自動送料帶式輸送機傳動裝置-一級圓柱齒輪減速器設計【F=2000N V=1.8m-s D=320mm】,F=2000N V=1.8m-s D=320mm,自動送料帶式輸送機傳動裝置-一級圓柱齒輪減速器設計【F=2000N,V=1.8m-s,D=320mm】,自動,送料帶式,輸送,傳動,裝置,一級,圓柱齒輪 說明書 一、傳動方案擬定…………….……………………………….2 二、電動機的選擇……………………………………….…….2 三、計算總傳動比及分配各級的傳動比……………….…….4 四、運動參數(shù)及動力參數(shù)計算………………………….…….5 五、傳動零件的設計計算………………………………….….6 六、軸的設計計算………………………………………….....12 七、滾動軸承的選擇及校核計算………………………….…18 八、鍵聯(lián)接的選擇及計算………..……………………………22 九、設計小結…………………………………………………..23 十、參考資料目錄……………………………………………..23 計算過程及計算說明 一、傳動方案擬定 第三組：設計單級圓柱齒輪減速器和一級帶傳動 （1） 工作條件：使用年限8年，工作為單班工作制，載荷平穩(wěn)，環(huán)境清潔。 （2） 原始數(shù)據(jù)：輸送帶拉力F=2000N；帶速V=1.8m/s； 滾筒直徑D=320mm；滾筒長度L=500mm。 二、電動機選擇 1、電動機類型的選擇： Y系列三相異步電動機 2、電動機功率選擇： （1）傳動裝置的總功率： η總=η帶×η2軸承×η齒輪×η聯(lián)軸器×η滾筒 =0.96×0.982×0.97×0.99×0.96 =0.885 (2)電機所需的工作功率： P工作=FV/1000η總 =2000×1.8/1000×0.94 =3.83KW 3、確定電動機轉速： 計算滾筒工作轉速： n筒=60×1000V/πD =60×1000×1.8/π×320 =107.05r/min 按手冊P7表1推薦的傳動比合理范圍，取圓柱齒輪傳動一級減速器傳動比范圍I’a=3~6。取V帶傳動比I’1=2~4，則總傳動比理時范圍為I’a=6~20。故電動機轉速的可選范圍為n’d=I’a× n筒=（6~20）×107.05=642.3~2141r/min 符合這一范圍的同步轉速有750、1000、和1500r/min。 根據(jù)容量和轉速，由有關手冊查出有三種適用的電動機型號：因此有三種傳支比方案：如指導書P15頁第一表。綜合考慮電動機和傳動裝置尺寸、重量、價格和帶傳動、減速器的傳動比，可見第2方案比較適合，則選n=1000r/min?。 4、確定電動機型號 根據(jù)以上選用的電動機類型，所需的額定功率及同步轉速，選定電動機型號為Y132M-4。 其主要性能：額定功率：4KW，滿載轉速1440r/min。 三、計算總傳動比及分配各級的傳動比 1、總傳動比：i總=n電動/n筒=1440/107.05=13.45 2、分配各級傳動比 （1） 據(jù)指導書P7表1，取齒輪i齒輪=6（單級減速器i=3~6合理） （2） ∵i總=i齒輪×I帶 ∴i帶=i總/i齒輪=13.45/3=4.48 四、運動參數(shù)及動力參數(shù)計算 1、計算各軸轉速（r/min） nI=n電機=1440r/min nII=nI/i帶=1440/4.48=321.43(r/min) nIII=nII/i齒輪=321.43/3=107.14(r/min) 2、 計算各軸的功率（KW） PI=P工作=Pmηc=5.5×0.95=5.23KW PII=PI×ηr×ηg=5.23×0.96=5.02KW PIII=PII×η軸承×η齒輪=5.02×0.98×0.96 =4.87KW 3計算各軸扭矩（N·mm） 4 To = 9550×Pm/Nm = 9550×5.5/1440 =36.48Nmm TI=9550×PI/nI=9550×5.23/1440 =34.69N·m TII=9550×PII/nII =9550×5.02/321.43 =149.15N·m Tw=9550×PW/nW=9550×4.87/107.14 =434.09N·m 五、傳動零件的設計計算 1、 皮帶輪傳動的設計計算 （1） 選擇普通V選帶截型 由課本P83表5-9得：kA=1.2 PC=KAP=1.2×3=3.9KW 由課本P82圖5-10得：選用A型V帶 （2） 確定帶輪基準直徑，并驗算帶速 由課本圖5-10得，推薦的小帶輪基準直徑為75~100mm 則取dd1=100mm>dmin=75 dd2=n1/n2·dd1=960/458.2×100=209.5mm 由課本P74表5-4，取dd2=200mm 實際從動輪轉速n2’=n1dd1/dd2=960×100/200 =480r/min 轉速誤差為：n2-n2’/n2=458.2-480/458.2 =-0.048<0.05(允許) 帶速V：V=πdd1n1/60×1000 =π×100×960/60×1000 =5.03m/s 在5~25m/s范圍內，帶速合適。 （3） 確定帶長和中心矩 根據(jù)課本P84式（5-14）得 0. 7(dd1+dd2)≤a0≤2(dd1+dd2) 0. 7(100+200)≤a0≤2×(100+200) 所以有：210mm≤a0≤600mm 由課本P84式（5-15）得： L0=2a0+1.57(dd1+dd2)+(dd2-dd1)/4a0 =2×500+1.57(100+200)+(200-100)2/4×500 =1476mm 根據(jù)課本P71表（5-2）取Ld=1400mm 根據(jù)課本P84式（5-16）得： a≈a0+Ld-L0/2=500+1400-1476/2 =500-38 =462mm (4)驗算小帶輪包角 α1=1800-dd2-dd1/a×57.30 =1800-200-100/462×57.30 =1800-12.40 =167.60>1200（適用） （5）確定帶的根數(shù) 根據(jù)課本P1=0.95KW △P1=0.11KW Kα=0.96 KL=0.96 得 Z=PC/P’=PC/(P1+△P1)KαKL =3.9/(0.95+0.11) ×0.96×0.96 =3.99 (6)計算軸上壓力 由課本表 查得q=0.1kg/m，單根V帶的初拉力： F0=500PC/ZV（2.5/Kα-1）+qV2 =[500×3.9/4×5.03×(2.5/0.96-1)+0.1×5.032]N =158.01N 則作用在軸承的壓力FQ， FQ=2ZF0sinα1/2=2×4×158.01sin167.6/2 =1256.7N 2、齒輪傳動的設計計算 （1）選擇齒輪材料及精度等級 考慮減速器傳遞功率不在，所以齒輪采用軟齒面。小齒輪選用40Cr調質，齒面硬度為240~260HBS。大齒輪選用45鋼，調質，齒面硬度220HBS；根據(jù)表選7級精度。齒面精糙度Ra≤1.6~3.2μm (2)按齒面接觸疲勞強度設計 由d1≥76.43(kT1(u+1)/φdu[σH]2)1/3 由式（6-15） 確定有關參數(shù)如下：傳動比i齒=6 取小齒輪齒數(shù)Z1=20。則大齒輪齒數(shù)： Z2=iZ1=6×20=120 實際傳動比I0=120/2=60 傳動比誤差：i-i0/I=6-6/6=0%<2.5% 可用 齒數(shù)比：u=i0=6 由表 取φd=0.9 (3)轉矩T1 T1=9.55×106×P/n1=9.55×106×2.4/458.2 =50021.8N·mm (4)載荷系數(shù)k 取k=1 (5)許用接觸應力[σH] [σH]= σHlimZNT/SH由課本查得： σHlimZ1=570Mpa σHlimZ2=350Mpa 由課本P133式6-52計算應力循環(huán)次數(shù)NL NL1=60n1rth=60×458.2×1×(16×365×8) =1.28×109 NL2=NL1/i=1.28×109/6=2.14×108 由課本查得接觸疲勞的壽命系數(shù)： ZNT1=0.92 ZNT2=0.98 通用齒輪和一般工業(yè)齒輪，按一般可靠度要求選取安全系數(shù)SH=1.0 [σH]1=σHlim1ZNT1/SH=570×0.92/1.0Mpa =524.4Mpa [σH]2=σHlim2ZNT2/SH=350×0.98/1.0Mpa =343Mpa 故得： d1≥76.43(kT1(u+1)/φdu[σH]2)1/3 =76.43[1×50021.8×(6+1)/0.9×6×3432]1/3mm =48.97mm 模數(shù)：m=d1/Z1=48.97/20=2.45mm 根據(jù)課本表 取標準模數(shù)：m=2.5mm (6)校核齒根彎曲疲勞強度 σF=(2kT1/bm2Z1)YFaYSa≤[σH] 確定有關參數(shù)和系數(shù) 分度圓直徑：d1=mZ1=2.5×20mm=50mm d2=mZ2=2.5×120mm=300mm 齒寬：b=φdd1=0.9×50mm=45mm 取b=45mm b1=50mm (7)齒形系數(shù)YFa和應力修正系數(shù)YSa 根據(jù)齒數(shù)Z1=20,Z2=120由表6-9相得 YFa1=2.80 YSa1=1.55 YFa2=2.14 YSa2=1.83 (8)許用彎曲應力[σF] [σF]= σFlim YSTYNT/SF 由設計手冊查得： σFlim1=290Mpa σFlim2 =210Mpa YNT1=0.88 YNT2=0.9 試驗齒輪的應力修正系數(shù)YST=2 按一般可靠度選取安全系數(shù)SF=1.25 計算兩輪的許用彎曲應力 [σF]1=σFlim1 YSTYNT1/SF=290×2×0.88/1.25Mpa =408.32Mpa [σF]2=σFlim2 YSTYNT2/SF =210×2×0.9/1.25Mpa =302.4Mpa 將求得的各參數(shù)代入式（6-49） σF1=(2kT1/bm2Z1)YFa1YSa1 =(2×1×50021.8/45×2.52×20) ×2.80×1.55Mpa =77.2Mpa< [σF]1 σF2=(2kT1/bm2Z2)YFa1YSa1 =(2×1×50021.8/45×2.52×120) ×2.14×1.83Mpa =11.6Mpa< [σF]2 故輪齒齒根彎曲疲勞強度足夠 (9)計算齒輪傳動的中心矩a a=m/2(Z1+Z2)=2.5/2(20+120)=175mm (10)計算齒輪的圓周速度V V=πd1n1/60×1000=3.14×50×458.2/60×1000 =1.2m/s 六、軸的設計計算 輸入軸的設計計算 1、按扭矩初算軸徑 選用45#調質，硬度217~255HBS 根據(jù)設計手冊例題，并查表10-2，取c=115 d≥115 (2.304/458.2)1/3mm=19.7mm 考慮有鍵槽，將直徑增大5%，則 d=19.7×(1+5%)mm=20.69 ∴選d=22mm 2、軸的結構設計 （1）軸上零件的定位，固定和裝配 單級減速器中可將齒輪安排在箱體中央，相對兩軸承對稱分布，齒輪左面由軸肩定位，右面用套筒軸向固定，聯(lián)接以平鍵作過渡配合固定，兩軸承分別以軸肩和大筒定位，則采用過渡配合固定 （2）確定軸各段直徑和長度 工段：d1=22mm 長度取L1=50mm ∵h=2c c=1.5mm II段:d2=d1+2h=22+2×2×1.5=28mm ∴d2=28mm 初選用7206c型角接觸球軸承，其內徑為30mm, 寬度為16mm. 考慮齒輪端面和箱體內壁，軸承端面和箱體內壁應有一定距離。取套筒長為20mm，通過密封蓋軸段長應根據(jù)密封蓋的寬度，并考慮聯(lián)軸器和箱體外壁應有一定矩離而定，為此，取該段長為55mm，安裝齒輪段長度應比輪轂寬度小2mm,故II段長： L2=（2+20+16+55）=93mm III段直徑d3=35mm L3=L1-L=50-2=48mm Ⅳ段直徑d4=45mm 由手冊得：c=1.5 h=2c=2×1.5=3mm d4=d3+2h=35+2×3=41mm 長度與右面的套筒相同，即L4=20mm 但此段左面的滾動軸承的定位軸肩考慮，應便于軸承的拆卸，應按標準查取由手冊得安裝尺寸h=3.該段直徑應?。海?0+3×2）=36mm 因此將Ⅳ段設計成階梯形，左段直徑為36mm Ⅴ段直徑d5=30mm. 長度L5=19mm 由上述軸各段長度可算得軸支承跨距L=100mm (3)按彎矩復合強度計算 ①求分度圓直徑：已知d1=50mm ②求轉矩：已知T2=50021.8N·mm ③求圓周力：Ft Ft=2T2/d2=50021.8/50=1000.436N ④求徑向力Fr Fr=Ft·tanα=1000.436×tan200=364.1N ⑤因為該軸兩軸承對稱，所以：LA=LB=50mm (1)繪制軸受力簡圖（如圖a） （2）繪制垂直面彎矩圖（如圖b） 軸承支反力： FAY=FBY=Fr/2=182.05N FAZ=FBZ=Ft/2=500.2N 由兩邊對稱，知截面C的彎矩也對稱。截面C在垂直面彎矩為 MC1=FAyL/2=182.05×50=9.1N·m (3)繪制水平面彎矩圖（如圖c） 截面C在水平面上彎矩為： MC2=FAZL/2=500.2×50=25N·m (4)繪制合彎矩圖（如圖d） MC=(MC12+MC22)1/2=(9.12+252)1/2=26.6N·m (5)繪制扭矩圖（如圖e） 轉矩：T=9.55×（P2/n2）×106=48N·m (6)繪制當量彎矩圖（如圖f） 轉矩產生的扭剪文治武功力按脈動循環(huán)變化，取α=1，截面C處的當量彎矩： Mec=[MC2+(αT)2]1/2 =[26.62+(1×48)2]1/2=54.88N·m (7)校核危險截面C的強度 σe=Mec/0.1d33=99.6/0.1×413 =14.5MPa< [σ-1]b=60MPa ∴該軸強度足夠。 輸出軸的設計計算 1、按扭矩初算軸徑 選用45#調質鋼，硬度（217~255HBS） 根據(jù)設計手冊表 取c=115 d≥c(P3/n3)1/3=115(2.168/76.4)1/3=35.08mm 取d=35mm 2、軸的結構設計 （1）軸的零件定位，固定和裝配 單級減速器中，可以將齒輪安排在箱體中央，相對兩軸承對稱分布，齒輪左面用軸肩定位，右面用套筒軸向定位，周向定位采用鍵和過渡配合，兩軸承分別以軸承肩和套筒定位，周向定位則用過渡配合或過盈配合，軸呈階狀，左軸承從左面裝入，齒輪套筒，右軸承和皮帶輪依次從右面裝入。 （2）確定軸的各段直徑和長度 初選7207c型角接球軸承，其內徑為35mm，寬度為17mm?？紤]齒輪端面和箱體內壁，軸承端面與箱體內壁應有一定矩離，則取套筒長為20mm，則該段長41mm，安裝齒輪段長度為輪轂寬度為2mm。 (3)按彎扭復合強度計算 ①求分度圓直徑：已知d2=300mm ②求轉矩：已知T3=271N·m ③求圓周力Ft： Ft=2T3/d2=2×271×103/300=1806.7N ④求徑向力Fr Fr=Ft·tanα=1806.7×0.36379=657.2N ⑤∵兩軸承對稱 ∴LA=LB=49mm (1)求支反力FAX、FBY、FAZ、FBZ FAX=FBY=Fr/2=657.2/2=328.6N FAZ=FBZ=Ft/2=1806.7/2=903.35N (2)由兩邊對稱，書籍截C的彎矩也對稱 截面C在垂直面彎矩為 MC1=FAYL/2=328.6×49=16.1N·m (3)截面C在水平面彎矩為 MC2=FAZL/2=903.35×49=44.26N·m (4)計算合成彎矩 MC=（MC12+MC22）1/2 =（16.12+44.262）1/2 =47.1N·m (5)計算當量彎矩：根據(jù)課本P235得α=1 Mec=[MC2+(αT)2]1/2=[47.12+(1×271)2]1/2 =275.06N·m (6)校核危險截面C的強度 由式（10-3） σe=Mec/（0.1d）=275.06/(0.1×453) =1.36Mpa<[σ-1]b=60Mpa ∴此軸強度足夠 七、滾動軸承的選擇及校核計算 根據(jù)根據(jù)條件，軸承預計壽命 16×365×8=48720小時 1、計算輸入軸承 （1）已知nⅡ=458.2r/min 兩軸承徑向反力：FR1=FR2=500.2N 初先兩軸承為角接觸球軸承7206AC型 軸承內部軸向 FS=0.63FR 則FS1=FS2=0.63FR1=315.1N (2) ∵FS1+Fa=FS2 Fa=0 故任意取一端為壓緊端，現(xiàn)取1端為壓緊端 FA1=FS1=315.1N FA2=FS2=315.1N (3)求系數(shù)x、y/ FA1/FR1=315.1N/500.2N=0.63 FA2/FR2=315.1N/500.2N=0.63 根據(jù)課本表 得e=0.68 FA1/FR148720h ∴預期壽命足夠 2、計算輸出軸承 (1)已知nⅢ=76.4r/min Fa=0 FR=FAZ=903.35N 試選7207AC型角接觸球軸承 根據(jù)課本 得FS=0.063FR,則 FS1=FS2=0.63FR=0.63×903.35=569.1N (2)計算軸向載荷FA1、FA2 ∵FS1+Fa=FS2 Fa=0 ∴任意用一端為壓緊端，1為壓緊端，2為放松端 兩軸承軸向載荷：FA1=FA2=FS1=569.1N (3)求系數(shù)x、y FA1/FR1=569.1/903.35=0.63 FA2/FR2=569.1/930.35=0.63 根據(jù)課本表 得：e=0.68 ∵FA1/FR148720h ∴此軸承合格 八、鍵聯(lián)接的選擇及校核計算 軸徑d1=22mm,L1=50mm 查手冊得，選用C型平鍵，得： 鍵A 8×7 GB1096-79 l=L1-b=50-8=42mm T2=48N·m h=7mm 得 σp=4T2/dhl=4×48000/22×7×42 =29.68Mpa<[σR](110Mpa) 2、輸入軸與齒輪聯(lián)接采用平鍵聯(lián)接 軸徑d3=35mm L3=48mm T=271N·m 查手冊P51 選A型平鍵 鍵10×8 GB1096-79 l=L3-b=48-10=38mm h=8mm σp=4T/dhl=4×271000/35×8×38 =101.87Mpa<[σp](110Mpa) 3、輸出軸與齒輪2聯(lián)接用平鍵聯(lián)接 軸徑d2=51mm L2=50mm T=61.5Nm 查手冊P51 選用A型平鍵 鍵16×10 GB1096-79 l=L2-b=50-16=34mm h=10mm σp=4T/dhl=4×6100/51×10×34=60.3Mpa<[σp] F=2000N V=1.8m/s D=320mm L=500mm n滾筒=76.4r/min η總=0.8412 P工作=2.4KW 電動機型號 Y132M-4 i總=12.57 據(jù)手冊得 i齒輪=6 i帶=2.095 nI =1440r/min nII=321.43r/min nIII=107.14r/min PI=5.23KW PII=5.02KW PIII=4.87KW T0=36.48Nmm TI=34.69N·mm TII=149.15N·mm TIII=434.09N·mm dd2=209.5mm 取標準值 dd2=200mm n2’=480r/min V=5.03m/s 210mm≤a0≤600mm 取a0=500 Ld=1400mm a0=462mm Z=4根 F0=158.01N FQ =1256.7N i齒=6 Z1=20 Z2=120 u=6 T1=50021.8N·mm αHlimZ1=570Mpa αHlimZ2=350Mpa NL1=1.28×109 NL2=2.14×108 ZNT1=0.92 ZNT2=0.98 [σH]1=524.4Mpa [σH]2=343Mpa d1=48.97mm m=2.5mm d1=50mm d2=300mm b=45mm b1=50mm YFa1=2.80 YSa1=1.55 YFa2=2.14 YSa2=1.83 σFlim1=290Mpa σFlim2 =210Mpa YNT1=0.88 YNT2=0.9 YST=2 SF=1.25 σF1=77.2Mpa σF2=11.6Mpa a =175mm V =1.2m/s d=22mm d1=22mm L1=50mm d2=28mm L2=93mm d3=35mm L3=48mm d4=41mm L4=20mm d5=30mm L=100mm Ft =1000.436N Fr=364.1N FAY =182.05N FBY =182.05N FAZ =500.2N MC1=9.1N·m MC2=25N·m MC =26.6N·m T=48N·m Mec =99.6N·m σe =14.5MPa <[σ-1]b d=35mm Ft =1806.7N FAX=FBY =328.6N FAZ=FBZ =903.35N MC1=16.1N·m MC2=44.26N·m MC =47.1N·m Mec =275.06N·m σe =1.36Mpa <[σ-1]b 軸承預計壽命48720h FS1=FS2=315.1N x1=1 y1=0 x2=1 y2=0 P1=750.3N P2=750.3N LH=1047500h ∴預期壽命足夠 FR =903.35N FS1=569.1N x1=1 y1=0 x2=1 y2=0 P1=1355N P2=1355N Lh =2488378.6h 故軸承合格 A型平鍵8×7 σp=29.68Mpa A型平鍵 10×8 σp=101.87Mpa A型平鍵 16×10 σp =60.3Mpa 減速器附件的選擇 通氣器 由于在室內使用，選通氣器（一次過濾），采用M18×1.5 油面指示器 選用游標尺M16 起吊裝置 潤滑與密封 一、 齒輪的潤滑 采用浸油潤滑，由于低速級周向速度為，所以浸油高度約為六分之一大齒輪半徑，取為35mm。 二、 滾動軸承的潤滑 由于軸承周向速度為，所以宜開設油溝、飛濺潤滑。 三、 潤滑油的選擇 齒輪與軸承用同種潤滑油較為便利，考慮到該裝置用于小型設備，選用L-AN15潤滑油。 四、 密封方法的選取 選用凸緣式端蓋易于調整，采用悶蓋安裝骨架式旋轉軸唇型密封圈實現(xiàn)密封。 密封圈型號按所裝配軸的直徑確定為（F）B25-42-7-ACM，（F）B70-90-10-ACM。 軸承蓋結構尺寸按用其定位的軸承的外徑決定。 設計小結 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。 特別感謝—程莉老師。 參考資料目錄 [1]《機械設計基礎》，機械工業(yè)出版社，任成高主編，2006年2月第一版； [2]《簡明機械零件設計實用手冊》，機械工業(yè)出版社，胡家秀主編，2006年1月第一版； [3]《機械設計-課程設計圖冊》，高等教育出版社，龔桂義主編，1989年5月第三版； [3]《設計手冊軟件》，網絡上下載； [4] 湖南工院學生論壇----機械制圖專欄---bbs.yeux.cn 一． 設計題目 1．設計題目名稱 自動送料帶式輸送機傳動裝置中的一級圓柱齒輪減速器。 2．運動簡圖 3．工作條件 輸送機連續(xù)單向運轉，載荷平穩(wěn)，兩班制工作，使用期限8年，小批量生產，輸送帶速度容許誤差±5%。 4，原始數(shù)據(jù) 1．輸送帶拉力 F=2000 N 2．輸送帶速度 V=1.8 m/s 3．滾筒直徑 D=320 mm 二．教學目的 1、綜合運用機械設計基礎課程及其它先修課程的理論和生產 實際知識進行機械設計訓練，使理論和產生實際知識密切地結合起來，從而使這些知識得到進一步鞏固、加深和擴展。 2學習和掌握通用零件、機械傳動裝置或簡單機械的一般設計方法，培養(yǎng)學生工程設計能力和分析問題、解決問題的能力。 3訓練學生進行工廠設計的思維方法，對學生在計算、制圖、運用設計資料（包括手冊、標準和規(guī)范等）以及經驗估計、考慮 設計 任務書 班 級 學 生 姓 名 學 生 學 號 總 課 時 數(shù) 2 周 指 導 教 師 教研室主任 發(fā)布日期 2006 年 11 月 25 日 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．amount 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