KR102073518B1 - Method for manufacturing axle housing - Google Patents

Abstract

This embodiment relates to a method of manufacturing an accelerator housing. According to one or more exemplary embodiments, a method of manufacturing an accelerator housing includes cutting a substrate material to form a unit plate; Molding the unit plate into a unit housing by a hot pressing method; Forming a joining surface of the unit housing; Coupling two unit housings together through the joining surface to form a first molded body; Coupling a reinforcement to the first molded body to form a second molded body; Cutting the inner diameter of the central hole of the second molded body, cutting the connection part of the second molded body a predetermined length, and cutting the central part of the second molded body to form a third molded body; Forming a fourth molded body by extending a portion of an inner circumferential surface of the central hole of the third molded body to form a coupling groove; And coupling the ring cover to the top surface of the fourth molded body, and coupling the bottom cover to the bottom surface of the fourth molded body.

Description

Method for manufacturing axle housing {Method for manufacturing axle housing}

This embodiment relates to a method of manufacturing an accelerator housing.

The vehicle is equipped with a rear accelerator for driving the front or rear wheels with torque output from the engine and converted in the transmission.

The rear accelerator has a differential for transmitting the driving force transmitted from the propeller shaft to the drive wheels.

The rear accelerator may include pinion gears, ring gears, differential gears and an accelerator shaft embedded in the accelerator housing. When the pinion gear connected to the propeller shaft is driven, the ring gear coupled to the pinion shaft is driven and the accelerator shaft is driven through the differential gear connected to the ring gear, so that the driving wheel can be rotated.

In addition, the accelerator housing covers pinion gears, ring gears, differential gears and accelerator shafts while preventing leakage of lubricant.

In general, the accelerator housing is a structure made of cast iron that surrounds an end gear (ring & pinon), a differential gear carrier, and an accelerator shaft, and is built up according to the type of part where the gear devices are contained. It is divided into type, split type and banjo type.

The build-up type is a type in which gears are pressed into the middle part of the accelerator housing, which is complicated in interior and relatively difficult to machine. The split type is a structure in which the accelerator housing is divided from the center to the left and right. The banjo type is a structure that is easy to handle and adjusts to mass production in adjusting the deceleration gear in a form that rounds the middle part of the accelerator housing so that the differential gear carrier can be detached from the accelerator housing.

In general, although a three-dimensional accelerator housing is produced by press molding a plate, which is a work object, cracking of the plate may occur in the forming process. In addition, since the implementation of a method of processing a unitary structure from a single plate at the time of manufacturing, the waste of raw materials is increased, causing a problem of cost loss.

The present invention has been proposed to improve the above problems, by implementing the structure of the accelerator housing in a structure in which a plurality of unit housings are separately manufactured and combined, can reduce the manufacturing cost, the general purpose of manufacturing design according to the size An object of the present invention is to provide a method for manufacturing an accelerator housing capable of securing an applicability.

According to the present embodiment, there is provided a method of manufacturing an accelerator housing, comprising: cutting a substrate material to form a unit plate; Molding the unit plate into a unit housing by a hot pressing method; Forming a joining surface of the unit housing; Coupling two unit housings together through the joining surface to form a first molded body; Coupling a reinforcement to the first molded body to form a second molded body; Cutting the inner diameter of the central hole of the second molded body, cutting the connection part of the second molded body a predetermined length, and cutting the central part of the second molded body to form a third molded body; Forming a fourth molded body by extending a portion of an inner circumferential surface of the central hole of the third molded body to form a coupling groove; And coupling the ring cover to the top surface of the fourth molded body, and coupling the bottom cover to the bottom surface of the fourth molded body.

According to the present embodiment, the housing structure can be implemented as a structure in which a plurality of unit housings are separately manufactured and combined, thereby reducing manufacturing costs and further securing universal applicability of manufacturing design according to the size of the accelerator housing. It has the effect of making it possible.

1 is a flow chart of the method of manufacturing an accelerator housing according to an embodiment of the present invention.
2 is a perspective view of a unit housing according to an embodiment of the present invention.
3 is a plan view illustrating a top surface of a unit housing according to an exemplary embodiment of the present invention.
4 is a cross-sectional view showing modifications of the joint surface coupling structure according to the embodiment of the present invention.
5 is a plan view showing a top surface of the first molded body according to the embodiment of the present invention.
6 is a plan view showing a top surface of a second molded article according to an embodiment of the present invention.
Figure 7 is a perspective view showing a state in which the reinforcing portion is coupled to the first molded body according to an embodiment of the present invention.
8 is a top view showing a top surface of a third molded product according to an embodiment of the present invention.
9 is a plan view showing a top surface of a fourth molded article according to an embodiment of the present invention.
10 is a perspective view of an accelerator housing according to an embodiment of the present invention.
11 is a cross-sectional view of a central portion according to an embodiment of the present invention.

Hereinafter, some embodiments of the present invention will be described through exemplary drawings. In describing the reference numerals in the components of each drawing, the same components are denoted by the same reference numerals as much as possible even though they are shown in different drawings.

In addition, in describing the components of the embodiments of the present disclosure, terms such as first, second, A, B, (a), and (b) may be used. These terms are only for distinguishing the components from other components, and the nature, order or order of the components are not limited by the terms. Where a component is described as being 'connected', 'coupled' or 'connected' to another component, the component may be directly connected, coupled or connected to the other component, but the component and its other components It is to be understood that another component may be 'connected', 'coupled' or 'connected' between the elements.

1 is a flowchart of a method of manufacturing an accelerator housing according to an exemplary embodiment of the present invention.

In the accelerator housing according to the exemplary embodiment of the present invention, an outer shape may be formed by combining the unit housing. The accelerator housing may be implemented by a structure in which a plurality of unit housings are divided and manufactured. The unit housing may be manufactured by forming a plurality of unit plates in the structure of the substrate material and molding the unit plates.

2 is a perspective view of a unit housing according to an exemplary embodiment of the present invention, and FIG. 3 is a plan view illustrating a top surface of the unit housing according to an exemplary embodiment of the present invention.

1 to 3, in the method of manufacturing an accelerator housing according to an exemplary embodiment of the present invention, first, a unit plate is formed by cutting a structure of a substrate material (S10). The unit plate is for forming the unit housing 100 as described above, and a plurality of unit plates may be manufactured from a single substrate material.

More specifically, the unit plate may be implemented by arranging the shape of the unit plate on a metal substrate and cutting the unit plate. The substrate material may be cut through a gas cutting method through CNC (Computer Numerical Control) processing. In the case of the separation coupling structure, design deformation within a margin of error required in a process such as expansion or contraction of fine dimensions can be freely implemented, and in the case of modifying the number or curvature of the unit housing 100, Bars can be manufactured by expanding or reducing the dimensions of the accelerator housing, and there is an advantage that can be suitably applied to various automobile standards. In addition, compared to forming a single plate for the formation of the accelerator housing in the conventional single substrate material, the substrate material can be used more effectively, there is an advantage that can reduce the manufacturing cost.

Next, the unit plate formed by cutting from the substrate material is molded into the unit housing 100 (S20). At this time, before molding to the unit housing 100, a process of removing the metal foreign matter remaining on the unit plate may be added. Since the unit plate is formed by cutting the substrate material, a plurality of metal foreign substances may be included in the cutting process. Therefore, the metal foreign matter may be removed through the air washer that discharges the air toward the unit plate.

Molding to the unit housing 100 may be formed by a forming (hot pressing) method (Hot pressing) method. Therefore, the unit housing 100 as shown in FIG. 2 may be formed by hot pressing the unit plate.

The unit housing 100 may include a central portion 110 and a connection portion 150. The central portion 110 and the connection portion 150 may be integrally formed. The central portion 110 may form a spherical space so that the differential gear for coupling with the central portion in the other unit housing to transfer the driving force of the engine to the pair of driving wheels is installed.

The central portion 110 may have a semicircular cross section. Hereinafter, an inner surface of the unit housing 100 and a side surface of the unit housing 100 opposite to the inner surface of the unit housing 100 may be combined with another unit housing to be described later among the side surfaces of the unit housing 100. Will be defined as the outer surface of the

The outer surface of the central portion 110 is formed of a curved surface having a constant curvature. An inner surface edge of the central portion 110 may be formed with a curved surface 112 and an inclined surface 114 connecting the curved surface 112 and the bonding surface 116 of the connection portion 150 to be described later. The curved surface 112 may have the same curvature as the outer surface of the central portion 110.

Grooves 102 may be formed on the inner surface of the central portion 110. The groove 102 may be a groove formed by recessing the remaining area except the edge area of the inner surface of the central portion 110 to the outside.

The connection part 150 may extend outward in the longitudinal direction on both sides of the central part 110, respectively. The connection part 150 may be combined with a connection part of another unit housing, and an accelerator shaft may be embedded inside. The plurality of connection parts 150 may be disposed to face each other with respect to the central part 110.

The outer surface of the connection part 150 may be flat. Unlike this, the outer surface of the connection part 150 may be formed as a curved surface having a predetermined curvature. The groove 102 may also be formed on the inner surface of the connection part 150. That is, the groove 102 may be a single groove on the inner surface of the unit housing 100. In addition, a bonding surface 116 may be formed at an inner surface edge of the connection part 150. The joint surface 116 may be a surface coupled with the joint surface of the other unit housing 100. The bonding surface 116 may be connected through the curved surface 112 and the inclined surface 115. The joint surface 116 may be disposed in parallel with an outer surface of the connection part 150. The inclined surface 114 may extend in a linear direction such that one end of the curved surface 112 and one end of the bonding surface 116 are connected to each other. The inclined surface 114 may have a shape in which the distance to the outer surface of the central portion 110 is closer to the central portion 110. In other words, the inclined surface 114 may have a shape in which the distance to the outer surface of the central portion 110 is farther away from the connection portion 150.

When the unit housing 100 is formed, the unit housing 100 is molded to the bonding surface 116 so that the unit housing 100 can be easily combined with another unit housing (S30).

4 is a cross-sectional view showing modifications of the joint surface coupling structure according to the embodiment of the present invention.

Referring to FIG. 4, the unit housing 100 may be coupled to another unit housing through the bonding surface 116. The joint surface 116 may be coupled to the joint surface of the other unit housing by welding. Therefore, the shape of the bonding surface 116 may be processed to facilitate coupling between the bonding surfaces 116.

Specifically, as shown in FIG. 4A, an inclined surface may be formed on the bonding surface 116. Therefore, as shown in FIG. 4C, the inclined surface structures corresponding to each of the plurality of bonding surfaces 116 coupled to each other may be formed to be coupled to each other. For this reason, the operator's convenience can be improved through the inclined structure between the joint surface 116 in the welding process.

However, it is not limited to the surface contact structure through the inclined surface between the joint surface 116, to form the same inclined surface in each of the plurality of unit housing 100, and to join by welding in the state in which only the end region in contact with It is also possible.

In contrast, the coupling between the bonding surface 116 may be made through a rib and rib groove structure. Specifically, the rib groove 116a formed in the recessed surface from the joint surface 116 is formed in the joint surface 116 of one unit housing 100a, and it joins to the joint surface 116 of the other unit housing 100b. A plurality of unit housings may be coupled to each other by forming a rib 116b that protrudes from the surface 116 and is coupled to the rib groove 116a. Therefore, there is an advantage that the bonding state of the plurality of unit housings before the welding process can be more stably supported. In this case, the other regions of the rib 116b and the rib groove 116a and the outer contact surface 116 may have a surface contact structure.

5 is a plan view illustrating an upper surface of the first molded body according to the exemplary embodiment of the present invention.

As described above, when molding of the bonding surface 116 is completed, the plurality of unit housings 100 are coupled to each other (S40). As a result, the first molded body 170 may be formed. The first molded body 170 may be formed by combining the first unit housing 100a and the second unit housing 100b with each other. A welding region may be formed between the bonding surface 116 of the first unit housing 100a and the bonding surface 116 of the second unit housing 100b. The welding area may be disposed in an area between the connection parts 150 of different unit housings. A space part (not shown) surrounded by the groove 102 is formed inside the connection part 150.

On the other hand, the central portion 178 of the first molded body 170 is formed by the combination of the central portion 110 of the first unit housing (100a) and the central portion 110 of the second unit housing (100b). In addition, a first hole 173 penetrating a lower surface from an upper surface may be formed at the center of the central portion 178 of the first molded body 170. The region in which the inner circumferential surface is defined by the inclined surface 114 among the regions in which the first hole 173 is formed may be defined as the second hole 172.

The second hole 172 may be formed by extending a predetermined distance outward from a portion of the first hole 173 compared to other areas. The second hole 172 may be provided in plural and may be disposed to face the first hole 173. When the first molded body 170 is viewed from the top or bottom surface, the second hole 172 may have an isosceles triangular shape in cross section by the inclined surface 114 between the plurality of unit housings.

6 is a plan view illustrating a top surface of a second molded article according to an embodiment of the present invention, and FIG. 7 is a perspective view showing a state in which a reinforcement part is coupled to a first molded article according to an embodiment of the present invention.

6 and 7, a reinforcing part 210 may be coupled to the first molded body 170. As a result, the second molded body 200 may be formed.

The reinforcement part 210 may be formed in a plate shape and coupled to cover the second hole 172. Sides of the reinforcement part 210 are coupled to the inclined surface 114 of the first unit housing 100a and the inclined surface 114 of the second unit housing 100b. To this end, a coupling surface 211 corresponding to the shape of the inclined surface 114 may be formed on the side surface of the reinforcement portion 210. The reinforcement part 210 may be formed in a substantially triangular shape, and the coupling surface 211 may be disposed on two sides disposed adjacent to each other. A second welding region 254 coupled by welding may be disposed between the coupling surface 211 and the inclined surface 114.

In addition, a curved surface 212 having a predetermined curvature may be formed at a side of the reinforcing part 210 facing the first hole 173. However, the present invention is not limited thereto, and a straight region may be formed in the curved surface 212.

The reinforcement part 210 may be coupled to the first molded body 170 by a magnet jig (M). The magnet jig M may have a cross-sectional area larger than that of the reinforcing part 210. Therefore, in a state in which the magnet jig M is coupled to one surface of the reinforcement part 210, the remaining area is coupled to the side surface of the first molded body 170 by magnetic force, so that the reinforcement part 210 and the The first molded body 170 may be primarily coupled to each other. As a result, an operator may more easily bond the reinforcement part 210 and the first molded part 170 to each other.

Welding may be performed while the reinforcement part 210 is coupled to the first molded body 170 through the jig M. As a result, the reinforcement part 210 and the first molded part 170 may be primarily coupled to each other (S50).

When the reinforcement part 210 is coupled to the first molded body by welding, the first molded body 170 and the reinforcement part 210 may be secondarily joined by welding. In this case, a first welding region 252 is formed between the plurality of unit housings 100, and a second welding region 254 is formed between the reinforcing portion 210 and the unit housing 100, respectively. Can be.

The material of the reinforcement part 210 may be different from the material of the unit housing 100. For example, the strength of the reinforcement 210 may be lower than the strength of the unit housing 100. For this reason, it is possible to reduce the material cost consumed in the accelerator housing and to lower the manufacturing cost. In addition, the center hole forming process in the accelerator housing to be described later may be made easier. That is, since the central hole is made through the first hole 173, the material of the reinforcement part 210 is formed of a material having a lower strength than that of other regions, so that an operator can easily form the central hole. . This will be described later.

8 is a top view illustrating a top surface of a third molded product according to an embodiment of the present invention.

6 and 8, the second molded body 200 in which the reinforcing part 210 and the first molded body 170 are coupled to each other has a first hole 173 penetrating the lower surface from the upper surface in the center thereof. It may include a central portion 178 is formed, and the connecting portion 179 extending outward from both sides of the central portion 178.

The central portion 178 may be formed by combining the central portions 110 of the plurality of unit housings 100 with each other. The connection part 179 may be formed by coupling the connection parts 150 of the plurality of unit housings 100 to each other.

In addition, an outer shape of the second molded body 200 may be processed to have an outer shape of the accelerator housing (S60). Specifically, in the external processing of the second molded body 200, cutting the inner diameter of the first hole 173, cutting the connection part 179 by a predetermined length, and cutting the upper surface of the central part 178. It may include the step.

The first hole 173 is a region in which the center hole 512 (see FIG. 11) is formed in the completed accelerator housing. The cutting of the inner diameter of the first hole 173 corresponds to the diameter of the center hole 512. It may be a step of cutting the inner circumferential surface of the first hole 173 so as to.

Some areas of both end areas may be cut from the remaining areas so that the connection part 179 also has a length corresponding to the connection part 514 of the accelerator housing.

In the cutting of the upper surface of the central portion 178, the upper surface of the central portion 178 is flat so that the ring cover 520 (see FIG. 11) to be described later is easily coupled to the upper surface of the central portion 178. It can be understood as cutting. An upper surface of the central portion 178 may form a plane.

Accordingly, as shown in FIG. 8, the third molded body 300 may include a central portion 320 in which the central hole 310 is formed, and a connecting portion 330 extending from opposite sides of the central portion 320. have. In this case, the diameter of the inner circumferential surface 312 of the central hole 310 formed on the upper surface of the central portion 320 may correspond to the diameter of the central hole 512 of the accelerator housing to be described later.

9 is a plan view illustrating a top surface of a fourth molded product according to an embodiment of the present invention.

8 and 9, in the method of manufacturing an accelerator housing according to an exemplary embodiment of the present invention, a coupling groove 415 is extended by extending a part of an inner circumferential surface of the central hole 310 in the third molded body 300. It may comprise the step of forming.

The coupling groove 415 is configured to be coupled to another area in the vehicle, and may be formed by extending a portion of the inner circumferential surface of the central hole 310 to the outside.

Accordingly, the fourth molded body 400 includes a central portion 420 in which the central hole 410 is formed, a plurality of connection portions 430 extending outwardly from the center portion 420, and the central hole ( It may include a coupling groove 415 formed to be recessed a predetermined distance to the outside with respect to the inner peripheral surface 412 of the 410. The coupling groove 415 may be provided in plural and disposed to face the center of the central hole 410.

10 is a perspective view of an accelerator housing according to an embodiment of the present invention, Figure 11 is a cross-sectional view of the central portion according to an embodiment of the present invention.

9 to 11, an accelerator housing 500 according to an exemplary embodiment of the present invention may be manufactured by coupling a ring cover 520 and a bottom cover 530 to the fourth molded body 400.

The ring cover 520 may be coupled to an upper surface of the central portion 510. The ring cover 520 may be coupled to the central portion 510 by welding or screwed through a screw.

The cross-sectional area of the ring cover 520 may be larger than the cross-sectional area of the first central hole 513. The ring cover 520 may be formed with a screw hole (not shown) to which the screw is fastened. Therefore, the screw is coupled to the screw hole, the accelerator housing 500 can be coupled in the vehicle. The screw holes may be provided in plurality, and may be disposed to be spaced apart from each other along the circumferential direction. On the other hand, the outer surface of the second molded body 200, the upper surface of the central portion 178 is cut so that the ring cover 520 can be easily coupled as described above.

A second central hole 515 may also be formed on the bottom surface of the central portion 510 to communicate the internal space 512 and the external region. Therefore, the bottom cover 530 may be coupled to the lower portion of the central portion 510 to cover the second central hole 515. An upper surface of the bottom cover 530 may be coupled to the lower surface of the central portion 510 by welding. Therefore, the inner space 512 communicates with the outer region of the accelerator housing 500 through the first central hole 513, and the lower region of the central portion 510 is covered by the bottom cover 530. Can be.

The internal space 512 in the central portion 510 may be provided with a differential gear for transmitting the driving force of the engine to a pair of drive wheels. In addition, components such as differential gears, pinion gears, and ring gears may be installed in the central portion 510 through the first central hole 513.

The axle shaft connected to the differential gear may extend in both directions along the connection portion 550. A spindle may be installed at the end of the connection portion 550.

In the above description, it is described that all the elements constituting the embodiments of the present invention are combined or operated in one, but the present invention is not necessarily limited to the embodiments. In other words, within the scope of the present invention, all of the components may be selectively operated in combination with one or more. In addition, the terms such as 'comprise', 'comprise' or 'having' described above mean that a corresponding component may be included unless otherwise stated, and thus, other components are excluded. It should be construed that it may further include other components instead. All terms, including technical and scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art unless otherwise defined. Terms used generally, such as terms defined in a dictionary, should be interpreted to coincide with the contextual meaning of the related art, and shall not be interpreted in an ideal or excessively formal sense unless explicitly defined in the present invention.

The above description is merely illustrative of the technical idea of the present invention, and those skilled in the art to which the present invention pertains may make various modifications and changes without departing from the essential characteristics of the present invention. Therefore, the embodiments disclosed in the present invention are not intended to limit the technical idea of the present invention but to describe the present invention, and the scope of the technical idea of the present invention is not limited by these embodiments. The protection scope of the present invention should be interpreted by the following claims, and all technical ideas within the scope equivalent thereto should be construed as being included in the scope of the present invention.

Claims (5)

A central portion having a first central hole formed at an upper surface thereof and a second central hole formed at a lower surface thereof;
A ring cover coupled to an upper surface of the central portion and disposed outside the first central hole;
A bottom cover coupled to a lower surface of the central portion and covered by the second central hole; And
In the manufacturing method of the accelerator housing comprising a pair of connecting portions extending to the outside of the central portion, facing the center portion relative to,
Cutting the substrate material to form a unit plate;
Molding the unit plate into a unit housing by a hot pressing method;
Forming a joining surface of the unit housing;
Coupling two unit housings together through the joining surface to form a first molded body;
Coupling a reinforcement to the first molded body to form a second molded body;
Cutting the inner diameter of the central hole of the second molded body, cutting the connection part of the second molded body a predetermined length, and cutting the central part of the second molded body to form a third molded body;
Forming a fourth molded body by extending a portion of an inner circumferential surface of the central hole of the third molded body to form a coupling groove; And
Coupling the ring cover to the top surface of the fourth molded body, and coupling the bottom cover to the bottom surface of the fourth molded body,
The unit housing includes a unit housing central portion and a plurality of unit housing connecting portions extending outwardly from both ends of the unit housing central portion.
The joining surface is disposed in the inner edge region of the connecting portion, the different joining surfaces are in surface contact with each other,
The first molded body includes a first hole disposed at the center, and a second hole disposed at an outer side of the first hole and a part of an inner circumferential surface thereof is defined by an inclined surface,
The reinforcement part is coupled to cover the second hole,
The material of the reinforcing part is different from the material of the unit housing between,
The reinforcing part is a material of strength lower than the strength of the unit housing,
Some areas of the side surfaces of the reinforcement part form a part of the inner peripheral surface of the central hole of the second molded body,
Ribs protruding from the joining surface are formed in the joining surface disposed in any one unit housing of the two unit housings, and rib grooves in which the ribs are coupled are formed in the joining surface disposed in the other unit housing.
The reinforcement parts are provided in plurality and are disposed to face each other based on the first hole.
The central portion of the unit housing has a semi-circular cross section is formed on the inner surface,
The inclined surface is disposed between the inner surface of the central portion of the unit housing and the inner surface of the unit housing connecting portion,
The inclined surface is arranged to connect the curved surface and the bonding surface,
The curved surface has the same curvature as the outer surface of the central portion of the unit housing,
The reinforcement part is fixed to the first molded body primarily through a magnet jig coupled to the outer surface of the reinforcement part and the outer surface of the first molded body by magnetic force, respectively.
When the first molded body and the reinforcement part are coupled through the magnet jig, an area between the reinforcement part and the first molded part is welded,
The upper surface of the central portion is flat,
The coupling groove is provided with a plurality, disposed to face the center portion,
And a direction connecting the pair of connection parts with respect to the center part and a direction connecting the plurality of coupling grooves are vertical.





delete delete delete delete

Images