24V车载电动工具的研制
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摘要
24V车载电动扳手主要应用于重型运输车辆轮胎的拆卸。在车辆行驶途中如果轮胎发生故障,此时车辆远离维修地点,既无专业的维修设备又无维修技师,因此整个轮胎的拆卸和安装过程都要由驾驶员亲自完成。以往的电动、风动扳手不仅体积和重量比较大,不便于随车携带,而且工作功率很高,相应的对于能量源的要求也很高。而汽车在行驶途中,唯有车载蓄电池可以作为能量源,且车载蓄电池的输出功率很低,所以现有的电动、风动扳手无法满足车载环境下的使用要求。因此设计一款体积小、重量轻、便于携带,能够以车载蓄电池作为能量来源的电动扳手是十分必要的。由于车载蓄电池输出功率的限制,采用传统的转矩电机搭配行星减速器的方案已经不能够满足工作的要求。因此本文提出了一种储能式的冲击机构方案,设计了以储能飞轮和冲击机构为核心的机械结构,且对关键零部件进行了有限元分析,对其刚度和局部强度进行了评价。
利用虚拟样机技术,对24V车载电动冲击扳手进行了三维实体建模,建立了动态仿真模型,模拟电动扳手的工作情况,验证了电动冲击扳手的输出力矩。在仿真结果的基础上,对冲击机构工作过程进行了深入分析,根据分析结果对冲击机构进行了结构改进,提高了冲击机构工作的可靠性。最后,利用实验室现有设备,设计了对电动冲击扳手进行输出力矩验证实验的检测装置以及实验台。实验装置通过对储能飞轮转速的测量,实现了间接测量输出力矩的目的。通过实验,得到了满意的测试结果。
本文通过对冲击机构工作数学模型的分析、冲击机构虚拟样机模型的模拟仿真和物理样机的实验结果三者的比较分析,最终验证了整个24V车载电动冲击扳手理论分析和结构设计上的正确性,为工程实际应用奠定了良好的基础。
24V vehicle electric wrench is mainly applied to dismantle tire of heavy transport vehicles. Tire is broken down on the way while vehicle is travelling far away from vehicle servicing station, in such a case, there are no Professional maintenance equipment and maintenance technician, so the drives must be accomplished the whole process of dismantling and fixing tire by themselves. Previous electric, pneumatic wrench are not inconvenient to carry because of large weight and huge volume ,furthermore, they demand high energy source in accord with the high efficiency, but vehicles on the way only carry vehicle battery with low power. so, previous electric, pneumatic wrench are only used in the workshop. Therefore, it is very necessary to design a small, lightweight and easily-carry electric wrench supplied by the vehicle battery. The traditional torque motor collocation planetary reducer scheme can no longer meet the requirements due to the limit of the vehicle battery’s output power. Thus this paper puts forward a impact mechanism scheme of energy storage, designs a mechanical structure whose score is storage flywheel and impact mechanism, adopt the finite element analysis on the key part as well as the evaluation of its stiffness and local strength.
The paper implements 3d entity modeling scheme on 24V vehicle electric impact wrench Using the virtual prototype technology, simulate the working condition of the electromotive spanner by establishing a dynamic simulation model to verify the output torque of electric impact wrench. Then it analyses the impact mechanism of working progress based on the results of the simulation, optimize the design of the impact mechanism to improve the reliability of the impact mechanism. Finally, this paper designs the detection device and experimental platform for validating the output torque by of the electric impact wrench by using the existing equipment of the laboratory. The purpose of measuring the output torque indirectly achieved by measuring the speed of the energy flywheel and the result is satisfied.
Finally, the paper verifies the theory of electric vehicle 24V impact wrench and the correctness of the structural design by comparing the following three parts, the analysis on the mathematical model of the impact mechanism, simulating the impact mechanism of virtual prototype model, experiment of the physical prototype, which lays a good foundation for engineering application.
利用虚拟样机技术,对24V车载电动冲击扳手进行了三维实体建模,建立了动态仿真模型,模拟电动扳手的工作情况,验证了电动冲击扳手的输出力矩。在仿真结果的基础上,对冲击机构工作过程进行了深入分析,根据分析结果对冲击机构进行了结构改进,提高了冲击机构工作的可靠性。最后,利用实验室现有设备,设计了对电动冲击扳手进行输出力矩验证实验的检测装置以及实验台。实验装置通过对储能飞轮转速的测量,实现了间接测量输出力矩的目的。通过实验,得到了满意的测试结果。
本文通过对冲击机构工作数学模型的分析、冲击机构虚拟样机模型的模拟仿真和物理样机的实验结果三者的比较分析,最终验证了整个24V车载电动冲击扳手理论分析和结构设计上的正确性,为工程实际应用奠定了良好的基础。
24V vehicle electric wrench is mainly applied to dismantle tire of heavy transport vehicles. Tire is broken down on the way while vehicle is travelling far away from vehicle servicing station, in such a case, there are no Professional maintenance equipment and maintenance technician, so the drives must be accomplished the whole process of dismantling and fixing tire by themselves. Previous electric, pneumatic wrench are not inconvenient to carry because of large weight and huge volume ,furthermore, they demand high energy source in accord with the high efficiency, but vehicles on the way only carry vehicle battery with low power. so, previous electric, pneumatic wrench are only used in the workshop. Therefore, it is very necessary to design a small, lightweight and easily-carry electric wrench supplied by the vehicle battery. The traditional torque motor collocation planetary reducer scheme can no longer meet the requirements due to the limit of the vehicle battery’s output power. Thus this paper puts forward a impact mechanism scheme of energy storage, designs a mechanical structure whose score is storage flywheel and impact mechanism, adopt the finite element analysis on the key part as well as the evaluation of its stiffness and local strength.
The paper implements 3d entity modeling scheme on 24V vehicle electric impact wrench Using the virtual prototype technology, simulate the working condition of the electromotive spanner by establishing a dynamic simulation model to verify the output torque of electric impact wrench. Then it analyses the impact mechanism of working progress based on the results of the simulation, optimize the design of the impact mechanism to improve the reliability of the impact mechanism. Finally, this paper designs the detection device and experimental platform for validating the output torque by of the electric impact wrench by using the existing equipment of the laboratory. The purpose of measuring the output torque indirectly achieved by measuring the speed of the energy flywheel and the result is satisfied.
Finally, the paper verifies the theory of electric vehicle 24V impact wrench and the correctness of the structural design by comparing the following three parts, the analysis on the mathematical model of the impact mechanism, simulating the impact mechanism of virtual prototype model, experiment of the physical prototype, which lays a good foundation for engineering application.
引文
1胡建峰.省力扳手.百度专利. 2007:1
2曾国华.可控扭矩电动扳手研究.电动工具. 2002(36):45
3朱鹤龄.国产冲击式气扳机评述.岩凿机械气动工具. 1988(8):28~30
4刘序.气动冲击扳手.机械工人. 1980(10):1~6
5王忠信. P3BK100型封闭式电冲击扳手.工程机械. 1983(01):22
6国家统计局. 2007年全国汽车保有量统计报告.搜狐新闻. 2007
7蒋鹏飞.与青年设计师谈电动工具设计.电动工具. 2009(2):5
8 Zeng Guohua. The Application of Planetary Gear Mechanism at Electric Wrench. electric wrench 2002(5):5
9张传富. 2008年上半年我国电动工具行业发展形势分析.电器工业.2008(8):5~8
10李克学.冲击气扳机的选择及应用.岩凿机械气动工具. 1985:37~38
11颜景平.气扳机冲击机构的设计与计算.凿岩机械气动工具. 1988(5):2~3
12陈利均.气扳机气控储能装置的工作原理.岩凿机械气动工具. 2005(2):2
13中国电器工业协会. 2008年电工行业经济运行情况及2009年走势预测.电气时代. 2009(1):58~59
14王云鹏.从中国专利看我国气动机具技术的发展.凿岩机械气动工具. 1998(2):53~58
15赵福江.风动工具气扳机定扭矩控制的研究.天津大学硕士学位论文.2005:1~2
16黎永泉.国外装配用气动工具现状.凿岩机械气动工具. 1993(l):35~36
17王敬梅.一种新型结构的气动冲击扳手.岩凿机械气动工具.1997(1):31~32
18徐晓东.汽车用品市场展现新利润点.消费日报. 2008.10(B02)
19吴立新.电动工具市场低价竞争的困局.电器工业. 2009(4):55
20孔德凯、罗敏.车载电热器具应用前景.交电商品科技情报,1995(02):23
21王忠发.实用新型气动冲击机构.岩凿机械气动工具. 1996(2):64
22 Jumei Cai,Henneberger G.Radial force of bearingless wound—rotor induction motor[C].8th International Symposium on MagneticBearings,Mito,Japan,2002:41~46
23 William E Boyes . Jigs and Fixtures. Dearborn Michigan Society of Manufacturing Engineering. 1982.
24时建平.储能冲击式气扳机冲击机构运动可靠性分析.岩凿机械气动工具. 1996(5):44~45
25欧云飞,梁以德.一种限速安全离心摩擦离合器.机械.2008(7):55~56
26 Kampe. Stephen L. A method to incorporate green engineering in materials selection and design. ASEE Annual Conference Proceedings. 2002 ASEE Annual Conference and Exposition. Vive L'ingenieur,2002:10711~10717.
27 James MG. Meehanies of Materials. Brooks/Cole.2001:53~60
28 Mingjiang Ma. Analysis and calculation on working time of collision.2004:15~16
29石力.输出轴材料的选取及工艺浅析.岩凿机械气动工具. 2000(1):47~48
30王忠信.电冲击扳手的理论冲击效率.工程机械.1987(5):13~15
31周详语.虚拟样机技术的机器人研究.哈尔滨工业大学硕士学位论文.2004:4~5
32 Noel O. Use of ADAMS in Dynamics Simulation of Landing Gear Retraction and Extension. 13th European ADAMS User’s Conference France. 1998:1~8
33白丽平.基于ADAMS的机器人动力学仿真分析.机电工程.2007(7):74~77
34 Narayana B Lakshmi, Ranganath R Nataraju. B. S. Studies on Docking Dynamics Using ADAMS. Jamal of Spacecraft Technology.2000(1):40~51
35 DIPL I, ANDREA A. Modelling and Contrsol of a Flexi-ble“Goliath”Robot a Case Study Using ADAMS/Controls[C]. 13th European ADAMS Users s Conference.France.1998:1~10
36 ARENZ A, BORCHERTW, SCHNIEDER E. Simulation of a“Goliath”Tranfer Robot Combining the Software Tools ADAMS and MATLAB [C].
11th European ADAMS Users Conference. Germany: [s, n], 1996:1~14
37王成忠.拧紧技术运用中的几个实际问题.凿岩机械气动工具.1998(4):34~36
38黄国政.冲击式电动工具检测流程与分析.台湾逢甲大学学报.2005
39 Zhao Yan. Research on Hydraulic Impact Mechanism of Concrete Pumping System. International Journal of Systems and Control.2008(2):55~57
40 Hannian Zhang, Huangqiu Zhu, Zhibao Zhang. Design and Simulation of Control System for Bearingless Synchronous Reluctance Motor[C]. the 8th International Conference on Electrical Machines and Systems, Nanjing,2005(1):54~58
41王忠信. P3BK200型电冲击扳手冲击机构的动力学设计.工程机械.1986(7):44~47
42刘宪文.冲击扳手可靠性的提高.工程机械.1988(8):24~25
43 Liu Xiaodong, Shi Yanyan, Li Shubo. A MCU-Based Arbitrary Waveform Generator for SLH Power Amplifier Using DDS Technique. IEEE. 2007: 4895~4899
44殷晓安,吴明亮.基于单片机的LED点阵显示条屏控制系统设计.世界科技研究与发展. 2008(2):14~15
45史淑芳. LED动态显示方法与驱动.科技资讯. 2008(7):22
46刘东,许自富.基于I2C总线的单片机键盘控制电路设计与实现.电脑知识与技术. 2007: 25~26
47 Chen Buyue, Wang Yinkun, Zhang Jin. Method of Creating Database for Test System Based on MCU. IEEE. 2007:36~37
48 John sprovieri. taking the pulse of power tools. Assembly, 1997(10):20~23
49 Hans Rudolf. Tightenitup. Assembly, 1997(11):32~41
50 Paulo Pinheiroda Silva, Norman W. Paton. User Interface Modelling with UML. EJC 2000:03~17
51 Khalil Arshak, Essa Jafer. Design of a Low Power Smart Wireless System Used for Multi-sensor Monitoring. IEEE. 2005: 295~298
52 Yukimitsu Sekimori, Yoshikazu Yoshida, Pressure Sensor for Micro Chemical System on a Chip. IEEE. 2004: 516~519
2曾国华.可控扭矩电动扳手研究.电动工具. 2002(36):45
3朱鹤龄.国产冲击式气扳机评述.岩凿机械气动工具. 1988(8):28~30
4刘序.气动冲击扳手.机械工人. 1980(10):1~6
5王忠信. P3BK100型封闭式电冲击扳手.工程机械. 1983(01):22
6国家统计局. 2007年全国汽车保有量统计报告.搜狐新闻. 2007
7蒋鹏飞.与青年设计师谈电动工具设计.电动工具. 2009(2):5
8 Zeng Guohua. The Application of Planetary Gear Mechanism at Electric Wrench. electric wrench 2002(5):5
9张传富. 2008年上半年我国电动工具行业发展形势分析.电器工业.2008(8):5~8
10李克学.冲击气扳机的选择及应用.岩凿机械气动工具. 1985:37~38
11颜景平.气扳机冲击机构的设计与计算.凿岩机械气动工具. 1988(5):2~3
12陈利均.气扳机气控储能装置的工作原理.岩凿机械气动工具. 2005(2):2
13中国电器工业协会. 2008年电工行业经济运行情况及2009年走势预测.电气时代. 2009(1):58~59
14王云鹏.从中国专利看我国气动机具技术的发展.凿岩机械气动工具. 1998(2):53~58
15赵福江.风动工具气扳机定扭矩控制的研究.天津大学硕士学位论文.2005:1~2
16黎永泉.国外装配用气动工具现状.凿岩机械气动工具. 1993(l):35~36
17王敬梅.一种新型结构的气动冲击扳手.岩凿机械气动工具.1997(1):31~32
18徐晓东.汽车用品市场展现新利润点.消费日报. 2008.10(B02)
19吴立新.电动工具市场低价竞争的困局.电器工业. 2009(4):55
20孔德凯、罗敏.车载电热器具应用前景.交电商品科技情报,1995(02):23
21王忠发.实用新型气动冲击机构.岩凿机械气动工具. 1996(2):64
22 Jumei Cai,Henneberger G.Radial force of bearingless wound—rotor induction motor[C].8th International Symposium on MagneticBearings,Mito,Japan,2002:41~46
23 William E Boyes . Jigs and Fixtures. Dearborn Michigan Society of Manufacturing Engineering. 1982.
24时建平.储能冲击式气扳机冲击机构运动可靠性分析.岩凿机械气动工具. 1996(5):44~45
25欧云飞,梁以德.一种限速安全离心摩擦离合器.机械.2008(7):55~56
26 Kampe. Stephen L. A method to incorporate green engineering in materials selection and design. ASEE Annual Conference Proceedings. 2002 ASEE Annual Conference and Exposition. Vive L'ingenieur,2002:10711~10717.
27 James MG. Meehanies of Materials. Brooks/Cole.2001:53~60
28 Mingjiang Ma. Analysis and calculation on working time of collision.2004:15~16
29石力.输出轴材料的选取及工艺浅析.岩凿机械气动工具. 2000(1):47~48
30王忠信.电冲击扳手的理论冲击效率.工程机械.1987(5):13~15
31周详语.虚拟样机技术的机器人研究.哈尔滨工业大学硕士学位论文.2004:4~5
32 Noel O. Use of ADAMS in Dynamics Simulation of Landing Gear Retraction and Extension. 13th European ADAMS User’s Conference France. 1998:1~8
33白丽平.基于ADAMS的机器人动力学仿真分析.机电工程.2007(7):74~77
34 Narayana B Lakshmi, Ranganath R Nataraju. B. S. Studies on Docking Dynamics Using ADAMS. Jamal of Spacecraft Technology.2000(1):40~51
35 DIPL I, ANDREA A. Modelling and Contrsol of a Flexi-ble“Goliath”Robot a Case Study Using ADAMS/Controls[C]. 13th European ADAMS Users s Conference.France.1998:1~10
36 ARENZ A, BORCHERTW, SCHNIEDER E. Simulation of a“Goliath”Tranfer Robot Combining the Software Tools ADAMS and MATLAB [C].
11th European ADAMS Users Conference. Germany: [s, n], 1996:1~14
37王成忠.拧紧技术运用中的几个实际问题.凿岩机械气动工具.1998(4):34~36
38黄国政.冲击式电动工具检测流程与分析.台湾逢甲大学学报.2005
39 Zhao Yan. Research on Hydraulic Impact Mechanism of Concrete Pumping System. International Journal of Systems and Control.2008(2):55~57
40 Hannian Zhang, Huangqiu Zhu, Zhibao Zhang. Design and Simulation of Control System for Bearingless Synchronous Reluctance Motor[C]. the 8th International Conference on Electrical Machines and Systems, Nanjing,2005(1):54~58
41王忠信. P3BK200型电冲击扳手冲击机构的动力学设计.工程机械.1986(7):44~47
42刘宪文.冲击扳手可靠性的提高.工程机械.1988(8):24~25
43 Liu Xiaodong, Shi Yanyan, Li Shubo. A MCU-Based Arbitrary Waveform Generator for SLH Power Amplifier Using DDS Technique. IEEE. 2007: 4895~4899
44殷晓安,吴明亮.基于单片机的LED点阵显示条屏控制系统设计.世界科技研究与发展. 2008(2):14~15
45史淑芳. LED动态显示方法与驱动.科技资讯. 2008(7):22
46刘东,许自富.基于I2C总线的单片机键盘控制电路设计与实现.电脑知识与技术. 2007: 25~26
47 Chen Buyue, Wang Yinkun, Zhang Jin. Method of Creating Database for Test System Based on MCU. IEEE. 2007:36~37
48 John sprovieri. taking the pulse of power tools. Assembly, 1997(10):20~23
49 Hans Rudolf. Tightenitup. Assembly, 1997(11):32~41
50 Paulo Pinheiroda Silva, Norman W. Paton. User Interface Modelling with UML. EJC 2000:03~17
51 Khalil Arshak, Essa Jafer. Design of a Low Power Smart Wireless System Used for Multi-sensor Monitoring. IEEE. 2005: 295~298
52 Yukimitsu Sekimori, Yoshikazu Yoshida, Pressure Sensor for Micro Chemical System on a Chip. IEEE. 2004: 516~519
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