DEVELOPMENT OF A SPECIAL DEVICE FOR MECHANIZING THE ASSEMBLY PROCESS OF SMALL PARTS AND JUSTIFICATION OF ITS PARAMETERS

Xoshimova Dilbaroy Olimjon qizi

Field of Study: Technological Machines and Equipment

Andijan State Technical Institute

Email: dilbaroydilbarxon691@gmail.com

Abstract. This article examines the specific features of the assembly process of small parts in the mechanical engineering and instrument-making industries, identifies existing challenges, and explores possible solutions. The high labor intensity, potential for human error, and low productivity associated with manual assembly operations are substantiated. Furthermore, the structural design, operating principle, and kinematic configuration of a newly developed special device intended for mechanizing assembly operations are presented. The proposed device makes it possible to increase production efficiency, improve product quality, and reduce the physical workload of operators.

Keywords: Small parts, assembly process, mechanization, special-purpose device, mechanical engineering, productivity, design.

INTRODUCTION. Nowadays, in such industries as precision instrument manufacturing, electronics, and automotive engineering, assembly operations involving micro-components and small-sized elements account for approximately 40–50% of the overall manufacturing process. Although leading mechanical engineering companies worldwide have achieved a high level of automation and mechanization in assembly operations, manual labor is still widely used in many small and medium-sized enterprises. This increases production costs and leads to assembly errors caused by human factors such as fatigue and inattention.

The reliability and durability of machines and mechanisms largely depend on the quality of their assembly. In particular, the joining and assembly of small components, including bolts, nuts, screws, pins, microconductors, and other elements, require a high degree of precision in the radio-electronics, instrument-making, and small-mechanism manufacturing industries.

Manual assembly operations place considerable demands on workers’ visual capabilities and fine motor skills, thereby reducing overall production efficiency. Therefore, the design of specialized technological devices intended for the rapid, accurate, and error-free assembly of small-sized components, as well as the scientific justification of their geometric and dynamic parameters, represents an important and relevant engineering challenge.

MAIN PART. Problem statement and analysis. Analysis indicates that assembly departments in many manufacturing enterprises are not sufficiently mechanized from a technological perspective. The main difficulties encountered when working with small components include:

1. Difficulties in holding and positioning components due to their small dimensions.
2. The risk of relative displacement or geometric misalignment of components during assembly.
3. Low labor productivity and increased worker fatigue resulting from the extensive use of manual labor.

Design and operating principle of the special-purpose device. the proposed special-purpose device consists of the following main components:

1. Main frame (housing): A rigid metal base that accommodates and supports all the components of the device.
2. Guiding mechanism: A system of mechanical grippers and clamps designed to ensure the accurate positioning and feeding of small components into the assembly area.
3. Pneumatic or mechanical clamping unit: A fixing mechanism that prevents components from shifting during the joining and assembly process.
4. Control handle: An ergonomic component designed to enable the operator to perform operations quickly and conveniently.

The operating principle of the device is as follows: the components to be assembled are placed into specially designed positioning slots. Using guiding elements, the components are brought into the required relative positions with the necessary degree of accuracy. Subsequently, the clamping unit generates the required pressure, ensuring that the components are securely joined.

Scientific and technical novelty and advantages. The distinguishing features and scientific novelty of the proposed special-purpose device compared with existing analogues are as follows:

1. Structural simplicity and flexibility: The device enables the assembly of small components of various dimensions and shapes through the use of interchangeable dies and punches.
2. Ergonomics and safety: Anthropometric requirements have been taken into account in the design of the operator’s workstation, helping to prevent physical fatigue during prolonged operation.
3. Accuracy and repeatability: The application of a self-centering mechanism that minimizes clearances (backlash) within the kinematic chain ensures component positioning accuracy within the range of 0.02–0.05 mm.

RESULTS AND DISCUSSION. The results of testing the developed special-purpose device under production conditions demonstrated the following improvements:

1. The time required for assembling small components was reduced by 1.8–2.2 times compared with the conventional manual assembly method.
2. The percentage of defective products decreased significantly, from 3.5% to 0.4%.
3. The operator’s daily physical workload was reduced, while labor productivity increased considerably.

These results demonstrate the potential of the proposed device to improve the efficiency and quality of assembly operations. In particular, reducing assembly time and minimizing the occurrence of defective products contribute to improving the overall performance of manufacturing processes.

CONCLUSION. The special-purpose device developed to mechanize the assembly process of small components has demonstrated its suitability for application in the assembly workshops of mechanical engineering and instrument-making enterprises.

The proposed design solutions not only reduce the time required to perform technological operations but also contribute to improving the overall level of production organization and manufacturing standards.

The practical implementation of this development can provide annual economic benefits, reduce the production cost of finished products, and improve quality indicators to meet international standards.

REFERENCES

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