鋁合金蝸輪蝸桿減速機的設計【含10張CAD圖紙、說明書】
畢業(yè)論文(設計)題 目 鋁合金蝸輪蝸桿減速機的設計 系 部 機械工程學院 專 業(yè) 機械設計制造及其自動化 年級 學生姓名 學 號 指導教師 專業(yè):機械設計制造及其自動化摘 要 在論文中,首先,對蝸輪蝸桿作了簡單的介紹,接著,闡述了蝸輪蝸桿的設計原理和理論計算。然后按照設計準則和設計理論設計了環(huán)面蝸輪蝸桿減速器。接著對減速器的部件組成進行了尺寸計算和校核。該設計代表了蝸輪蝸桿設計的一般過程。對其他的蝸輪蝸桿的設計工作也有一定的價值。 目前,在環(huán)面蝸輪蝸桿減速器的設計、制造以及應用上,國內與國外先進水平相比仍有較大差距。國內在設計制造環(huán)面蝸輪蝸桿減速器過程中存在著很大程度上的缺點,正如論文中揭示的那樣,重要的問題如:輪齒的根切;蝸桿毛坯的正確設計;蝸輪蝸桿的校核。關鍵詞:蝸輪蝸桿減速器, 蝸桿, 滾動軸承AbstractIn this paper, firstly, the worm are introduced, then, expounds the design principle and the theoretical calculation of the worm and worm gear. Then in accordance with the design criteria and design theory to the design of toroidal worm reducer. Then the components of the reducer to the size of the calculation and verification. The design represents the general process of worm gear design. On the other worm design work also has a certain value.At present, the torus worm reducer design, manufacture and application of domestic, compared with foreign advanced level there are still large gaps. There are a lot of defects in the design and manufacture of toroidal worm reducer process, as revealed by the paper, important issues such as: cutting the root of the tooth; Worm rough the correct design; the worm check.Key words: worm gear reducer, worm, rolling bearing目 錄摘 要2Abstract3目 錄41 選定設計方案52 電動機的選擇62.1 初選電動機類型和結構型式62.2 電動機的功率62.3運動參數(shù)計算82.3.1蝸桿軸的輸入功率、轉速與轉矩82.3.2蝸輪軸的輸入功率、轉速與轉矩82.3.3傳動滾筒軸的輸入功率、轉速與轉矩82.4蝸輪蝸桿的傳動設計92.5蝸桿、蝸輪的基本尺寸設計132.6蝸輪軸的尺寸設計與校核142.7減速器箱體的結構設計153 軸的校核183.1蝸桿軸的強度校核183.2蝸輪軸的強度校核213.3 滾動軸承的選擇及校核243.3.1 蝸桿軸滾動軸承的選擇及校核243.3.2 蝸輪軸上軸承的校核263.4 鍵聯(lián)接的強度校核28.3.4.1 蝸桿軸上安裝聯(lián)軸器處的鍵聯(lián)接283.4.2 蝸輪軸上裝蝸輪處的鍵聯(lián)接293.4.3 蝸輪軸上裝聯(lián)軸器處的鍵聯(lián)接293.5 減速器的潤滑和密封29總結31參考文獻32致 謝331 選定設計方案根據(jù)設計要求并結合以上分析,我們在設計中采用環(huán)面蝸桿減速器。具體設計方案是:選用的電動機由凸緣聯(lián)軸器將電動機軸和準平行嚙合線環(huán)面蝸桿減速器的輸入軸相聯(lián)接,經(jīng)過減速器的減速,再有凸緣聯(lián)軸器將減速器的輸出軸與滾筒軸聯(lián)接,將減速器輸出軸的轉速傳給滾筒。擬采用蝸輪蝸桿減速器,傳動簡圖如圖1.1所示。圖1.1 傳動裝置簡圖1電動機 2、4聯(lián)軸器 3級蝸輪蝸桿減速器5傳動滾筒 6輸送帶2 電動機的選擇2.1 初選電動機類型和結構型式 馬達點和兩種直流電動機的交流電動機。由于生產單位普遍使用,因為這對一個三相交流電源,當所述三相交流電動機,三相異步交流電機其中使用最廣泛的應選擇沒有特殊的要求。根據(jù)不同的保護要求,也有開放式電動機,防護樣式,封閉風扇冷卻,防爆結構,例如不同的類型。Y系列三相籠型異步電動機是全封閉的,因為其結構簡單,可靠,成本低,維護方便風冷電機用于一般用途,它被廣泛使用的非易燃,不易爆,無腐蝕性氣體并沒有特別的要求,對機械,如金屬切削機床,輸送機,鼓風機,混合機等,對于頻繁起動,制動扭轉機械,如起重,吊裝設備,電機的轉動慣量和更大的重載較小的那一刻在冶金,起重三相異步電動機YZ型(籠),或YZR型(傷口)被使用。 (1)選擇電動機的類型按工作條件和要求,選用一般用途的Y系列三相異步電動機,封閉式結構,電壓380V。(2)選擇電動機的功率電動機所需的功率 = /式中 工作機要求的電動機輸出功率,單位為KW; 電動機至工作機之間傳動裝置的總效率; 工作機所需輸入功率,單位為KW;輸送機所需的功率輸送機所需的功率P=Fv1000w2.2 電動機的功率電動機的選擇由于該生產單位采用三相交流電源,可考慮采用Y系列三相異步電動機。三相異步電動機的結構簡單,工作可靠,價格低廉,維護方便,啟動性能好等優(yōu)點。一般電動機的額定電壓為380V根據(jù)生產設計要求,假設該減速器卷筒直徑D=350mm。運輸帶的有效拉力F=7000N,帶速V=0.4m/s,載荷平穩(wěn),常溫下連續(xù)工作,工作環(huán)境多塵,電源為三相交流電,電壓為380V。1、 按工作要求及工作條件選用三相異步電動機,封閉扇冷式結構,電壓為380V,Y系列2、 傳動滾筒所需功率電動機輸出功率: kw工作機所需的功率: =2.8 kw 所以 kw=4.11kw因載荷輕微振動,電動機即可,故3、 傳動裝置效率:(根據(jù)參考文獻機械設計課程設計 劉俊龍 何在洲 主編 機械工業(yè)出版社 第133-134頁表12-8得各級效率如下)其中:蝸桿傳動效率1=0.70 攪油效率2=0.95 滾動軸承效率(一對)3=0.98聯(lián)軸器效率c=0.99 傳動滾筒效率cy=0.96所以: =1233c2cy =0.70.990.9830.9920.96 =0.633 電動機所需功率: Pr= Pw/ =3.0/0.633=4.7KW 傳動滾筒工作轉速: nw601000v / 35021.8r/min根據(jù)容量和轉速,根據(jù)參考文獻機械零件設計課程設計 毛振揚 陳秀寧 施高義 編 浙江大學出版社 第339-340頁表附表15-1可查得所需的電動機Y系列三相異步電動機技術數(shù)據(jù),查出有四種適用的電動機型號,因此有四種傳動比方案,如表3-1: 表3-1方案電動機型號額定功率Ped kw電動機轉速 r/min額定轉矩同步轉速滿載轉速1Y132S1-25.5300029002.02Y132S-45.5150014402.23Y132M2-65.510009602.04Y160M-85.57507202.0綜合考慮電動機和傳動裝置的尺寸、重量、價格和減速器的傳動比,可見第3方案比較適合。因此選定電動機機型號為Y132M2-6其主要性能如下表3-2:表3-2中心高H外形尺寸L(AC/2AD)HD底角安裝尺寸AB地腳螺栓孔直徑K軸身尺寸DE裝鍵部位尺寸FGD132515(270/2210)3152161781238801033382.3運動參數(shù)計算2.3.1蝸桿軸的輸入功率、轉速與轉矩P0 = Pr=4.7kw n0=960r/minT0=9.55 P0 / n0=4.7103=46.7N .m2.3.2蝸輪軸的輸入功率、轉速與轉矩P1 = P001 = 4.70.990.990.70.992 =3.19 kw n= = = 27.4 r/minT1= 9550 = 9550 = 1111.84Nm2.3.3傳動滾筒軸的輸入功率、轉速與轉矩P2 = P1ccy=3.190.990.99=3.13kwn2= = = 21.8 r/minT2= 9550 = 9550 = 1089.24Nm運動和動力參數(shù)計算結果整理于下表4-1: 表4-1類型功率P(kw)轉速n(r/min)轉矩T(Nm)傳動比i效率蝸桿軸4.796046.75 10.679蝸輪軸3.1927.41111.84 35傳動滾筒軸3.1327.41089.242.4蝸輪蝸桿的傳動設計蝸桿的材料采用45鋼,表面硬度45HRC,蝸輪材料采用ZCuA110Fe3,砂型鑄造。以下設計參數(shù)與公式除特殊說明外均以參考由機械設計 第四版 邱宣懷主編 高等教育出版社出版 1996年 第13章蝸桿傳動為主要依據(jù)。具體如表31: 表51蝸輪蝸桿的傳動設計表項 目計算內容計算結果中心距的計算蝸桿副的相對滑動速度參考文獻5第37頁(23式)4m/sVs7m/s當量摩擦系數(shù)4m/sVs51.7100mm又因軸上有鍵槽所以D6增大3%,則D6=67mm計算轉矩 Tc=KT=K9550=1.595503.19/27.4=1667.76N.M51.7100mm又因軸上有鍵槽所以D6增大3%,則D6=67mmD6=672.7減速器箱體的結構設計參照參考文獻機械設計課程設計(修訂版) 鄂中凱,王金等主編 東北工學院出版社 1992年第19頁表1.5-1可計算得,箱體的結構尺寸如表8.1:表8.1箱體的結構尺寸減速器箱體采用HT200鑄造,必須進行去應力處理。設計內容計 算 公 式計算結果箱座壁厚度=0.04225+3=12mma為蝸輪蝸桿中心距取=12mm箱蓋壁厚度1=0.8512=10mm取1=10mm機座凸緣厚度bb=1.5=1.512=18mmb=18mm機蓋凸緣厚度b1b1=1.51=1.510=15mmb1=18mm機蓋凸緣厚度PP=2.5=2.512=30mmP=30mm地腳螺釘直徑dd=20mmd=20mm地腳螺釘直徑dd=20mmd=20mm地腳沉頭座直徑D0D0=48mmD0=48mm地腳螺釘數(shù)目n取n=4個取n=4底腳凸緣尺寸(扳手空間)L1=32mmL1=32mmL2=30mmL2=30mm軸承旁連接螺栓直徑d1d1= 16mmd1=16mm軸承旁連接螺栓通孔直徑d1d1=17.5d1=17.5軸承旁連接螺栓沉頭座直徑D0D0=32mmD0=32mm剖分面凸緣尺寸(扳手空間)C1=24mmC1=24mmC2=20mmC2=20mm上下箱連接螺栓直徑d2d2 =12mmd2=12mm上下箱連接螺栓通孔直徑d2d2=13.5mmd2=13.5mm上下箱連接螺栓沉頭座直徑D0=26mmD0=26mm箱緣尺寸(扳手空間)C1=20mmC1=20mmC2=16mmC2=16mm軸承蓋螺釘直徑和數(shù)目n,d3n=4, d3=10mmn=4d3=10mm檢查孔蓋螺釘直徑d4d4=0.4d=8mmd4=8mm圓錐定位銷直徑d5d5= 0.8 d2=9mmd5=9mm減速器中心高HH=340mmH=340mm軸承旁凸臺半徑RR=C2=16mmR1=16mm軸承旁凸臺高度h由低速級軸承座外徑確定,以便于扳手操作為準。取50mm軸承端蓋外徑D2D2=軸承孔直徑+(55.5) d3取D2=180mm箱體外壁至軸承座端面距離KK= C1+ C2+(810)=44mmK=54mm軸承旁連接螺栓的距離S以Md1螺栓和Md3螺釘互不干涉為準盡量靠近一般取S=D2S=180蝸輪軸承座長度(箱體內壁至軸承座外端面的距離)L1=K+=56mmL1=56mm蝸輪外圓與箱體內壁之間的距離=15mm取=15mm蝸輪端面與箱體內壁之間的距離=12mm取=12mm機蓋、機座肋厚m1,mm1=0.851=8.5mm, m=0.85=10mmm1=8.5mm, m=10mm以下尺寸以參考文獻機械設計、機械設計基礎課程設計 王昆等主編 高等教育出版社 1995年表6-1為依據(jù)蝸桿頂圓與箱座內壁的距離=40mm軸承端面至箱體內壁的距離=4mm箱底的厚度20mm軸承蓋凸緣厚度e=1.2 d3=12mm箱蓋高度220mm箱蓋長度(不包括凸臺)440mm蝸桿中心線與箱底的距離115mm箱座的長度(不包括凸臺)444mm裝蝸桿軸部分的長度460mm箱體寬度(不包括凸臺)180mm箱底座寬度304mm蝸桿軸承座孔外伸長度8mm蝸桿軸承座長度81mm蝸桿軸承座內端面與箱體內壁距離61mm3 軸的校核3.1蝸桿軸的強度校核1繪軸的計算簡圖在確定軸承支點位置時,應從手冊上查取a值,對于30207型單列圓錐滾子軸承,a=16mm,所以,作為簡支梁的軸的支撐跨距=(20+43.75+34)+(20+43.75+34) =97.75+97.75=195.5mm 2計算作用在軸上的力=736.67N, =6179.88N, 3計算支點反力水平反力: 垂直反力: 4計算彎矩,作彎矩圖水平彎矩: 垂直彎矩: 合成彎矩 5扭矩圖由機械零件課程設計表618 查得折算系數(shù) 6校核軸的強度由機械設計表15-1查得: ,強度足夠。 見圖5-3。圖5-3 軸的強度3.2蝸輪軸的強度校核 1繪軸的計算簡圖在確定軸承支點位置時,應從手冊上查取a值,對于30212列圓錐滾子軸承,a=22mm,作為簡支梁的軸的支撐跨距 =(20+43.75+34)+(20+43.75+34) =97.75+97.75=195.5mm 2計算作用在軸上的力=6179.88N, =736.67N, 3計算支點反力水平反力: 垂直反力: 4計算彎矩,作彎矩圖水平彎矩: 垂直彎矩: 合成彎矩: 5扭矩圖由機械零件課程設計表618 查得折算系數(shù) 6校核軸的強度由機械設計表15-1查得: , ,強度足夠。 見圖5-4。圖5-4軸的強度3.3 滾動軸承的選擇及校核3.3.1 蝸桿軸滾動軸承的選擇及校核1軸承的徑向載荷的計算 2派生軸向力的計算查手冊得,圓錐滾子軸承30207型的=14o02,10, 查表d=35mm時,e=0.37,y=1.6;故 所以,軸承2受壓則: 3求當量動載荷 所以,對于軸承1 x=1 , y=0 對于軸承2 x=0.4 , y=1.6 4校核軸承的壽命查手冊得c=51.5KN =10/3 n=940r/min 故 此軸承的壽命滿足要求 3.3.2 蝸輪軸上軸承的校核1求徑向載荷 2計算派生軸向力查手冊得,圓錐滾子軸承30212型的 , y=1.5故 則:軸承2受壓所以, 3求當量動載荷所以,對于軸承1:x=1 ,y=0 對于軸承2:x=1 ,y=0 4校核軸承的壽命查手冊 c=97.8KN ,=10/3 ,n=18.8r/min 故 此軸承壽命滿足要求。3.4 鍵聯(lián)接的強度校核.3.4.1 蝸桿軸上安裝聯(lián)軸器處的鍵聯(lián)接由機械零件課程設計表81 選用普通平鍵 87mm, 取L45mm。 由機械零件課程設計表87 查得,鍵的工作長度lLb45837mm, 鍵的工作高度k3mm。 由機械零件課程設計表88 查得,鍵聯(lián)接的許用壓力 , 所以,所選平鍵合適。 3.4.2 蝸輪軸上裝蝸輪處的鍵聯(lián)接由機械零件課程設計表81 選用普通平鍵 1811mm, 取L45mm 由機械零件課程設計表87 查得鍵的工作長度lLb4518=27mm 鍵的工作高度k5.5mm 由機械零件課程設計表88 查得鍵聯(lián)接的許用壓力 所以,所選平鍵合適。 3.4.3 蝸輪軸上裝聯(lián)軸器處的鍵聯(lián)接由機械零件課程設計表81 選用普通平鍵 1610mm, 取L100mm。 由機械零件課程設計表87 鍵的工作長度lLb10016=84mm 鍵的工作高度k5mm 由機械零件課程設計表88 查得鍵聯(lián)接的許用壓力 所以, 所選平鍵合適。 3.5 減速器的潤滑和密封減速器的傳動零件的軸承都需要喲良好的潤滑,這不僅可以減少磨損損失,提高傳動效率,還可以防止銹蝕,降低噪聲。1 潤滑油選擇對于蝸桿傳動的潤滑油類型的選擇無明顯的區(qū)分界限,德國推薦對重負荷淬硬蝸桿和起動頻繁的蝸桿傳動要選用含有極壓添加劑的潤滑油。對于蝸桿傳動潤滑油的粘度選擇有三種方法供使用,一種是按滑動速度選取,一種是按中心距及蝸桿轉速選取,還有一種是根據(jù)力速度因子選取。其中根據(jù)滑動速度選取的依據(jù)如下:表5-1滑動速度選?。夯瑒铀俣?.51.53.53.51010粘度值612414506288352198242ISO-VG或GB-N級680460320220由于蝸桿的滑動速度為2m/s,所以潤滑油的粘度選為4602潤滑方式的選擇由于所設計減速器采用蝸桿下置式傳動,且轉速不高,故選擇浸油潤滑。蝸桿浸油深度h11個螺牙高,但不高于蝸桿軸軸承的最底滾動體的中心。潤滑時,傳動件的浸入油中的深度要適當,既要避免攪由損失過大,又保證充分的潤滑,油池應保持一定的深度和貯油量。如下圖所示:圖5-5 潤滑方式40總結畢業(yè)設計是培養(yǎng)我們綜合運用所學知識 ,發(fā)現(xiàn),提出,分析和解決實際問題,鍛煉實踐能力的重要環(huán)節(jié),是對我們的實際工作能力的具體訓練和考察過程.隨著科學技術發(fā)展的日新月異。讓我們從理論到實踐,在這段日子里,可以學到很多很多的東西,同時不僅可以鞏固了以前所學過的知識,而且學到了很多在書本上所沒有學到過的知識。在這個過程中我去查了很多圖書資料,自然在無奈的情況下走了很多彎路,還通過網(wǎng)絡資源找了很多東西,特別是查詢材料方面得到了鍛煉,同時word和cad也得到了一定提高。通過這次設計使我們懂得了理論與實際相結合是很重要的,只有理論知識是遠遠不夠的,只有把所學的理論知識與實踐相結合起來,從理論中得出結論,才能真正為社會服務,從而提高自己的實際動手能力和獨立思考的能力。在設計的過程中遇到問題,可以說得是困難重重,這畢竟第一次做的,難免會遇到過各種各樣的問題,同時在設計的過程中發(fā)現(xiàn)了自己的不足之處,對一些前面學過的知識理解得不夠深刻,掌握得不夠牢固,比如說齒輪的設計,電機的選用通過這次課程設計之后,我們把前面所學過的知識又重新溫故了一遍,但是由于時間緊迫,所以這次的設計存在許多缺點,比如說箱體結構龐大,重量也很大。齒輪的計算不夠精確等等缺陷,我相信,通過這次的實踐,能使我在以后的設計中避免很多不必要的工作,有能力設計出結構更緊湊,傳動更穩(wěn)定精確的設備。收獲知識,提高能力的同時,我也學到了很多人生的哲理,懂得怎么樣去制定計劃,怎么樣去實現(xiàn)這個計劃,并掌握了在執(zhí)行過程中怎么樣去克服心理上的不良情緒。原來生活也和畢業(yè)設計一樣,要好好的去計劃,去探索,這樣才會有真正的東西,那樣才體會到樂趣。因此在以后的生活和學習的過程中,我一定會把設計的精神帶到生活中,不畏艱難,勇往直前! 參考文獻1.機械工程手冊第二版(傳動設計卷) 機械工業(yè)出版社 20002.實用機械設計手冊 吳相憲 王正為 黃玉堂 主編 中國礦業(yè)大學出版社 20013.機械設計 濮良貴 紀名剛 主編 高等教育出版社 19964.機械制造工藝學趙志修 主編 北京: 機械工業(yè)出版社 1984.2 5.機械制造工藝及專用夾具設計指導孫麗媛 主編 北京:冶金工業(yè)出版社 2002 6.機械加工工藝手冊李洪 主編 北京: 北京出版社 1990,127.金屬工藝學鄧文英 主編 北京: 高等教育出版社 20008.機械設計課程設計 華中理工大學 王昆 同濟大學 高等教育出版社19869.齒輪手冊 機械工業(yè)出版社 200210.機械加工余量與公差手冊 馬賢智 北京:中國標準出版社,199411.高等學校畢業(yè)設計指導M,周永強,北京:中國建材工業(yè)出版社,200212. 機械制造工藝學習題集 李益民 主編 黑龍江: 哈兒濱工業(yè)大學出版社 1984 致 謝 感謝我的指導老師劉老師,他嚴謹細致、一絲不茍的作風一直是我工作、學習中的榜樣;循循善誘的教導和不拘一格的思路給予我無盡的啟迪。導師淵博的專業(yè)知識,嚴謹?shù)闹螌W態(tài)度,精益求精的工作作風,誨人不倦的高尚師德,嚴以律己、寬以待人的崇高風范,樸實無華、平易近人的人格魅力對我影響深遠。不僅使我樹立了遠大的學術目標、掌握了基本的研究方法,還使我明白了許多待人接物與為人處世的道理。在此,謹向導師表示崇高的敬意和衷心的感謝!“師恩難忘,友誼長存!”本論文的順利完成,離不開各位老師、同學和朋友的關心和幫助。在此,向曾經(jīng)幫助我的老師和同學表示衷心的感謝。在論文即將完成之際,我的心情無法平靜,從開始進入課題到論文的順利完成,有多少可敬的師長、同學、朋友給了我無言的幫助,在這里請接受我誠摯的謝意! 一、 什么是減速器減速器是一種動力傳達機構,利用齒輪的速度轉換器,將馬達的回轉數(shù)減速到所要的回轉數(shù),并得到較大轉矩的機構。1、減速器的作用 1)降速同時提高輸出扭矩,扭矩輸出比例按電機輸出乘減速比,但要注意不能超出減速器額定扭矩。 2) 減速同時降低了負載的慣量,慣量的減少為減速比的平方。大家可以看一下一般電機都有一個慣量數(shù)值。2、減速器的種類 一般的減速器有斜齒輪減速器(包括平行軸斜齒輪減速器、蝸輪減速器、錐齒輪減速器等等)、行星齒輪減速器、擺線針輪減速器、蝸輪蝸桿減速器、行星摩擦式機械無級變速機等等。3、常見減速器 1) 蝸輪蝸桿減速器的主要特點是具有反向自鎖功能,可以有較大的減速比,輸入軸和輸出軸不在同一軸線上,也不在同一平面上。但是一般體積較大,傳動效率不高,精度不高。 2) 諧波減速器的諧波傳動是利用柔性元件可控的彈性變形來傳遞運動和動力的,體積不大、精度很高,但缺點是柔輪壽命有限、不耐沖擊,剛性與金屬件相比較差。輸入轉速不能太高。 3) 行星減速器其優(yōu)點是結構比較緊湊,回程間隙小、精度較高,使用壽命很長,額定輸出扭矩可以做的很大。但價格略貴一、對裝配前零件的要求 :1.滾動軸承用汽油清洗,其他零件用煤油清洗。所有零件和箱體內不許有任何雜質存在。箱體內壁和齒輪(蝸輪)等未加工表面先后涂兩次不被機油侵蝕的耐油漆,箱體外表面先后涂底漆和顏色油漆(按主機要求配色)。 2.零件配合面洗凈后涂以潤滑油二、安裝和調整的要求 1.滾動軸承的安裝滾動軸承安裝時軸承內圈應緊貼軸肩,要求縫隙不得通過0.05mm 厚的塞尺。 2.軸承軸向游隙對游隙不可調整的軸承(如深溝球軸承),其軸向游隙為0.250.4mm;對游隙可調整的軸承軸向游隙數(shù)值見表。點擊查看圓錐滾子軸承軸向游隙;角接觸球軸承軸向游隙 3.齒輪(蝸輪)嚙合的齒側間隙可用塞尺或壓鉛法。即將鉛絲放在齒槽上,然后轉動齒輪而壓扁鉛絲,測量兩齒側被壓扁鉛絲厚度之和即為齒側的大小。 4.齒面接觸斑點圓柱齒輪齒面接觸斑點2-10-4;圓錐齒輪齒面接觸斑點2-11-4;蝸桿傳動接觸斑點2-12-4 三、密封要求 1.箱體剖分面之間不允許填任何墊片,但可以涂密封膠或水玻璃以保證密封; 2.裝配時,在擰緊箱體螺栓前,應使用0.05mm的塞尺檢查箱蓋和箱座結合面之間的密封性; 3.軸伸密封處應涂以潤滑脂。各密封裝置應嚴格按要求安裝四、潤滑要求 1.合理確定潤滑油和潤滑脂類型和牌號 2.軸承脂潤滑時,潤滑脂的填充量一般為可加脂空間的1/22/3。 3.潤滑油應定期更換,新減速器第一次使用時,運轉714天后換油,以后可以根據(jù)情況每隔36個月?lián)Q一次油。五、試驗要求 1.空載運轉:在額定轉速下正、反運轉12小時; 2.負荷試驗:在額定轉速、額定負荷下運轉,至油溫平衡為止。對齒輪減速器,要求油池溫升不超過35oC,軸承溫升不超過40oC;對蝸桿減速器,要求油池溫升不超過60oC,軸承溫升不超過50oC; 3.全部試驗過程中,要求運轉平穩(wěn),噪聲小,聯(lián)接固定處不松動,各密封、結合處不 六、包裝和運輸要求 1.外伸軸及其附件應涂油包裝; 2.搬運、起吊時不得使用吊環(huán)螺釘及吊耳以上技術要求不一定全部列出,有時還需另增項目,主要由設計的具體要求而定。七、技術要求 1.裝配前,所有零件用煤油清洗,滾動軸承用汽油清洗,不許有任何雜物存在。內壁涂上不被機油腐蝕的涂料兩次; 2.嚙合側隙用鉛絲檢驗不小于0.16mm,鉛絲不得大于最小側隙的4倍; 3.用涂色法檢驗斑點。按齒高接觸點不小于40%;按齒長接觸斑點不小于50%。必要時可用研磨或刮后研磨以便改善接觸情況; 4.應調整軸承軸向間隙:40為0.05-0.1mm,55為0.08-0.15mm; 5.檢驗減速器剖分面、各接觸面及密封處,均不許漏油。剖分面允許涂以密封油漆或水玻璃,不允許使用任何填料; 6.機座內裝N100潤滑油至規(guī)定高度。八、下面我介紹我國減速器的發(fā)展現(xiàn)狀(一)、國內的減速器多以齒輪傳動、蝸桿傳動為主,但普遍存在著功率與重量比小,或者傳動比大而機械效率過低的問題。另外,材料品質和工藝水平上還有許多弱點,特別是大型的減速器問題更突出,使用壽命不長。國內使用的大型減速器(500kw以上),多從國外(如丹麥、德國等)進口。60年代開始生產的少齒差傳動、擺線針輪傳動、諧波傳動等減速器具有傳動比大,體積小、機械效率高等優(yōu)點?。但受其傳動的理論的限制,不能傳遞過大的功率,功率一般都要小于40kw。由于在傳動的理論上、工藝水平和材料品質方面沒有突破,因此,沒能從根本上解決傳遞功率大、傳動比大、體積小、重量輕、機械效率高等這些基本要求。90年代初期,國內出現(xiàn)的三環(huán)(齒輪)減速器,是一種外平動齒輪傳動的減速器,它可實現(xiàn)較大的傳動比,傳遞載荷的能力也大。它的體積和重量都比定軸齒輪減速器輕,結構簡單,效率亦高。由于該減速器的三軸平行結構,故使功率/體積(或重量)比值仍小。且其輸入軸與輸出軸不在同一軸線上,這在使用上有許多不便。北京理工大學研制成功的內平動齒輪減速器不僅具有三環(huán)減速器的優(yōu)點外,還有著大的功率/重量(或體積)比值,以及輸入軸和輸出軸在同一軸線上的優(yōu)點,處于國內領先地位。國內有少數(shù)高等學校和廠礦企業(yè)對平動齒輪傳動中的某些原理做些研究工作,發(fā)表過一些研究論文,在利用擺線齒輪作平動減速器開展了一些工作。(二)、平動齒輪減速器工作原理簡介,平動齒輪減速器是指一對齒輪傳動中,一個齒輪在平動發(fā)生器的驅動下作平面平行運動,通過齒廓間的嚙合,驅動另一個齒輪作定軸減速轉動,實現(xiàn)減速傳動的作用。平動發(fā)生器可采用平行四邊形機構,或正弦機構或十字滑塊機構。本成果采用平行四邊形機構作為平動發(fā)生器。平動發(fā)生器可以是虛擬的采用平行四邊形機構,也可以是實體的采用平行四邊形機構。有實用價值的平動齒輪機構為內嚙合齒輪機構,因此又可以分為內齒輪作平動運動和外齒輪作平動運動兩種情況。外平動齒輪減速器構,其內齒輪作平動運動,驅動外齒輪并作減速轉動輸出。該機構亦稱三環(huán)(齒輪)減速器。由于內齒輪作平動,兩曲柄中心設置在內齒輪的齒圈外部,故其尺寸不緊湊,不能解決體積較大的問題。內平動齒輪減速,其外齒輪作平動運動,驅動內齒輪作減速轉動輸出。由于外齒輪作平動,兩曲柄中心能設置在外齒輪的齒圈內部,大大減少了機構整體尺寸。由于內平動齒輪機構傳動效率高、體積小、輸入輸出同軸線,故由廣泛的應用前景。(三)、本項目的技術特點與關鍵技術 1.本項目的技術特點,本新型的內平動齒輪減速器與國內外已有的齒輪減速器相比較,有如下特點:(1)傳動比范圍大,自I=10起,最大可達幾千。若制作成大傳動比的減速器,則更顯示出本減速器的優(yōu)點。(2)傳遞功率范圍大:并可與電動機聯(lián)成一體制造。(3)結構簡單、體積小、重量輕。比現(xiàn)有的齒輪減速器減少1/3左右。(4)機械效率高。嚙合效率大于95%,整機效率在85%以上,且減速器的效率將不隨傳動比的增大而降低,這是別的許多減速器所不及的。 (5)本減速器的輸入軸和輸出軸是在同一軸線上。本減速器與其它減速器的性能比較見表1。因缺少數(shù)據(jù),表中所列的各減速器的功率/重量比是最優(yōu)越的。各類減速器比較 型號 功率(kw) 減速比 質量(kg) QI-450 93 31.5 1820 ZSY-250 95 31.5 540 NGW-92 88.1 31.5 577 SEW(德國) 90 28.61 1300 NP-100? 100 30 400 注:NP-100為內平動齒輪減速器,SEW減速器的質量含電機。2.本項目的關鍵技術。由圖2可知,內平動齒輪減速器是由內齒輪Z2、外齒輪Z1和平行四邊形機構組合而成的。它的傳動原理是:電機輸入旋轉運動,外齒輪作平行移動,其圓心的運動軌跡是一個圓,與之嚙合的內齒輪則作定軸轉動。因為外齒輪作平行移動,所以稱謂平動齒輪機構。齒輪的平行移動需要有輔助機構幫助實現(xiàn)的,可采用(612副)銷軸、滾子作為虛擬輔助平動機構,也可以采用偏心軸作為實體輔助平動機構。內平動齒輪減速器的關鍵技術和關鍵工藝是組成平行四邊形構件的尺寸計算及其要求的加工精度、輪齒主要參數(shù)的選擇。這些因數(shù)都將影響傳動的能力和傳動的質量??偟恼f,組成本減速器的各零部件都要求有較高的精度,它們將決定著減速器的整體傳動質量。3.本項目的概況本項目已獲得中國實用新型專利,專利號:ZL95227767.0。本項目自1995年試制出第一臺樣機(功率2.5kW,傳動比I=32)后,陸續(xù)與一些廠礦合作,設計了下面幾種不同功率、不同傳動比的減速器。(1)電動推拉門用減速器,功率550W,傳動比I=26,與電機連成一體。(2)攪拌機用減速器,功率370W,傳動比I=17。(3)某軍品用的兩種減速器,一種功率370W,傳動比I=23.5;另一種功率370W,傳動比I=103的二級傳動減速器。(4)鋼廠大包回轉臺減速器,功率7.5kw,傳動比I=64。(5)鋼廠輥道減速器,功率7.5kw,傳動I=11。在本專利的基礎上,已研制出一種新型超大型減速器,功率可達1000kw,目前正在研制超小型(外型尺寸為毫米級)的微型減速器。 Mineral product monorail reduction gear synopsisFirst:what is reducerReducer is a dynamic communication agencies, the use of gear speed converters, motor rotational speed reducer to the Rotary to be few, and have greater torque institutions. The reducer role 1) velocity at the same time increase the output torque, torque output ratio by motor output by slowdown, but the attention should be paid to exceed the rated torque reducer. 2) the speed at the same time reduce the inertia load, the inertia of deceleration than reduced to the square. We can look at the General Motors has a value of inertia. The type of reducer General helical gear reducer has reducer (including parallel shaft helical gear reducer, a worm reducer, bevel gear reducer, etc.), planetary gear reducer, Cycloid reducer, a worm reducer, a planetary friction CVT mechanical machines. Common reducer 1) worm reducer is the main characteristics of a reverse self-locking function, can be larger than a slowdown, input shaft and output shaft axis is not the same, nor in the same plane. But generally larger, transmission efficiency is not high, the accuracy is not high. 2) Harmonic Harmonic Drive reducer is controllable using flexible components to transfer elastic deformation and dynamic movement, not volume, high precision, but the disadvantage is that flexible wheel limited life, impatient shocks, rigidity and pieces of metal relatively poor. Not too high speed input. 3) planetary reducer its comparative advantage is compact structure, the return gap small, high precision, and have a long life span rated output torque can be done great. However, a price slightly expensive, the requirements of parts before assembly 1. Rolling cleaning with gasoline, kerosene other parts cleaning. All parts and Xiangbenna not allowed to have any impurities exist. Gear box and the inner wall (Worm), unprocessed surface has not been coated twice erosion-resistant oil paint, box has the outer surface coated primer and paint color (color requested by host). 2. Parts coated with a face wash after lubricants Second, the requirements of installation and adjustment 1. Rolling installation Rolling bearing inner ring should be installed at the shaft shoulder close to gap must not pass 0.05 mm thick Cypriot feet. 2. Bearing axial clearance of the clearance can not be adjusted bearings (such as deep groove ball bearings), axial clearance of 0.25 to 0.4 mm; the clearance adjustable bearing axial clearance numerical table. Click Tapered Roller Bearings axial clearance; angular contact ball bearing axial clearance 3. Gear (Worm) meshing tooth space available Cypriot side foot of lead or pressure. Will be lead wire on the alveolar, and then turning gear and squash lead wire, measuring two teeth side was crushed lead wire thickness and the size of which is adjacent teeth. 4. Tooth contact dot cylinder gear tooth contact Dot 2-10-4; bevel gear tooth contact Dot 2-11-4; Gearing contact Dot 2-12-4 Third, seal requirements 1. Box partition between the surface does not allow any pads filled, but can be coated or water glass sealant to ensure that the seal; 2. Assembly, the bolt tightening box, before using 0.05 mm Cypriot-foot inspection Covers Block with me and between the sealing surface; 3. Shaft seal should stretch to smear grease. The seal should be installed in strict accordance with the requirements Forth, lubrication requirements 1. Rationally determine the types of lubricants and greases and grades 2. Bearing lubrication fat, grease filled in the general Fatliquor space can be 1 / 2 to 2 / 3. 3. Lubricants should be regularly replaced, the new reducer used for the first time, the operation of oil-7 14 days, according to the situation can be after every 3 to 6 months for first oil. Fifth, the test requirements 1. Empty operation: at rated speed is, anti-running 1 to 2 hours; 2. Load test: at rated speed, rated load operation, the oil temperature balance to date. On the gear reducer, requested the pool temperature is not more than 35 oC, bearing temperature rise no more than 40 oC; the worm reducer, requested the pool temperature not more than 60 oC, bearing temperature of not more than 50 oC; 3. Entire testing process for the smooth operation, noise, not loosening the fixed link, sealed, not with the Sixth, packaging and transportation requirements 1. Protruding shaft and its annex should Oiler packaging; 2. Handling, lifting may not use screw rings and lug all of the above technical requirements are not necessarily listed, and sometimes also by other projects, mainly by the specific design requirements. Seventh. Technical requirements 1. Assembly, all parts cleaning with kerosene, gasoline Rolling cleansing, while the existence of any debris. Oil is not painted wall corrosion coatings twice; 2. Backlash with lead wire mesh test of not less than 0.16 mm, lead wire Backlash may not exceed the smallest of the four times; 3. Used Tu-color dot test. Tooth high point of contact by not less than 40% of contact spots on teeth not less than 50 per cent. Can be used when necessary, grinding or scraping after grinding to improve contacts; 4. Bearing axial clearance should be adjusted: 40 0.05 - 0.1 mm, 55 0.08 - 0.15 mm; 5. Test reducer subdivision surface, the contact surface and seal, oil spills are not allowed. Split-Tu allowed to paint or water glass seal and allow the use of any filler; 6. Engine lubricants to the contents N100 provisions height;Below I introduce our country reduction gear the development present situation First, the domestic reduction gear many by the gear drive, the worm drive primarily, but has the power and the load ratio generally is small, or velocity ratio great and mechanical efficiency excessively low question.Moreover, in the material quality and the technological level also has many weakness, the large-scale reduction gear question is specially more prominent, the service life is not long.The domestic use large-scale reduction gear (above 500kw), many from overseas (for example Denmark, Germany and so on) imports The 60s start few tooth reduction gears and so on difference transmission, cycloid pin gear transmission, overtone transmission which produces has the velocity ratio to be big, volume small, mechanical efficiency higher merit? .But its transmission theory limit, cannot transmit the oversized power, the power all must be smaller than generally 40kw. Because in the transmission theoretically, the technological level and the material quality aspect has not broken through, therefore, has not been able fundamentally to solve the transmission power in a big way, the velocity ratio big, the volume small, the weight light, mechanical efficiency higher these requests basically.The 90s initial period, the home appears three links (gear) the reduction gear, is one kind of outside stable motion gear drive reduction gear, it may realize the great velocity ratio, transmission load ability is also big. Its volume and the weight are all lighter than the dead axle speed reducer gear, the structure is simple, the efficiency is also high.Because this reduction gear three axle parallel structure, therefore caused the power/volume (or weight) the ratio is still small.Also its input axis and the output shaft on the identical spool thread, this do not have in the use many inconveniently. Not only Beijing Institute of Technology develops in successful stable motion speed reducer gear to have outside three link reduction gear merit, but also has the big power/weight (or volume) the ratio, as well as the input axis and the output shaft on identical spool thread merit, is at the domestic leading position.The home has the minority college and the factory and mining enterprise does the research work to in stable motion gear drive certain principles, has published some research paper, in has done some work using the cycloidal tooth crop rotation stable motion reduction gear.Second, the stable motion speed reducer gear principle of work synopsis, the stable motion speed reducer gear is refers to in a counter gear transmission, a gear in the stable motion generator actuation mean plane parallel motion, meshing through tooth profile between, actuates another tooth crop rotation dead axle to decelerate the rotation, the realization reduction gear function.The stable motion generator may use the parallelogram organization, either sine organization or cross slide organization.This achievement uses the parallelogram organization to take the stable motion generator. The stable motion generator may be the hypothesized use parallelogram organization, also may be the entity use parallelogram organization.Has the practical value stable motion gear mechanism for in counter gear organization, therefore may divide into the internal tooth crop rotation stable motion movement and the external tooth crop rotation stable motion movement two kind of situations.Outside the stable motion gear reduction organization, its internal tooth crop rotation stable motion movement, actuates the external gear and makes the deceleration rotation output.This organization also calls three links (gear) the reduction gear. As a result of the internal tooth crop rotation stable motion, two crank centers establish outside the annular gear tooth ring, therefore its size is not compact, cannot solve the volume major problem.? In stable motion gear reduction, its external tooth crop rotation stable motion movement, actuation internal tooth crop rotation deceleration rotation output.As a result of the external tooth crop rotation stable motion, two crank centers can establish in the external gear tooth ring, reduced the organization overall size greatly. Because in stable motion gear mechanism transmission efficiency high, volume small, input output coaxial line, therefore by widespread application prospect.Third, this project technical characteristic and key technologies? 1. this project technical characteristics, in this new stable motion speed reducer gear and domestic and foreign had the speed reducer gear compares, has the following characteristic: (1) velocity ratio scope is big, gets up from I=10, may reach most greatly several thousand.If manufactures the great velocity ratio the reduction gear, then demonstrates this reduction gear the merit.(2) transmission power scope is big: And may connect a body manufacture with the electric motor. (3) structure simple, the volume small, the weight is light.Reduces about 1/3 compared to the existing speed reducer gear.(4) mechanical efficiency is high.95 (5) this reduction gear input axis and the output shaft are on the identical spool thread.This reduction gear see Table 1 with other reduction gear performance comparison. Because lacks the data, various reduction gears power/load ratio which in the table arranges in order is most superior.? Table 1? Each kind of reduction gear comparison model power (kw) reduction gear ratio quality (kg) QI-450? 93 31.5 1820 ZSY-250? 95 31.5 540 NGW-92 88.1 31.5 577 SEW (Germany)? 90 28.61 1300 NP-100? 100 30 400 Note: NP-100 is in the stable motion speed reducer gear, the SEW reduction gear quality contains the electrical machinery.2. this project key technologies? May know by Figure 2, in “stable motion speed reducer gear is by annular gear Z2, external gear Z1 and the parallelogram organization combination becomes.Its transmission principle is: The electrical machinery input rotary motion, the external tooth crop rotation parallel migration, its center of circle path is a circle, makes the dead axle rotation with it meshing annular gear. Because external tooth crop rotation parallel migration, therefore name stable motion gear mechanism.The gear parallel migration needs to have the auxiliary body help realization, may use (612) to sell the axis, the roller takes the hypothesized auxiliary stable motion organization, also may use the eccentric shaft to take the entity auxiliary stable motion organization.In the stable motion speed reducer gear key technologies and the essential craft are the composition parallelogram component size computation and the request processing precision, the gear teeth main parameter choice. These factors will all affect the transmission ability and the transmission quality.Overall speaking, the group cost reduction gear various spare parts all request to have the high precision, they will be deciding the reduction gear overall transmis3. this project survey this project has obtained the Chinese practical new patent, the patent number: ZL95227767.0? .? This project trial produced the first prototype from 1995 (power 2.5kW, after velocity ratio I=32), with some factory and mine cooperation, has one after another designed following several kind of different powers, the different velocity ratio reduction gear.(1) electrically operated on rollers gate uses the reduction gear, power 550W, velocity ratio I=26, is united as one body with the electrical machinery.sion quality. (2) mixer uses the reduction gear, power 370W, velocity ratio I=17.(3) some military goods use two kind of reduction gears, one kind of power 370W, velocity ratio I=23.5; Another kind of power 370W, velocity ratio I=103 two level of transmission reduction gear.(4) steel mill large package rotary abutment reduction gear, power 7.5kw, velocity ratio I=64.(5) steel mill table reduction gear, power 7.5kw, transmission I=11. In this patent foundation, has developed one kind of new ultra-large reduction gear, the power may reach 1000kw, at present is developing subminiature (outlook size for a millimeter level) miniature reduction gear. Graduation design task First, a design Monorail Driver Design reducer Second, the design of the original data 1 Monorail drive reducer Power Rating: 7.5 KW; 2 Monorail reducer drive the total transmission ratio: 15 around; 3 Monorail reducer drive car driven by the side of the output shaft from the race distance of not more than 200 mm; 4 Monorail reducer drive the total length of less than 420 mm, the width is not more than 450 mm and the total height of not more than 690 mm; Third, the equipment and the working environment This can be used to mine underground, open-air, dust, humidity, air quality, bad comparison bad work environment, and the operational requirements of a safe space. Fourth, the design requirements To meet the application requirements under the premise that the minimum cost of manufacturing. From the following aspects considered; (L) to streamline the shape of each parts, machinery simple structure; (2) merge the functions of spare parts, reducing the types or quantities of spare parts; (3) Application of the new structure, new technology, new materials, product reliability; (4) decomposition components, its assembly, the assembly of the most simple structure; (5) similar to parts of the division; (6) standards for similar products by product serial number sequence analysis; (7) The realization of the common parts of the product and standardization. (8) assembly equipment design a map (0), the Six Parts (3), the design specification of a (not less than 30,000 words), and the design of technical and economic analysis.
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