Mechanical Assembly and Adjustment Technology Comprehensive Training Equipment

I. Product Overview

This mechanical assembly and adjustment technology comprehensive practical training device is based on relevant national vocational and industry standards, combined with the "Numerical Control Technology and Its Applications" curriculum of secondary vocational schools.Developed to cultivate targets such as "Machinery Manufacturing Technology," "Mold Manufacturing Technology," "Installation and Maintenance of Mechanical and Electrical Equipment," and "Application of Mechanical and Electrical Technology." Mainly to train students in skills such as reading and drawing assembly and part drawings, basic lathe operations, assembly and adjustment of components and mechanisms, and assembly quality inspection. Enhance students' employment capabilities in front-line process assembly and implementation in machinery manufacturing enterprises and related industries, installation and debugging of mechanical and electrical equipment, mechanical processing quality analysis and control, and grassroots production management positions.

II. Product Features

1. Strong Practicality: Designed based on national professional standards, industry standards, and job requirements, various actual tasks are set up. With vocational practice as the main thread, students truly enhance their hands-on skills and employability through "learning by doing."

2. Broad Application: Designed based on fundamental operations in mechanical assembly technology, including fitting, assembly, measurement, adjustment, and quality inspection, this meets the needs for practical training teaching, engineering practice, and vocational skill competitions.

3. Modular Design - Composed of various mechanical workbenches, which can be trained independently as modules or in combination. Examples include: 2D workbench, multi-speed gear box, intermittent rotation workbench, stamping mechanism, feeding mechanism, clutch mechanism, etc.

4. Strong in integration, cultivating students' comprehensive abilities in mechanical drawing, selection and use of common tools and gauges, mechanical parts and assembly technology, and quality inspection of assembly.

Section 3: Comprehensive Technical Training Equipment for Mechanical Assembly and Adjustment Techniques

1. Input Power: Single-phase three-wire AC 220V±10% 50Hz

2. One交流减速电机: Rated power 90W, reduction ratio 1:25

3. Dimensions (training table): 1800mm x 700mm x 820mm

4. Equipment Weight: 600 kg;

5. Safety Protection: Features leakage current protection, meeting national safety standards.

IV. System Composition and Structure

This mechanical assembly and adjustment training device primarily consists of the training bench, power source, assembly objects (including mechanical transmission mechanisms, multi-speed gearboxes, gear reducers, clutch mechanisms, feeding mechanisms, two-dimensional worktables, intermittent rotation worktables, press mechanisms, etc.), common tooling for fitters, and measuring tools. The following image provides a simple introduction to the components of the mechanical adjustment assembly area, including design and实物 images.

1. Comprehensive Mechanical Assembly and Adjustment Training Station: Constructed with a double-layered iron matte textured spray-painted structure, it includes two sections: the operation area and the mechanical assembly and adjustment area. The operation area is mainly composed of solid wood countertops, rubber pads, and vise clamps (as shown in the figure below), used for machining and assembling various mechanical components; the mechanical assembly and adjustment area features a casting workbench surface (the iron flat in Figure 3), where students can install and adjust various mechanical mechanisms.

2. Mechanical Transmission System: Comprises primarily of clutch transmission (as shown in the following illustration), synchronous belts, chains, gears, worm gears, and other transmission mechanisms (refer to Figure 2 or Figure 3). Through students' installation, adjustment, and testing on the platform, skills in assembling and adjusting the mechanical transmission system are mastered.

3. Multi-Stage Transmission: Features dual shaft three-speed output, with one shaft providing forward and reverse functionality, protected by an acrylic cover on top. Mainly composed of the housing, gears, spline shaft, spacer sleeves, keys, angular contact bearings, deep groove ball bearings, clips, end caps, and manual shift mechanism, as shown in the following illustration, enabling practical training in the assembly process of multi-stage transmissions.

4. 2D Workbench: Composed mainly of ball screw, linear guide rail, work surface, pads, bearings, supports, end caps, etc. (As shown in the figure below). It is divided into two layers, with the lower layer controlled by a multi-stage transmission gear system to achieve reciprocating movement of the workbench. The work surface is equipped with a stroke switch for limit protection function. The upper layer can be manually controlled; capable of completing assembly technology and precision testing for linear guide rail, ball screw, and 2D workbench.

The specific composition includes: base plate, middle slider, top slider, linear guide rails, ball screw, bearing bracket, inner bearing spacer, outer bearing spacer, bearing pre-tension sleeve, bearing cover, bearing cap, screw nut bracket, round nut, limit switch, handwheel, gears, level washers, radial segment, elastic retaining ring for shaft, angular contact ball bearing (7202AC), deep groove ball bearing (6202-2RZ), and other components.

5. Gearbox: Mainly composed of straight tooth cylindrical gears, angular contact bearings, deep groove ball bearings, brackets, shafts, end caps, keys, etc. (As shown in the following figure). Can complete the assembly process training for the gearbox.

Its specific composition includes: left and right baffles, cylindrical gears, bearing seat sleeves, input shaft, intermediate shaft, output shaft, shaft sleeves, bearing cover, bearing cover, gear outer sleeve, top cover, angular contact bearings (7003AC), deep groove ball bearings (6003-2RZ), shaft elastic retaining rings, and gear reducer base, etc.

6. Intermittent Rotation Workbench: Composed mainly of four-slot sprocket mechanism, worm gear and worm, thrust ball bearing, angular contact bearing, worktop, and bracket, as shown in the following illustration. The intermittent rotation function is achieved through a multi-speed transmission system, which includes chain drive, gear drive, worm and worm gear drive, and the indexing by the four-slot sprocket mechanism. It is capable of completing the assembly and adjustment training for worm gears, four-slot sprockets, bearings, and more.

The components include: small cone gear shaft, cone gear, cylindrical gear, bearing housing, bearing cover, bearing inner sleeve, bearing outer sleeve, shaft sleeve, gear speed shaft, groove wheel shaft, material tray, thrust ball bearing limit block, flange, nut for worm shaft end, worm, worm gear, worm shaft, bearing housing for worm shaft, upright plate, base plate, base plate for small cone gear, base plate for intermittent rotation worktable, locking arc, four-slot groove wheel, pinion, angular contact ball bearings (7000AC, 7002AC, 7203AC), deep groove ball bearings (6002-2RZ), thrust ball bearings (51120), tapered roller bearings (30203), elastic retaining rings for shafts, etc.

7. Punching Machine Mechanism: Composed mainly of crankshafts, connecting rods, sliders, brackets, bearings, etc. (as shown in the figure below), it coordinates with the intermittent rotation worktable to simulate the material pressing function. It can complete the assembly process training for the punching machine mechanism.

The specific components include: shaft, crankshaft disk, intermediate shaft, shaft bushes, upper and lower crankshaft covers, headstock connection, ball joint swivel, simulated punch, swivel upper cover, bearing dust cap, bearing vent cap, automatic punch press upper and lower pulling plates, sliding sleeve fixing plate pads, sliding sleeve fixing plate, punch guide sleeve, left and right drive shaft bushings, automatic punch press left and right baffles, and sealing plates, etc.

8. Power Source: Equipped with an AC variable speed motor, speed controller, and power control box, providing power for the mechanical system. The power control box includes an interface for the variable speed motor power connection and a stroke switch interface.

9. Assembly Tools: Includes a set of tools (55 pieces), bench vise, marking board, puller, copper rod, impact sleeve, chain cutter, impact wrench. The set of tools consists of a tool box, hex wrench, socket wrench, adjustable wrench, file, tap, spanner, compass, center punch, hammer, nut driver, saw frame, needle-nose pliers, and clamps.

10. Standard Measuring Tools: Primarily composed of calipers, angle gauges, width rules, micrometers, feelers, and level instruments; by using these tools for measurements, students will master the operation of common measuring tools and the methods for inspecting mechanical assembly.

V. Design Concept

1. Based on relevant national vocational standards, industry standards, and job requirements, various practical work tasks are set up. These tasks are centered around vocational practice, enhancing students' hands-on skills and employability through the "learning by doing" approach.

2. Designed based on the fundamental operations of machining, assembly, measurement, adjustment, and quality inspection in mechanical assembly technology, it meets the requirements for practical training and vocational skill competitions.

3. Composed of various mechanical modules, these can be trained individually or in combination. Examples include a 2D worktable, feeding mechanism, clutch transmission, gear reducer, multi-speed transmission, indexing rotary table, and automatic punch press mechanism. Each module is equipped with a corresponding manual adjustment mechanism.

4. Comprehensive: Cultivates students' comprehensive abilities in mechanical drawing, selection and use of common tools and gauges, mechanical component and mechanism processing and adjustment, and assembly quality inspection.

5. Involves some typical skill points and knowledge areas in the assembly of various mechanical and electrical equipment. For example: assembly and adjustment of belt and chain transmission mechanisms, transmission assembly, bearing assembly and adjustment (deep groove ball bearings, angular contact bearings, tapered roller bearings, thrust ball bearings), ball screw assembly, linear guide assembly and adjustment, and related parallelism and perpendicularity measurements.

6. Safety: Comprehensive consideration of civilized production and personal safety protection measures.

Section 6: Typical Work Assignment Content

Project One: Basic Wrenching Operation Skills Training

Task One: Underline Skill Training

Task 2: File Shaping Skill Training

Task 3: Sawing Skills Training

Task 4: Drilling Skill Training

Task 5: Thread Cutting Skills Training

Task Six: Deburring Skill Training

Project Two: Clutch Assembly and Adjustment

According to the assembly drawing and assembly process requirements, complete the installation and adjustment of the clutch.

Project 3: Feeding Mechanism Assembly and Adjustment

Based on the assembly drawings and assembly process requirements, complete the installation and adjustment of the feeding mechanism.

Project 4: Transmission Assembly and Adjustment

As per the assembly drawings and manufacturing process requirements, assemble and adjust bearings, shafts, keys, sliding gears, and cases, etc.

Project 5: Gearbox Assembly and Adjustment

As per the assembly drawing and assembly process requirements, complete the installation and adjustment of the gear reducer.

Project Six: Press Mechanism Assembly and Adjustment

According to the assembly drawings and assembly process requirements, complete the installation and adjustment of the press mechanism.

Project 7: Assembly and Adjustment of the Intermittent Rotation Workbench

As per the assembly drawings and process requirements, assemble and adjust the worm gears, four-slot sprockets, bearings, supports, and the like.

Project 8: Assembly and Adjustment of the 2D Workbench

As per assembly drawings and process requirements, assemble and adjust linear guides, ball screws, bearings, mounts, etc.

Project 9: Installation and Adjustment of Mechanical Transmission

Assembly and adjustment of the drive unit with a transmission mechanism.

Task 2: Assembly and Adjustment of the Chain Drive Mechanism

Task 3: Assembly and Adjustment of the Gear Transmission Mechanism.

Project 10: Mechanical System Operation and Adjustment

As per the general assembly drawing requirements, assemble the individual units into a system, adjust as required, and achieve the predetermined functions.

Section 7: Key Skills Focus of the Equipment Training

Primarily focuses on honing the core skills of assembly fitters, with the training for assembly fitters mainly reflected in the following aspects:

1. Image recognition capability;

2. Bearing assembly

3. Assembly with drive transmission

Gear assembly

5. Worm gear assembly

6. Linear guide installation

7. Ball screw assembly

8. Standardized Assembly

1. Image Recognition Ability

(1) The assembly drawing clearly shows the assembly relationship between parts, the operating principle, and function of the mechanism.

(2) Understand the technical requirements in the drawings, the assembly methods of basic component structures, and the adjustment of precision for bearings, gears, guides, worm gears, and worm shafts.

(3) Learn and formulate assembly processes, apply what you've learned, master various functional modules, and skillfully apply them to other scenarios for innovative design.

2. Bearing assembly

(1) Bearing cleaning.

(2) The assembly method for bearings should not be done by盲目敲打.

(3) Add an appropriate amount of lubricant based on the movement part requirements.

(4) Bearing alignment.

(5) Assembly direction and load-bearing of angular contact ball bearings.

(6) Angular Contact Ball Bearing Clearance Adjustment: Generally, measure the difference between the inner and outer rings, grind the spacer sleeve, and adjust its preload by the difference in thickness of the inner and outer ring circles.

3. Driven assembly

(1) The wheel-mounted positioning is reliable for carrying loads.

(2) Ensure radial runout and parallelism.

4. Gear assembly

(1) Gears are reliably positioned for load-bearing and the flexibility of gear movement.

(2) During the rotation process, the gears must be properly lubricated.

(3) Gear clearance adjustment.

(4) The transmission should be smooth without any impact.

5. Worm gear and worm assembly

(1) Determination of assembly sequence.

(2) Gearbox worm and worm gear center alignment adjustment.

6. Linear Guide Installation

(1) Note the datum plane.

Ensure parallelism of the two guide rails.

(3) Assembly sequence for the fastening screws.

7. Ball Screw Assembly

(1) Pay attention to the direction of the bearing to prevent its movement

(2) Pay attention to the equal height of the bearing bases.

8. Standardized Assembly

(1) Reasonable assembly sequence

(2) Lubrication of moving parts

(3) Adjust the gap of mating parts, ensuring flexibility without excessive space. Prevent impact or interference between gears.

Summary:

(1) Learning and practical operation of assembly mechanics can enhance the contestant's comprehensive technical skills, ability to read blueprints, on-the-spot performance, and proficiency in assembly.

(2) Emphasize the importance of assembly processes. Since processes serve as the operational guide in assembly, help us understand the design philosophy and technical requirements, and ensure assembly quality, our students must thoroughly understand the assembly processes and procedures. This includes mastering how to assemble, how to do it rationally, and the assembly sequence, ensuring the quality of the assembly.

(3) Promote the standardization of assembly.

I. Pay attention to operation safety.

II. Tools and measuring instruments should be used properly.

III. Parts, tools, and gauges must be neatly arranged.

(4) Suggestions for the Comprehensive Practical Training Equipment of Guantian Mechanical Assembly and Adjustment Technology

I. Pay attention to the psychological characteristics of students and enhance their literacy.

II. Enhance practical legal guidance, improve students' empathy abilities.

III. Practical basic skills operation, fostering the development of good habits.

Section 8: Equipment Operation Precautions

1. Electrical Control Section

(1) Power Control Box

I. Master power switch: Equipped with residual current leakage protection, controlling the main power supply of the training device.

II. Power Indicator: The indicator light illuminates when the device's power supply is connected and the main power switch is turned on.

III. Speed Controller: Provides adjustable power supply for AC variable-speed motors.

IV. "Reset" Button: After the 2D worktable triggers the limit switch and stops during movement, pressing this button combines with the gear shift of the transmission to restore normal operation.

V. Power Operation and Precautions:

Connect the single-phase three-wire power supply to the device, and then connect the AC motor and the limit switch to the motor interface and limit switch interface respectively, which are brought out from the training device.

Turn on the main power switch, rotate the speed controller's speed knob counterclockwise to the bottom, then switch the controller's switch to "RUN", and rotate the speed knob clockwise; the motor will start running.

When shutting off the motor power, first turn the speed regulator's adjustment knob counterclockwise to the bottom, stop the motor, then switch the regulator's switch to "STOP," and turn off the main power switch.

When the 2D worktable encounters a limit switch and stops, it is mandatory to first change the direction of the 2D worktable movement through the transmission gear, then press the "Reset" button on the control panel. Release the "Reset" button when the 2D worktable moves away from the limit switch. It is prohibited to press the "Reset" button on the control panel without changing the direction of the 2D worktable movement.

(2) Power Control Interface

The "Power Control Interface" panel is mounted on the back of the training workbench, serving as the input/output interface for the power control box.

220V power input interface: Connect the dedicated power cord to supply power to the training device.

Motor and limit switch interface: The motor section is connected to an AC reducer motor, powered by a speed controller to provide adjustable power; the limit switch section is connected to the limit switches at the end of the two rows of travel on the two-axis worktable.