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長(zhǎng)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 reducer
Device 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 of
Reducer is mainly composed of transmission parts (gear or worm), shaft, bearing, box and its accessories. Its basic structure has three parts:
1．gear, shaft and bearing combination
Pinion 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． body
Enclosure 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 fittings
In 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 don't 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 load
Machine 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 program
A, the original design information and data
1． 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.
3．the prime mover for machine and connection way of the reducer, shaft and if there is a radial force and axial force.
4．installation type (reducer and prime mover, the relative position of working machine, vertical and horizontal).
5．transmission ratio and its error is allowed.
6．the size and weight requirements.
7．to the degree of service life, safety and reliability requirements.
8．environmental 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.
9．to the requirements of operation and control.
10． the source of material, blank, standard parts and inventory.
11．factory manufacturing capabilities.
12．on 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 type
Three, set at the beginning of each process methods and parameters
Selected 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 series
According to the total transmission ratio, to determine the transmission series and all levels of the transmission ratio.
Five, the initial geometry parameters
Early calculate gear transmission center distance (or pitch diameter), modulus and other geometric parameters.
Six, the overall design scheme
Determine the structure of the reducer, shaft size, span and the bearing model, etc.
Seven, check
Check the strength of the gear, shaft, key load, calculation of bearing life.
Eight, lubrication cooling calculation
To determine the speed reducer and accessory
Ten, gear carburized depth is determined
When necessary for tooth form and tooth to fix quantity calculation process data.
Eleven, drawing construction drawing
In the design should implement national and industry related standards.
Using the classification
1． 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.
2．general 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 reducer
Single stage level 2, level 2, level 2 above. Decorate a form: expansion, shunt type, coaxial type.
2) cone gear reducer
Used for the input shaft and output shaft position into the intersection.
3) worm gear reducer
Is 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 reducer
If gear drive level at high speed, the structure is compact;
If worm transmission at high speed, high efficiency.
5) planetary gear reducer
With a range of high transmission efficiency, transmission ratio, transmission power is 12 w ~ 50000 kw, small volume and weight
3．common types of reducer
1) 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, don't 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 principle
1． 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;
3．minimize the reducer for the shape of the size or weight, etc
Model selection
As far as possible choose close to ideal reduction ratio:
Reduction ratio = / servo motor speed reducer output shaft speed
Torque 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 super
Maximum 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 method
The 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 maintenance
Different 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 check
Cut 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 oil
Cut 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 screw
3．the oil replacement
After 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 solve
Speed reducer leakage oil cause analysis and solution
Analysis of the causes
1．the pressure inside the tank
In 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.
2．the structure of the speed reducer design is not reasonable cause oil leakage
Such as design of reducer without ventilation hood, pressure reducer can not be achieved, in the pressure more and more high, oil leakage occurs.
3．a(chǎn)mount to much
Reducer 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.
4．improper maintenance technology
In 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 scheme
Governance 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 trend
1．high 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.
2．modular 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.
3．style 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