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基于优化设计的WS-55140碗头锁紧销装配工装研发

Research and Development of WS-55140 Bowl Head Locking Pin Assembly Tool Based on Optimized Design

  • 摘要: 针对WS-55140碗头挂板锁紧销装配过程中,原有DHKX-2型锁紧销开销机载荷不足、装配一致性差等问题,开展压装工装的研发。选用STG-80-150-20-8T-50型气液增力缸作为动力核心,经计算与校核完成选型,并通过力学与静力学分析完成工装性能校验。结果表明,在9033.48N的极限峰值压装载荷下,核心承压构件的强度安全系数高于行业规范规定的最低限值1.5,有效消除了工件压装变形缺陷,降低了人工操作安全风险,实现该型号高压输电金具装配的精益化、标准化生产,可为电力金具行业同类装配工艺及设备改造提供工程参考。

     

    Abstract: To address issues during the assembly process of the WS-55140 bowl head hanging plate locking pin—such as insufficient load capacity of the original DHKX-2 pin puller, low efficiency of manual pressing on ordinary punching machines, poor assembly consistency, easy deformation of workpieces, and obvious safety risks—we carried out the development and performance verification of a dedicated automated pressing tool. The study adopted a pneumatic-hydraulic boosting transmission scheme, using the STG-80-150-20-8T-50 pneumatic-hydraulic booster cylinder as the power core. After calculating load margins and checking structural strength and stiffness, we finalized the selection of the power components. We also designed precision positioning and clamping fixtures along with a linkage control system, integrating all processes including positioning and clamping, pressing and holding, and automatic resetting, forming an all-in-one automated pressing tool. The tool’s performance was verified through mechanical analysis and on-site trial assembly tests. On-site results showed that the tool’s rated pressing force can reach 80kN, with stable pressure output and a wide adjustment range. The assembly efficiency for a single workpiece increased by about 60% compared to traditional manual pressing, with product assembly qualification rates exceeding 99.5%. This effectively eliminated workpiece pressing deformation defects, reduced safety risks of manual operation, and realized lean, standardized, and safe production for high-voltage transmission fittings of this model. It can serve as an engineering reference for similar assembly processes and equipment upgrades in the power fittings industry.

     

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