to control the booster cylinder to realize the hydraulic pressure boost of the system to meet the high pressure requirements of the working cylinder.
(4) A medium voltage pressure relay SP 1 is selected to control the fast forward and work forward conversion of the working cycle, and a high pressure pressure relay SP controls the work advance and rewind conversion of the working cycle. The pressure relay SP is converted into a pressure signal by the system to control the two time relays in the circuit system, thereby achieving the purpose of controlling the commutation time of the solenoid valve, thus controlling the fast-moving, working forward and retreating of the working cylinder. The required time can realize the jog of the work cycle, the single stroke automatic, and the continuous automatic control.
4 Hydraulic riveting machine oil pump and motor selection According to the design requirements, the riveting power cylinder needs to have the maximum working pressure = 31.5MPa. The pump pump model is YB A16B FL, its rated pressure is 6.3MPa, displacement q = 26mL / r. The pressure cylinder is 1:5 supercharged, and the working pressure can be realized. The motor is driven by the elastic coupling. The motor speed is n=1440r/min. The selection of the motor is calculated by the matching power between the motor and the oil pump: Sun Kunlong, male, August 1938 Sheng, currently a professor at the School of Mechanical and Electronic Engineering of Nanjing Forestry University.
Always choose model Y vertical four-stage motor N = 5.5kW, design and manufacture of main components of 5 hydraulic riveting machine (1) Design and manufacture of hydraulic riveting machine power cylinder and bow arm Hydraulic riveting machine Power cylinder and bow arm structure image 3.
1 hydraulic riveting machine power cylinder design. In the general hydraulic cylinder design, the cylinder tube adopts a double-end cover structure. The design of the high-pressure chamber is made into a monolithic structure, and the low-pressure chamber adopts an end cap structure, which increases the complexity of the cylinder processing, but fundamentally solves the serious leakage problem of the high-pressure cylinder in use, and prevents the end cover from being impacted. The hazard of the accident. In 1.Yx sealing ring 2. Compression nut 3. Handle 4. Pipe joint 5. Cylinder 6. Piston 7. Pressure ring 8. V-type seal 9. Fixing nut 10. Cylinder head 11. Piston rod 12. Riveting Die 13. Lower rivet die 14. Bow arm 15. The lower end of the fastening nut cylinder is designed with a knurled handle that can be held by the operator. The hollow part of the handle is mounted to control the riveted electrical control button for automatic control.
2 Hydraulic rivet machine power cylinder wall thickness calculation. Because the power cylinder is subjected to high pressure, a thick-walled cylinder is required. Therefore, its strength calculation requires calculation formula of thick-walled cylinder strength. The calculation formula is as follows: where: t—cylinder wall thickness p—cylinder working pressure, take pψ― Strength factor, take ψ = 1 (when it is a seamless steel pipe).
The parameters are substituted into the formula to obtain the outer diameter of the cylinder, and the wall thickness of the cylinder is t=12.5mm, and the outer diameter of the cylinder D3 is hydraulically riveted. The power cylinder is a high-pressure cylinder, and the seal design of the high-pressure cylinder is extremely important. In the design, the piston and the cylinder tube adopt two Yx polyurethane wear-resistant seal rings, and the piston rod and the end cover hole adopt a V-shaped seal ring, in order to improve the sealing effect, the addition is increased. Sealing factor, and the design of the adjustable sealing ring elastic nut device, the connection of the cylinder into and out of the oil pipe, the use of tapered thread plus combination seal. After adopting the above sealing measures, the produced power cylinder basically does not leak during the 40MPa withstand voltage test, and meets the design requirements.
4 Hydraulic riveting machine piston rod selection and strength calculation. Usually in the design of heavy-duty high-pressure cylinders, 40CrNiM alloy steel is recommended for piston rod materials. Considering that the material is expensive and the heat treatment process is complicated, the design uses 40Cr steel, after quenching and tempering treatment, the surface is high-frequency fire and hard chrome-plated after finishing, which can meet the design and production requirements and save valuable materials. Reduced production costs.
The formula for calculating the strength of the piston rod is as follows: where: d—piston rod diameter F—squeezing force, taking F [σ]—material allowable stress, taking [σ] = design considering rigidity and dimensional standard, taking d = 50mm.
2 hydraulic riveting machine bow arm manufacturing. The hydraulic rivet machine bow arm requires the use of integral free forging, so that the metal fiber does not break, and the gas cutting forming process is not allowed, thus ensuring the strength and rigidity of the bow arm, thereby meeting the design requirements of the production. After machining, tighten with a double nut and cylinder. In order to make the structure compact, the operation and maintenance are convenient, and the rivet forming riveting is designed to be replaceable.
(2) Design and manufacture of hydraulic riveting machine integrated block and booster cylinder The structure of hydraulic riveting machine integrated block and booster cylinder is shown in Figure 4.
1. Integrated block type 2.0 sealing ring 3. Sealing gear Figure 4. Spring washer 5. Hexagon screw 6. Piston rod 7. Booster cylinder 8.0 type sealing ring 9. Sealing pad 10. Hexagon screw 1 Hydraulic riveting machine integrated block design And manufacturing. The hydraulic riveting machine adopts a plate type control valve and connects the valves with an integrated block. Because this machine is a special hydraulic equipment, the hydraulic pressure of some oil passages reaches 31.5MPa, it is difficult to select standard integrated blocks and superimposed valves. Therefore, the integral integrated blocks are designed according to the schematic diagram, and 48 oil passages are distributed on each surface of the rectangular parallelepiped block. The holes are respectively connected with the pump, the output input oil pipe, the pressure gauge and the valves, the process hole is blocked by the blockage and the combined sealing block, and the middle block of the integrated block is made into the high pressure small cylinder of the boosting cylinder. Instead of adopting a design in which the control valve is generally installed on the three sides of the manifold and the inlet and outlet pipes are connected to the other side, the inlet and outlet pipes are arranged in the lower part of the manifold, and the equations can be obtained by using the conditions and boundary conditions of the second derivative. formula.
(3) Simulation graphics and simulation results It should be noted here that the simulation maps used here are relatively dimensionless coordinates. The simulation object used in this paper is: the fourth type of composite gear pump sample of the displacement gear. Its main parameter is the debugging passed on the integrated debugger. The program is mainly composed of three sub-programs: one completes the calculation of the coordinate block diagram to complete the calculation of the theoretical flow, and draws the simulation curve to complete the calculation of the transient flow, and draws the simulation curve. as shown in picture 2.
Pump Dimensional Flow Characteristic Curve 4 Conclusion The simulation simulation results show that the flow characteristics are in line with the results derived previously.
And the uniformity of the composite gear pump flow is significantly better than the general gear pump. As to whether the flow characteristic curve of the actual sample is consistent with the theoretical derivation, it needs to be tested by further testing of the sample. Only theoretical discussion and simulation are made here.
1 Fan Minghao? Basic theoretical research on balanced compound gear pump? Master's thesis of Huainan Institute of Technology, 1999.6 2 Zhao Lianchun, Xu Xianliang, etc.? Theoretical research on compound gear pumps? Mechanical Engineering 3 Zhao Lianchun, Yang Qingwen, etc.? What is the effect of gear displacement on the flow characteristics of the second type of compound gear pump? Journal of Chongqing University, 1999 (3): pp1~5 4 Wang Qiangru, Li Lanyou? C language drawing and computer simulation technology? Beijing: Beijing University of Aeronautics and Astronautics Press, 1995.8 5 Xu Shiliang? C language commonly used algorithm assembly? Beijing: Tsinghua University Press, the output and return pipes are placed on the top of the manifold, and the design of each control valve is arranged on all four sides of the manifold. This design can make the structure compact, reduce the leakage of high-pressure oil, and the appearance of the whole machine is also beautiful, which brings convenience for maintenance and installation. The integrated block is the key component of the machine. The design is made of 40Cr steel forging roughing and then refined and refined. The machining of the integrated block cavity and 48 oil passages is the key to ensure the quality of the riveting machine. It must be carefully crafted. The tunnel must be cleaned repeatedly and subjected to a pressure test after processing.
2 hydraulic riveting machine booster cylinder design. When the hydraulic riveting machine is riveted, it needs to be pressurized to 31.5 MPa. When the pressure ratio is 1:5, it can meet the pressure requirements. Through calculation and simplifying manufacturing, the diameter D of the large cylinder of the booster cylinder is taken as mm, and the diameter d of the small cylinder is 50mm. The design of the riveting machine is considered to be compact, and the high pressure small cylinder of the boosting cylinder is designed in the middle of the integrated block, and the low pressure large cylinder is separate. The design adopts a separate structure and is connected with a spring and a spring pad to form a whole body, which is convenient for installation and maintenance.
Boost ratio calculation: boost ratio i = where: p - vane pump rated pressure, p D - boost cylinder large cylinder diameter, D = mm d - boost cylinder diameter diameter, d = 50mm - boost cylinder efficiency, The η is the boost ratio. It is known by calculation that the boost ratio meets the design requirements.
The hydraulic riveting machine is equipped with a two-stage O-ring seal with a single-sided retaining ring and a two-way O-ring seal for the low-pressure chamber. The sealing effect is better after practice.
6 Conclusion JMY31.5A hydraulic riveting machine has passed the scientific and technical product appraisal organized by Jiangsu Science and Technology Commission. Experts believe that compared with the pneumatic riveting machine, the hydraulic riveting machine has a large riveting force, and the riveting efficiency can be increased by more than ten. The utility model has the advantages of low noise, obviously improving the working condition and improving the work safety. Compared with the existing riveting equipment in the country, the pressure is high, the hydraulic temperature rise is low, the electrical control device is simple and reliable, the shape is well-proportioned, and the structure is arranged reasonably. The economic and social benefits are remarkable and have reached the domestic advanced level. The products have been mass-produced. After being used in the production line of the manufacturer, the unit reflects that the hydraulic riveting machine has stable performance and can meet the raw requirements of the production line, and the riveting quality is good.
1 mechanical design manual joint writing group? Mechanical Design Manual (2)? Chemical Industry Press, 1987 2 Editor-in-Chief of Lei Tianjue? Hydraulic Engineering Design Manual? Mechanical Industry Press, 1990 3 Yang Baoguang and other editors? Forging machinery hydraulic transmission? Mechanical Industry Press, 1983 4 edited by Zhang Renjie? Design, manufacture and maintenance of hydraulic cylinders? Mechanical Industry Press,
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