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顺槽架空人车及其减速器的设计 摘要 进入21世纪，科学技术有着飞速的发展，伴随着科学技术的发展机械制造技术也有了较大的发展。面对我国经济近年来的快速发展，机械行业的壮大，在国民经济中占重要地位的制造业领域得以健康快速的发展。由于减速器应用广泛，为了提高质量，降低成本，便于专业化生产和用户选用，使得作为制造行业重要设备的各类机加工艺装备也有了许多新的变化。设计既是产品开发周期中的关键环节，有贯穿于产品开发过程的始终。设计决定了实现产品功能和目标的方案，结构和选材。制造手段以及产品运行，使用和维修方法。设计不合理会导致产品功能不完善，成本提高或可靠性，安全性不好。产品设计上的缺陷造成的先天不足，难以采取制造和使用措施加以弥补。少数情下，即有可能，损失也大。严重的设计不合理甚至会造成的产品不能用或产品制造不出来，导致产品开发失败。减速器的装配图是用来表达减速器的工作原理及各零件间装配关系的图样，也是制造、装配减速器和拆绘减速器零件图的依据，故附减速器装配图。关键词：机械制造技术；减速器；优化设计 Foreword Enter the twenty-first Century, science and technology have developed rapidly, with the development of science and technology of mechanicalmanufacturing technology has made great progress.With the rapid development of Chinas economy in recent years,machinery industry growth, occupy the important position in the nationaleconomy in the manufacturing industry can be healthy and rapid development. The speed reducer is widely used, in order to improve the quality, reduce the cost, convenient for the specialized production and the user selects, making all kinds of machining equipment as an important equipment manufacturing industry also has many new changes.Design is not only the key link in the cycle of product development, hasconsistently throughout the product development process. The designdetermines the realization of product function and objectives of thescheme, structure and material. Running manufacture method as well as the product, use and repair method. The design unreasonable can cause the product function is not perfect, cost and reliability, the security is not good. The product design defects caused by the hard to be congenitally deficient, take measures to make up for the manufacture and use of. In a few cases, where it is possible, the loss is great.Serious design unreasonable or even cause the product can not be used or product does not come out, cause product failure.The reduction gear assembly drawing is used to express assembly relation principle of gear reducer and parts manufacturing, assemblydrawings, but also speed reducer and the demolition of paintingreducer parts drawing basis, therefore attaches the reducer assembly drawings.Keywords: Machinery Manufacturing Technology Retarder OptimumDesign 参考文献【1】吴宗泽机械零件设计手册。机械工业出版社.2003.【2】陈立德机械设计基础课程设计高等教育出版社.2006【3】孙本绪.熊万武机械加工余量手册国防工业出版社.1999.【4】 曾志新.吕明机械制造技术基础.武汉理工大学出版社.2001.【5】 姚云英.公差配合与测量技术.机械工业出版社.2004.【6】 李海萍.机械设计基础北京工业出版社.1999.【7】 陈宏钧实用机械加工工艺手册（第2版）机械工业出版社.2004.【8】 李益明.工艺设计简明手册哈尔滨工业大学出版社.1993.【9】 安琦.顾大强机械设计北京科学技术出版社.2004.【10】王世刚.张秀亲机械设计实践（修订版）哈尔滨工业大学出版社.2003.【11】王文斌.机械设计手册机械工业出版社.2004.【12】陈心昭.机械加工工艺装备设计手册.机械工业出版社，1998.【13】杨叔子机械加工工艺师手册机械工业出版社.1997.【14】李洪.机械加工技术手册.北京出版社.1989.【15】邓文英.金属工艺学.高等教育出版社.1991.外文翻译 Hardened gear reducerHardened gear reducer include all kinds of expansion - gear reducer,the coaxial gear reducer, planetary gear reducer of various types of special gear and various groups of the derivative products, gearcarburizing, quenching, grinding technology, precision grade 47,widely used in metallurgy, mining, lifting, petrochemical, building,building materials, light industry and energy industry. Its main features are:1) the main specification parameters (center distance, transmission ratio) the number priority priority number system, and meet the relevant standards.2) the main structure size parameters, the optimization design of gear transmission. Standardization, high level of generalization, about 1500parts, a speed reducer 4500 different capacity, different transmission ratio, different assembly type.3) gear made of high strength alloy steel forging quality. Hardened gearreducer after carburizing, quenching, grinding, precision. Allowablebearing capacity of bearing capacity of old products for more than 3 times. Hardened gear with a special modulation processing, precisiongear hobbing. Design life of 10 years.4) the performance of reducer through bench test and practicalappraisal to achieve the advanced level of similar products in the world80 years. Can replace imported products, can be exported.5) product quality inspection and grading, loading test, reliability test,use and maintenance of related technique and technical specifications.But generally limited in:Gearbox high-speed shaft is not higher than 1500r/min;Slow speed gear circle is not higher than 20m/s;Deceleration working environment temperature is 40 45 degrees Celsius -, below 0 degrees Celsius, before the start of the lubricating oil should be preheated.If the utility conditions beyond a limit, and the design or manufacturingunits, a negotiated solution.Selection method:Bearing capacity standard reducer by the mechanical strength and heatbalance two allowable power limit. Therefore the reducer must beaccording to the two power meter and related coefficient to choose.Firstly, according to the mechanical reducer strength permissiblenominal power selection. If the input speed and carrying capacity inthree (15001000750) speed of relative error less than 4%, it should bethe nominal power according to the practical speed reducer selectionat. Then check reducer heat balance allowable power (the thermal power) if the shaft extension in addition to withstand the torque, but alsobear the axial, radial load, should check the shaft extension factor of safety and service life of bearing. Should also check the peak loadwhen necessary.Particular attention should be paid to the choice is, in addition to considering load coefficient, but also by the importance of equipmentand the accuracy of load actual size master selection of adequate safety factor.The hardened gear reducer price situation is analyzed briefly.1 gear reducer product prices are fluctuating between 2.56 million / ton, as the single weight, precision, material type, matching pieces ofdifferent level etc. In general, higher requirements of platform weightlight using imported parts or materials and precision, the price upper limit, lower limit of general price should be stated, because it is notserious domestic market order is not standard and individualproduction enterprises in the production process, the market is flooded with a certain proportion of not in strict accordance with the productionprocess in hard surface for the production of products, its prominent characteristic is the short life, because the tooth surface withoutgrinding, noise is large, the products to the market low price shocks,some users due to the production process of reducer products is not familiar with, or due to other reasons, it only takes the price as the mainpurchase basis, often leads to the regular manufacturers products to enter the procurement perspective, to the user also causedunnecessary losses, but also to the illegal manufacturers an opportunity,seriously affecting a mature reducer products market development and growth.The 2 planetary gear reducer and includes many kinds of products,such as low speed heavy planetary gear box, all kinds of special rotaryplanetary gear and planetary transmission device, the general external gear carburized gear grinding, gear quenched and tempered or nitrideon GM products, prices generally in the 36 million / ton, for rotary typeplanetary single table light weight reducer, the table of valuation, the price slightly higher than the former, in general, the planetary gear reducer, the manufacturing and assembly process are more complex,so the price is hardened cylinder gear reducer to be higher. Such asfittings imported bearings, and purchasing high-quality gear steel, the price will be higher.3 price analysis, according to the number of domestic productionenterprises of the reducer, and the level of the status quo, the industry price competition in a certain scope and time will still be very fierce.Especially with the impending entry into the WTO, foreign products willenter the domestic market, some foreign manufacturers have startedtheir localization strategy, resulting in product competition, pricecompetition will more hasten is intense.But it is unavoidable, because of limitation of the means of production,management level, enterprise scale and the ability of independent development, at present domestic enterprises price competition is also general level of the product, with the further enhancement of the quality of the user awareness. The rise of industrycompetition further differentiation and domestic well-known brand,market competition includes price competition will tend to be rationaland normative agriculture step. Development situation and contrastthroughout the industry, there are two points should be attracted industry attention, (1) large-scale production advantage should not be ignored,Only up to a certain size is likely to form the economies of scale, to reduce costs and enhance competitiveness, therefore, qualified enterprises can be through the expansion of scale, capital operation and other means to promote enterprise production scale, and enhancemarket competition ability. (2) to strengthen the ability of product development, with special attention to changes of the market, timely adjustment of product development strategy, to update the oldgeneration products, constantly with new products in large-scale production to replace old products, occupy the city often present the domestic gear reducer industry has not yet appeared to have adapted to the scale and level with foreign counterparts competition of enterprises with high technology content of products, in product development and upgrading also teeter, product specifications, typesand level compared with foreign counterparts have a certain gap, thissituation is not changed as soon as possible, will have a serious impact on after Chinas entry into the WTO transmission foundation industry the survival and development, so we should pay attention to, hope industry colleagues together, work together, to change the situation as soon as possible, so that the reducer industry of our country in a fair, orderlycompetition and healthy development.Reduction gear transmission device with a fixed gear ratio to realize deceleration. Often installed as an independent component in the box body. Reducer due to its compact structure, high efficiency, accurate and reliable transmission of motion, good lubrication, long service life,simple maintenance and can be mass production, it is widely used in modern machines.There are many kinds of reducer, according to the type of transmission,a gear reducer, the worm reducer, gear worm reducer, planetary gear reducer; according to the drive series, there are 1 stage reducer, 2 stage reducer, 3 stage reducer and multi-stage reducer; according to the shaft position, vertical type and the horizontal reducer; according to the power transmission line, a expansion, coaxial and split reducer.Reducer box should have sufficient rigidity, so as to avoid excessive deformation after loading affect the transmission quality, usually made of gray cast iron, a small amount of production is available whenwelding structure, mass production of small reducer can be used for sheet metal and. Lubricating gear speed reducer drive the oil bath lubrication, for heavy or high-speed transmission should adopt oillubrication; lubrication of bearings generally use the splash lubrication(circumferential speed in the 2 3 meters / seconds) or scraping lubrication (peripheral speed at 2 3 M / s below). In addition, similarwith the speed reducer, also use the accelerator in a few cases, it is closed with a gear fixed transmission ratio of the transmission device in the box body.Domestic reducer industry key enterprises product varieties,specifications and parameters coverage in recent years are in constantexpansion, product quality has reached the international advanced level of similar products in the industrial countries, can undertake to provideany heavy transmission device for supporting national economic industries, some products are also exported to Europe and Southeast asia.At present, the standard series of various types of domestic general reducer has reached hundreds of, can basically meet the industrydemand for general reducer. Based on the first generation of generalhardened gear reducer and circular cylindrical worm reducer series of products, a new generation of cylindrical and conical study by XianHeavy Machinery fell developed and completed standardized -cylindrical gear reducer and circular cylindrical worm reducer hasinvestment market. Prominent features of the new generation of the speed reducer is not only in product performance parameters on furtheroptimization, and fully comply with the modular design principle in theseries design, product appearance more beautiful, more suitable formass production, more adapt to the development of modern industryand higher on the basis of the product and matching requirements. In addition, the Nanjing high precision gear Limited by Share Ltd alsopromoted the PR Series modular gear reducer series product. But overall, the domestic development and update the reducer series products in the past few years, progress is slow, with foreign counterparts in this aspect have widened the gap between the trend.But with the market demand is also very does not adapt, Xian Heavy Machinery Research Institute and other units have embarked on the development level of standardization work this year.In general reducer manufacturing device, domestic manufacturersnumber, such as various types of cylindrical gear machine taper -cylindrical gear or gear - worm reducer series products, the major domestic manufacturers have Nanjing high precision gear Limited by Share Ltd, Ning Bodong force transmission equipment Co., Ltd.,Jiangyin gear box manufacturing Co., Ltd., Jiangsu Taixing reducerCompany Limited, Jiangsu Jinxiang reducer Co. Ltd., Shanxi Pingyao reducer factory. Object worm reducer, the current domestic production of arc cylindrical worm reducer, cone enveloping cylindrical worm reducer, two plane enveloping toroidal worm reducer and other types,the major manufacturers have Jiangsu Jinxiang reducer Co., ShougangMachinery manufacturing company, Hangzhou vacuum machine factory,Hangzhou Wanjie speed reducer Co. Ltd., Tianjin million speed reducer factory, Shanghai Pujiang reducer Co. Ltd., the universal planetary gear reducer NGW series planetary gear, including the standard speed reducer, including various kinds of rotary planetary reducer and closed planetary gear. The Jingzhou Jujing movingmachinery Co. Ltd., Luoyang heavy gear box Co. Ltd., Xian Heavy Machinery Research Institute, Shijiazhuang, a heavy industry limited company, Inner Mongolia Xinghua Machinery factory.In the development of machine manufacturing various types of specialtransmission device, the domestic in recent years made significant progress, such as MDH28 type mill edge Chongqing gearbox limited liability company production drive transmission, its maximum power isup to 7000KW, torque reaches 5000KN.m, weight 46 tons, maximum modulus of main drive gear box have 1700 Hot Strip mill yield is 30, the weight of 180 tons. Gear box gear box Co. Ltd. the production of type gwc70/76 and 12000 tons container ship by Hangzhou advance,transmission power has reached 6250KW. By the Nanjing high precision gear Limited by Share Ltd and Chongqing gear box company limited production of the grinding gear box maximum power has reached 3800KW, heavy-duty planet gear box series products fromXian Heavy Machinery Research Institute, Luoyang heavy gear box Co. Ltd., Jingzhou Jujing Transmission Machinery Co., Ltd., the development of manufacturing in the mine, metallurgy, building materials, coal and water and electricity industries have also beenwidely used, the input power development of Xian Heavy Machinery Research Institute of the cement industry roller suspension series planetary gear box has reached 1250KW, used for aluminum made millplanetary gear box with wind power gear box Company Ltd., Hangzhouimport and on the box, Xian Heavy Machinery Development Co. Ltd.the series of products are gradually replace imported products, widely used in the domestic wind power industry. In the manufacture of largegear ring, currently the largest diameter of 9.936 meters, gear ring netweighing 80 tons has been manufactured by CITIC Heavy machinerycomplete, and for the Wuhan Iron and Steel Group 5000000 tons annual production capacity of oxidized ball production line, thus for largedriving device of large sintering machine, ball mill, rotary kiln as well as for the converter and sintering equipment large flexible transmission device can trap domestic supply, without the need to re import.In the development of new products and other types of enterprises, the industry has also made a lot of achievements, the large ring gear box of large mine differential energy saving control device, Luoyang heavygear box Co. Ltd. as Xian Heavy Machinery Research Institutedeveloped engineering vehicle gear box and the fan and pump hoist of planetary gear box, mill Jiangsu Jinxiang the driving gear box reducer,Beijing tieforce drive Co. Ltd. and the transmission device, arewelcomed by the market and be widely applied.In the capacity expansion and technological transformation ofenterprises, in recent years, showing a rapid development, on the one hand, due to the recent years the strong market demand, on the other hand is driven by the subjective desire of enterprises to expand production scale, enhance the level of manufacturing, processing andenhance the competitiveness of enterprises, the key processingequipment at home the main products manufacturers in recent two years, purchased, such as large grinding machine, milling machine,technical center and heat treatment equipment, a total of more thanmore than 200 Taiwan (sets), industry production capacity is expectedto expand by more than one time, technical work for solid and objective effect of industry scale and concentration of production andcompetitiveness, but because still industry enterprise quantity is many,small size and level of such practical problems as uneven, with the decline in market demand and foreign manufacturers have entered the domestic market, competition will be further intensified, which will promote the integration of merger, enterprises and transformation.In product sales market competition, foreign manufacturers in recent years in China expansion momentum is increasingly strong, SEW company continues on the national deployment of the production and sales base, expand market share. FLEDER company, state flying company, Bray Vinnie and FORK, Sumitomo and other companieshave also increased to establish a production base and sales center in the pace of China, actively to the infiltration of various industries, foreign manufacturers of advanced management, business philosophy, rich market competition and development experience and unique series of products will highlight the challenges and the impact on the domesticmanufacturers, domestic production enterprises feel will be increasinglyfierce trade competition.In the expansion of domestic transmission products, at present still withsmall power, small size, products exported or with the host exports as the main form, on the one hand, the president share is still relatively small, and strive to improve product quality and scalability, and actively explore the international market, should be an important the way for domestic enterprises market development.Looking at the status quo and reducer industry, in order to maintain industry health sustainable development fully affirmed in industry development, progress at the same time, should also see the problems,and actively study countermeasures, measures, and strive to within a short time progress. At present, the deceleration problems device industry there is ability to develop new products, the whole industry is weak, technological innovation and the low level of management,enterprise management mode is more extensive, a considerable proportion of the products is still low, the lack of international influence of the brand, the industry as a whole,is still very seriousdisorder scattered. Based on this, promote the integration of merger and acquisition, enterprise inter industry, as soon as possible the formation of a certain brand in the market influence, larger scale and strength, has a strong product development and technical supportcapabilities of such a group enterprise, so put can maintain a certain advantage in competition with foreign count constantlydevelopment.中文译文硬齿面齿轮类减速器：硬齿面齿轮类减速器包括了各类展开式圆模齿轮减速器、同轴齿轮减速器、行星齿轮减速器各类专用齿轮装置以及各类组各派生产品，齿轮采用渗碳、淬火、磨齿工艺、精度47级，广泛应用于冶金、起重、矿山、石化、建筑、建材、轻工及能源等行业。其主要特点有：1）主要规格参数（中心距、传动比等）采用优先数系的优先数，并符合有关标准。2）齿轮传动参数、主要结构尺寸经优化设计。标准化、通用化程度高，约1500种零件，组成4500多台不同承载能力、不同传动比、不同装配型式的减速器。3）齿轮材料采用锻造优质高强度合金钢。硬齿面齿轮类减速器经渗碳、淬火、磨齿，精度高。许用承载能力为旧产品承载能力的3倍以上。中硬齿面齿轮经特殊调制处理、精滚齿。设计寿命10年。4）减速器的性能经台架试验与实用考核达到80年代世界同类产品的先进水平。可以替代进口产品，可以出口。5)产品质量的检验和分等、加载试验、可靠性考核、使用维护等均有相应的配套技术和技术规范。但一般限制在：减速器高速转轴不高于1500r/min；减速器齿轮圆周速度不高于20m/s；减速器的工作环境温度为4045摄氏度，低于0摄氏度时,启动前润滑油应预热。如果实用条件超越以上限制时，可与设计或制造单位联系，协商解决办法。选用方法：标准减速器的承载能力受机械强度和热平衡两许用功率限制。因此减速器必须按两个功率表及有关系数来选用。首先按减速器机械强度许用公称功率选择。如果实用输入转速与承载能力表中的三档（1500，1000，750）转速之一相对误差不超过4，则应按实用转速折算减速器的公称功率选取。然后校核减速器热平衡许用功率（简称热功率）如果轴伸除承受转矩外，还承受轴向、径向载荷，应校核轴伸安全系数与轴承寿命。必要时还应校核尖峰载荷。应该特别注意的是，选用时除考虑工况系数外，还要按设备的重要性和对负载实际大小掌握的准确程度选择足够的安全系数。现对硬齿面齿轮减速器的价格现状进行简要的分析。 1齿轮减速器产品的价格目前波动在2.56万/吨之间，视单机重量、精度高低、材质种类、配套件水平等而有所不同。一般平台重量轻者、要求采用进口配套件或材质及精度要求较高者，价格偏上限，通用产品价格偏下限应当说明的是，由于国内目前市场秩序的不规范和个别生产企业生产工艺的不严肃性，市场上充斥着一定比例的未严格按硬齿面生产工艺要求进行生产的产品，其突出特征是寿命短，由于齿面未进行磨削，噪声也较大，该类产品以低价格冲击市场，部分用户由于对减速器产品的生产工艺情况并不熟悉，或由于其它原因，采购中一味地只以价格作为主要采购依据，常导致正规厂家产品难以进入采购视野，给用户也造成了不应有的损失，也给不法生产厂家以可乘之机，严重影响了一个成熟的减速器产品市场的发展和成长。 2行星齿轮减速器又包括了许多产品种类，如一般低速重载行星齿轮箱，各类专用回转行星齿轮箱和行星传动装置等，一般外齿轮渗碳淬火磨齿，内齿轮调质或氮化，价格方面对通用产品一般在36万/吨左右，对于单台重量轻的回转类行星减速器，多以台计价，价格略高于前者，总体而言，对行星齿轮减速器，由于制造装配工艺均较为复杂，因此价格较硬齿面圆柱齿轮减速器要高些。如要求配套件为进口轴承，并采购优质齿轮钢，则价格会更高些。 3价格分析，根据国内生产减速器企业的数量，现状及水平，行业价格竞争在一定范围和时间内仍会十分激烈。特别是随着入世的迫近，国外产品也必将大举进入国内市场，有的国外厂商也已开始了他们的本土化战略，因而导致产品竞争，包括价格竞争也会更趋激烈。 然而不容回避的是，由于受生产手段、管理水平、企业规模及自主开发能力的制约，国内企业目前的价格竞争还多集中在一般层面的产品上，随着用户质量意识的进一步增强。行业竞争的进一步分化及国内知名品牌的崛起，市场竞争包括价格竞争将会农步趋于理性和规范。纵观该行业的发展现状及对比，有两点应引起国内业界的关注，（1）规模化生产优势应不容忽视，只有达到一定规模才有可能形成经济规模，才能降低成本和提升竞争力，因此有条件的企业可通过规模扩张，资本运作等手段尽快提升企业生产规模，进而增强市场竞争能力。（2）产品开发能力的加强，要特别注意研究市场的变化，及时调整产品的研发战略，及时更新老一代产品，不断地用适应于规模化生产的新产品取代老产品，用较高技术含量的产品占领市常目前国内齿轮减速器行业还没有出现能有适应规模及水平与国外同行竞争的企业，在产品开发及更新换代方面也步履蹒跚，产品规格、种类和总体水平较之国外同行们有一定差距，这一状况如不尽快改变，将对入世后我国传动基础件行业的生存发展产生严重影响，因此应予高度重视，希望行业同仁团结一致，共同努力，尽快改变上述状况，使我国的减速器行业在公平、有序的竞争中健康地向前发展。 减速器以固定的传动比实现减速的齿轮传动装置。常安装在箱体内成为独立部件。减速器由于结构紧凑、效率较高、传递运动准确可靠、润滑良好、使用寿命长、维护简单且可成批生产，所以在现代机器中广泛应用。 减速器种类很多，按传动类型分，有齿轮减速器、蜗杆减速器、齿轮蜗杆减速器、行星齿轮减速器等；按传动级数分，有1级减速器、2级减速器、3级减速器和多级减速器；按轴的位置分，有立式和卧式减速器；按功率传递路线分，有展开式、同轴式和分流式减速器。减速器的箱体应具有足够的刚度，以免受载后变形过大而影响传动质量，一般用灰铸铁铸成，少量生产时可用焊接结构，大量生产小型减速器可采用板材冲压而成。减速器中传动的润滑一般采用油池润滑，对于重载或高速传动宜采用喷油润滑；轴承的润滑一般采用飞溅润滑