單級直齒圓柱齒輪減速器設計【F=2350N V=1.5m-s D=300】,F=2350N V=1.5m-s D=300,單級直齒圓柱齒輪減速器設計【F=2350N,V=1.5m-s,D=300】,單級直齒,圓柱齒輪,減速器,設計 設 計 說 明 書 一、前 言 (—)課程設計的目的(參照第1頁) 機械零件課程設計是學生學習《機械技術》（上、下）課程后進行的一項綜合訓練，其主要目的是通過課程設計使學生鞏固、加深在機械技術課程中所學到的知識，提高學生綜合運用這些知識去分析和解決問題的能力。同時學習機械設計的一般方法，了解和掌握常用機械零部件、機械傳動裝置或簡單機械的設計方法與步驟，為今后學習專業(yè)技術知識打下必要的基礎。 (二)傳動方案的分析(參照第10頁) 機器一般是由原動機、傳動裝置和工作裝置組成。傳動裝置是用來傳遞原動機的運動和動力、變換其運動形式以滿足工作裝置的需要，是機器的重要組成部分。傳動裝置是否合理將直接影響機器的工作性能、重量和成本。合理的傳動方案除滿足工作裝置的功能外，還要求結構簡單、制造方便、成本低廉、傳動效率高和使用維護方便。 本設計中原動機為電動機，工作機為皮帶輸送機。傳動方案采用了兩級傳動，第一級傳動為帶傳動，第二級傳動為單級直齒圓柱齒輪減速器。 帶傳動承載能力較低．在傳遞相同轉(zhuǎn)矩時，結構尺寸較其他形式大，但有過載保護的優(yōu)點，還可緩和沖擊和振動，故布置在傳動的高速級，以降低傳遞的轉(zhuǎn)矩，減小帶傳動的結構尺寸。 齒輪傳動的傳動效率高，適用的功率和速度范圍廣，使用壽命較長，是現(xiàn)代機器中應用最為廣泛的機構之—。本設計采用的是單級直齒輪傳動(說明直齒輪傳動的優(yōu)缺點)。 說明減速器的結構特點、材料選擇和應用場合(如本設計中減速器的箱體采用水平剖分式結構，用HT200灰鑄鐵鑄造而成)。 設計說明書 二、傳動系統(tǒng)的參數(shù)設計 已知輸送帶的有效拉力Fw＝2350，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)、單向運轉(zhuǎn)。 1)選擇合適的電動機；2)計算傳動裝置的總傳動比，分配各級傳動比；3)計算傳動裝置的運動參數(shù)和動力參數(shù)。 解：1、選擇電動機 (1)選擇電動機類型：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機。 (2)選擇電動機容量 工作機所需功率： ,其中帶式輸送機效率ηw=0.94。 電動機輸出功率： 其中η為電動機至滾筒、主動軸傳動裝置的總效率，包括V帶傳動效率ηb、一對齒輪傳動效率ηg、兩對滾動軸承效率ηr2、及聯(lián)軸器效率ηc，值 計算如下：η=ηb ·ηg ·ηr 2·ηc=0.90 由表10—1(134頁)查得各效率值，代入公式計算出效率及電機輸出功率。使電動機的額定功率Pm＝(1～1.3)Po，由表10—110(223頁)查得電動機的額定功率Pm=5.5。 (3)選擇電動機的轉(zhuǎn)速 計算滾筒的轉(zhuǎn)速：95.49 根據(jù)表3—1確定傳動比的范圍：取V帶傳動比ib＝2～4，單級齒輪傳動比ig＝3～5，則總傳動比的范圍：i＝(2X3)～(4X5)＝6～20。 電動機的轉(zhuǎn)速范圍為n′=i·nw(6~20)·nw=592.94~1909.8 在這個范圍內(nèi)電動機的同步轉(zhuǎn)速有1000r／min和1500r／min，綜合考慮電動機和傳動裝置的情況，同時也要降低電動機的重量和成本，最終可確定同步轉(zhuǎn)速為1000，根據(jù)同步轉(zhuǎn)速確定電動機的型號為Y132M2-6，滿載轉(zhuǎn)速960。（223頁） 型號 額定功率 滿載轉(zhuǎn)速 同步轉(zhuǎn)速 Ｙ１３２Ｍ２－６ ５．５ ９６０ 1000 2、計算總傳動比并分配各級傳動比 (1)計算總傳動比：i=nm／nW=8～14 (2)分配各級傳動比：為使帶傳動尺寸不至過大，滿足ibLh， 合適 (二)從動軸承的選擇與驗算 已知軸頸直徑d3=60，n11=96，RvA=3063，Rw=3063，運轉(zhuǎn)過程中有輕微沖擊 計算項目 計算內(nèi)容 計算結果 1、確定軸承的基本參數(shù) 2、計算當量動負荷P 3、計算基本額定壽命 由軸承型號查課程設計附表得軸承的基本參數(shù) P二RvA、RⅧ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 代入計算得：Lh= 故所選軸承合適。(1h’可查表或按大修期確定) P=1.2 Lh>Lh， 合適 注意：如壽命過大，則重選軸承型號，取輕或特輕系列 八、聯(lián)軸器的選擇與驗算 已知聯(lián)軸器用在減速器的輸出端，從動軸轉(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 計算項目 計算內(nèi)容 計算結果 1、類犁選擇 2、計算轉(zhuǎn)矩 3、型號選擇 為減輕減速器輸出端的沖擊和振動，選擇彈性柱 銷聯(lián)軸器，代號為HL。 由教材表43-l，選擇工作情況系數(shù)K=1.25 Tc=K·TⅡ=631.96 按計算轉(zhuǎn)矩、軸徑、轉(zhuǎn)速，從標準中選取HL3型 彈性柱銷聯(lián)軸器，采用短圓柱形軸孔。 公稱轉(zhuǎn)矩：Tn=630>Tc 許用轉(zhuǎn)速：n1=1000>n11 主動端：了型軸孔、A型鍵槽、軸徑d1=，半聯(lián)軸 器長度L： HL彈性柱銷聯(lián)軸 器 Tc=631.96 聯(lián)軸器的選擇結果 型 號 軸孔直徑 軸孔長度 公稱轉(zhuǎn)矩 許用轉(zhuǎn)速 HL4 45 112 1250 4000 九、箱體、箱蓋主要尺寸計算 箱體采用水平剖分式結構，采用HT200灰鑄鐵鑄造而成。箱體主要尺寸計算如下： 名稱 符號 尺寸 箱體厚度 具體內(nèi)容參照23頁表5-1 8mm 十、齒輪和滾動軸承潤滑與密封方式的選擇 (一)減速器的潤滑 1、齒輪的潤滑：根據(jù)齒輪的圓周速度6.28 選擇10mm 潤滑，浸油深度 ，(36頁)潤滑油粘度為59 。(41頁) 2、軸承的潤滑：滾動軸承根據(jù)軸徑 選擇 脂 潤滑，潤滑脂的裝填量 ，潤滑脂的類型為鈣基2號 鈉基2號 。(39-40頁．) (．-2：)減速器的密封(42—46頁) 1、軸伸出處密封：軸伸出處密封的作用是使?jié)L動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、減速器附件的設計 說明：按課程設計47—53頁進行設計，對每一種附件，說明其作用，并畫出結構示意圖。 (一)窺視孔蓋和窺視孔的設計 作用：檢查傳動件的嚙合、潤滑、接觸斑點、齒側(cè)間隙及向箱內(nèi)注入潤滑油 結構示意圖 窺視孔開在機蓋的頂部，應能看到傳動零件嚙合，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，設在箱座底部 結構示意圖 放油孔的位置應在油池最低處，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，其結構如圖 十二、設計參考資料目錄 所用到的參考資料都可以列出，如： 1、機械設計基礎課程設計：張建中主編，徐州：中國礦業(yè)大學出版社， 2、 一一一”． 十三、結束語 由于時間緊迫，所以這次的設計存在許多缺點，比如說箱體結構龐大，重量也很大。齒輪的計算不夠精確等等缺陷，我相信，通過這次的實踐，能使我在以后的設計中避免很多不必要的工作，有能力設計出結構更緊湊，傳動更穩(wěn)定精確的設備。 長春理工大學光電信息學院畢業(yè)設計 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