單級(jí)圓柱齒輪減速器設(shè)計(jì)
單級(jí)圓柱齒輪減速器設(shè)計(jì),單級(jí)圓柱齒輪減速器設(shè)計(jì),圓柱齒輪,減速器,設(shè)計(jì)
目 錄設(shè)計(jì)計(jì)劃任務(wù)書 1傳動(dòng)方案說明2電動(dòng)機(jī)的選擇3傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)5傳動(dòng)件的設(shè)計(jì)計(jì)算6軸的設(shè)計(jì)計(jì)算8 聯(lián)軸器的選擇10 滾動(dòng)軸承的選擇及計(jì)算13 鍵聯(lián)接的選擇及校核計(jì)算14 減速器附件的選擇15 潤滑與密封16 設(shè)計(jì)小結(jié)16 參考資料161.擬定傳動(dòng)方案為了估計(jì)傳動(dòng)裝置的總傳動(dòng)比范圍，以便選擇合適的傳動(dòng)機(jī)構(gòu)和傳動(dòng)方案，可先由已知條件計(jì)算其驅(qū)動(dòng)卷筒的轉(zhuǎn)速nw,即v=1.1m/s;D=350mm; nw=60*1000*v/(*D)=60*1000*1.1/(3.14*350) 一般常選用同步轉(zhuǎn)速為r/min或r/min的電動(dòng)機(jī)作為原動(dòng)機(jī)，因此傳動(dòng)裝置總傳動(dòng)比約為7或25。2.選擇電動(dòng)機(jī)）電動(dòng)機(jī)類型和結(jié)構(gòu)形式按工作要求和工作條件，選用一般用途的（）系列三相異步電動(dòng)機(jī)。它為臥式封閉結(jié)構(gòu)。）電動(dòng)機(jī)容量（）卷筒軸的輸出功率F=2800r/min; Pw=F*v/1000=2800*1.1/1000 (2)電動(dòng)機(jī)輸出功率PdPd=Pw/t傳動(dòng)裝置的總效率t=t1*t22*t3*t4*t5式中，t1,t2,為從電動(dòng)機(jī)到卷筒之間的各傳動(dòng)機(jī)構(gòu)和軸承的效率。由表查得：彈性聯(lián)軸器 1個(gè)t4=0.99; 滾動(dòng)軸承2對(duì)t2=0.99; 圓柱齒輪閉式1對(duì)t3=0.97; V帶開式傳動(dòng)1幅t1=0.95; 卷筒軸滑動(dòng)軸承潤滑良好1對(duì)t5=0.98; 則t=t1*t22*t3*t4*t5=0.95*0.992*0.97*0.99*0.980.8762 故Pd=Pw/t=3.08/0.8762 （）電動(dòng)機(jī)額定功率Ped由第二十章表選取電動(dòng)機(jī)額定功率ped=4KW。3）電動(dòng)機(jī)的轉(zhuǎn)速為了便于選擇電動(dòng)事，先推算電動(dòng)機(jī)轉(zhuǎn)速的可選范圍。由表查得V帶傳動(dòng)常用傳動(dòng)比范圍24，單級(jí)圓柱齒輪傳動(dòng)比范圍36，可選電動(dòng)機(jī)的最小轉(zhuǎn)速Nmin=nw*6=60.0241*6=360.1449r/min 可選電動(dòng)機(jī)的最大轉(zhuǎn)速Nmin=nw*24=60.0241*24=1440.6 r/min同步轉(zhuǎn)速為960r/min選定電動(dòng)機(jī)型號(hào)為321。）電動(dòng)機(jī)的技術(shù)數(shù)據(jù)和外形、安裝尺寸由表、表查出321型電動(dòng)機(jī)的方根技術(shù)數(shù)據(jù)和外形、安裝尺寸，并列表刻錄備用。電機(jī)型號(hào)額定功率同步轉(zhuǎn)速滿載轉(zhuǎn)速電機(jī)質(zhì)量軸徑mmY132M1-64Kw10009607328大齒輪數(shù)比小齒輪數(shù)=101/19=5.3158 計(jì)算傳動(dòng)裝置總傳動(dòng)比和分配各級(jí)傳動(dòng)比）傳動(dòng)裝置總傳動(dòng)比nm=960r/min; i=nm/nw=960/60.0241=15.9936 ）分配各級(jí)傳動(dòng)比取V帶傳動(dòng)比為i1=3; 則單級(jí)圓柱齒輪減速器比為i2=i/i1=15.9936/3=5.3312 所得i2值符合一般圓柱齒輪和單級(jí)圓柱齒輪減速器傳動(dòng)比的常用范圍。計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)）各軸轉(zhuǎn)速電動(dòng)機(jī)軸為軸，減速器高速軸為軸，低速軸為軸，各軸轉(zhuǎn)速為n0=nm; n1=n0/i1=60.0241/3=320r/min n2=n1/i2=320/5.3312=60.0241r/min ）各軸輸入功率按機(jī)器的輸出功率Pd計(jì)算各軸輸入功率，即P0=Ped=4kw 軸I 的功率P1=P0*t1=4*0.95=3.8kw 軸II功率P2=P1*t2*t3=3.8*0.99*0.97=3.6491kw ）各軸轉(zhuǎn)矩T0=9550*P0/n0=9550*4/960=39.7917 Nm T1=9550*P1/n1=9550*3.8/320=113.4063 Nm T2=9550*P2/n2=9550*3.6491/60.0241=580.5878 Nm 二、設(shè)計(jì)帶輪1、計(jì)算功率P=Ped=4Kw 一班制，工作小時(shí)，載荷平穩(wěn)，原動(dòng)機(jī)為籠型交流電動(dòng)機(jī)查課本表，得KA=1.1; 計(jì)算功率Pc=KA*P=1.1*44.4kw 2選擇普通帶型號(hào)n0 =960r/min 根據(jù)Pc=4.4Kw，n0=960r/min,由圖13-15（205頁）查得坐標(biāo)點(diǎn)位于A型d1=80100、確定帶輪基準(zhǔn)直徑表及推薦標(biāo)準(zhǔn)值小輪直徑d1=100mm; 大輪直徑d2=d1*3.5=100*3.5=350mm 取標(biāo)準(zhǔn)件d2=355mm; 4、驗(yàn)算帶速驗(yàn)算帶速v=*d1*n0/60000=3.14*100*960/60000=5.0265m/s 在525m/s范圍內(nèi)從動(dòng)輪轉(zhuǎn)速n22=n0*d1/d2=960*100/355=270.4225m/s n21=n0/3.5=960/3.5=274.2857m/s 從動(dòng)輪轉(zhuǎn)速誤差=(n22-n21)/n21=270.4225-274.2857/274.2857=-0.0141 5、V帶基準(zhǔn)長度和中心距初定中心距中心距的范圍amin=0.75*(d1+d2)=0.75*(100+355)=341.2500mm amax=0.8*(d1+d2)=0.8*(100+355)=364mm a0=350mm; 初算帶長Lc=2*a0+pi*(d1+d2)/2+(d2-d1)2/4/a0 Lc = 1461.2mm 選定基準(zhǔn)長度表8-7,表8-8查得Ld=1600mm; 定中心距a0+(Ld-Lc)/2=(1600-1461.3)/2=419.4206mm a=420mm; amin=a-0.015*Ld=420-0.015*1600=396mm amax=a+0.03*Ld=420+0.03*1600=468mm 6、驗(yàn)算小帶輪包角驗(yàn)算包角180-(d2-d1)*57.3/a=180-(355-100)*57.3/a145.2107 120度 故合格7、求V帶根數(shù)Z由式（13-15）得查得 n1=960r/min , d1=120mm查表13-3 P0=0.95由式13-9得傳動(dòng)比i=d2/(d1(1+0.0141)=350/(100*(1+0.0141)=3.5查表（13-4）得由包角145.21度查表13-5得Ka=0.92KL=0.99z=4.4/(0.95+0.05)*0.92*0.99)=38、作用在帶上的壓力F查表13-1得q=0.10故由13-17得單根V帶初拉力三、軸初做軸直徑： 軸I和軸II選用45#鋼 c=110d1=110*（3.8/320）(1/3)=25.096mm取d1=28mmd2=110*(3.65/60)（1/3）=43.262mm由于d2與聯(lián)軸器聯(lián)接，且聯(lián)軸器為標(biāo)準(zhǔn)件，由軸II扭矩，查162頁表取YL10YLd10聯(lián)軸器Tn=630580.5878Nm 軸II直徑與聯(lián)軸器內(nèi)孔一致取d2=45mm四、齒輪1、齒輪強(qiáng)度由n2=320r/min,P=3.8Kw,i=3采用軟齒面，小齒輪40MnB調(diào)質(zhì)，齒面硬度為260HBS，大齒輪用ZG35SiMn調(diào)質(zhì)齒面硬度為225HBS。因，SH1=1.1， SH2=1.1，因：，SF=1.3所以2、按齒面接觸強(qiáng)度設(shè)計(jì)設(shè)齒輪按9級(jí)精度制造。取載荷系數(shù)K=1.5，齒寬系數(shù)小齒輪上的轉(zhuǎn)矩 按 計(jì)算中心距u=i=5.333mm齒數(shù)z1=19,則z2=z1*5.333=101模數(shù)m=2a/(z1+z2)=2.0667 取模數(shù)m2.5 確定中心矩a=m(z1+z1)/2=150mm齒寬b=b1=70mm,b2=60mm3、驗(yàn)算彎曲強(qiáng)度齒形系數(shù)YF1=2.57，YF2=2.18按式（11-8）輪齒彎曲強(qiáng)度4、齒輪圓周速度按162頁表11-2應(yīng)選9做精度。與初選一致。五、軸校核：圓周力Ft=2T/d1徑向力Fr=Ft*tan =20度 標(biāo)準(zhǔn)壓力角d=mz=2.5*101=252.5mmFt=2T/d1=2*104.79/252.5=5852.5NFr=5852.5*tan20=2031.9N1、求垂直面的支承壓力Fr1,Fr2 由Fr2*L-Fr*L/2=0得Fr2=Fr/2=1015.9N2、求水平平面的支承力FH1=FH2=Ft/2=2791.2N3、畫垂直面彎矩圖L=40/2+40/2+9010=140mmMavFr2*L/21015.9*140/2=71.113Nm4、畫水平面彎矩圖MaH=FH*L/2=2791.2*140/2=195.384Nm5、求合成彎矩圖6、求軸傳遞轉(zhuǎn)矩T=Ft*d2/2=2791.2*2.5*101/2=352.389Nm7、求危險(xiǎn)截面的當(dāng)量彎矩從圖可見a-a截面是最危險(xiǎn)截面，其當(dāng)量彎矩為軸的扭切應(yīng)力是脈動(dòng)循環(huán)應(yīng)力取折合系數(shù)a=0.6代入上式可得8、計(jì)算危險(xiǎn)截面處軸的直徑軸的材料，用45#鋼，調(diào)質(zhì)處理，由表14-1查得由表13-3查得許用彎曲應(yīng)力，所以考慮到鍵槽對(duì)軸的削弱，將軸的最小危險(xiǎn)直徑d加4%。故d=1.04*25.4=26.42mm由實(shí)際最小直徑d=40mm,大于危險(xiǎn)直徑所以此軸選d=40mm,安全六、軸承的選擇由于無軸向載荷，所以應(yīng)選深溝球軸承6000系列徑向載荷Fr=2031.9N，兩個(gè)軸承支撐，F(xiàn)r1=2031.9/21015.9N工作時(shí)間Lh3*365*8=8760（小時(shí)）因?yàn)榇笮奁谌?，可更換一次軸承所以取三年由公式式中 fp=1.1,P=Fr1=1015.9N,ft=1 (工作環(huán)境溫度不高)（深溝球軸承系列）由附表選6207型軸承七、鍵的選擇選普通平鍵A型由表10-9按最小直徑計(jì)算，最薄的齒輪計(jì)算b=14mm,h=9mm,L=80mm,d=40mm由公式所以選變通平鍵，鑄鐵鍵所以齒輪與軸的聯(lián)接中可采用此平鍵。八、減速器附件的選擇1、通氣器：由于在外界使用，有粉塵，選用通氣室采用M181.52、油面指示器：選用油標(biāo)尺，規(guī)格M163、起吊裝置：采用箱蓋吊耳，箱座吊耳4、放油螺塞：選用外六角細(xì)牙螺塞及墊片M161.55、窺視孔及視孔蓋選用板結(jié)構(gòu)的視孔蓋九、潤滑與密封：1、齒輪的潤滑：采用浸油潤滑，由于低速級(jí)大齒輪的速度為：查課程設(shè)計(jì)P19表3-3大齒輪浸油深度為六分之一大齒輪半徑，所以取浸油深度為30mm。2、滾動(dòng)軸承的潤滑采用飛濺潤滑在箱座凸緣面上開設(shè)導(dǎo)油溝，并設(shè)擋油盤，以防止軸承旁齒輪嚙合時(shí)，所擠出的熱油濺入軸承內(nèi)部，增加軸承的阻力。3、潤滑油的選擇齒輪與軸承用同種潤滑油較為便利，考慮到該裝置用于小型設(shè)備選用L-AN15潤滑油4、密封方式選取：選用凸緣式端蓋，易于調(diào)整軸承間隙，采用端蓋安裝氈圈油封實(shí)現(xiàn)密封。軸承蓋結(jié)構(gòu)尺寸按用其定位的軸承外徑?jīng)Q定。設(shè)計(jì)小結(jié)：二、課程設(shè)計(jì)總結(jié)設(shè)計(jì)中運(yùn)用了Matlab科學(xué)工程計(jì)算軟件，用notebook命令調(diào)用MSWord來完成設(shè)計(jì)說明書及設(shè)計(jì)總結(jié)，在設(shè)計(jì)過程中用了機(jī)械設(shè)計(jì)手冊(cè)2.0 軟件版輔助進(jìn)行設(shè)計(jì)，翻閱了學(xué)過的各種關(guān)于力學(xué)，制圖，公差方面的書籍，綜合運(yùn)用了這些知識(shí)，感覺提高許多，當(dāng)然尤其是在計(jì)算機(jī)軟件CAD 方面的運(yùn)用，深切感到計(jì)算機(jī)輔助設(shè)計(jì)給設(shè)計(jì)人員帶來的方便，各種設(shè)計(jì)，計(jì)算，制圖全套完成。由于沒有經(jīng)驗(yàn)，第一次做整個(gè)設(shè)計(jì)工作，在設(shè)計(jì)過程中出現(xiàn)了一些錯(cuò)誤比如線形，制圖規(guī)格，零件設(shè)計(jì)中的微小計(jì)算錯(cuò)誤等都沒有更正，設(shè)計(jì)說明書的排版也比較混亂等等。對(duì)圖層，線形不熟悉甚至就不確定自己畫出的線，在出圖到圖紙上時(shí)實(shí)際上是什么樣子都不知道 ，對(duì)于各種線寬度，沒有實(shí)際的概念。再比如標(biāo)注較混亂，還是因?yàn)榈谝淮巫稣麄€(gè)設(shè)計(jì)工作，沒有經(jīng)驗(yàn)，不熟悉。這次設(shè)計(jì)的目的是掌握機(jī)械設(shè)計(jì)規(guī)律，綜合運(yùn)用學(xué)過的知識(shí)，通過設(shè)計(jì)計(jì)算，繪圖以及運(yùn)用技術(shù)標(biāo)準(zhǔn)，規(guī)范設(shè)計(jì)手冊(cè)等有關(guān)設(shè)計(jì)資料進(jìn)行全面的機(jī)械設(shè)計(jì)技能訓(xùn)練。目的已經(jīng)達(dá)到，有許多要求、標(biāo)準(zhǔn)心中雖然明確理解掌握但是要全力，全面的應(yīng)用在實(shí)際中，還有待于提高水平。雖然它可能不是良好、優(yōu)秀，但是既然教學(xué)環(huán)節(jié)、課程設(shè)計(jì)目的已經(jīng)達(dá)到，那么這次設(shè)計(jì)做的就是完全合格的。當(dāng)然還受軟件的熟悉，運(yùn)用程度的影響，所有這些必須得參加實(shí)踐，接觸實(shí)際工程設(shè)計(jì)中才能提高。帶輪，齒輪，軸，軸承這些關(guān)鍵的設(shè)計(jì)計(jì)算都達(dá)到合格，并且用機(jī)械設(shè)計(jì)手冊(cè)2.0 軟件版的驗(yàn)證了。 通過這次課程設(shè)計(jì)，感到機(jī)械設(shè)計(jì)綜合了力學(xué)，公差，材料，制圖等學(xué)科的知識(shí)，要好了這些功課，才能做好機(jī)械設(shè)計(jì)。參考資料：工程力學(xué)，機(jī)械設(shè)計(jì)基礎(chǔ)，機(jī)械設(shè)計(jì)指導(dǎo)，互換性技術(shù)與測量，機(jī)械制圖Nw=60.0241r/minPw=3.08Kw效率t=0.8762Pd = 3.5150 Ped=4Kwi=15.9936i1=3i2=5.3312n0=960r/minn1=320r/minn2=60.0241r/minP0=4KwP1=3.8KwP2=3.6491KwT0=39.7917NmT1=113.4063NmT2=589.5878NmKA=1.1Pc=4.4Kwd1=100mmd2=355mm初定中心距a0=350mmLc=1461.3mmLd=1600mm中心距a=420mmz=3根預(yù)緊力FQ274.3Nd1=28mmd2=45mmYL10YLd10T1=113.4063Nmm=2.5a=150mm =20度Ft=5582.5NFr=2031.9NFH1=FH2=2791.2NMav=71.113NmMaH=195.38NmMa216.16NmMe=457.15NmFr1=1015.9NLh=8760小時(shí)6207型bhL=1498019長春理工大學(xué)光電信息學(xué)院畢業(yè)設(shè)計(jì)Introduction to the common speed reducerDevice overview：Reducer is the prime mover and work machine independent closed between the transmission device, used to reduce speed and increase torque, in order to meet the job needs, also used for growth in some occasions, known as the accelerator.When choosing reducer should be according to the selection of working machine conditions, technical parameters, the performance of the engine, the factors such as economy, comparing the gabarite of different types and varieties of reducer, transmission efficiency and carrying capacity, quality, price, etc., choose the most suitable speed reducer.Reducer is a relatively sophisticated machinery, the use of its purpose is to reduce rotation speed, increase torque.Structural characteristics ofReducer is mainly composed of transmission parts (gear or worm), shaft, bearing, box and its accessories. Its basic structure has three parts:1gear, shaft and bearing combinationPinion and shaft made of an organic whole, gear shaft, this structure is used in the gear shaft and the diameter of the diameter of the weather related, if the diameter of the shaft is d, the gear tooth root circle diameter for df, when df - d 6 7 mn or less, this structure should be adopted. And when df - d 6 7 mn, separated with gear and shaft for the two parts of the structure, such as low speed shaft and large gear. The gear and shaft circumferential fixed flat linkage, shaft parts shaft shoulder, shaft sleeve and bearing cover is used as the axial fixation. Two shaft adopts the deep groove ball bearings. This combination, the less used to bear radial load and axial load. When the axial load is larger, should adopt angular contact ball bearing, taper roller bearing and deep groove ball bearing and thrust bearing of composite structures. Bearing is the use of the gear rotates splashing through the thin oil, lubrication. Box medium oil pool of the lubricating oil, the rotation gear splash splash into the lid on the inner wall of the inner flow box side groove to points, through the oil flow into the bearing. Nu when oiled gear circumferential speed 2 m/s, or less grease lubricated bearings should be adopted, in order to avoid possible wash it splashing through the thin oil lubricating grease, the oil retaining ring can be used to separate it. To prevent loss of lubricating oil and dust into the trunk, between bearing end cover and outrigger shaft equipped with sealing element.2 bodyEnclosure is the important part in the reducer parts. It is the base of the transmission parts, should have sufficient strength and rigidity.Cabinet is usually made of grey cast iron, for overloading or cast steel casing impact load reducer can also be used. Monomer production reducer, in order to simplify the process, to reduce the cost, can use steel plate welded box.Gray cast iron has good casting and vibration reduction performance. To facilitate the shafting parts installation and disassembly, made along the axis line horizontal split-casing box body. On the box cover and the lower box body with a bolt connection into a whole. The connecting bolt of the bearing should be close to the bearing hole, and the bearing seat at the side of convex set, should have enough supporting material surface, in order to place the connecting bolt, and to ensure that the wrench to tighten bolts need to space. In order to ensure the body has enough stiffness, plus support rib near the bearing hole. In order to ensure the stability and reduce as much as possible on the basis of speed reducer in the mechanical processing of base plane of the area, the case base is generally not used the complete plane.3 reducer fittingsIn order to guarantee the normal work of the speed reducer, in addition to combination of gear, shaft, bearing and the structure design of box body is to give enough attention, also should be considered as reducer oil lubricating oil pool, oil discharge, check the oil level height, processing, maintenance when assembling and disassembling of the box cover and the box of accurate positioning, loading auxiliary parts and components, such as reasonable selection and design.1) inspection to check the meshing condition of transmission parts, and to infuse lubricating oil contents, should be set in the appropriate location of the box body inspection hole. Inspection hole is located in the top lid can be observed directly on the gear mesh part. Normally, inspection hole of cover plate on the box cover with screws.2) the ventilator speed reducer is working, the casing temperature, gas expansion pressure, to make overall thermal air free to discharge, to maintain pressure balance inside and outside, not make the lubricating oil or shaft extension along the points box surface seal leakage cracks and other, usually on the top of the box body installed ventilator.3) bearing cover for the fixed shaft parts of axial position and carry axial load, the bearing hole on both ends with bearing cover closed. Bearing bore of flange type and embedded two kinds. Use hex bolt fixed on the box body, bearing cover is overhang shaft hole, which is equipped with sealing device. Flange type bearing cover has the advantage of tear open outfit, easy to adjust the bearing, but compared with the embedded bearing cover, the number of parts is bigger, the size is bigger, appearance is not smooth.4) positioning pin every time in order to ensure the container cover, remained bearing hole processing accuracy, should be in before finishing the bearing hole, in the box cover and the box seats on the connecting flange of the locating pin. Placed vertically on both sides of the enclosure on the connecting flange, symmetrical body should be symmetrical arrangement, in order to avoid mistake.5) oil level indicator to check the oil in the oil pool reducer hight, often maintain oil pool with just the right amount of oil, usually in the box body is convenient for observation, the oil level is relatively stable, installing the oil level indicator.6) oil drain plug oil change, dirty oil and cleaner emissions, should be in the box seat, at the bottom of the oil pool of the lowest opening oil drain hole location, usually with a screw oil drain plug, oil drain plug and body joint face between gasket shall be leak proof.7) seal screw for strengthening qi box, usually during assembly on housing subdivision surface coated with sodium silicate or sealant, when remove often due to the cementation close is difficult to open. So often the appropriate placement of the box cover connecting flange, work out 2 screw holes, screwing in enlightening the box with a cylindrical side or flat side box screws. Gyration rev box screws can will cover on top. Small reducer also dont have rev. Cases of screw, when the lid with a screwdriver to pry out of the box cover, and the box can be the same as the size of the screw to the connecting bolt at the flange.Main loadMachine with reducer connection work load condition is more complex, has much effect on the speed reducer, is one of the important factors, selection and calculation speed reducer the load state of the work machine (motivation) is the load condition, usually divided into three categories:(1) - even load;(2) - medium impact load;(3) - strong impact load.Design programA, the original design information and data1 the type of prime mover, specifications, speed, power (or torque), the startup characteristic, short-term overload capacity, the moment of inertia, etc.2 the type of machine, specifications, use, speed, power (or torque). Working system: the constant load or changing load and variable load load diagram; Rev., braking and short-time overload torque, start frequency; Shock and vibration levels; Direction of rotation, etc.3the prime mover for machine and connection way of the reducer, shaft and if there is a radial force and axial force.4installation type (reducer and prime mover, the relative position of working machine, vertical and horizontal).5transmission ratio and its error is allowed.6the size and weight requirements.7to the degree of service life, safety and reliability requirements.8environmental temperature, dust concentration, air velocity and environmental conditions such as ph value; (if there is a circulating lubrication and cooling conditions, lubrication station) and the limitation on the vibration and noise.9to the requirements of operation and control.10 the source of material, blank, standard parts and inventory.11factory manufacturing capabilities.12on volume, cost and price requirements.13, the delivery date.The article in the first four is a prerequisite, other aspects according to conventional design, such as the design life is generally! Years. Used for important occasions, reliability should be higher.Second, select the type of gear reducer and installation typeThree, set at the beginning of each process methods and parametersSelected performance level, set at the beginning of the main parts of the gear and the material, heat treatment, finishing methods, lubrication, and lubrication oil.Fourth, determine the transmission seriesAccording to the total transmission ratio, to determine the transmission series and all levels of the transmission ratio.Five, the initial geometry parametersEarly calculate gear transmission center distance (or pitch diameter), modulus and other geometric parameters.Six, the overall design schemeDetermine the structure of the reducer, shaft size, span and the bearing model, etc.Seven, checkCheck the strength of the gear, shaft, key load, calculation of bearing life.Eight, lubrication cooling calculationTo determine the speed reducer and accessoryTen, gear carburized depth is determinedWhen necessary for tooth form and tooth to fix quantity calculation process data.Eleven, drawing construction drawingIn the design should implement national and industry related standards.Using the classification1 reducer in use can be divided into two categories, general reducer and special reducer, design, manufacture and use of the two characteristics of each are not identical. 70-80 - s of the 20th century, reducer technology has made great development in the world, and closely integrated with the development of new technology revolution. The main types: gear reducer; Worm gear reducer; Gear - worm reducer; Planetary gear reducer.2general reducer has a helical gear reducer (including parallel shaft helical gear reducer, worm gear reducer, bevel gear reducer, etc.), planetary gear reducer, cycloid pin wheel reducer, the worm gear and worm reducer, planetary friction type mechanical stepless variable speed machine, and so on.1) cylindrical gear reducerSingle stage level 2, level 2, level 2 above. Decorate a form: expansion, shunt type, coaxial type.2) cone gear reducerUsed for the input shaft and output shaft position into the intersection.3) worm gear reducerIs mainly used for transmission ratio 10 occasions, I drive more compact structure. Its defect is low efficiency. Wide application of Archimedes worm gear reducer.4) gear - worm reducerIf gear drive level at high speed, the structure is compact;If worm transmission at high speed, high efficiency.5) planetary gear reducerWith a range of high transmission efficiency, transmission ratio, transmission power is 12 w 50000 kw, small volume and weight3common types of reducer1) the main characteristics of worm gear and worm reducer is a reverse self-locking function, can have a large reduction ratio, the input shaft and output shaft is not in the same axis, is not in the same plane. But generally larger, transmission efficiency is not high, the accuracy is not high.2) harmonic reducer harmonic drive is to use the elastic deformation of flexible components controlled to transfer movement and power, small size, high precision, but the disadvantage is that soft wheel life is limited, dont impact resistance, rigidity compared with metal parts. Input speed cannot be too high.3) planetary gear reducer, its advantage is more compact in structure, return clearance is small, high precision, long service life, rated output torque can do a lot of. But the price a little expensive. Reducer: in short, generally after the machine power in design and manufacture, the rated power will not change, at this time, the greater the speed, the smaller is the torque (or torque); Speed is smaller, the greater the torque.The transmission ratio distribution principle1 to make the bearing capacity of transmission at all levels are equal;2 make all levels of transmission gear oil immersion depth is roughly similar in;3minimize the reducer for the shape of the size or weight, etcModel selectionAs far as possible choose close to ideal reduction ratio:Reduction ratio = / servo motor speed reducer output shaft speedTorque calculation:For the life of the reducer, torque calculation is very important, and should pay attention to the maximum torque value of the acceleration (TP), which is superMaximum load torque of reducer.Apply power is usually the servo on market model for power, the applicability of the speed reducer is very high, can remain above 1.2 coefficient of work, but in use can also with their own needs to decide:There are two main points:A. choose servo motor output maximum diameter of axle diameter of axle is not greater than form.B. If the computed torque, rotational speed can meet the normal operation, but in the net output servo have insufficient phenomenon, we can in the motor drive, do current limit control, or on the mechanical shaft torque protection, it is very necessary.Installation methodThe correct installation, use and maintenance of the reducer, it is an important link in ensure the normal operation of machinery and equipment. When you install reducer, therefore, please be sure to use related matters in strict accordance with the following installation, assembly and use seriously.The first step is to install before confirm the motor and reducer are intact, and strict inspection of motor and reducer connected each part size matches, here is the positioning convex table of the machine, input shaft and gear reducer groove size and tolerance, etc.The second step is to unscrew the gear reducer dustproof holes on flange lateral screw, adjust the clamping ring dustproof holes and side holes to make it align with each other, and insert the socket head screw. After taking the motor shaft key.The third step is to connect the motor and the reducer nature. Connection must be to ensure the output gear reducer input shaft and motor shaft concentricity is consistent, and the outer flange is parallel. Such as concentricity is inconsistent, can lead to broken motor shaft or reducer gear wear and tear.Check the maintenanceDifferent lubricant mixed ban each other. Oil level screw, oil drain plug and the location of the ventilator is determined by the installation position. Their relative position refer to the installation drawing to determine that speed reducer.One, the oil level checkCut off the power supply, prevent to get an electric shock! Waiting for reducer cooling!Remove the oil level screw check filled with oil.Install the oil level screw.Second, the check of oilCut off the power supply, prevent to get an electric shock! Waiting for reducer cooling!Open the oil plug, pick up sample.Check the oil viscosity index- if oil significantly turbidity, it is recommended that the replacement as soon as possible.To bring oil level screw speed reducer- check the oil level, whether qualified- the installation of oil level screw3the oil replacementAfter cooling oil viscosity increases with difficulty, reducer should be under the running temperature oil change.Cut off the power supply, prevent to get an electric shock! Waiting for reducer cooled down no burning danger!Note: when an oil change speed reducer should still keep warm.Under the oil drain screw one by oil pan.Open the oil level screw, ventilator and oil drain plug.All the oil out.Install drain plug.Injection with brand new oil.Oil shall conform to the installation location.Check the oil level in the oil level screw.Tighten the oil level screw and ventilator.Failure to solveSpeed reducer leakage oil cause analysis and solutionAnalysis of the causes1the pressure inside the tankIn closed reducer, each pair of gears meshing friction will emit heat, according to the Boyle trails by specific law, as the lengthen of running time, the deceleration box temperature gradually raised, and the reduction volume inside the case, so the pressure increase, in the case of lubricating oil splash, sprinkle on the inner wall of the deceleration box. Because the permeability of oil is strong, the overall pressure, which a seal is lax and the oil bleeding out from where.2the structure of the speed reducer design is not reasonable cause oil leakageSuch as design of reducer without ventilation hood, pressure reducer can not be achieved, in the pressure more and more high, oil leakage occurs.3amount to muchReducer in the process of operation, oil pool was badly agitation, lubricating oil splash around in the machine, if the amount is overmuch, make a lot of the place such as lubricating oil accumulation in the shaft seal, joint surface and lead to leakage.4improper maintenance technologyIn equipment maintenance, due to the combined surface dirt removal is not complete, or sealant improper selection, seal, not timely replacement of seals, etc way can also cause oil leakage.Treatment schemeGovernance using polymer composite materials to repair speed reducer leakage oil, polymer composite materials based on polymer, metal or ceramic powder, fiber and other materials for, under the action of curing agent, curing catalyst of composite materials. All kinds of material in performance from each other each other, to produce synergistic effect, the comprehensive performance is better than the original ingredients of composite materials. Have extremely strong sticky relay, mechanical properties, and chemical corrosion resistance and other performance, and therefore is widely used in metal equipment, mechanical wear, scratches, pits, cracks, leakage, repair such as casting sand holes, and chemistry of chemical storage tank, reaction tank, pipe anti-corrosion protection and restoration. For reducer static seal leakage point can use the ka wah polymer composite materials and technology field leakage of governance, without disassembly, polymer composite materials in the leakage of external governance, save time and effort, the effect is immediate, the product has excellent adhesion, oil resistance, and 350% of the tensile strength, overcome the impact of reducer vibration, well solved for many years for the enterprise is unable to solve the problem. If reducer running in static seal leak, the oil level of emergency repairing adhesive available surface engineering technologies NianDu, so as to achieve the aim of eliminate oil leakage.Development trend1high level and high performance. Widely used cylindrical gear carburizing and quenching, grinding, carrying capacity increased by more than 4 times, small volume, light weight, low noise, high efficiency and high reliability.2modular combination design. Basic parameters using priority number, size, parts versatility and interchangeability, series of easy to expand and newer, conducive to tissue mass production and reduce cost.3style diversification, variant design. To get rid of the traditional single base installation, added a hollow shaft mounted, floating bearing base, motor and reducer one-piece, different types, such as multiple mounting surface
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