AT THE EXHIBITION OF ACHIEVEMENTS OF THE NATIONAL ECONOMY OF THE USSR

EQUIPMENT FOR THE MECHANIZED ASSEMBLY

OF MACHINERY

V . K. Z a m y a t i n UDC 658.515.061.4(047)

The show "Mechanizat ion and Automat ion of the Assembly Operat ions in Machine Building" was held f r o m D e c e m b e r 20, 1978, to March 31, 1979, in the "Mechanical Engineering" pavil l ion at the Exhibition of Achievements of the National Economy of the USSR. The leading machine-bui ld ing m i n i s t r i e s par t ic ipa ted in the show by exhibit ing p r o g r e s s i v e means for the mechanizat ion and automation of a s s emb ly of products which in many cases consis t of typefied pa r t s . This makes it poss ib le to apply them in d i f ferent branches of m e c h - anical engineer ing.

The IE-3115A and IE-3112 e l ec t r i c a l manual impact (churn) nut t igh teners can be used fo r the a s s e m b l y and d ismant l ing of th readed connections at industr ial f i r m s . The IE-3115A t igh tener is intended for the ca l i - bra ted t ightening of bolts s ize M18-M30, s t rength c lass 3.6-6.6, and bolts s ize M12-M20, s t rength c lass 6.8- 14.9. I t cons is t s of an e l ec t r i c m o t o r , a p lane ta ry reducing gea r , an impac t m e c h a n i s m , a handle with switch, the cu r r en t - supp ly cable , and a device fo r the e l iminat ion of radio in te r fe rences . The IE-3112 nut t ightener is intended for the ca l ibra ted t ightening of h igh-s t rength bolts of different s izes (M22-M30) or med iu m-s t r en g th bolts (35 steel) with d i a m e t e r s up to M42 ram. The t igh tener is a r e v e r s i b l e tool and is equipped with a p r o - tec t ive swi tch-off device.

Technica l C ha rac t e r i s t i c s of the Nut T ig theners

IE -3115A IE -3112

Impac t ene rgy , J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 100 Impac t f requency, impac t s /min . . . . . . . . . . . . . . . . . . . . 120 24 E lec t r i c motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . commuta to r , asynchronous ,

s i ng l e -phase with t h r e e - p h a s e , double insulation ro ta t ing type

Dimensions (length x width x height) , m m . . . . . . . . . . . . . 470 • 79 • 130 447 x 153 x 410 M a s s (without cable , key, and

switch-off device) , kg . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 12.4

The IE-3115A nut t ightener is manufac tured by the "E lek t ro ins t rumen t" Product ion Associa t ion at Ros tov-on-Don and the IE-3112 t ightener by the "E lek t ro ins t rumen t " Plant at Vyborg.

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Fig. 1. Tightening of a plate heat exchanger with the dual -spindle t ightner : 1) heat ex- changer ; 2) c r a n e suspension; 3) t igh tener at the s t a r t and 4) at the end of the tightening.

T rans l a t ed f rom Khimicheskoe i Neftyanoe Mashinos t roenie , No. 11, pp. 36-38, November , 1979.

0009-2355/79/1112-0879507.50 �9 Plenum Publishing Corpora t ion 879

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Fig. 2. Stand for the grinding of valve seats in cast iron fittings: 1) lap rotation mechanism; 2) assembled plate; 3) four-way valve; 4) base; 5) rotating body; 6) e lec t r ic motor ; 7) belt,

The "Uralkhimmash" Production A ssociat ion produces a dual-spindle nut t ightener intended for the tightening of the plates of plate heat exchangers during hydraulic test ing and final assembly. The tightener has an upper and lower head, a gear box, telescopic head links, a suspension support, and a control panel. By suspension from a crane the t ightener is placed on the nuts of the plate heat exchanger (Fig. 1). The e l ec - t r ic motor of the t ightener sets the spindles into rotation through the gear box and worm reductors of the upper and lower heads. The spindles have ball inser ts with an internal hexagon. The nuts of the heat exchanger bolts are located in the hexagons of the inserts . The telescopic Link compensates deviatiqns from the distance between the bolts and nuts of the heat exchanger. The outer spherical surface of the inser ts compensates the face slackness of the nuts of the heat exchanger during tightening. As the spindles rota te , the t ightener t ravels together with the nuts in the direct ion of tightening until the required tightening s t r ess is reached. This is followed by hydraulic test ing of the heat exchanger.

Technical Charac te r i s t i cs of the Nut Tightener

Maximum torque in tightening on one spindle, k g f - m . . . . . . . . . . . . . . . . . . 240 Tightening length (travelling path of nuts) . . . . . . . . . . . . . . . . . . . . . . . . . unlimited Power consumption of e lec t r ic motor , kW . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Dimensions, mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . ~ 710 x 480~2!15 Mass, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800

The introduction of the nut t ightener has re leased workers f rom laborious manual tightening and dis- mantling of the plate packets.

Spanners (wrenches) with mechanical intensif iers have been introduced at the "Dvigatel v Revolyutsii" Plant at Gor 'k i i , intended for the screwing on and off of bolts, nuts, and screws with high tightening s t r esses . There are two spanners; the s t ress coefficient of each spanner is equal to 4. The two spanners can be com- bined, so that the s t ress coefficient becomes 16. The s t ress coefficient is achieved by a difference between the number of teeth of the s traight- tooth cylindrical gears with external engagement, mounted on a gear with internal engagement which represents the housing of the wrench.

The wrench is activated by rec iproca l movement of a ratchet spanner. The ratchet spanner has a r egu- lating device in the handle which can be adjusted to a given torque. The wrenches are equipped with special inser ts so they can be used on M24-M60 threads. When a load of, say, 10 kgf is applied to the handle of the

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Fig. 3. Scheme of the con- servat ion of machinery; 1) tank with the test ing (or con- servation) liquid; 2) hydraul ic working par t ; 3) vapor s e c - tion; 4) condenser ; 5) dosage pump; 6) p re se rv ing solution.

small ra tchet spanner, the torque of the large wrench amounts to 20-30 kgf" m. When the same load is ap- plied to the end of the handle of the ratchet spanner, the torque of the large wrench will be equal to ~40-60 kgf. m. When using the combined wrenches , one worker can apply torques of ~200-300 k g f . m . The d imen- sions (length x width x height) of the small and large wrenches are 580 x 80 x 95 and 1080 x 95 x 110 mm, respect ively; their masses are 4.8 and 9 kg, respect ively . The utilization of the wrenches has resul ted in an improved assembly of the a r t ic les , in better working conditions of the assembly worke r s , and has reduced the labor requi rement by a factor of 2.

A t ranspor table hydraulic p ress has been developed at the "Novo-Kramatorsk i i Mashinostroi te l 'nyi Zavod" Product ion Associat ion for the p ress ing of bushings into the naves of gear wheels and other parts . It consists of a table ca r ry ing a large and a small hydraulic cyl inder , pumps with hydraul ic dr ives , three four - way slide valves with e lec t romagnet ic control for setting one of the cylinders into operat ion, and an oil tank. The p ress ing s t r e s s is car r ied by the body of the hydraul ic cylinder. Such an operat ing scheme of the hydrau- lic press el iminates columns f rom its construct ion, as well as a slide block and c ross bars , and provides a favorable combination of the units with rapid insert ion and removal of the par ts .

T e c h n i c a l C h a r a c t e r i s t i c s o f t h e P r e s s

Large hydraul ic cyl inder: force applied to the rod, kgf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41,000 cylinder d iameter , m m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 rod t ravel , mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 bushing d iameter , mm :

external . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-300 internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-270

Small hydraul ic cylinder: force applied to the rod, kgf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15,000 cylinder d iamete r , mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 rod t ravel , m m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 external bushing d iameter , mm . . . . . . . . . . . . . . . . . . . . . . . . . . . up to 50

P res s ing speed, mm/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100 Dimensions, mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1210 x1310 x 1300 Mass, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500

Application of the p ress has increased the productivity of labor by a fac tor of 3.

A stand for the mechanized grinding of valve seats in cast iron fittings for general use (valves, s top- 3ks, etc.) is being manufactured by the Ar tem "Dneprotyazhbummash" Production Associat ion. The stand

(Fig. 2) consists of the lap rotat ion mechanism, a plate (assembled), the base, a pneumatic cylinder, an e l ec - t r ic motor , andcontrol valve. The valve (or stopcock) housing is installed on the support and fixed with r - shaped clamps. The lap is supplied to the g~inding zone by means of a pneumatic drive, and the e lectr ic motor is

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switched on, which sets into motion the rotation mechanisms of the lap. The kinematics of the mechanism provide also a r eve r se rotat ing of the lap. The rotation angles of the lap are adjustable. The grinding dura - tion depends on the type and size of the fitting and var ies f rom 3-5 min, giving a c lass 8-9 finish of the s u r - face.

Technical Charac te r i s t i cs of the Stand

Diameter of the nominal clearance of the fitting t o b e ground, mm . . . . . . : . . . . . . . . . . . . . . . . . . . . . 65, 80, 150, 200

Elec t r i c motor of the drive: type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AO2-31-6 power consumption, kW . . . . . . . . . . . . . . . . . . . . . . . 1.5 rotation speed, rpm . . . . . . . . . . . . . . . . . . . . . . . . . . 950

Travel of pneumatic cylinder rod, mm . . . . . . . . . . . . . . . 200 Force created by the cylinder, kgf . . . . . . . . . . . . . . . . . . 130 Dimensions, mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 x 660 x 872 Mass, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Introduction of the stand in production has replaced manual grinding of the valve seat, increased the productivity of labor by a factor of 2, and improved the quality of the ar t ic les .

The "VPTIs t ro idormash" Scientific and Production Associat ion at Khimki (Moscow region) has developed a t i l ter for the rotation of products in assembly and welding operations. The position of the t i l ter can be fixed. When the s teer ing wheel is turned, the position of the t i l ter is automatically re leased and it can be turned into a new position. As the s teer ing wheel is stopped, the t i l ter is rel iably fixed in the new position.

Technical Charac te r i s t i cs of the Ti l ter

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . manual Number of fixed positions . . . . . . . . . . . . . . . . . . . . . . . 30 Division angle, degrees . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dimensions, mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 • 550 • 660 Mass, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

The t i l ter improves the working conditions of the assembly worker (or welder) and reduces the time required to tilt the product during work.

A device for the assembly of ar t ic les for welding has been developed at the "Novo-Kramatorsk t i Mashi- nostroi te l 'nyi Zavod" Production Associa t ion, which provides an improved precis ion in the assembly of a r t i - cles such as shafts and axles with ar t ic les of different type and size welded to them.

The par ts to be assembled are placed on spring-loaded adjustable elements. The shaft (or axle) is then placed on supporting ro l l e r s , lifted to their ext reme top position, until it touches the stop. The supporting ro l le r s are then lowered to their lowest position together with the shaft (or axle) which then res t s on the par ts to be welded to it, holding them f i rmly in position. In this position f i r s t a pre l iminary tack welding and then the final welding of the par ts to the shaft (or axle) is car r ied out. The power cylinders of the lifting mech- an isms , the angular orientation, and press ing together is controlled f rom a control panel. The device is uni- versa l and can be used for the assembly of different ar t ic les . It has the dimensions 686 • 3915 • 900 mm and a mass of 710 kg.

A unit for the conservation of machinery without dismantl ing (Fig. 3) has been developed by VNIITnasos- mash at Kazan ' , intended for the conservation of pumps during test ing on tes t stands. The technology of con- servation of machinery without dismantl ing is based on the use of solutions of corros ion inhibitors for the test ing of the working section of hydraulic machines. The proposed approach differs f rom the exis t ingmethods of conservation in that the p rese rv ing solution is pumped through immediately af ter hydraulic test ing or test ing with the use of another medium. The liquid film remaining on the internal surfaces acts as a conservation film and reliably protects the ar t ic le for at least three months.

The introduction of the technology of conservation without dismantling el iminates the assembly and d is - mantling operat ions, improves the quality of the ar t ic les produced, and achieves the mechanization and auto- mation of the conservation process .

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The Scient i f ic -Research and Design Ins t i tu te of Mechanical Engineering (NIIPTmash) at Kramato r sk has developed the USB-1 to USB-4 devices intended for the static balancing of par ts such as gear wheels , disks, f lywheels, etc. without placing on shafts and testing mandre ls . The unbalance is determined when the axis of the ar t ic le tested is in a ver t ica l position which simplifies the removal of the unbalanced mass . All devices have the same construct ion, the main par ts of which are a ball support, the clamping and center ing mechanism, and a disengaging coupling with a lock.

In compar ison with the existing balancing methods (on stands with paral le l p r i sms , on ro l le r and disc devices , etc. ) the method of removing the imbalance by means of the proposed devices is s impler . The need for the prepara t ion of special tes t mandrels is el iminated, production surface a rea is l iberated, and the labor required for the operation is reduced by a fac tor of 2-2.5.

Technical Charac te r i s t i cs of the Devices

USB-1 USB-2 P a r a m e t e r s of the par t to be

balanced: opening d iameter , mm . . . . . . . . . . 100-200 150-250 maximum width, mm . . . . . . . . . . . 280-350 380-440 maximum mass , kg . . . . . . . . . . . . 500 1200

Dimensions (diameter x height), mn~ . . 100 x 575 150 x 755 Mass, kg . . . . . . . . . . . . . . . . . . . . . 6.6 20

USB-3 USB-4

240-460 400-560 620-800 970-1120

3200 12,000 240x1075 375x1390

64 290

A console manipulator for the lifting and t ranspor t of loads with a mass of up to 250 kg, for use in mechanical assembly , has been developed by the VPTI tyazhmash in Moscow. It consis ts of a column mounted on a base which ca r r i e s a double-arm crane beam which moves in a horizontal plane. The rotating axes of the beam are equipped with pneumatic brake sleeves.

Technical Charac te r i s t i cs of the Manipulator

Height of the manipulator , mm . . . . . . . . . . . . . . . . . . . . . . 2800 Overhanging length of beam, m m . . . . . . . . . . . . . . . . . . . . 4000 Lifting height of load, mm . . . . . . . . . . . . . . . . . . . . . . . . . 2350 Ground surface a rea , m 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Mass, kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

At the end of the manipulator beam a t ract ion winch (hoist) is mounted, with a counterweight, a te le - scopic suspension pole, as well as a pole with a control handle at one end. The handle se rves to switch on the t ract ion winch and to manipulate the brake s leeves during horizontal movement of the beam with the load.

The show "Mechanization and Automation of the Assembly Operations in Machine Building" has demon- s t ra ted that in the va r ious branches of mechanical engineering the improvement of means for the mechaniza- tion and automation of assembly operations p r o g r e s s e s continuously. Highly efficient devices are being in t ro- duced in production, such as multi-spindle mechanized assembly tools , typefied readjustable equipment of aggregate design, nonsynchronous production l ines, automated assembly devices, semiautomatic devices , units and stands, robots and manipulators . All these facil i t ies increase the productivity of labor , improve the quality of assembly , as well as the working conditions of the assembly workers .

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