單級(jí)直齒圓柱齒輪減速器設(shè)計(jì)【F=2350N V=1.5m-s D=300】
單級(jí)直齒圓柱齒輪減速器設(shè)計(jì)【F=2350N V=1.5m-s D=300】,F=2350N V=1.5m-s D=300,單級(jí)直齒圓柱齒輪減速器設(shè)計(jì)【F=2350N,V=1.5m-s,D=300】,單級(jí)直齒,圓柱齒輪,減速器,設(shè)計(jì)
設(shè) 計(jì) 說 明 書 一、前 言 ()課程設(shè)計(jì)的目的(參照第1頁) 機(jī)械零件課程設(shè)計(jì)是學(xué)生學(xué)習(xí)機(jī)械技術(shù)(上、下)課程后進(jìn)行的一項(xiàng)綜合訓(xùn)練,其主要目的是通過課程設(shè)計(jì)使學(xué)生鞏固、加深在機(jī)械技術(shù)課程中所學(xué)到的知識(shí),提高學(xué)生綜合運(yùn)用這些知識(shí)去分析和解決問題的能力。同時(shí)學(xué)習(xí)機(jī)械設(shè)計(jì)的一般方法,了解和掌握常用機(jī)械零部件、機(jī)械傳動(dòng)裝置或簡(jiǎn)單機(jī)械的設(shè)計(jì)方法與步驟,為今后學(xué)習(xí)專業(yè)技術(shù)知識(shí)打下必要的基礎(chǔ)。 (二)傳動(dòng)方案的分析(參照第10頁) 機(jī)器一般是由原動(dòng)機(jī)、傳動(dòng)裝置和工作裝置組成。傳動(dòng)裝置是用來傳遞原動(dòng)機(jī)的運(yùn)動(dòng)和動(dòng)力、變換其運(yùn)動(dòng)形式以滿足工作裝置的需要,是機(jī)器的重要組成部分。傳動(dòng)裝置是否合理將直接影響機(jī)器的工作性能、重量和成本。合理的傳動(dòng)方案除滿足工作裝置的功能外,還要求結(jié)構(gòu)簡(jiǎn)單、制造方便、成本低廉、傳動(dòng)效率高和使用維護(hù)方便。 本設(shè)計(jì)中原動(dòng)機(jī)為電動(dòng)機(jī),工作機(jī)為皮帶輸送機(jī)。傳動(dòng)方案采用了兩級(jí)傳動(dòng),第一級(jí)傳動(dòng)為帶傳動(dòng),第二級(jí)傳動(dòng)為單級(jí)直齒圓柱齒輪減速器。 帶傳動(dòng)承載能力較低在傳遞相同轉(zhuǎn)矩時(shí),結(jié)構(gòu)尺寸較其他形式大,但有過載保護(hù)的優(yōu)點(diǎn),還可緩和沖擊和振動(dòng),故布置在傳動(dòng)的高速級(jí),以降低傳遞的轉(zhuǎn)矩,減小帶傳動(dòng)的結(jié)構(gòu)尺寸。 齒輪傳動(dòng)的傳動(dòng)效率高,適用的功率和速度范圍廣,使用壽命較長(zhǎng),是現(xiàn)代機(jī)器中應(yīng)用最為廣泛的機(jī)構(gòu)之。本設(shè)計(jì)采用的是單級(jí)直齒輪傳動(dòng)(說明直齒輪傳動(dòng)的優(yōu)缺點(diǎn))。 說明減速器的結(jié)構(gòu)特點(diǎn)、材料選擇和應(yīng)用場(chǎng)合(如本設(shè)計(jì)中減速器的箱體采用水平剖分式結(jié)構(gòu),用HT200灰鑄鐵鑄造而成)。設(shè)計(jì)說明書 二、傳動(dòng)系統(tǒng)的參數(shù)設(shè)計(jì) 已知輸送帶的有效拉力Fw2350,輸送帶的速度Vw=1.5,滾筒直徑D=300。連續(xù)工作,載荷平穩(wěn)、單向運(yùn)轉(zhuǎn)。 1)選擇合適的電動(dòng)機(jī);2)計(jì)算傳動(dòng)裝置的總傳動(dòng)比,分配各級(jí)傳動(dòng)比;3)計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)參數(shù)和動(dòng)力參數(shù)。 解:1、選擇電動(dòng)機(jī) (1)選擇電動(dòng)機(jī)類型:按工作要求和條件選取Y系列一般用途的全封閉自扇冷鼠籠型三相異步電動(dòng)機(jī)。 (2)選擇電動(dòng)機(jī)容量 工作機(jī)所需功率: ,其中帶式輸送機(jī)效率w=0.94。電動(dòng)機(jī)輸出功率: 其中為電動(dòng)機(jī)至滾筒、主動(dòng)軸傳動(dòng)裝置的總效率,包括V帶傳動(dòng)效率b、一對(duì)齒輪傳動(dòng)效率g、兩對(duì)滾動(dòng)軸承效率r2、及聯(lián)軸器效率c,值計(jì)算如下:=b g r 2c=0.90 由表101(134頁)查得各效率值,代入公式計(jì)算出效率及電機(jī)輸出功率。使電動(dòng)機(jī)的額定功率Pm(11.3)Po,由表10110(223頁)查得電動(dòng)機(jī)的額定功率Pm=5.5。(3)選擇電動(dòng)機(jī)的轉(zhuǎn)速計(jì)算滾筒的轉(zhuǎn)速:95.49 根據(jù)表31確定傳動(dòng)比的范圍:取V帶傳動(dòng)比ib24,單級(jí)齒輪傳動(dòng)比ig35,則總傳動(dòng)比的范圍:i(2X3)(4X5)620。電動(dòng)機(jī)的轉(zhuǎn)速范圍為n=inw(620)nw=592.941909.8在這個(gè)范圍內(nèi)電動(dòng)機(jī)的同步轉(zhuǎn)速有1000rmin和1500rmin,綜合考慮電動(dòng)機(jī)和傳動(dòng)裝置的情況,同時(shí)也要降低電動(dòng)機(jī)的重量和成本,最終可確定同步轉(zhuǎn)速為1000,根據(jù)同步轉(zhuǎn)速確定電動(dòng)機(jī)的型號(hào)為Y132M2-6,滿載轉(zhuǎn)速960。(223頁)型號(hào)額定功率滿載轉(zhuǎn)速同步轉(zhuǎn)速1000 2、計(jì)算總傳動(dòng)比并分配各級(jí)傳動(dòng)比 (1)計(jì)算總傳動(dòng)比:i=nmnW=814 (2)分配各級(jí)傳動(dòng)比:為使帶傳動(dòng)尺寸不至過大,滿足ibig,可取ib23,則齒輪傳動(dòng)比igiib(在4左右,取小數(shù)點(diǎn)后兩位,不隨意取整)。3、計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù) (1)各軸的轉(zhuǎn)速:n1=nm/ib n11=n1/ig nw=n11(2)各軸的功率:P1=Pmb P11=P1rg Pw=P11rc(3)各軸的轉(zhuǎn)矩:T0=9550Pm/nm T1=9550P1/n1 T11=9550P11/n11 Tw=9550Pw/nw最后將計(jì)算結(jié)果填入下表:參數(shù)軸名電機(jī)軸I軸II軸滾筒軸轉(zhuǎn)速n(r/min)nm=960n1=384n11=96nw=96功率P(kW)Pm=5.5P1=5.28P11=5.08Pw=4.99轉(zhuǎn)矩T(Nm)T0=54.71T1=131.31T11=505.67Tw=496.5傳動(dòng)比iib=2.5ig=4.021效率b=0.96nbr=0.96rc=0.98三、帶傳動(dòng)的設(shè)計(jì)計(jì)算已知帶傳動(dòng)選用Y系列異步電動(dòng)機(jī),其額定功率Pm=5.5,主動(dòng)輪轉(zhuǎn)速nw=960,從動(dòng)輪的轉(zhuǎn)速n1=384,ib=2.5。單班制工作。有輕度沖擊。計(jì)算項(xiàng)目計(jì)算內(nèi)容計(jì)算結(jié)果 確定設(shè)計(jì)功率 選V帶型號(hào) 確定帶輪直徑 驗(yàn)算帶速 確定帶的基準(zhǔn)長(zhǎng)度和 驗(yàn)算小帶輪包角 計(jì)算帶的根數(shù) 計(jì)算初拉力 計(jì)算對(duì)軸的壓力帶輪結(jié)構(gòu)設(shè)計(jì)繪工作圖 查表343,取KA:12,故 Pd=KAP=12 11=6.05kW根據(jù)Pd和nl查圖349,選B型普通V帶由表344,取小帶輪基準(zhǔn)直徑ddl=125mm傳動(dòng)比 2.5大帶輪基準(zhǔn)直徑dd2=idd1 2.94125=312.5mm圓整da2=315mm驗(yàn)算 = 由0.7(dd1+dd2)a02(dd1+dd2)初定中心距a0700mm帶的基準(zhǔn)長(zhǎng)度為傳動(dòng)中心距 Ld02700+(125+375)+(375-125)2=2208mm查表342,取Ld=2800mm由式(349),實(shí)際中心距 a=a0+ =647mma1180-57.3155由式(3411),z=由ddl=125mm,n1=960rmin,查表345,P1=0.8kW 查表346,B型帶,Kb=26710-3,查表347,由I=25,得Ki=114P1=2.6710-3960=0.32kWKa=1.25(1-5-a1/180)=1.25(1-5-160/180)=0.937查表342,由Ld=2800mm,得KL=1.03則Z=6.7取c7根 查表341,B型帶,q=017kgm;由式(3413)得F0=5000.176.352=249.1N由式(34-14)得=2zFosin251sin3434。4NPd=6.05kwB型dd1=125mmdd2=375mmV=628ms合適2800mma=700mma1=155合適Z=3四、齒輪的設(shè)計(jì)計(jì)算已知傳遞的名義功率P15.28,小齒輪轉(zhuǎn)速n436.36,傳動(dòng)比ig4.05連續(xù)單向運(yùn)轉(zhuǎn),傳動(dòng)尺寸無嚴(yán)格限制;電動(dòng)機(jī)驅(qū)動(dòng)。計(jì)算項(xiàng)目計(jì)算內(nèi)容計(jì)算結(jié)果1. 選精度等級(jí)、材料及齒數(shù)2. 按齒面接觸強(qiáng)度設(shè)計(jì)3傳動(dòng)尺寸計(jì)算1) 精度等級(jí)選用8級(jí)精度;2) 試選小齒輪齒數(shù)z124,大齒輪齒數(shù)z296的;因?yàn)榈退偌?jí)的載荷大于高速級(jí)的載荷,所以通過低速級(jí)的數(shù)據(jù)進(jìn)行計(jì)算按式(1021)試算,即 dt按式查表35-12得Ka=1初估速度=4由圖35-30b查得Kv=1.1取=0由式=1.88-3.2(+ )cos =1.713取=1由圖35-31得,K=1.46由圖35-32得,K=1.05所以K=1.364d61.4v= =3.08因與初估圓周速度相差較大,故應(yīng)修正載荷系數(shù)及小齒輪直徑由圖35-30b得Kv=1.03,K=1.276,d1=59.5,=147.6,取150mm=2.48,取m=2.5d1= =60d2=ud1=240b= =取b1=70,b2=603) 結(jié)構(gòu)設(shè)計(jì)以大齒輪為例。因齒輪齒頂圓直徑大于160mm,而又小于500mm,故以選用腹板式為宜。其他有關(guān)尺寸參看大齒輪零件圖。Z1=24Z2=96五、軸的設(shè)計(jì)計(jì)算(一)主動(dòng)軸的設(shè)計(jì)計(jì)算已知傳遞的功率為P1=5.28,主動(dòng)軸的轉(zhuǎn)速為n1=384,小齒輪分度圓直徑d1=60,嚙合角d=20,輪轂寬度B小齒輪700mm,工作時(shí)為單向轉(zhuǎn)動(dòng)。解:1、選擇軸的材料、熱處理方式,確定許用應(yīng)力(按教材表391、398)軸名材料熱處理硬度抗拉強(qiáng)度許用彎曲應(yīng)力主動(dòng)軸45號(hào)鋼調(diào)制217255650MPa60MPa2、畫出軸的結(jié)構(gòu)示意圖:3、計(jì)箅軸各段直徑 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容計(jì)算結(jié)果1、計(jì)算d12、計(jì)算d23、計(jì)算d:4、計(jì)算山5、計(jì)算d5由教材表39-7得:A=118106,取A=118(取較大值)d127.14,軸上有一個(gè)鍵槽,故軸徑增大d1=d1”(1+5%)28.50 按138頁圓整dl=30 d2=d1+2a=d1+2(007-01)d1=34.2-36,因d2必須符合軸承密封元件的要求,取d2=35。(191頁) d3=d2(15)mm36-40,d3必須與軸承的內(nèi)徑一致,圓整d340。所選軸承型號(hào)為6208,B18,D80,G22.8,C0r=15.8 d4=d3+(1-5)mm=41-45,為裝配方便而加大直徑,應(yīng)圓整為標(biāo)準(zhǔn)直徑;一般取0,2,5,8為尾數(shù)。取d4=45 d5=d3=40,同一軸上的軸承選用同一型號(hào),以便于軸承座孔鏜制和減少軸承類型。d1=30d2=35d3=40d4=45d5=404、計(jì)笪軸各段長(zhǎng)度 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果1、計(jì)算Ll2、計(jì)算L23、計(jì)算L34、計(jì)算L45、計(jì)算L5B帶輪=(Z一1)e+2f=,e、f值查教材表34-8L1=(1.52)d1,按138頁取Ll=58L2=l1+e+m=50e=1.2d3,其中d3為螺釘直徑,查表51(23頁)m=L-3-B軸承小=6+C1+C2+(38)-3小一B軸承小=20式中6、Cl、C2查表51。l1、3小查表68(75頁,按凸緣式端蓋查l1),若me取m=e即可。L3=B軸承小+2小+3小,2小查表68(75頁)1015,故小齒輪做成齒輪軸,L4B小齒輪L5=L3L1=58L2=50L3=40L4=70L5=405、校核軸的強(qiáng)度 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果1 求軸上的載荷Mm=316767N.mmT=925200N.mm6. 彎扭校合6、畫出軸的工作圖,標(biāo)出具體尺寸和公差(二)從動(dòng)軸的設(shè)計(jì)計(jì)算 已知傳遞的功率為P11=5.08,從動(dòng)軸的轉(zhuǎn)速為n11=96,大齒輪分度圓直徑d2=240嚙合角=20輪轂寬度B大齒輪600mm,工作時(shí)為單向轉(zhuǎn)動(dòng)。 解:1、選擇軸的材料、熱處理方式,確定許用應(yīng)力(按教材表391、398) 軸名 材料熱處理 硬度抗拉強(qiáng)度ob許用彎曲應(yīng)力o川b從動(dòng)軸45號(hào)鋼正火170-217600MPa55MPa畫出軸的結(jié)構(gòu)示意圖計(jì)算軸各段直徑 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容計(jì)算結(jié)果1、計(jì)算d,2、計(jì)算d23、計(jì)算d34、計(jì)算d45、計(jì)算d56、計(jì)算d6由教材表39-7得:A=118106,取A=115 (取較大值) d1,軸上有一個(gè)鍵槽,故軸徑增大5d1=d1”(1+5%)45,為使所選軸徑與聯(lián)軸器的孔徑相適應(yīng),故需同時(shí)選取聯(lián)軸器。查184頁,相配合的聯(lián)軸器選 HL4 型彈性柱銷聯(lián)軸器,軸徑相應(yīng)圓整為dl,半聯(lián)軸器長(zhǎng)l=112。 d2=d1+2a1=d1十2(0.07-0.1)dl=36.48-38.4,因d2必須符合軸承密封元件的要求,取d2=55。(191頁) d3=d2+(15)mm=41-45,d3必須與軸承的內(nèi)徑一致,圓整d3=。所選軸承型號(hào)為6212,B=22,D=110,Cr=36.8,Cor=27.8 d4=d3+(15)mm=,為裝配方便而加大直徑,應(yīng)圓整為標(biāo)準(zhǔn)直徑:一般取0,2,5,8為尾數(shù)。取d4=62 d5=d4+2a4=d4+2(0.07-0.1)d4,d5=75(取整) d6=d3=60,同一軸上的軸承選用同一型號(hào),以便于軸承座孔鏜制和減少軸承類犁。d1=45d2=55d3=60d4=62d5=75d6=60 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果 1、計(jì)算Ll 2、計(jì)算L2 3、計(jì)算13 4、計(jì)算L4 5、計(jì)算L5 6,計(jì)算L6 半聯(lián)軸器的長(zhǎng)度l=112,為保證軸端擋圈只壓在半聯(lián)軸器上,而不壓在軸的端面上,故第1段的長(zhǎng)度應(yīng)比l略短一些,按138頁取L1=82 l2=l1+e+m=50 e=12d3,其中d3為螺釘直徑,查表51(23頁) m=L-3-B軸承小=6+C1+C2+(38)-3小一B軸承小=20式中6、Cl、C2查表51。l1、3小查表68(75頁,按凸緣式端蓋查l1),若me取m=e即可。L3=B軸承大+2大+3大,2大2小=54(公式中為齒輪寬度) L4=B大齒輪一260 L5=b=1.4a4=12取整) L6=Bz軸承大2大+3大L5=31L1=82L2=50L3=54L4=58L5=22L6=455、校核軸的強(qiáng)度 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果2 求軸上的載荷Mm=316767N.mmT=925200N.mm6. 彎扭校合6、畫出軸的工作圖,標(biāo)出具體尺寸和公差(例圖) 略計(jì)算注意事項(xiàng):1、主動(dòng)軸與從動(dòng)軸的e應(yīng)相等,2、主、從動(dòng)軸m+3+B螈應(yīng)相等(一)主動(dòng)軸外伸端處鍵的校核 已知軸與帶輪采用鍵聯(lián)接,傳遞的轉(zhuǎn)矩為T1131,軸徑為d1=30,軸長(zhǎng)L1=58帶輪材料為鑄鐵,軸和鍵的材料為45號(hào)鋼,有輕微沖擊六、鍵的選擇與驗(yàn)算 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果1)鍵的類型 及其尺寸 選擇2)驗(yàn)算擠壓 強(qiáng)度3)確定鍵槽尺寸及相應(yīng)的公差帶輪傳動(dòng)要求帶輪與軸的對(duì)中性好,故選擇A型平鍵聯(lián)接。根據(jù)軸徑d=30,由表10-33(165頁),查得:鍵寬b=8,鍵高h(yuǎn)=7,因軸長(zhǎng)L1=58,故取鍵長(zhǎng)L=50將I=Lb,k=0.4h代入公式得擠壓應(yīng)力為 53.82Mpa由教材表333查得,輕微沖擊時(shí)的許用擠壓應(yīng)力5060MPa,ap,故擠壓強(qiáng)度足夠。 (以為例)由附表10-33(165頁)得,軸槽寬為20N9-0520,軸槽深t=75mm,r6對(duì)應(yīng)的極限偏差為:。轂槽寬為20Js90.026,轂槽深h=4.9 mm。H7對(duì)應(yīng)的極限偏差為0.030 鍵bh 鍵長(zhǎng)L=5053.58apOp強(qiáng)度足夠4)繪制鍵槽工作圖 (二)從動(dòng)軸外伸端處鍵的校核 已知軸與聯(lián)軸器采用鍵聯(lián)接,傳遞的轉(zhuǎn)矩為T11=505軸徑為d1=45,寬度L1=82。聯(lián)軸器、軸和鍵的材料皆為鋼,有輕微沖擊 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果1)鍵的類型 及其尺寸 選擇2)驗(yàn)算擠壓 強(qiáng)度3)確定鍵槽尺寸及相應(yīng)的公差帶輪傳動(dòng)要求帶輪與軸的對(duì)中性好,故選擇A型平鍵聯(lián)接。根據(jù)軸徑d=45,由表10-33(165頁),查得:鍵寬b=12,鍵高h(yuǎn)=8,因軸長(zhǎng)L1=82,故取鍵長(zhǎng)L=70將I=Lb,k=0.4h代入公式得擠壓應(yīng)力為 52.41Mpa由教材表333查得,輕微沖擊時(shí)的許用擠壓應(yīng)力5060MPa,ap,故擠壓強(qiáng)度足夠。 (以為例)由附表10-33(165頁)得,軸槽寬為20N9-0520,軸槽深t=75mm,r6對(duì)應(yīng)的極限偏差為:。轂槽寬為20Js90.026,轂槽深h=4.9 mm。H7對(duì)應(yīng)的極限偏差為0.030 鍵bh 鍵長(zhǎng)L=7052.41apOp強(qiáng)度足夠 (三)從動(dòng)軸齒輪處鍵的校核 已知軸與齒輪采用鍵聯(lián)接,傳遞的轉(zhuǎn)矩為T11=505,軸徑為d1=52,寬度L4=58。齒輪、軸和鍵的材料皆為鋼,有輕微沖擊 計(jì)算項(xiàng)目 計(jì) 算 內(nèi) 容 計(jì)算結(jié)果1)鍵的類型 及其尺寸 選擇2)驗(yàn)算擠壓 強(qiáng)度3)確定鍵槽尺寸及相應(yīng)的公差帶輪傳動(dòng)要求帶輪與軸的對(duì)中性好,故選擇A型平鍵聯(lián)接。根據(jù)軸徑d=30,由表10-33(165頁),查得:鍵寬b=14,鍵高h(yuǎn)=9,因軸長(zhǎng)L1=60,故取鍵長(zhǎng)L=45將I=Lb,k=0.4h代入公式得擠壓應(yīng)力為 59.17Mpa由教材表333查得,輕微沖擊時(shí)的許用擠壓應(yīng)力5060MPa,ap,故擠壓強(qiáng)度足夠。 (以為例)由附表10-33(165頁)得,軸槽寬為20N9-0520,軸槽深t=75mm,r6對(duì)應(yīng)的極限偏差為:。轂槽寬為20Js90.026,轂槽深h=4.9 mm。H7對(duì)應(yīng)的極限偏差為0.030 鍵bh 鍵長(zhǎng)L=4559.17apLh,合適 (二)從動(dòng)軸承的選擇與驗(yàn)算 已知軸頸直徑d3=60,n11=96,RvA=3063,Rw=3063,運(yùn)轉(zhuǎn)過程中有輕微沖擊 計(jì)算項(xiàng)目 計(jì)算內(nèi)容 計(jì)算結(jié)果 1、確定軸承的基本參數(shù) 2、計(jì)算當(dāng)量動(dòng)負(fù)荷P 3、計(jì)算基本額定壽命 由軸承型號(hào)查課程設(shè)計(jì)附表得軸承的基本參數(shù) P二RvA、R中較大者 因球軸承,故c二3,查教材表38-10,取fd=1, 查教材表38-11,取gT=1 代入計(jì)算得:Lh= 故所選軸承合適。(1h可查表或按大修期確定)P=1.2LhLh,合適注意:如壽命過大,則重選軸承型號(hào),取輕或特輕系列八、聯(lián)軸器的選擇與驗(yàn)算 已知聯(lián)軸器用在減速器的輸出端,從動(dòng)軸轉(zhuǎn)速nh=96,傳遞的功率為P11=5.08傳遞的轉(zhuǎn)矩為T=505 ,軸徑為d1=45 計(jì)算項(xiàng)目 計(jì)算內(nèi)容 計(jì)算結(jié)果1、類犁選擇 2、計(jì)算轉(zhuǎn)矩 3、型號(hào)選擇為減輕減速器輸出端的沖擊和振動(dòng),選擇彈性柱銷聯(lián)軸器,代號(hào)為HL。由教材表43-l,選擇工作情況系數(shù)K=1.25Tc=KT=631.96按計(jì)算轉(zhuǎn)矩、軸徑、轉(zhuǎn)速,從標(biāo)準(zhǔn)中選取HL3型彈性柱銷聯(lián)軸器,采用短圓柱形軸孔。公稱轉(zhuǎn)矩:Tn=630Tc許用轉(zhuǎn)速:n1=1000n11主動(dòng)端:了型軸孔、A型鍵槽、軸徑d1=,半聯(lián)軸器長(zhǎng)度L:HL彈性柱銷聯(lián)軸器Tc=631.96聯(lián)軸器的選擇結(jié)果 型 號(hào) 軸孔直徑 軸孔長(zhǎng)度 公稱轉(zhuǎn)矩 許用轉(zhuǎn)速HL44511212504000九、箱體、箱蓋主要尺寸計(jì)算箱體采用水平剖分式結(jié)構(gòu),采用HT200灰鑄鐵鑄造而成。箱體主要尺寸計(jì)算如下:名稱符號(hào)尺寸箱體厚度具體內(nèi)容參照23頁表5-18mm十、齒輪和滾動(dòng)軸承潤(rùn)滑與密封方式的選擇(一)減速器的潤(rùn)滑1、齒輪的潤(rùn)滑:根據(jù)齒輪的圓周速度6.28 選擇10mm 潤(rùn)滑,浸油深度 ,(36頁)潤(rùn)滑油粘度為59 。(41頁)2、軸承的潤(rùn)滑:滾動(dòng)軸承根據(jù)軸徑 選擇 脂 潤(rùn)滑,潤(rùn)滑脂的裝填量 ,潤(rùn)滑脂的類型為鈣基2號(hào) 鈉基2號(hào) 。(39-40頁)(-2:)減速器的密封(4246頁)1、軸伸出處密封:軸伸出處密封的作用是使?jié)L動(dòng)軸承與箱外隔絕防止?jié)櫥停ㄖ┞┏龊拖渫怆s質(zhì),水基灰塵等侵入軸承室避免軸承急劇磨損和腐蝕,采用墊圈密封方式2、軸承室內(nèi)側(cè)密封:采用擋油環(huán)密封方式,其作用是防止過多的油,雜質(zhì)以及嚙合處的熱油沖入軸承室3、箱蓋與箱座接合面的密封:采用密封條密封方法畫出封油環(huán)與氈圈示意圖(46頁與191頁)十一、減速器附件的設(shè)計(jì)說明:按課程設(shè)計(jì)4753頁進(jìn)行設(shè)計(jì),對(duì)每一種附件,說明其作用,并畫出結(jié)構(gòu)示意圖。(一)窺視孔蓋和窺視孔的設(shè)計(jì)作用:檢查傳動(dòng)件的嚙合、潤(rùn)滑、接觸斑點(diǎn)、齒側(cè)間隙及向箱內(nèi)注入潤(rùn)滑油 結(jié)構(gòu)示意圖窺視孔開在機(jī)蓋的頂部,應(yīng)能看到傳動(dòng)零件嚙合,并有足夠的大小,以便于檢修。(二)排油孔與油塞作用:排放污油,設(shè)在箱座底部結(jié)構(gòu)示意圖放油孔的位置應(yīng)在油池最低處,并安排在減速器不與其他部件靠近的一側(cè),以便于放油,放油孔用螺塞堵住,其結(jié)構(gòu)如圖 十二、設(shè)計(jì)參考資料目錄所用到的參考資料都可以列出,如:1、機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì):張建中主編,徐州:中國(guó)礦業(yè)大學(xué)出版社,2、 一一一” 十三、結(jié)束語由于時(shí)間緊迫,所以這次的設(shè)計(jì)存在許多缺點(diǎn),比如說箱體結(jié)構(gòu)龐大,重量也很大。齒輪的計(jì)算不夠精確等等缺陷,我相信,通過這次的實(shí)踐,能使我在以后的設(shè)計(jì)中避免很多不必要的工作,有能力設(shè)計(jì)出結(jié)構(gòu)更緊湊,傳動(dòng)更穩(wěn)定精確的設(shè)備。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 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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