減速器-二級(jí)圓柱斜齒輪減速器設(shè)計(jì)【含箱體】【F=1660N V=1.5ms D=230mm】
減速器-二級(jí)圓柱斜齒輪減速器設(shè)計(jì)【含箱體】【F=1660N V=1.5ms D=230mm】,含箱體,F=1660N V=1.5ms D=230mm,減速器-二級(jí)圓柱斜齒輪減速器設(shè)計(jì)【含箱體】【F=1660N,V=1.5ms,D=230mm】,減速器,二級(jí),圓柱,齒輪,設(shè)計(jì),箱體,ms,mm,妹妹
機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)
二級(jí)減速器計(jì)算說(shuō)明書(shū)
題 目
指導(dǎo)教師
院 系
班 級(jí)
學(xué) 號(hào)
姓 名
摘 要
機(jī)械設(shè)計(jì)課程設(shè)計(jì)主要是培養(yǎng)理論聯(lián)系實(shí)際的設(shè)計(jì)思想。本次設(shè)計(jì)包括的主要內(nèi)容有：決定傳動(dòng)裝置的總體設(shè)計(jì)方案；選擇電動(dòng)機(jī)；計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)；傳動(dòng)零件、軸的設(shè)計(jì)計(jì)算；軸承、聯(lián)接件、潤(rùn)滑密封和聯(lián)軸器及校驗(yàn)計(jì)算；機(jī)體結(jié)構(gòu)及其附件的設(shè)計(jì)；繪制裝配圖及零件工作圖；編寫(xiě)計(jì)算說(shuō)明書(shū)以及進(jìn)行設(shè)計(jì)答辯。
設(shè)計(jì)的一般過(guò)程為：首先明確設(shè)計(jì)任務(wù)，制定設(shè)計(jì)任務(wù)書(shū)；其次，提供方案并進(jìn)行評(píng)價(jià)；再次，按照選定的方案進(jìn)行各零部件的總體布置，運(yùn)動(dòng)學(xué)和零件工作能力計(jì)算，結(jié)構(gòu)設(shè)計(jì)和繪制總體設(shè)計(jì)圖；然后，根據(jù)總體設(shè)計(jì)的結(jié)果，考慮結(jié)構(gòu)工藝性等要求，繪出零件工作圖；然后，審核圖紙；最后，整理設(shè)計(jì)文件，編寫(xiě)說(shuō)明書(shū)。
39
目 錄
目 錄 3
第1章 設(shè)計(jì)任務(wù)書(shū) 4
第2章 傳動(dòng)方案擬定 5
第3章 電動(dòng)機(jī)的選擇 6
3.1選擇電動(dòng)機(jī)類型 6
3.2選擇電動(dòng)機(jī)的容量計(jì)算 6
3.3電動(dòng)機(jī)轉(zhuǎn)速選擇及型號(hào)確定 6
第4章 傳動(dòng)裝置總體設(shè)計(jì) 8
4.1計(jì)算傳動(dòng)比及分配各級(jí)傳動(dòng)比總傳動(dòng)比 8
4.2計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù) 8
第5章 齒輪傳動(dòng)設(shè)計(jì) 10
5.1高速級(jí)齒輪傳動(dòng)設(shè)計(jì) 10
5.2 低速級(jí)齒輪傳動(dòng)設(shè)計(jì) 14
第6章 軸的設(shè)計(jì) 19
6.1高速軸(I)的設(shè)計(jì) 19
6.2中速軸(II)的設(shè)計(jì) 22
6.3低速軸(Ⅲ)設(shè)計(jì) 25
第7章 軸的校核 29
第8章 軸承的選擇和校核計(jì)算 31
8.1高速軸Ⅰ上的軸承選擇與計(jì)算 31
8.2中速軸Ⅱ上的軸承選擇與計(jì)算 31
8.3低速軸Ⅲ上的軸承選擇與計(jì)算 32
第9章 鍵連接的選擇與校核計(jì)算 33
第10章 減速器附件設(shè)計(jì) 35
第11章 潤(rùn)滑方式及密封形式的選擇 36
第12章 箱體設(shè)計(jì) 37
第13章 總結(jié) 38
參考文獻(xiàn) 39
第1章 設(shè)計(jì)任務(wù)書(shū)
項(xiàng)目
內(nèi)容
結(jié)果
1.1工作條件
見(jiàn)附圖
1.2加工條件
中等規(guī)模機(jī)械廠，可加工7~8級(jí)精度齒輪。
1.3設(shè)計(jì)工作量
◆減速器裝配圖1張（A0或A1）
◆零件圖3張，箱體圖，輸出軸，齒輪圖
◆設(shè)計(jì)說(shuō)明書(shū)1份
1.4設(shè)計(jì)參數(shù)
◆運(yùn)輸帶工作拉力F()：
◆運(yùn)輸帶工作速V()：
◆卷筒直徑D()：
第2章 傳動(dòng)方案擬定
傳動(dòng)方案擬定
兩級(jí)分流式圓柱斜齒輪減速器
第3章 電動(dòng)機(jī)的選擇
項(xiàng)目
內(nèi)容
結(jié)果
3.1選擇電動(dòng)機(jī)類型
按已知工作條件和要求查[1]表12-1，選用Y系列1般用途的3相異步電動(dòng)機(jī)
3.2選擇電動(dòng)機(jī)的容量計(jì)算
(1)求,
卷筒所需總功率
卷筒的轉(zhuǎn)速
r/min
(2)求
電動(dòng)機(jī)至滾筒之間傳動(dòng)裝置的總效率為：
式中，， 分別為傳動(dòng)系統(tǒng)中聯(lián)軸器、每對(duì)軸承、圓柱齒輪傳動(dòng)的效率，查[1]表1-7的
=0.99、=0.99、=0.97
=0.99
=0.99
=0.97
(3)求
所需電動(dòng)機(jī)的功率：
查[1]表12-1取額定功率：
3.3電動(dòng)機(jī)轉(zhuǎn)速選擇及型號(hào)確定
(1)求
該傳動(dòng)系統(tǒng)為分流式圓柱齒輪傳動(dòng)，查閱[2]表2-3傳比為
卷筒轉(zhuǎn)速
電動(dòng)機(jī)轉(zhuǎn)速可選范圍
(2)確定型號(hào)
可見(jiàn)同步轉(zhuǎn)速為1500r/min ，3000r/min的電動(dòng)機(jī)都符合，這里初選同步轉(zhuǎn)速為1500r/min ，3000r/min的兩種電動(dòng)機(jī)進(jìn)行比較，如下表3-1
表3-1電動(dòng)機(jī)技術(shù)數(shù)據(jù)比較
方案
電動(dòng)機(jī)型號(hào)
額定功率
電動(dòng)機(jī)轉(zhuǎn)速
質(zhì)量/kg
同步轉(zhuǎn)速
滿載轉(zhuǎn)速
1
Y100L-2
3
3000
2880
2.2
33
2
Y100L2-4
3
1500
1440
2.2
38
綜合考慮電動(dòng)機(jī)和傳動(dòng)轉(zhuǎn)至尺寸、重量、價(jià)格和帶傳動(dòng)、減速器傳動(dòng)比，選擇Y100L2-4型電動(dòng)機(jī)。電動(dòng)機(jī)的外形、安裝尺寸見(jiàn)表2
表3-2電動(dòng)機(jī)的外形、安裝尺寸
型號(hào)
A
B
C
D
E
F
G
H
Y100L2-4
216
178
89
80
10
33
132
K
AB
AC
AD
HD
BB
L
12
280
270
210
315
200
475
Y100L2-4
第4章 傳動(dòng)裝置總體設(shè)計(jì)
項(xiàng)目
內(nèi)容
結(jié)果
4.1計(jì)算傳動(dòng)比及分配各級(jí)傳動(dòng)比總傳動(dòng)比
(1)總傳動(dòng)比
(2)分配傳動(dòng)比
由[2]得分流式減速器中取,這里取高速級(jí)傳動(dòng)比,則低速級(jí)傳動(dòng)比為
4.2計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)
(1)各軸轉(zhuǎn)速
電動(dòng)機(jī)軸為軸,減速器高速級(jí)軸為軸Ⅰ,中速軸為軸Ⅱ,低速級(jí)軸為軸Ⅲ，滾筒軸為軸Ⅴ，則
卷筒轉(zhuǎn)速在運(yùn)輸帶允許誤差之內(nèi)，合適
(2)各軸功率
(3)各軸轉(zhuǎn)矩
第5章 齒輪傳動(dòng)設(shè)計(jì)
項(xiàng)目
內(nèi)容
結(jié)果
5.1高速級(jí)齒輪傳動(dòng)設(shè)計(jì)
(1)選擇材料、精度及參數(shù)
按圖1所示傳動(dòng)方案，選用斜齒圓柱齒輪傳動(dòng)，帶式運(yùn)輸機(jī)為1般工作機(jī)器，速度不高，故選用7級(jí)精度（GB10095-88）
查圖表[3]表11-1，選擇:
小齒輪材料為40Cr（調(diào)質(zhì)），硬度為217~286HBS，
大齒輪材料為45鋼（調(diào)質(zhì)），硬度為197~286HBS。
初選小齒輪齒數(shù)，
則大齒輪齒數(shù),取
初選螺旋角：
查[3]表11-5 取,.，齒輪彎曲疲勞許用應(yīng)力
則=（+）/2
=（700+600）/2=650MPa
齒輪接觸疲勞許用應(yīng)力
小齒輪材料為40Cr（調(diào)質(zhì)），硬度為260HBS
大齒輪材料為45鋼（調(diào)質(zhì)），硬度為220 HBS
(2)按齒面接觸強(qiáng)度設(shè)計(jì)
依式計(jì)算
1)確定公式內(nèi)各計(jì)算數(shù)值
a．載荷系數(shù)
初選載荷系數(shù)
b．小、大齒輪齒數(shù)、，齒數(shù)比
初選小齒輪齒數(shù)，
則大齒輪齒數(shù),取
實(shí)際齒數(shù)比:
C．小齒輪傳遞的轉(zhuǎn)矩
其中
d．選、
查[3] (P171)選取節(jié)點(diǎn)區(qū)域系數(shù)
查[3]表11-4彈性系數(shù)
e．螺旋角及其系數(shù)
初選螺旋角：
螺旋角系數(shù)：
f．齒寬系數(shù)
由[3]表11-6知，軟齒面、對(duì)稱分布?。?
g計(jì)算小齒輪分度圓直徑
按式①計(jì)算小齒輪分度圓直徑
2)計(jì)算圓周速度
=3.14×30.78×1420/（60×1000）m/s
=2.29m/s
3)計(jì)算齒寬b及模數(shù)
4)計(jì)算載荷系數(shù)
根據(jù)有輕微沖擊,使用系數(shù);
根據(jù)V=1.64 m/s，7級(jí)精度查[4]圖9-23得動(dòng)載系數(shù);
查[4]表10-4接觸疲勞齒向載荷分布系數(shù) 的值與直齒輪相同得：;
查[4]圖10-13得彎曲強(qiáng)度計(jì)算齒向載荷系數(shù)：;
查[4]表10-3得齒間載荷分布系數(shù)：
則載荷系數(shù)
5)按實(shí)際載荷系數(shù)校正所得分度圓直徑
由式得:
(3)按齒根彎曲疲勞強(qiáng)度設(shè)計(jì)
按式計(jì)算
1)確定公式內(nèi)各計(jì)算數(shù)值
a.載荷系數(shù)
b.計(jì)算當(dāng)量齒數(shù)、
c.齒形系數(shù)
查[3]圖11-8 ，
d.齒根修正系數(shù)
查[3]圖11-9 ，
e.計(jì)算大小齒輪的并加以比較
=2.66×1.61/336=0.01275
=2.23×1.78/252=0.01575，
0.01275<0.01575
大齒輪值大
f.計(jì)算模數(shù)
由[3]表4-1取
(4)幾何尺寸計(jì)算
1)中心距
將中心距圓整為112mm
2)修正螺旋角
按圓整的中心距修正螺旋角
因值改變不多，故參數(shù) ， ，等不必修正
3)計(jì)算大小齒輪的分度圓直徑、
4)計(jì)算齒輪寬度、
由于需要2個(gè)齒輪分開(kāi)處理，這樣太薄強(qiáng)度不夠，故意數(shù)據(jù)取得大一些。
圓整后取 ，
(5)驗(yàn)算齒面接觸強(qiáng)度
將各參數(shù)代入[3]式(11-8)得
安全
安全
(6)齒輪的圓周速度
對(duì)照[3]表11-2選7級(jí)精度是適宜的
適宜
(7)結(jié)構(gòu)設(shè)計(jì)
由小齒輪做成齒輪軸，
由160mm<<500mm ，大齒輪采用腹板式結(jié)構(gòu)
5.2 低速級(jí)齒輪傳動(dòng)設(shè)計(jì)
(1)選擇材料、精度及參數(shù)
按圖1所示傳動(dòng)方案，選用斜齒圓柱齒輪傳動(dòng)，帶式運(yùn)輸機(jī)為1般工作機(jī)器，速度不高，故選用8級(jí)精度（GB10095-88） 查圖表[3]表11-1，選擇:
小齒輪材料為40Cr（調(diào)質(zhì)），硬度為217~286HBS，
大齒輪材料為45鋼（調(diào)質(zhì)），硬度為197~286HBS。
初選小齒輪齒數(shù)，
則大齒輪齒數(shù),取
初選螺旋角：
查[3]表11-5 取,.，齒輪彎曲疲勞許用應(yīng)力
則=（+）/2
=（700+600）/2=650MPa
齒輪接觸疲勞許用應(yīng)力
小齒輪材料為40Cr（調(diào)質(zhì)），硬度為260HBS
大齒輪材料為45鋼（調(diào)質(zhì)），硬度為220 HBS
(2)按齒面接觸強(qiáng)度設(shè)計(jì)
依式計(jì)算
1)確定公式內(nèi)各計(jì)算數(shù)值
a.載荷系數(shù)
初選載荷系數(shù)
b.小、大齒輪齒數(shù)、，齒數(shù)比
初選小齒輪齒數(shù)，
則大齒輪齒數(shù),取
實(shí)際齒數(shù)比:
c.小齒輪傳遞的轉(zhuǎn)矩
d.選、
查[3] (P171)選取節(jié)點(diǎn)區(qū)域系數(shù)
查[3]表11-4彈性系數(shù)
e．螺旋角及其系數(shù)
初選螺旋角：
螺旋角系數(shù)：
f.齒寬系數(shù)
由[3]表11-6知，軟齒面、對(duì)稱分布?。?
g.計(jì)算小齒輪分度圓直徑
計(jì)算小齒輪分度圓直徑
2)計(jì)算圓周速度
3)計(jì)算齒寬b及模數(shù)
4)計(jì)算載荷系數(shù)
根據(jù)有輕微沖擊,使用系數(shù)：;
根據(jù)V=0.83m/s，7級(jí)精度查[4]圖9-23得動(dòng)載系數(shù)：;
查[4]表10-4接觸疲勞齒向載荷分布系數(shù)：
;
查[4]圖（圖10-13）彎曲強(qiáng)度計(jì)算齒向載荷系數(shù)得;
查[4]表（表10-3）得齒間載荷分布系數(shù)
則載荷系數(shù)
5)按實(shí)際載荷系數(shù)校正所得分度圓直徑
由式得:
6)模數(shù)
(3)按齒根彎曲疲勞強(qiáng)度設(shè)計(jì)
式計(jì)算
1)確定公式內(nèi)各計(jì)算數(shù)值
a.載荷系數(shù)
b.齒形系數(shù)
查[3]圖11-8 ，
c.齒根修正系數(shù)
查[3]圖11-9 ，
d.計(jì)算大小齒輪的并加以比較
=2.6×1.63/336=0.01261
=2.25×1.77/252=0.01580，
0.01261<0.01580
大齒輪值大
e.計(jì)算模數(shù)
由以上計(jì)算結(jié)果對(duì)比，由齒面疲勞接觸強(qiáng)度計(jì)算的法面模數(shù)大于由齒根彎曲疲勞接觸強(qiáng)度計(jì)算的法面模數(shù)，取，已可滿足彎曲強(qiáng)度
(4)幾何尺寸計(jì)算
1)中心距
將中心距圓整為182mm
2)修正螺旋角
按圓整的中心距修正螺旋角
因值改變不多，故參數(shù) ， ，等不必修正
2)計(jì)算大小齒輪的分度圓直徑、
3)計(jì)算齒輪寬度、
圓整后取 ，
(5)驗(yàn)算輪齒彎曲強(qiáng)度
由[3]式11-5
安全
(6)齒輪的圓周速度
對(duì)照[3]表11-2選8級(jí)精度是適宜的
適宜
(7)結(jié)構(gòu)設(shè)計(jì)
小齒輪（齒輪3）采用實(shí)心結(jié)構(gòu)，大齒輪（齒輪4）采用腹板式結(jié)構(gòu)
各齒輪參數(shù)見(jiàn)表6-1
表6-1各齒輪參數(shù)
模數(shù)m
齒數(shù)Z
分度圓直徑d
中心距a
高速級(jí)小齒輪
2
22
45.63
112
高速級(jí)大齒輪
86
178.37
低速級(jí)小齒輪
3
30
93.33
182
低速級(jí)大齒輪
87
270.67
第6章 軸的設(shè)計(jì)
6.1高速軸(I)的設(shè)計(jì)
項(xiàng)目
內(nèi)容
結(jié)果
已知
高速軸傳遞功率，轉(zhuǎn)速，轉(zhuǎn)矩，每個(gè)齒輪傳遞轉(zhuǎn)矩
齒輪1和分度圓直徑齒寬
1. 求作用在齒輪上的力
圓周力、徑向力及軸向力的方向如圖7-3所示
圖7-3 圓周力 ，徑向力及軸向力的方向
2.定軸的最小直徑
先按式
初步估算軸的最小直徑。選取軸的材料為45號(hào)鋼r，調(diào)質(zhì)處理。查[3]圖表14-2，取，得
該軸直徑，有1個(gè)鍵槽，軸頸增大5%～7%,安全起見(jiàn)，取軸頸增大5%則
，圓整后取。輸入軸的最小直徑是安裝大帶輪處的直徑?？紤]到該段軸徑取得太小，軸承的壽命可能滿足不了減速器預(yù)期壽命的要求，初定軸段①的直徑d1=30mm。
3.軸結(jié)構(gòu)設(shè)計(jì)
擬定軸上零件的裝配方案如圖所示7-4根據(jù)軸向定位的要求確定軸的各段直徑和長(zhǎng)度
圖7-4高速軸上零件的裝配方案
(1) 帶輪和軸段①
軸段①的直徑d1=30mm，帶輪輪彀的寬度為（1.5~2.0）d1=45~60mm，取帶輪輪彀的寬度L帶輪=58mm，軸段①的長(zhǎng)度應(yīng)略小于彀孔的寬度，取L1 =55mm
L帶輪
=58mm
L1 =55mm
(2) 密封圈與軸段②
在確定軸段②的軸徑時(shí)，應(yīng)考慮帶輪的軸向固定及密封圈的尺寸。用軸肩定位，軸肩高度h=(0.07~0.1)d1=(0.07~0.1) ×30=2.1~3mm。軸段②的軸徑d2=d1+2×(2.1~3)=34.2~36mm，其最終由密封圈確定。該處軸的圓周速度小于3m/s，可選用氈圈油封，查參考文獻(xiàn)[1]中表7-12選氈圈 35，則d2=35mm
d2=35mm
(3)軸承與軸段③及軸段⑦
該傳動(dòng)方案沒(méi)有軸向力，高速軸轉(zhuǎn)速較高，載荷不大，故選用深溝球軸承。根據(jù)，查GB/T276-1994初步取0組游隙，0級(jí)公差的深溝球軸承6008，其尺寸為
d×D×B=40mm×68mm×15mm ，內(nèi)圈定位軸肩直徑，外圈定位內(nèi)徑，故取軸段③的直徑。軸承用脂潤(rùn)滑，需要用擋油環(huán)阻止箱體內(nèi)潤(rùn)滑油濺入軸承座。為補(bǔ)償箱體的鑄造誤差和安裝擋油環(huán)，軸承靠近箱體內(nèi)壁的端面距箱體內(nèi)壁距離取，齒輪2左端面與箱體內(nèi)壁距離與齒輪2＇右端面與箱體內(nèi)壁距離均取為，則
通常1根軸上的兩個(gè)軸承應(yīng)取相同相同的型號(hào)，則
(4)齒輪與軸段④和⑥
該段④、⑥上安裝齒輪1和1＇，為便于齒輪的安裝，應(yīng)略大于，可初定，則由參考文獻(xiàn)[1]中表4-1知該處鍵的截面尺寸為b×h=12mm×8mm,由于54＜2×42故該軸設(shè)計(jì)成齒輪軸，則有，
(5)軸段⑤
由、低速小齒輪齒寬，則：
該軸段直徑可略大于軸承定位軸肩的直徑，則
(6)軸段②的長(zhǎng)度
該軸段的長(zhǎng)度除與軸上的零件有關(guān)外，還與軸承座寬度有關(guān)及軸承端蓋等零件有關(guān)。軸承座的寬度為：，由參考文獻(xiàn)[1]中表11—1知，下箱座壁厚：，取。由參考文獻(xiàn)1中表15—1知：地腳螺釘直徑
，取地腳螺栓為M18。，則取軸承旁螺栓直徑為M14，查參考文獻(xiàn)[1]中表11—2知，
則箱體軸承座寬度
取。，
則取機(jī)蓋與機(jī)座連接螺栓直徑為M10。
，則取軸承端蓋直徑為M8。，則取軸承端蓋凸緣厚度，取軸承端蓋與軸承座間的調(diào)整墊片厚度為mm。為方便在不拆卸帶輪的條件下，可以裝拆軸承端蓋連接螺栓，取帶輪凸緣端面距軸承端面表面距離，帶輪采用腹板式，螺栓的裝拆空間足夠。則
(7)軸上力作用點(diǎn)的間距
軸承反力的作用點(diǎn)距軸承外圈大端面的距離a3=31.8mm，則由圖7-4所示可得軸的支點(diǎn)及受力點(diǎn)間的距離為
4．軸上零件的周向定位
帶輪與軸段①間采用C型普通平鍵連接，
按L1 =55mm
查[1]圖表4-1取各鍵的尺寸為：
軸段①選鍵：b×h×L=C10mm×8mm×45mm
滾動(dòng)軸承的周向定位靠過(guò)渡配合來(lái)保證，選公差為m6
5.確定軸上圓角和倒角尺寸
查[1]表1-27，取軸端倒角為1.5×，各軸肩處圓角半徑為R1
6.2中速軸(II)的設(shè)計(jì)
已知
中速軸的傳遞功率，轉(zhuǎn)速，
轉(zhuǎn)矩，齒輪2和分度圓直徑，齒輪寬度，齒輪3分度圓直徑，齒輪寬度
1．求作用在齒輪上的力
軸上力的方向如下圖7-1所示
圖7-1軸上力的方向
2．初步確定軸的最小直徑
根據(jù)式初步確定軸的最小直徑，選取軸的材料為45鋼，調(diào)質(zhì)處理。查[3]圖表14-2，取，得
該軸直徑，有1個(gè)鍵槽，軸頸增大5%～7%,安全起見(jiàn)，取軸頸增大5%則
，
該軸的最小直徑為安裝軸承處的直徑，取為
3．軸的結(jié)構(gòu)設(shè)計(jì)
擬定軸上零件的裝配方案如圖7-2所示根據(jù)軸向定位的要求確定軸的各段直徑和長(zhǎng)度
圖7-2中速軸上零件的裝配方案
(1)軸承與軸段①及軸段⑥
由于配對(duì)的斜齒輪相當(dāng)于人字齒，軸II相對(duì)于機(jī)座固定，故初步選取0組游隙，0級(jí)公差6009軸承，其尺寸為d×D×B=45mm×75mm×16mm,內(nèi)圈定位軸肩直徑，外圈定位內(nèi)徑，故取軸段①和軸段⑥的直徑
(2)齒輪2、2＇、軸段②和軸段⑤的設(shè)計(jì)
軸段②上安裝齒輪2，軸段⑤上安裝齒輪2＇，為了便于齒輪的安裝，和應(yīng)分別大于和，可取
齒輪2左端采用軸肩定位，右端采用套筒定位，套筒外徑取60mm。寬度取b=10mm，齒輪2＇左端采用軸肩定位右端采用套筒定位
(3)齒輪3和軸段③
由于齒輪3的直徑比較小，采用實(shí)心式，由為了齒輪3便于安裝取。取其輪轂寬度與齒輪寬度相等，右端采用軸肩定位，左端采用套筒定位固定。為使套筒端面能夠頂?shù)烬X輪端面，軸段③的長(zhǎng)度應(yīng)比相應(yīng)齒輪的輪轂略短，故取。
(4)軸段②和軸段⑤的長(zhǎng)度
因?yàn)?，
(5)軸段④
齒輪2＇左端采用軸肩定位，根據(jù) 則：
，
，取
，取
(6)箱體內(nèi)壁之間距離 軸段①和⑥長(zhǎng)度
齒輪2左端面與箱體內(nèi)壁距離與齒輪2＇右端面與箱體內(nèi)壁距離均取為則箱體內(nèi)壁之間的距離為：
該減速器齒輪的圓周速度小于3m/s，故軸承采用脂潤(rùn)滑，需要用擋油環(huán)阻止箱體內(nèi)潤(rùn)滑油濺入軸承座，軸承內(nèi)端面距離箱體內(nèi)壁的距離取為，中間軸上兩個(gè)齒輪的固定均有擋油環(huán)完成，擋油環(huán)軸孔寬度初定為
軸段①的長(zhǎng)度為：
軸段⑥的長(zhǎng)度為：
7)軸上零件的周向定位
齒輪的周向定位都采用普通平鍵型鍵連接按:
，；
，；
，。
查[1]圖表4-1取各鍵的尺寸為：
軸段②和⑤選鍵：b×h×L=14mm×9mm×40mm
軸段③選鍵：b×h×L=16mm×10mm×70mm
滾動(dòng)軸承的周向定位靠過(guò)渡配合來(lái)保證，選公差為m6
(8)確定軸上圓角和倒角尺寸
查[1]表1-27，取軸端倒角為1.5×，各軸肩處圓角半徑為R1
6.3低速軸(Ⅲ)設(shè)計(jì)
項(xiàng)目
內(nèi)容
結(jié)果
已知
已知低速軸的傳遞功率，轉(zhuǎn)速，轉(zhuǎn)矩
齒輪4分度圓直徑，齒輪寬度
1．求作用在齒輪上的力
2．初步確定軸的最小直徑
根據(jù)式初步確定軸的最小直徑，選取軸的材料為45鋼，調(diào)質(zhì)處理。查[3]圖表14-2，取，得
該軸直徑，有2個(gè)鍵槽，軸頸增大5%～7%,安全起見(jiàn)，取軸頸增大10-5%則
3．軸的結(jié)構(gòu)設(shè)計(jì)
擬定軸上零件的裝配方案如圖所示7-5根據(jù)軸向定位的要求確定軸的各段直徑和長(zhǎng)度
圖7-5低速軸上零件的裝配方案
(1)聯(lián)軸器和軸段⑧
該軸的最小直徑為安裝聯(lián)軸器處的直徑，選取聯(lián)軸器的型號(hào)。查[3] 圖
表17-1，取=1.5 ，則
根據(jù)，查[1]表8-7標(biāo)準(zhǔn)GB/T5014-2003考慮到帶式運(yùn)輸機(jī)運(yùn)轉(zhuǎn)平穩(wěn)，帶具有緩沖的性能，選用LX4型彈性柱銷聯(lián)軸器, J型軸孔,選取軸孔直徑d=50mm，其軸孔長(zhǎng)度L=84mm，則軸的最小直徑，相應(yīng)的軸端①的直徑，取長(zhǎng)度略小于轂空寬度取
(2) 密封圈與軸段⑦
在確定軸段⑦的軸徑時(shí)，應(yīng)考慮聯(lián)軸器的軸向固定及軸承蓋密封圈的尺寸。聯(lián)軸器用軸肩定位，軸肩高度
。軸段⑦的軸徑，最終由密封圈確定。該處軸的圓周速度小于3m/s，可選用氈圈油封，查參考文獻(xiàn)[1]中表7-12選氈圈 60，則d7=60mm
(3)軸承與軸段①和⑥
根據(jù)軸上受力及軸頸，初步選用0組游隙，0級(jí)公差的深溝球軸承6013，其尺寸為d×D×B=65mm×100mm×18mm，內(nèi)圈定位軸肩直徑，外圈定位內(nèi)徑故
軸承采用脂潤(rùn)滑，需要用擋油環(huán)，擋油環(huán)寬度初定為B1=22mm，
故
(4)軸段⑦長(zhǎng)度
軸段⑦的長(zhǎng)度除與軸上零件有關(guān)外，還與軸承座寬度及軸承端蓋等零件有關(guān)。軸承端蓋連接螺栓為M8×25，其安裝圓周大于聯(lián)軸器輪轂外徑，輪轂外徑不與端蓋螺栓的拆裝空間干涉，故聯(lián)軸器輪轂端面的距離為。由軸承端蓋凸緣厚度，取軸承端蓋與軸承座間的調(diào)整墊片厚度為mm則有
(4)齒輪與軸段③
該段上安裝齒輪4，為便于齒輪的安裝，應(yīng)略大于，可初定，齒輪4輪彀的寬度范圍為（1.2~1.5）d3=84~105mm，取其寬度為，其右端采用軸肩定位，左端采用套筒固定。為使套筒端面能夠頂?shù)烬X輪端面，軸段⑤的長(zhǎng)度應(yīng)比輪彀略短，故取
(5)軸段④
齒輪4右端采用軸肩定位
，取
軸段④的軸徑，取
(6)軸段②和⑤
軸段①軸承采用套筒定位，取，
軸段⑥軸承用軸肩定位，于是取
(7)軸上力作用點(diǎn)的間距
由圖7-5所示可知軸的支點(diǎn)及受力點(diǎn)間的距離為
(8)軸上零件的周向定位
齒輪的周向定位都采用普通平鍵型鍵連接
查[1]圖表4-1取各鍵的尺寸為：
軸段③選鍵：b×h×L=20mm×12mm×70mm
軸段⑧選鍵：C b×h×L=16mm×10mm×70mm
滾動(dòng)軸承的周向定位靠過(guò)渡配合來(lái)保證，選公差為m6
(9).確定軸上圓角和倒角尺寸
查[1]表1-27，取軸端倒角為1.5×，各軸肩處圓角半徑為R1
第7章 軸的校核
項(xiàng)目
內(nèi)容
結(jié)果
已知
(1)求支承反力
垂直面支承反力
水平面支承反力
F力在支點(diǎn)產(chǎn)生的反力
(2)求彎矩
垂直面彎矩
水平面彎矩
F力在支點(diǎn)產(chǎn)生彎矩圖
F在a-a截面力產(chǎn)生的彎矩為：
a-a截面總彎矩
支點(diǎn)2總彎矩
(3)求軸傳遞的轉(zhuǎn)矩
(4)彎矩和扭矩圖
彎矩和扭矩見(jiàn)圖8-1
(5)按彎扭合成應(yīng)力校核軸的強(qiáng)度
由圖8-1g可見(jiàn)a-a截面最危險(xiǎn)，其當(dāng)量彎矩
對(duì)危險(xiǎn)截面進(jìn)行校核，認(rèn)為軸扭轉(zhuǎn)切應(yīng)力是脈動(dòng)循環(huán)變應(yīng)
力，取折合系數(shù)α=0.6，軸的計(jì)算應(yīng)力
前已選定軸的材料為45鋼，調(diào)質(zhì)處理，
查[3]表14-3得因此，故軸安全。
安全
圖8-1彎矩和扭矩圖
另外兩個(gè)軸的校核方法類似，經(jīng)校核安全
第8章 軸承的選擇和校核計(jì)算
8.1高速軸Ⅰ上的軸承選擇與計(jì)算
項(xiàng)目
內(nèi)容
結(jié)果
由軸I的設(shè)計(jì)知，初步選用深溝球軸承6008，由于受力對(duì)稱，只需要計(jì)算1個(gè)，其受力，=0，ε=3 ，轉(zhuǎn)速n=654.54r/min
(1) )查表
查[1]表6-1滾動(dòng)軸承樣本知深溝球軸承6008的基本額定動(dòng)載荷，基本額定靜載荷
(2)求軸承當(dāng)量動(dòng)載荷P
因?yàn)?0，徑向載荷系數(shù)X=1，軸向載荷系數(shù)Y=0，
則
(3)驗(yàn)算軸承壽命
因工作情況平穩(wěn)，查[3]表16-8取查[3]表16-9，取=1.2
故所選用軸承滿足壽命要求。確定使用深溝球軸承6008
滿足要求
8.2中速軸Ⅱ上的軸承選擇與計(jì)算
項(xiàng)目
內(nèi)容
結(jié)果
由軸II的設(shè)計(jì)知，初步選用深溝球軸承6013，由于受力對(duì)稱，只需要計(jì)算1個(gè)，其受力
=0，ε=3 ，轉(zhuǎn)速
(1) )查表
查[1]表6-1知深溝球軸承6009的基本額定動(dòng)載荷，基本額定靜載荷
(2)求軸承當(dāng)量動(dòng)載荷P
因?yàn)?0，徑向載荷系數(shù)X=1，軸向載荷系數(shù)Y=0，，則
(3)驗(yàn)算軸承壽命
驗(yàn)算軸承壽命因工作情況平穩(wěn)，查[3]表16-8取
查[3]表16-9，取=1.2
故所選用軸承滿足壽命要求。確定使用深溝球軸承6009
滿足要求
8.3低速軸Ⅲ上的軸承選擇與計(jì)算
由軸IV的設(shè)計(jì)知，初步選用深溝球軸承6013，由于受力對(duì)稱，只需要計(jì)算1個(gè)，其受力，=0，ε=3 ，轉(zhuǎn)速n=70.1/min
(1)查表
查[1]表6-1知深溝球軸承6013的基本額定動(dòng)載荷
，基本額定靜載荷
(2)求軸承當(dāng)量動(dòng)載荷P
因?yàn)?0，徑向載荷系數(shù)X=1，軸向載荷系數(shù)Y=0
則
(3)驗(yàn)算軸承壽命
查[3]表16-8取查[3]表16-9，取=1.2
故所選用軸承滿足壽命要求。確定使用深溝球軸承6013
滿足要求
第9章 鍵連接的選擇與校核計(jì)算
項(xiàng)目
內(nèi)容
結(jié)果
1．帶輪與高速軸I的鍵連接
(1) 已知
由高速軸I的設(shè)計(jì)知初步選用c型鍵：
(2)校核鍵連接的強(qiáng)度
鍵和軸材料都是鋼，輪轂的材料是鑄鐵，查[3]表10-10得許用應(yīng)力：=50~60MPa，取=55MPa。
鍵的工作長(zhǎng)度
由式可得
可見(jiàn)連接的強(qiáng)度足夠，選用
滿足要求
2．齒輪2、與中速軸II的鍵連接
(1) 已知
由中速軸II的設(shè)計(jì)知初步選用A型鍵：，
(2)校核鍵連接的強(qiáng)度
鍵、軸和輪轂的材料都是鋼，查[3]表10-10得許用應(yīng)力：=100-120MPa，取。
鍵的工作長(zhǎng)度：。
由式可得
可見(jiàn)連接的強(qiáng)度足夠，選用鍵
滿足要求
3．齒輪3與中速軸II的鍵連接
(1) 已知
由中速軸II的設(shè)計(jì)知初步選用A型鍵:
(2)校核鍵連接的強(qiáng)度
鍵、軸和輪轂的材料都是鋼，查[3]表10-10得許用應(yīng)力：
=100-120MPa，取。
鍵的工作長(zhǎng)度：。
由式可得
可見(jiàn)連接的強(qiáng)度足夠，選用鍵
滿足要求
4．齒輪4與低速軸III的鍵連接
(1)已知
由低速軸III的設(shè)計(jì)知初步選用A鍵：
(2)校核鍵連接的強(qiáng)度
鍵、軸和輪轂的材料都是鋼，查[3]表10-10得許用應(yīng)力=100-120MPa，取。
鍵的工作長(zhǎng)度：。
由式可得：
可見(jiàn)連接的強(qiáng)度足夠，選用鍵
滿足要求
5．聯(lián)軸器與低速軸III的鍵連接
(1)已知
由低速軸III的設(shè)計(jì)知初步選用C型鍵：
(2)校核鍵連接的強(qiáng)度
鍵、軸和輪轂的材料都是鋼，查[3]表10-10得許用應(yīng)力=100-120MPa，取。
鍵的工作長(zhǎng)度：。
由式可得
可見(jiàn)連接的強(qiáng)度足夠，選用鍵
滿足要求
第10章 減速器附件設(shè)計(jì)
項(xiàng)目
內(nèi)容
結(jié)果
1．視孔蓋
查[1]表11-4選用的視孔蓋。
2．通氣器
查[1]表11-5選用通氣罩M18×1.5
M18×1.5
3．油面指示器
查[1]表7-10選用桿式油標(biāo)M16
M16
4．油塞
查[1]表7-11選用M18×1.5型油塞和墊片
M18×1.5
5．起吊裝置
查[1]3-18箱蓋選用A型吊耳環(huán)M20 GB/T 825-1988
M20
6．定位銷
查[1]表4-4選用圓柱銷GB/T119.1 8 m6×30
M6×30
7．起蓋螺釘
查[1]表3-16選用螺釘M8×18 GB/T68-2000
M8×18
第11章 潤(rùn)滑方式及密封形式的選擇
項(xiàng)目
內(nèi)容
結(jié)果
1．齒輪的潤(rùn)滑
采用浸油潤(rùn)滑，由于高速級(jí)大齒輪浸油深度不小于10mm，取為油深h=50mm。查[1]表7-1，選用全損耗系統(tǒng)用油(GB/T 443-1989)L-AN22。
L-AN22
2．滾動(dòng)軸承的潤(rùn)滑
由于軸承值所以采用通用鋰基潤(rùn)滑脂(GB 7321-1994)潤(rùn)滑，選用ZL-2潤(rùn)滑脂。
ZL-2潤(rùn)滑脂
3．密封方法的選取
由于凸緣式軸承端蓋易于調(diào)整軸向游隙，軸Ⅰ、軸Ⅱ及軸Ⅲ的軸承兩端均采用凸緣式端蓋。由于采用脂潤(rùn)滑，軸端采用間隙密封，用氈圈密封。
氈圈密封
第12章 箱體設(shè)計(jì)
根據(jù)[1]表11-1得箱體有關(guān)參數(shù)見(jiàn)表13-1
表13-1箱體有關(guān)參數(shù)
名稱
符號(hào)
設(shè)計(jì)依據(jù)
設(shè)計(jì)結(jié)果
箱座壁厚
9
箱蓋壁厚
8
箱座凸緣厚度
13.5
箱蓋凸緣厚度
12
箱座底凸緣厚度
22.5
地腳螺釘直徑
M18
地腳螺釘數(shù)目
4
軸承旁聯(lián)結(jié)螺栓直徑
14
蓋與座聯(lián)接螺栓直徑
10
軸承端蓋螺釘直徑和數(shù)目
,
8，4
窺視孔蓋螺釘直徑
6
定位銷直徑
8
、、至外箱壁距離
表11-2
20
至凸緣邊緣距離
表11-2
18
軸承旁凸臺(tái)半徑
18
凸臺(tái)高度
由軸承座外徑確定
50
外箱壁至軸承座端面距離
45
大齒輪頂圓距內(nèi)壁距離
?1
15
齒輪端面與內(nèi)壁距離
?2
12
箱蓋、箱座肋厚
、
10
第13章 總結(jié)
機(jī)械設(shè)計(jì)課程設(shè)計(jì)的過(guò)程是艱辛而又充滿樂(lè)趣的，期間我們不僅對(duì)機(jī)械的設(shè)計(jì)的基本過(guò)程有了1個(gè)初步的認(rèn)識(shí)和了解，即初步接觸到了1個(gè)真機(jī)器的計(jì)算和結(jié)構(gòu)的設(shè)計(jì)，也通過(guò)查閱大量的書(shū)籍，對(duì)有關(guān)于機(jī)械設(shè)計(jì)的各種標(biāo)準(zhǔn)有了1定的認(rèn)識(shí)，也加強(qiáng)了對(duì)課本的學(xué)習(xí)和認(rèn)識(shí)。在老師的指導(dǎo)下鍛煉了自己綜合運(yùn)用工程圖學(xué)的理論，結(jié)合實(shí)際機(jī)件繪制標(biāo)準(zhǔn)機(jī)械圖樣的能力，并使所學(xué)知識(shí)得到進(jìn)1步的鞏固和深化。
參考文獻(xiàn)
機(jī)械設(shè)計(jì)機(jī)械原理教學(xué)組.機(jī)械設(shè)計(jì)課程設(shè)計(jì)指導(dǎo)書(shū)[M].2009.12
濮良貴等.機(jī)械設(shè)計(jì)[M].北京：高等教育出版社，2006.5
孫桓等.機(jī)械原理[M]. 北京：高等教育出版社，2006.5
劉鴻文等.材料力學(xué)[M]. 北京：高等教育出版社，2004.1
鄧志平等.機(jī)械制造技術(shù)基礎(chǔ)[M].成都：西南交通大學(xué)出版社，2008.8
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 for expanding the
收藏