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黃河科技學(xué)院畢業(yè)設(shè)計(jì)（外文翻譯） 第 10 頁(yè)
JK1 建筑卷?yè)P(yáng)機(jī)結(jié)構(gòu)改進(jìn)
近幾年來(lái)，建筑卷?yè)P(yáng)機(jī)得到了較大的發(fā)展，但由于各種原因，我國(guó)目前生產(chǎn)的建筑卷?yè)P(yáng)機(jī)還存在著品種雜亂、同一噸位產(chǎn)品的傳動(dòng)型式結(jié)構(gòu)差別大，選用不便、維修困難，系列化、通用化、標(biāo)準(zhǔn)化程度低等問(wèn)題。
許多建筑機(jī)械廠在80 年代末期生產(chǎn)的JK1卷?yè)P(yáng)機(jī)大都是新外型，結(jié)構(gòu)緊湊，布局合理，技術(shù)參數(shù)比較先進(jìn)，使用性能良好，制動(dòng)可靠，維修方便，操作靈活。但經(jīng)多年生產(chǎn)，也發(fā)現(xiàn)存在一些問(wèn)題，為此，我們進(jìn)行了以下改進(jìn)
1 、減速箱體密封性能改進(jìn)
在JKI卷?yè)P(yáng)機(jī)使用過(guò)程中發(fā)現(xiàn)減速箱體滲漏油，部位集中在高速軸與輸出軸的密封處及輸出軸與箱體之間。經(jīng)分析測(cè)量，發(fā)現(xiàn)滲漏油的原因是軸承蓋與輸出軸之間毛氈密封不可靠，密封效果達(dá)不到設(shè)計(jì)要求；而高速軸與輸出軸之間滲油主要原因是孔套內(nèi)外徑的圓柱度及同軸度未達(dá)到設(shè)計(jì)要求的精度，而要達(dá)到圖紙?jiān)O(shè)計(jì)精度要求需增加磨削工序和配套工藝裝備，這樣增加了制造成本。因此，我們對(duì)這兩處的結(jié)構(gòu)進(jìn)行了改進(jìn)，在孔套的外徑上加工密封槽，放置0 型密封圈，這樣既降低孔套外徑形位精度且密封效果良好。另外把軸承蓋的毛氈密封改為0 型密封，效果良好。
2、聯(lián)軸器型式的改進(jìn)
JKI 卷?yè)P(yáng)機(jī)原設(shè)計(jì)采用輪胎式聯(lián)軸器，這種聯(lián)軸器結(jié)構(gòu)簡(jiǎn)單，彈性好，扭轉(zhuǎn)剛度小，減振能力強(qiáng)，補(bǔ)償兩軸相對(duì)位移量大；但徑向外形尺寸大，附加軸向載荷大，且輪胎易老化，在實(shí)際使用中，拆裝復(fù)雜，增加了裝配難度。經(jīng)對(duì)目前國(guó)內(nèi)生產(chǎn)的聯(lián)軸器比較，改用了梅花型彈性聯(lián)軸器。它具有結(jié)構(gòu)簡(jiǎn)單、彈性好、扭轉(zhuǎn)剛度小等優(yōu)點(diǎn)，而且外形尺寸小、軸向載荷小、拆裝簡(jiǎn)單、彈性元件使用壽命長(zhǎng)。通過(guò)幾年使用證明，梅花型彈性聯(lián)軸器安全性、可靠性都優(yōu)于原設(shè)計(jì)的輪胎式聯(lián)軸器。
3 、齒輪材料的改進(jìn)
JKI 卷?yè)P(yáng)機(jī)原設(shè)計(jì)齒輪材料為ZG340 ~ 640（ZG55），加工工藝性差，鑄造缺陷造成很高的廢品率，生產(chǎn)成本很高。用OT700-2 球墨鑄鐵取代ZG55，采用球鐵齒輪。校核其接觸強(qiáng)度和彎曲強(qiáng)度都好于鑄鋼齒輪，鑄造廢品率也大大降低，機(jī)加工工藝性也有了一定的改善。
4、 控制電路的改進(jìn)
JKI 卷?yè)P(yáng)機(jī)原設(shè)計(jì)采用電磁起動(dòng)器控制電路，安全性差，事故較頻繁。根據(jù)GBI3329—9I《建筑卷?yè)P(yáng)機(jī)安全規(guī)程》和JG/T503I—93《建筑卷?yè)P(yáng)機(jī)設(shè)計(jì)規(guī)范》，進(jìn)行了重新設(shè)計(jì)。新設(shè)計(jì)的電控箱采用一個(gè)主接觸器和一對(duì)控制電機(jī)正反轉(zhuǎn)的接觸器，另加熱繼電器作過(guò)載保護(hù)，控制采用按鈕盒，可實(shí)現(xiàn)遠(yuǎn)距離操作，在電控箱中預(yù)留了接線端子，可串接上、下限位和極限裝置。為實(shí)現(xiàn)與我廠生產(chǎn)的SSI00提升機(jī)配套使用，還增加了相序繼電器。改進(jìn)后的電控箱能實(shí)現(xiàn)急停短路、過(guò)載和失壓、零位、缺斷相保護(hù)，增強(qiáng)了使用安全性和可靠性，完善了整機(jī)技術(shù)性能，在用戶中樹(shù)立了良好的信譽(yù)，提高了我廠卷?yè)P(yáng)機(jī)在市場(chǎng)的占有率
5、采用少齒差傳動(dòng)機(jī)構(gòu)
利用采用少齒差傳動(dòng)機(jī)構(gòu)的優(yōu)越性可改進(jìn)和提高建筑機(jī)械等設(shè)備的傳動(dòng)結(jié)構(gòu)技術(shù)性能，將漸開(kāi)線少齒差行星齒輪傳動(dòng)應(yīng)用于建筑卷?yè)P(yáng)機(jī)的動(dòng)力傳輸系統(tǒng)，是使傳統(tǒng)卷?yè)P(yáng)機(jī)減小體積、優(yōu)化結(jié)構(gòu)、降低成本、提高性能的有效途徑，具有廣闊的前景
5、1 齒輪正確嚙合傳動(dòng)的前提下的變位系數(shù)的選擇
齒輪正確嚙合傳動(dòng)的前提下，在設(shè)計(jì)少齒差減速機(jī)構(gòu)時(shí)通過(guò)改變內(nèi)、外齒輪的齒數(shù)可以得到不同的傳動(dòng)比，如果內(nèi)齒輪齒數(shù)（Z 2）不變，其外齒輪齒數(shù)（Z 1）越大，則其齒數(shù)差（Z1）越小，傳動(dòng)比也就越大。但對(duì)于齒頂高h(yuǎn) a= 1 ，原始齒形角α = 20 的標(biāo)準(zhǔn)內(nèi)齒輪傳動(dòng)副，在Z1小到一定程度時(shí)由于內(nèi)外齒輪的齒廓發(fā)生重迭，則無(wú)法按原設(shè)計(jì)的中心距進(jìn)行裝配。為了在Z1很小時(shí)內(nèi)外齒輪副仍能正常嚙合傳動(dòng)，現(xiàn)有兩條途徑可循；一是降低齒頂高度，采用短齒齒形以消除齒廓重迭；二是通過(guò)選擇適當(dāng)?shù)淖兾幌禂?shù)，增大內(nèi)齒輪齒間寬度，減少外齒輪齒頂厚度，從齒間間隙上消除齒廓重迭。實(shí)施中可同時(shí)采用上述兩種方法，以期達(dá)到最佳嚙合傳動(dòng)的效果。值得注意的是，當(dāng)內(nèi)外齒輪副采用短齒齒形且內(nèi)外齒輪進(jìn)行變位后，其齒厚、齒高、公法線長(zhǎng)度、中心距、嚙合角及嚙合性能等都同時(shí)發(fā)生改變，由此內(nèi)外齒輪變位系數(shù)的選擇就成了關(guān)鍵。
5、2 齒輪變位的合適范圍
齒輪變位后應(yīng)保證齒頂高系數(shù)Se ／m =0. 4 ，且齒頂部分仍為漸開(kāi)線齒廓。一般少齒差建筑卷?yè)P(yáng)機(jī)的技術(shù)參數(shù)選擇均能滿足要求，故可省略檢驗(yàn)。
5、3 內(nèi)齒輪傳動(dòng)副的干涉
根據(jù)傳動(dòng)比及強(qiáng)度計(jì)算等條件決定了少齒差傳動(dòng)副的主要技術(shù)參數(shù)后，能否保證其順利安裝和正常運(yùn)轉(zhuǎn)關(guān)鍵是考慮其它不發(fā)生干涉的條件是否也能滿足要求。
（1）漸開(kāi)線干涉在Z 2一定的條件下Z 1大于一定值，漸開(kāi)線干涉就不會(huì)發(fā)生。由于少齒差齒輪傳動(dòng)中內(nèi)外齒輪的齒數(shù)較接近，且Z 1一直大于發(fā)生漸開(kāi)線干涉的極限值，所以此條件無(wú)須驗(yàn)算。
（2）過(guò)渡干涉因?yàn)椴迩袃?nèi)齒輪插齒刀的頂高比正常齒高出一個(gè)齒頂間隙的高度，而且少齒差內(nèi)外齒輪副采用短齒制齒形（h a=0. 8 ），所以無(wú)論對(duì)于內(nèi)齒和外齒發(fā)生過(guò)渡干涉的可能性都很小，實(shí)際節(jié)點(diǎn)對(duì)方齒相碰設(shè)計(jì)中也可以免于驗(yàn)算。
（3）齒頂相碰裝配
內(nèi)齒輪副時(shí)為防止發(fā)生圖1 所示的情況，即節(jié)點(diǎn)對(duì)方的齒頂相碰，保證正常運(yùn)轉(zhuǎn)，須使內(nèi)齒輪副節(jié)點(diǎn)對(duì)方的齒頂徑向間隙合理，應(yīng)予檢驗(yàn)。
6、加工注意事項(xiàng)
少齒差傳動(dòng)建筑卷?yè)P(yáng)機(jī)在加工制作中與其它傳動(dòng)方式的卷?yè)P(yáng)機(jī)有許多不同，應(yīng)予注意。
6、1 選材合理
JK1 型建筑卷?yè)P(yáng)機(jī)采用的是銷軸式少齒差傳動(dòng)機(jī)構(gòu)，其零件材料的選擇既要考慮到機(jī)械設(shè)備的使用要求、加工制作工藝條件，更要考慮到所選材料在技術(shù)性能和經(jīng)濟(jì)成本上的合理性。經(jīng)多方比較筆
者認(rèn)為，其主傳動(dòng)軸、行星齒輪等零件可選用45號(hào)鋼或40cr 鋼，銷軸、銷軸套可選用Gcrl5 ，銷軸改用45 號(hào)、銷軸套改用40cr 鋼仍可滿足使用要求；輸出軸可選用ZG45 或ZG55 ，內(nèi)齒輪宜選用Tl20 -l 或T60 （70 、80 ）-2 ；其余支撐件和卷筒可選用HT200 等，這樣既可降低成本又可確保機(jī)械性能。值得注意的是必須對(duì)其進(jìn)行合理的熱處理，才能充分發(fā)揮所選材料的優(yōu)良性能，對(duì)于鑄、鍛、焊件一定要進(jìn)行時(shí)效處理，以消除內(nèi)應(yīng)力、改善加工性能、防止機(jī)加工后變形。
6、2 精度適當(dāng)
適當(dāng)?shù)募庸ぞ仁谴_保產(chǎn)品質(zhì)量性能的前提。少齒差傳動(dòng)結(jié)構(gòu)緊湊、形位公差要求較高，除軸徑公差、一般耦合件可按常規(guī)要求選擇外還應(yīng)注意下列幾點(diǎn)。
（l）內(nèi)外齒輪的加工精度不宜低于Gbl0095 -88 中的7 -8 級(jí)精度，其齒厚偏差可依據(jù)側(cè)隙要求在FL 或GM 中靈活選擇，如877HK 等。
（2）行星輪銷孔、輸出軸及銷軸架銷孔的孔徑公差可按H8 選取，銷軸軸徑可按h7、銷軸套外徑可按f 7選取。值得注意的是以上三者的同軸度誤差孔位分布誤差應(yīng)盡可能地小，一般銷孔相鄰誤差。
與累積誤差公差分別控制在0. 04mm 和0. 08mm 以內(nèi)，否則可能造成較大聲響，影響其傳輸性能。
（3）行星輪銷孔的公稱尺寸除按銷軸套外徑加兩倍偏心距外還應(yīng)增加適當(dāng)?shù)难a(bǔ)償量，引入是為了補(bǔ)救銷軸、銷孔、銷套的加工和裝配誤差， 過(guò)小則需提高相關(guān)件的加工精度，否則裝配困難、運(yùn)轉(zhuǎn)卡塞；過(guò)大可能導(dǎo)致銷軸負(fù)載不均，易造成軸斷或套裂。
（4）主傳動(dòng)軸的偏心距公差受銷孔公差及補(bǔ)償尺寸 值的限制，可按 0. 025mm 考慮。加工精度的選擇與設(shè)備使用條件及生產(chǎn)制造上的可能性關(guān)系密切，在滿足使用要求的前提下適當(dāng)降低加工精度是明智之舉，在這方面實(shí)踐性很強(qiáng)，可根據(jù)實(shí)際情況自定。
JK1structure improvement of construction winches
In recent years, construction winches have achieved great development, but due to various reasons, China's current production of construction hoists has varieties of problems such as disordered organization, structural differences in the same tonnage product transmission type, inconvenience of use , difficulty of repair ，the low rate of serialization generalization, standardization and so on.
A new type of JK1 winch has been produced by many construction machinery factories in the late 80’s. It has advantages of compact structure, reasonable layout, more advanced technical parameters reliable braking, convenient repairing flexible operation. But after years of production, there still exists some problems, for this, we performed the following improvements.
1. The improvement in sealing properties of transmission
In the JKI winch are found in the use of gear box oil leakage, site focused on the high speed shaft and the output shaft and the output shaft seal and cabinet. By the analysis of measurement, found the cause of oil leakage is bearing cover and between the output shaft and the felt is unreliable in sealing, the sealing effect can not reach the design requirements; and the high speed shaft and output shaft oil leakage is the main cause of hole inner and outer diameter of cylinder and coaxial degree did not meet the design requirements of accuracy, in order to achieve the design accuracy is required to increase grinding process and related process equipment, so as to increase the manufacturing cost. Therefore, we of the two structure was improved, the sleeve in the bore diameter on processing sealing groove, placed0type sealing ring, which reduces the outer diameter of the sleeve hole position accuracy and good sealing effect. In addition to the bearing cover, felt seal to 0type sealing can get good results.
2. The improvement of coupling type
the original design of JK1 hoist choose the tire coupling ,the coupling has the advantages of simple structure, good elasticity, torsion stiffness, damping capacity, compensation relativity great displacement; but the radial dimensions big, additional axial load, and the tire aging, in actual use, disassembly and assembly of complex, increased the difficulty of assembling. The current domestic production of couplings comparison, use a quincunx elastic coupling. It has the advantages of simple structure, good elasticity, torsion stiffness of small advantages, and small size, the axial load is small, simple disassembly and assembly, long service life of the elastic element. Through years of use，a quincunx elastic coupling safety, reliability than the original design of the tire coupling.
3. The improvement of gear materials
The original design of JKI hoist gear materials for ZG340 ~ 640 ( ZG55), poor processing technology, casting defects caused high scrap rate, high production costs. Using OT700-2to replace ZG55 with nodular cast iron, ductile iron gear. Check the contact strength and bending strength are better than the cast steel gear, casting scrap rate is greatly reduced, the machining process has been improved.
4. Improvement of control circuit
The original design by JKI hoist electromagnetic starter control circuit, poor safety, accident is frequent. According to GBI3329- 9I" building hoist safety regulations" and JG / T503I - 93" building hoist design standard", is a new design. The new design of the electric control box with a main contactor and a pair of motor control contactors， relays the other heating for overload protection, control the button box, the realization of the remote operation, the electronic control box in the reserved wiring terminal, and can be connected in series, lower limit and limit device. In order to realize and I plant the production of SSI00 lifting machine, also increased the phase sequence relay. The improved electric control box can realize the quick stop short circuit, overload and pressure loss, zero, broken phase protection, enhance the safety and reliability, improve the overall technical performance, users establish a good reputation, improve my plant hoister in market share.
5. The gear transmission mechanism with small tooth difference
Use of the gear transmission mechanism with small tooth difference superiority can improve and enhance the construction machinery and equipment of the transmission structure technical performance, the planetary gear drive with small teeth difference is applied to building hoist engine power transmission system, is to make the traditional hoist volume is reduced, optimize a structure, reduce cost, improve performance in an effective way, which has broad prospects
5.1 The correct gear meshing transmission under the condition of selecting the modification coefficient.
The correct gear meshing transmission under the premise, in the design of few teeth difference speed reducing mechanism by changing the internal, external gear tooth number can get different drive ratio, if the internal gear tooth number ( Z 2) unchanged, the outer gear tooth number ( Z 1) is bigger, the tooth number difference ( Z1) smaller, the transmission ratio is bigger. But for the tooth top height h a! = 1, the original tooth angle!0 =20standard internal gear pair, in Z1to a certain extent because of internal and external gear tooth profile to an eclipse, not according to the original design of the center distance of the assembly. In Z1 very hour gear side can still normally meshing transmission, the existing two ways to follow; one is to reduce the tooth top height, using short tooth shape to remove the tooth outline overlap; two is through the selection of proper modification coefficient, increase the internal gear tooth width, reduced thickness from top gear, tooth gap eliminating tooth outline overlap. The implementation of the above two methods can be adopted at the same time, in order to achieve the best effect of meshing transmission. Notably, when the internal and external gear pair with short gear and internal gear are changed, the tooth thickness, tooth height, length of cable, center distance, the meshing angle and meshing performance are also changed, from inside and outside the choice of gear modification coefficient is key.
5.2 The reasonable range of displacement gear
Gear should ensure the addendum coefficient Se / M=0.4, and the tooth top still for tooth profile. Generally less tooth difference construction hoist technical parameters can meet the requirements， it can be omitted in inspection
5.3 internal gearing with interference
According to the transmission ratio and strength calculation conditions of the small tooth difference transmission pair of main technical parameters, can ensure its smooth installation and the normal operation of the key is to consider other without interference conditions can also meet the requirements.
（1）Interference in Z 2under the condition of Z 1is larger than a certain value, the interference does not occur. As a result of less tooth difference gear drive gear tooth number is closer to1, and Z has been greater than the incidence of inv interference limit value, so this condition without checking.
（2） the transition interference because of slotting internal gear slotting cutter of the top than the normal tooth height of a tooth tip clearance height, and few teeth difference internal gear pair made of short tooth for tooth ( h a! = 0.8), so both inner and outer tooth gear transition is the possibility of interference are small, actual node other teeth touch design can be from checking.
（3）Addendum together assembly
Internal gear pair in order to prevent the occurrence of those shown in Figure 1, the node of the tooth top touching each other, ensure the normal operation, to make internal gear pair of nodes each tooth top radial clearance should be reasonable, inspection.
6. Notes about processing
Small tooth difference transmission construction hoist in manufacture and other modes of transmission winch has many different, should be noted.
6.1 Ways of selection
JK1 type construction hoist is used in a pin shaft type gear transmission mechanism with small tooth difference, the selection of parts materials should not only consider the use of mechanical equipment requirements, processing conditions, but also to take into account the selected materials in the technical performance and cost reasonableness. comparison of pen. Thinking of that the main drive shaft, planetary gear and other parts can choose45 steel and 40Cr steel, pin, shaft sleeve can choose Gcrl5, pin45, pin shaft sleeve to switch to 40Cr steel can meet the using requirements; the output shaft can be ZG45or ZG55, internal gear should be chosen,Tl20or l T60(70,80) - 2; the support and the reel can choose HT200, so that not only can reduce the cost and ensure the mechanical properties. Notable is must carry on the reasonable heat treatment, in order to give full play to the selected material with excellent properties, for casting, forging, welding pieces must be aging treatment, to eliminate the internal stress, improve the processing performance.
6.2 Precision should be appropriate.
Proper machining accuracy is to ensure that product quality performance. Small tooth difference transmission has the advantages of compact structure, form and position tolerance requirements higher, except the shaft diameter tolerances.
（1）General coupling piece can be routinely asked to choose should also pay attention to the following points, gear machining accuracy not less than Gbl0095 - precision, the tooth thickness deviation based on clearance requirements in FL or GM flexible options, such as 877HK etc..
（2）A planet wheel pin hole, the output shaft and a pin shaft frame pinhole aperture tolerances can be selected by H8, pin shaft diameter according to the H7, pin shaft sleeve outer diameter can be selected according to f 7. Notable is the three above the coaxial error of hole distribution error should be as small as possible, general pin hole adjacent error. With the cumulative error tolerances are under the control of the 004mm and0 08mm within, or it may cause large noise, affect the transmission performance.
（3）A planet wheel pin hole of nominal size in addition to the pin shaft sleeve outer diameter and two times the eccentricity should also increase the appropriate amount of compensation, is introduced to remedy the pin shaft, pin, sets of processing and assembly error, is too small to improve related parts processing precision, otherwise difficult assembly, operation of case; too large may lead to pin loads are easily made into shaft break, or sets of crack.
（4） The eccentricity tolerance of the main drive shaft is limited by tolerance and compensation size of pin hole. considering this ,we could take 0.025mm into consideration .we should take it in mind that the selection of machining accuracy, the use conditions of equipment and the possibility of production have a close relationship. Under the premise of meeting the use requirements, to reduce the processing precision appropriately is wise. In this area, it has lots of practical use, we should make decisions according to the actual situation.