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关键词：: 电动扳手扳手机械设计机械课程毕业设计电动扳手的设计

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电动扳手设计

电动扳手的设计【优秀机械全套课程毕业设计含26张CAD图纸】

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电动扳手设计

[摘要] 在大型钢结构建筑中，广泛使用高强度螺栓链接。这种螺栓连接，在施工中要求用规定的拧紧力矩锁紧螺母，以保证链接的可靠性。

由于高强度螺栓的材料和热处理是严格控制和检查的，因此螺栓定力矩切口处的扭剪断裂力矩能够控制在一个比较准确的范围，从而能保证螺栓连接的可靠性。当拧紧力矩过大时，不能保证螺栓的强度；当拧紧力矩过小时，又不能保证连接的可靠性。因此这种螺栓连接，在施工中要求用规定的拧紧力矩锁紧螺母，以保证链接的可靠性。另外，高强度螺栓往往成批使用，并且工作的环境也比较坚苦，如果是用普通扳手进行定力矩拧紧，工人拧紧螺母的过程中会有很多不便，工作效率也会很低。综合以上三点原因，在拧紧高强度螺栓时，我们采用电动扳手代替手从扳手进行拧紧。

电动扳手以220V交流电源为动力进行工作，可以保证每个螺栓的拧紧力都在规定的范围内，同时，采用电动扳手代替手动扳手可以大大提高螺栓拧紧的速度，提高工人的工作效率，改善工人的劳动强度

[关键词] 电动扳手谐波传动柔轮

Electric Wrench Design

[Abstract] In large steel structures, widely used in high strength bolts links. This bolt connection, in accordance with requirements of the construction of torque lock nut and to guarantee the reliability of the link.

Due to the high strength bolts of material and heat treatment is strict inspection and control, thus shall the bolt torque incision torshear fracture in a moment can control the accuracy and can guarantee, the reliability of the bolt connection. When large torque, cannot guarantee the strength bolt, When the torque, and after hours cannot guarantee the reliability of the connection. Therefore the bolt connection, in accordance with requirements of the construction of torque lock nut and to guarantee the reliability of the link. Additionally, high strength bolts, and often used to working environment is hard, and if it's used for torque wrench on ordinary workers, tighten lock nut process will have a lot of inconvenience, the working efficiency is also very low. Three reasons, in comprehensive above tighten high strength bolts, we adopt electromotive spanner from wrench to replace hand tighten.

Electromotive spanner to ac power for power on 220V work, can guarantee each bolt tightened force within a prescribed scope, at the same time, using electric wrench instead of manual wrench screw bolts can greatly improve the speed, improve work efficiency, improve the worker labor intensity

[Key words] Electric wrench Harmonic Drive Flexspline

前言 ……………………………………………………………………………1

第 1 章设计任务分析 ……………………………………………………………2

1.1 设计任务 …………………………………………………………………2

1.2 设计意义 …………………………………………………………………2

第 2 章方案设计 …………………………………………………………………3

2.1 基本结构的分析与选择 …………………………………………………3

2.2 总体方案的拟定 …………………………………………………………5

第 3 章电动扳手的动力与运动分析计算 ………………………………………8

3.1 整机传动比的确定 ………………………………………………………8

3.2 各传动比的确定 …………………………………………………………8

3.3 谐波齿轮传动和行星轮系运动分析 ……………………………………9

第 4 章传动部件的设计与校核…………………………………………………11

4.1 定轴轮系的设计…………………………………………………………11

4.1.1 .按齿面接触疲劳强度设计 ……………………………………11

4.1.2 按齿根弯曲疲劳强度设计………………………………………12

4.1.3 设计计算…………………………………………………………13

4.2 谐波齿轮传动的设计……………………………………………………14

4.2.1 谐波齿轮传动参数的确定………………………………………14

4.2.2 柔轮结构形式的选择……………………………………………15

4.2.3 谐波齿轮轮齿的耐磨计算………………………………………15

4.3 柔轮强度计算……………………………………………………………16

4.4 行星齿轮传动的设计……………………………………………………17

4.4.1 齿轮啮合参数的确定……………………………………………17

4.4.2 齿轮强度计算特点 ……………………………………………17

第 5 章标准件的选择与校核……………………………………………………21

5.1 轴承的选择与校核………………………………………………………21

5.1.1 轴承的选择………………………………………………………21

5.1.2 轴承的校核………………………………………………………22

5.1.3 轴承的润滑方式…………………………………………………22

5.2 键的选择与校核…………………………………………………………22

5.2.1 键的选择…………………………………………………………22

5.2.2 键的校核…………………………………………………………22

5.3 圆柱螺旋压缩弹簧的设计………………………………………………23

第 6 章电动扳手中重要零件的材料……………………………………………27

结论 ………………………………………………………………………………29

致谢 ………………………………………………………………………………30

参考文献 ………………………………………………………………………31

前言

螺栓连接是一种普遍可靠的连接方式。其中高强度螺栓链接广泛使用在大型钢结构建筑中。

电动扳手以220V交流电源为动力进行工作，可以保证每个螺栓的拧紧力都在规定的范围内，同时，采用电动扳手代替手动扳手可以大大提高螺栓拧紧的速度，提高工人的工作效率，改善工人的劳动强度。

在长期的使用中，电动扳手充分发挥了它的设计有点——体积小、重量轻、操作方便快捷、安全可靠，从而使电动扳手成为施工现场不可缺少、不可替代的专用工具。从总体上看，电动扳手基本上可在设计寿命范围正常工作，无需大修，施工现场也未发生任何由于漏电等原因引起的安全事故，从而得到使用单位的好评。

个别的电动扳手，在使用中曾发生柔轮筒体底部断裂失效的现象，这一事实验证了柔轮光弹性试验得到的结论——柔轮工作时的切应力及壳壁内的正应力的最大值均发生在柔轮的根部（并有应力集中的影响），根部是最危险的截面。因此，改善柔轮根部的结构和加工品质是提高强度和使用寿命的关键措施。

多年的生产实践表明，自行研制的电动扳手成功替代了进口产品，为国家节省了大量外汇，也为生产研制单位带来了可观的经济效益。

由于时间仓促和作者的知识水平有限，论文中的错误和不足在所难免，请各位老师给予批评指正。

参考文献

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[4] 陈立周.飞剪机剪切机构的合理设计. 北京：钢铁学院学报 1980年1月

[5] Simon，J.M.Computerized Synthesis of Straight Line Four-Bar Linkages from Inflection Circle Properties . Transactions of the ASME.Journal of Engineering for Industry. August 1977:610-614

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[7] 李克涵.应用鲍尔点（Ball Point）理论设计连杆直移机构.机械设计.1982

[8] 李克涵.新型150kN曲柄连杆式钢坯飞剪机的研制.冶金设备.1991

[9] 李克涵.工业机械手运动参数的分析与综合.机械设计.1993

[10] 沈允文，叶庆泰.谐波齿轮传动的理论和设计. 北京：机械工业出版社.1985

[11] 许洪基主编.现代机械传动手册. 北京：机械工业出版社.1995

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[13] 雷廷权等主编.30CrMnSiA钢调质-旋压-时效工艺研究.黑龙江机械.1981，No.3

[14] M.Frocht.光测弹性力学.陈森译. 北京：科学出版社，1994

[15] 罗祖道，吴连元.弹性圆柱薄壳的一般稳定性.力学学报.1962，Vol.5,No.1

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[18] 卜炎主编. 中国机械设计大典.南昌:江西科学技术出版社.2002年1月

[19] 朱孝录主编. 中国机械设计大典.南昌:江西科学技术出版社.2002年1月

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内容简介：: Int J Adv Manuf Technol (2002) 20:639648Ownership and Copyright 2002 Springer-Verlag London LimitedAn Advanced Ultraprecision Face Grinding MachineJ. Corbett1, P. Morantz1, D. J. Stephenson1and R. F. Read21School of Industrial & Manufacturing Science, Cranfield University, Bedford, UK;2Cranfield Precision, Division of Landis Lund,Cranfield University, Cranfield, Bedford, UKCranfield Precision, Division of Landis Lund, has recentlydeveloped an ultraprecision face grinding machine which incor-porates several automatic supervision features. The companysupplied the machine to Cranfield Universitys Precision Engin-eering Group in order that the group can undertake research,particularly in the area of damage-free grinding with highsurface and subsurface integrity. The paper discusses thedesign of the machine, initial machining trials and potentialresearch projects. Such projects will benefit from the avail-ability of such an advanced machine system which incorporatesmany state-of-the-art features for the automatic supervisionand control of the machining process.Keywords: Automatic supervision; Grinding; Machine tooldesign; Precision machining1. IntroductionCranfield Precision, which is a UNOVA Company, specialisesin the design and manufacture of machines for cost-effectiveproduction of components in advanced materials includingceramics, glasses, intermetallics and hard alloy steels. TheSchool of Industrial and Manufacturing Science (SIMS), Cran-field University, places great importance on developing closecollaborative links with industry and is currently undertakinga range of ultraprecision and high-speed machining researchprojects including superabrasive machining, ductile machiningof brittle materials and precision machining for the automotiveindustry. The complementary research interests of the twoorganisations have resulted in Cranfield Precision developingand supplying an advanced ultraprecision face grinding machineto the Precision Engineering Research Group within SIMS.This will enable the group to undertake a wide range ofresearch programmes, particularly in the area of damage-freegrinding with high surface and sub surface integrity.Correspondence and offprint requests to: Prof. J. Corbett, School ofIndustrial and Manufacturing Science, Cranfield University, BedfordMK43 0AL, UK. E-mail: j.corbettL50560cranfield.ac.uk.Materials processing with nanometric resolution and controlis viewed as a mid- to long-term solution to the cost and timeproblems that plague the manufacturing of electro-optics andother precision components. For example, ductile grinding ofbrittle materials can provide surfaces, as ground, to nanometresmoothness and figure accuracy at higher production rates thanusually encountered 1. More significantly, a ductile groundsurface experiences little or no subsurface damage, therebyeliminating the need for the subsequent polishing step associa-ted with conventional grinding. The performance of many“microfeatured” products (e.g. semiconductor, optical communi-cations systems, computer peripherals, etc.), as well as largercomponents for aerospace and automotive applications, dependsincreasingly on higher geometric accuracies and micro- andnanostructured surfaces. Recently, the automotive industry hasindicated a future requirement for the surfaces of certain keytransmission components to be of “optical” quality, with targetsof 10 nm Ra surface finish to be economically produced onhardened steel by direct machining, without polishing.The conditions under which damage-free surfaces can beproduced on glasses and ceramics, and “optical” surfaces canbe produced on hardened steel, are exacting, requiring (a) theuse of a class of machine tool not normally found in even thebest production facilities, e.g. high accuracy, smoothness ofmotion, loop stiffness 2, (b) the incorporation of ancillaryfeatures specially developed to suit the particular application(e.g. grinding wheel truing and conditioning), and (c) the useof the correct grinding technology for the application (manyvariables wheel type, coolant, speeds, feeds, etc). All theconditions must be satisfied and the wafer face grindingmachine has been developed to meet them.2. ObjectivesIn order to meet the demands of surface integrity and pro-ductivity mentioned above, for a wide range of components,the principal objectives include the development of:1. A machining process capability for the manufacture ofsizeable components with high levels of surface/subsurfaceintegrity.nts640 J. Corbett et al.2. Optimised “ductile mode” machining processes for brittlematerials (glasses and ceramics).3. A single process, with only one set-up, to replace the typicalthree-stage lapping, etching and polishing process, resultingin much higher productivity.3. The ProcessA prime requirement of the process is that it should be capableof machining extremely flat surfaces on workpieces up to 350mm diameter. Further, the surfaces should be smooth (50 nmRa) and have minimum subsurface damage. Ideally the surfaceshould be close to the quality obtained by polishing. In orderto meet these demanding requirements rotation grinding isutilised. A feature of rotation grinding is that unlike conven-tional surface grinding, it has a constant contact length andconstant cutting force. Figure 1 illustrates the grinding prin-ciple. Both the cup grinding wheel and workpiece rotate andthe axial feed of the grinding wheel removes stock from thesurface of the workpiece until it reaches its finalthickness/geometry.4. The MachineThe demanding requirements of the process and componentquality necessitate a machine of extremely high loop stiffness.The design targets for the face grinding machine (Fig. 2) are:1. Loop stiffness better than 200 N H9262mH110021with good dynamicdamping, required to achieve submicron subsurface damage.2. Control of pitch (wheel to component surface) to betterthan 0.333 arc seconds, required to achieve a total thicknessvariation (TTV) tolerance of 0.5 H9262m.3. Control of cut-depth to better than 0.1 H9262m, required toachieve submicron subsurface damage.4. Axial error motions of spindles better than 0.1 H9262m, requiredto achieve submicron subsurface damage.5. Measurement and feedback of component thickness to 0.5H9262m, required to achieve micron thickness tolerance.Fig. 1. Face grinding operation.The geometry of the ground flat surface is determined by therelative position of the rotary axes of the grinding wheel andworkpiece. Figure 3 indicates the relative machine motions andaxes. There are 11 axes, plus three automatic robot loadingmotions (not shown), all driven under servo control. These are:S1 Grinding spindleC Workhead spindleZ InfeedX CrossfeedS2 Truing spindleW Dressing axisA Tilt pitchB Tilt yawS3 Chuck wash brushP Probe thicknessWash armAs described below, the flatness accuracy can be achievedby the superimposed rotations of the rotary axes coupledwith an appropriate spindle alignment strategy. Further, thisprototype research machine benefits from the incorporation ofthe following state-of-the-art features for the automaticsupervision and control of the machining process.4.1 Adjustment of the Workpiece and GrindingWheel PlanarityThe relative alignment of the two rotary spindles S1 and C(Fig. 3) is simplified because the geometry of the groundsurface can be described by geometrical equations. The grind-ing process requires a specific angle between the plane of thegrinding wheel and the plane of the workpiece to be maintainedas the Z-axis infeed is applied. This angle is typically muchless than a degree, so that the workpiece and wheel are nearlyparallel. This angle is monitored by three gauging LVDTsensors which measure the displacement between the grindingspindle housing, and a precision-machined surface on the work-spindle housing. The gauging sensors are placed around thegrinding spindle housing, roughly equidistant from the centreof the wheel spindle axis in the plane of the wheel, at aknown separation. The information from these sensors is fedback into the control system to amend the control for the A-(pitch), B- (yaw) and Z- (infeed) axes. This is a unique featureof the machine, to maintain workpiece flatness because, as theworkpiece subsurface damage reduces and the surface finishimproves the grinding forces increase significantly. This hasthe effect of distorting the grinding spindle to workhead align-ment, which then produces non-flat surfaces. On conventionalmachines this alignment is adjusted by mechanical trial-and-error adjustment, and relies on the force and deflection alwaysbeing uniform. However, on this machine if the process con-ditions are changed, the alignment is automatically compensatedfor. This can then be optimised to suit the material and wheelconditions by changes in the software of the control system.A functional block diagram for the servo control of the Z-axisis illustrated in Fig. 4.ntsUltraprecision Face Grinding Machine 641Fig. 2. Face grinding machine.Fig. 3. Axes nomenclature.4.2 Grinding WheelsThe roughing and finishing wheels are concentrically mountedon one spindle via a patented system which incorporates anadvance/retract mechanism for the roughing wheel, as shownin Fig. 5. In order to maximise component throughput, a coarse-grained wheel is first used to obtain a high material removalrate. The fine-grained finishing wheel is then used to obtainthe finished size and surface integrity.4.3 Detecting Grinding Wheel ContactAcoustic emission (AE) sensors are used to establish the initialtouch between the grinding wheel and component. Because ofthe importance of establishing first touch to very fine limits,when finish grinding, ring sensors are used on the workheadand grinding spindles. These are extremely sensitive and arelocated at the front of the spindles, close to the signal source.An on-machine grinding wheel truing spindle is also fittedwith AE sensors which enables “touch dressing” of the grind-ing wheel.4.4 Automatic Measurement of Grinding ForcesGrinding forces are measured via sensors placed within theforce loop away from external forces, such as lead screw nutsand their associated friction. Measurement of the grindingforces gives a good indication of grinding wheel wear.4.5 Measurement of Grinding Wheel Wear andComponent ThicknessGrinding wheel wear is monitored together with componentthickness. A specially designed anvil and LVDT probeassembly are used to measure component thickness. This isdone by initially datuming the anvil and probe on to the porousceramic vacuum chuck face to which the component is fixed.When measuring the component thickness, the anvil, which ison the same slideway as the probe, contacts the chuck datumand the LVDT probe makes contact with the face of thecomponent, thus giving a measurement of thickness. Grindingwheel wear can be found by reading directly the position ofthe Z-axis, and relating this to the chuck face datum position.Thermal growth is measured by pairs of eddy current probesmounted on the workhead and grinding spindles. Any growthis automatically compensated by adjusting the relative positionsof the two spindles.nts642 J. Corbett et al.Fig. 4. Z-axis functional block diagram.Fig. 5. Single axis dual wheel system.4.6 Ancillary FeaturesThe machine also has facilities for on machine component andchuck washing and also a robotic loading and unloading capa-bility to load and unload automatically components onto andfrom the workhead spindle.5. Machine CommissioningMachine services consist of an air supply, grinding coolantsupply and motor coolant supply, as well as three-phase electri-cal power. Air is provided by a high performance supply andconditioning system, which delivers clean dry air at 13 bar atover 5000 l minH110021. The air consumption within the face grindermachine is around 2000 l minH110021in the air bearings, the remain-der being for the various air purge and cleansing systems. Theair is filtered to 0.1 H9262m and dried to a pressure dewpoint ofH1100240C as required for the operation of ultraprecision air bear-ings.Coolant supply is by recirculating water. This is pumped at4.5 bar at a flow rate of up to 100 l minH110021. Coolant isdistributed to various coolant nozzles, under individual control,as required by the machine process. Used coolant is returnedto the collection tank, and then fed to the main coolant tankby a scavenge pump. Some water-borne debris (workpiece andgrinding wheel residues) settles out here; the remainder isremoved by filtration on the machine in various stages downto 0.01 H9262m.Services provision requires a multiplicity of controlled pro-cess fluid distribution points, together with appropriate safetyinterlock and performance monitoring systems.5.1 The Control SystemThe control system is in two parts, based on an industrystandard Isagraph PLC, and a Cranfield Precision CNC system.Machine I/O is on a distributed Interbus S system and servocontrol is implemented by a Sercos fibre-optic ring.The PLC program required only minor modification duringcommissioning, most effort being concentrated in further devel-opment of the CNC program, particularly in grinding touchsensing, and in the truing and grinding operations.5.2 Machine PreparationIn preparation for grinding operations, an assessment of severalareas was critical:1. Machine alignments.2. Balance of spindles.3. Condition of wheels.4. Application of coolant.5. Control of machine motions.ntsUltraprecision Face Grinding Machine 643Fig. 6. Grinding spindle horizontal amplitude response to out-of-balance forces.These are the major determinants of grinding surface quality,and were tackled in order.5.3 Machine AlignmentsThe machine tool builders had set most machine alignmentsaccurately; metrology checks confirmed these to be in order.However, the critical alignment datum (alignment betweenworkspindle axis and grinding spindle axis) had been lost,since the grinding spindle had to be removed, prior to relocatingthe machine in the Precision Engineering Laboratory.This alignment datum had to be re-established by using aminiature eddy current probe (with a measurement range ofaround 6 H9262m) mounted on the grinding spindle faceplate. Aspecial purpose alignment jig was mounted on the workspindlefaceplate. Measuring the variation of distance of the probefrom features on the alignment jig, as the two spindles wereindependently rotated, allowed the angular alignment of thetwo spindle axes to be determined, using a multiparameterleast squares fit.Fig. 7. Grinding spindle horizontal phase response to out-of-balance forces.5.4 Wheel BalanceThe machine is configured to enable automatic balancing onthe grinding spindle. This is included on the machine toaccommodate the automatic selection of grinding wheels. Thegrinding spindle carries two concentric segmented cup wheels,rough and fine grit; the rough wheel is of slightly largerdiameter. The roughing wheel can be selected automaticallyby sliding it parallel to the spindle axis, under air pistoncontrol, to engage in one of two face tooth couplings, so thatit either projects or is just below the face of the fine wheel.These two configurations, with rough or fine wheel selected,have marginally different out-of-balance moments, and theautomatic balancing is included to compensate for this.Figures 6 and 7 show the amplitude and phase response fora balance (displacement) sensor in a horizontal orientation,located at the grinding spindle nose, over a range of revolutionsper minute (rpm) shown along the x-axis of the figure. The y-axis represents a nominal peak-to-peak displacement at thatrotation rate of the grinding spindle. These data were obtainedsubsequent to fine (single plane) balancing of the grindingnts644 J. Corbett et al.Fig. 8. Grinding spindle vertical amplitude response to out-of-balance forces.spindle. A strong resonant response can be seen at around1200 rpm (or 20 Hz). Figure 8 shows the amplitude responsefor the balance (displacement) sensor in a vertical orientation.The resonant behaviour is entirely absent. Subsequent investi-gation has revealed that the source of the resonance is com-pliance in the “B” grinding wheel tilt axis (a vertical axis), asshown in Fig. 3, which is why this is only apparent to ahorizontally oriented sensor.The truing wheel balance is also critical. Figure 9 showsthe horizontal response of the truing spindle, subsequent tofine balancing. Again a small resonance is apparent in thehorizontal direction, at around 4000 rpm (67 Hz). The truingspindle is mounted on the X-axis carriage, and this horizontalresonance is in the direction of the X-axis motion. Once morethis is due to the compliance of the motion system in its drivedirection. This has a lower impact on grinding performancethan grinding spindle balance, although truing the spindle out-Fig. 9. Truing spindle horizontal amplitude response to out-of-balance forces.of-balance motion will impart a small-scale cyclic topographyon to grinding wheels, which in turn affects grinding quality.5.5 Wheel ConditionOn this machine, wheel form is imparted through a truingoperation, and wheel condition is maintained through sub-sequent dressing, in between relatively infrequent truing oper-ations. The truing (forming) operation specified in the machinedesign involves a plunge “grind” similar to the wafer grindingoperation, although in this case the cup grinding wheel andparallel truing wheel make contact at their periphery. Thegrinding wheel form was found to be in error by 0.2 (12minutes of arc). The truing operation was amended to rectifythis. Truing is now accomplished by a plunge and a subsequenttraverse of the X-axis. Correctly applied, this can produce thentsUltraprecision Face Grinding Machine 645correct (planar) wheel form, since the grinding spindle axishad previously been set accurately to be perpendicular to theX-axis motion.5.6 Coolant ApplicationConsiderable effort was concentrated in the alignment

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