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小功率机械摩擦式无级变速器结构设计【8张CAD图纸+毕业论文】【答辩优秀】

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小功率机械摩擦式无级变速器结构设计

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关键词：: 功率机械摩擦磨擦无级变速器结构设计全套 cad 图纸毕业论文答辩优秀优良

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摘要2

Abstract:3

第一章绪论4

§1.2 机械无级变速器的特征和应用5

§1.3机械无级变速器的选用和润滑密封7

§1.4 本文的主要内容及要求9

第二章摩擦无级变速器的机械特性加压装置和调速机构10

§2.1 机械特性10

§2.2 调速操纵机构11

§2.3 加压装置12

第三章摩擦式无级变速器设计说明和计算过程13

§3.1 摩擦机械无级变速器的工作原理13

§3.2 摩擦无级变速器的特点14

§3.3 锥轮的设计与计算14

§3.4 钢环的设计与计算18

1、钢环尺寸和参数的确定18

2、强度验算21

§3.5 轴系的设计21

§3.6 轴的结构设计22

第四章主要零件的校核24

§4.1 ．输出，输入轴的校核24

§4.2 . 轴承的校核25

总结26

致谢27

参考文献资料28

附录：文献翻译………………………………………………………29

摩擦式机械无级变速器结构设计

摘要

在某种控制的作用下，使机器的输出轴转速可在两个极值范围内连续变化的无级变速器传动随着机械、材质及加工工艺的高速发展和其需求量日益增多而得到广泛应用和发展。无级变速器的主动和从动两根轴通过传递转矩的中间介质（机械构件、流体、电磁流等）把两根轴直接或间接地联系起来并传递动力。当对主、从动轴的联系关系进行控制时，则两轴间的传动比发生变化（在两极值范围内连续而任意地变化）。用机械构件作为中间介质的为机械无级变速器，其包括摩擦式和脉动式。无级变速器与定传动比传动及有级变速传动（它只有有限的几种传动比）相比，其优点是能够根据工作需要在一定范围内连续变换速度，以适应输出转速和外界负载变化的要求，摩擦式机械无级变速器依靠传动元件之间的摩擦进行传动，钢材材质、加工工艺水平和润滑油料品质等因素是摩擦式机械式无级变速器不断发展的重要保证。本文通过查阅相关的诸多文献和书籍手册等进行钢环式无级变速器原理及其结构、变速原理的传动结构的实现的研究，并对摩擦式机械无级变速器进行结构设计，可直接作为设计文件或指导文件进行生产加工。

关键词：无级变速器；摩擦式；传动；润滑；

The structure design of CVT machine of friction type

Abstract:

Under the action of some kind of control which can make the output of the machine spindle speed in two extreme CVT within the framework of the continuous variation of the transmission with the high-speed development of machinery, materials and processing technology and its demand is growing and is widely used and CVT transmission of the driving and driven by passing two shaft torque in the middle of the medium (mechanical components, fluid, electromagnetic flow, etc.), the two shaft linked directly or indirectly, and transfer power.When were related to the Lord, driven shaft to control, is the ratio between the two axis change (within the scope of the two extreme consecutive and arbitrarily change).With mechanical components as a medium for mechanical CVT, among which include friction and pulsation.CVT and constant transmission ratio transmission and continuously variable transmission (it's only a limited number of transmission ratio), compared to its advantage is the ability to work according to the need to continuous transformation rate within a certain scope, to adapt the demand of output speed and external load, the friction type CVT depend on mechanical transmission device for transmission, the friction between the steel material, processing technology level and the quality of lubricating oil is factors such as friction type mechanical stepless transmission the important guarantee of continuous development.This article through the consult literature and books, manuals, etc for the steel ring type stepless transmission principle and structure, the realization of the principle of variable speed drive structure research, and the friction type mechanical CVT structure design, can be directly as a guide for design documents or files for production and processing.

Keyword:CVT;Friction type;Transmission;Lubrication;

第一章绪论

§1.1机械无级变速器的发展背景及现状

无级变速器在输入转速不变的情况下，能实现输出轴的转速在一定范围内连续变化，以满足机器或生产系统在运转过程中各种不同工况的要求；其结构特征主要是由变速传动机构、调速机构以及加压装置或输出机构三部分组成，无级变速器分为机械无级变速器，液压传动无级变速器，电力传动无级变速器三种。本设计任务要求把无级变速器安装在自行车上，采用机械无级变速器，本文主要介绍机械无级变速器的发展概况。

机械无级变速器最早是出现在十九世纪九十年代，到二十世纪三十年代逐渐开始发展起来，由于材质与工艺等方面的技术发展缓慢导致了无级变速也发展迟缓，随着现代科学技术的高速发展，尤其是七十年代以后，随着先进的冶炼和热处理技术，精密加工和数控机床技术以及牵引传动理论与高品质油的出现和发展，解决了许多研制和生产无级变速器的限制因素，同时，生产工艺流程实现机械化、自动化以及机械工作性能的改进，都促进了无级变速器的快速发展，在不同的领域，大量机器设备需要采用无级变速，尤其在汽车行业需求更为突出，因此，机械无级变速器得到广泛迅速的发展。国内无级变速器大约在二十世纪六十年代前后起步，当时主要是作为专业机械配套零部件，用于专业机械厂进行仿制和生产，如用于纺织机械的齿链式，化工机械的多盘式以及切削机床的Kopp型无级变速器等，但品种规格不多，产量不大，年产量仅数千台。直至八十年代中期以后，随着国外先进设备的大量引进，工业生产现代化及自动流水线的迅速发展，对各种类型机械无级变速器的需求大幅度增加，专业厂才开始建立并进行规模化生产，一些高等院校也开展了该领域的研究工作，又经过二三十年的发展，由于真空冶炼技术的应用、超精密工艺的日臻完善以及润滑油料摩擦特性方面的改进，使得机械无级变速器已经系列化生产，并以通过部件的形式供应于市场，近十年来，由于能源危机的出现，人们对机械无级变速器在交通运输工具上应用又进行了大量的研究，并取得了一定的成效。

摩擦式无级变速器是机械无级传动系统中的常用部件之一，它依靠摩擦力传递转矩和运动，所以它基本上由传递运动和动力的摩擦变速传动机构、保证产生摩擦力所需的加压装置和实现变速的调速机构三部分组成。近年来摩擦式无级变速器在国外获得了较快的发展，其传动功率从几十到几千瓦，并可在接近于0~10000转/分的输出速度下工作，效率约为75%到95%，与传统的齿轮传动、链传动及皮带传动相比，不仅可实现无级变速而且传动零件的形状比较简单无需很高的精度因此加工费用较低，现已获得人们普遍地重视。目前国内使用的摩擦式无级变速装置大多属于直接传动式、中间元件式、行星传动式三种类型：主、从动摩擦元件直接接触传动的直接传动式，主、从动元件通过中间元件进行传动的中间元件式，以及中间元件作行星运动的行星传动式。调速结构则分为一元件相对于另一元件沿接触面移动和转动（或偏转）两种形式。因此，合理地设计传动机构的结构和形式是提高传动构件受力的均匀性和传动平稳性及效率的关键，其速比的变换则通过改变主动轮从动轮和中间构件三者的相对位置来获得，这些摩擦式无级变速器的缺点主要是传动效率低、运行中难以保持稳定的速比、变速操作困难在高速运行时变速易使传动零件过早的磨损以及对于低速大扭矩传动传动装置的体积与重量较大。

目前对摩擦无级变速器的传动机理研究得并不充分，有待深入研究。选择和发展新的润滑剂，以进一步提高摩擦拖动率；研究具体结构设计的合理性及其优化问题，突破瓶颈，实现无级变速器新的突破，真正做到广泛应用和产业化。

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内容简介：: Vibration Control of RelativeTool-Spindle Displacement forComputer Numerically ControlledLathe With Pipe Frame StructureYoshitaka MorimotoMem. ASMEProfessorDirector of Advanced Materials ProcessingResearch Laboratory,Kanazawa Institute of Technology,3-1 Yatsukaho, Hakusan,Ishikawa 924-0838, Japan;e-mail: mosandb1neptune.kanazawa-it.ac.jpNaohiko SuzukiTakamatsu Machinery Co., Ltd.,3-1 Asahigaoka, Hakusan,Ishikawa 924-8558, Japane-mail: suzukitakamaz.co.jpYoshiyuki KanekoTakamatsu Machinery Co., Ltd.,3-1 Asahigaoka, Hakusan,Ishikawa 924-8558, Japane-mail: kanekotakamaz.co.jpMinoru IsobeTakamatsu Machinery Co., Ltd.,3-1 Asahigaoka, Hakusan,Ishikawa 924-8558, Japane-mail: kanekotakamaz.co.jpA new computer numerically controlled (CNC) lathe with a pipeframe bed has been developed. This structure is expected to haveenough space between the truss bars to solve the space problemand have enough rigidity for machine tools. Therefore, a CNClathe whose frame consists of pipes, joints, and diagonal braceshas been developed with enough rigidity and space utility for chipevacuation. From the viewpoint of machine tool usage, real-timevibration control theory is applied to control the relative displace-ment between the tool post and the spindle to suppress specificrelative vibration modes. DOI: 10.1115/1.4027594IntroductionConventional beds or frames for machine tools generally con-sist of cast iron or welded steel plates. These structures are suita-ble from the viewpoint of the machine tools dynamiccharacteristics. Although the demand for downsizing machinetools (such as in desktop machines) is increasing, there is a strictvolumetric limitation to obtain enough space for sufficient chipevacuation. In this case, there are problems of heat conductionand heat transfer. To solve these problems, we propose a tradi-tional but new frame structure for machine tools that consists ofpipes and connecting parts. We looked at the flexibility of theframe design using a pipe frame structure. The frame structurecan be arranged with standardized pipe (diameter and length) anda connecting block. In the case of a lathe, this structure allows fora change in size based on the spindle unit and X-axis table, whichare designed as standardized units.For developing a CNC lathe using this structure 1, the follow-ing problems are assumed:(1) structural vibration generated by the spindle motor unbal-ance and the cutting force disturbance,(2) thermal deformation due to the low heat capacity,(3) insufficient rigidity between the spindle and the X- and Zaxis tables.In this report, we focus on the vibration problem. There havebeen several prior studies 27 on the applications of vibrationcontrol for machine tools. In these research papers, the controlmethods have been applied to the tool post of the lathe machine.These results demonstrated the superiority of vibration control ofthe tool post displacement but do not consider the structural vibra-tion modes that appear in the low-frequency range compared withthe local vibration modes, such as the boring bar and tool post.Developed CNC LatheA unique CNC lathe has been developed based on the idea of apipe frame structure. The specifications are shown in Table 1, anda schematic view is shown in Fig. 1.A maximum spindle speed of 10,000 minC01can be obtained.The smallest resolution for the X and Z axes is set to 0.1lm. Thelathe weighs only 525 kg (including the covers) and fits within aspace of 440 WC21450 LC21050 H mm3, which is sufficientlycompact. The CNC controller (Mitsubishi Electric Co., Ltd.,M700V) is set beside the machine body.Vibration Control MethodThe most important vibratory motion for the CNC lathe is therelative displacement between the spindle and the tool post. Themachined workpiece is often influenced by the antiphase motionbetween the spindle and the tool; this motion is generated by theresonant frequency. In this case, the antiphase motion is the mostimportant behavior for the workpieces geometric error. Thismotion can be evaluated by measuring the relative vibrationbetween the spindle and the tool. Although this displacementshould be measured directly by a displacement sensor during cut-ting, it is very difficult to position the sensor because of the spaceconstraints, coolant, and chips. Figure 2 shows the typical compli-ance transfer function between the spindle head and the represen-tative frame-connected block. There are several peaks. When wetry to apply vibration control using this data, the control point ishardly determined. Then, two small acceleration sensors are usedto detect the relative vibration mode. One is set on the spindle unitcase and is measured as the signal xs; the other is set on the toolpost of the X-axis table and is measured as the signal xt.The relative vibration x is expressed as follows:x xsC0 xt(1)Then, the difference between the two acceleration sensor meas-urements in Eq. (1) is calculated and used to extract the antiphasemotion between them. The result of the calculated transfer func-tion is shown in Fig. 3. A frequency peak at 45 Hz can beobserved, and it can be considered a simple one-degree-of-free-dom system. We can use this differential signal as the output ofthe vibration response.Then, modal analysis can be used to obtain the vibration modes,to decide the target vibration mode, and to determine where to setthe actuator for the vibration control. The synthesized mode shapevector at 45 Hz is shown in Fig. 4. The antiphase mode betweenthe spindle and the tool post is actually seen from the vectorContributed by the Manufacturing Engineering Division of ASME for publicationin the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript receivedFebruary 20, 2013; final manuscript received April 11, 2014; published online May21, 2014. Assoc. Editor: Tony Schmitz.Journal of Manufacturing Science and Engineering AUGUST 2014, Vol. 136 / 044502-1CopyrightVC2014 by ASMEDownloaded From: / on 05/26/2014 Terms of Use: /termsntsfigure. The mode vectors at the head stock for the spindle ( andfi) are so small that the ends of the two actuators can be set atthese points. Based on this result, the other ends of the actuatorsare set on connecting blocks below the X-axis table to control theantiphase vibration mode, as shown in Fig. 1. These two actuatorsgenerate the control forces to suppress the vibratory motion by theactive vibration control method.The relative displacement, velocity, and acceleration aredefined as x, _x, and x, respectively. Assuming that xdand _xddenote the desired relative displacement and the relative velocity,the relative displacement and the relative velocity are defined asxdC0x;_xdC0 _xThe controlled force can be expressed as follows:Kv_xdC0 _xKdxdC0x (2)where the weight coefficients Kdand Kvare used. The equation ofmotion is described as follows when a harmonic force faejxtactson this system:mxc_xkx faejxtKv_xdC0 _xKdxdC0x (3)Because the desired relative displacement xdand relativevelocity _xdare to be zero, Eq. (3) is described as follows:mx cKv_x k Kdx faejxt(4)In Eq. (2), substituting f faejxt, the following equation can bederived:x_xC26C27C0c=m C0k=m10C20C21_xxC26C271=m0C20C21f (5)This equation of motion is rewritten as the following stateequation:_X AXBF (6)In the case of applying a control force that is proportional to thestate vector X, the control force is described as F C0KX.Then,substituting this into Eq. (6), the following state equation is obtained:_X AC0BKX (7)Once this equation can be obtained, the only thing to dois calculate the feedback gain K using MATLAB (MathWorksMATLAB and Simulink). To calculate this coefficient K, the modalparameters m, c, and k must first be determined. We calculatedthese values using the simple “mass response method” becausethe vibratory motion can be assumed to be one-degree-of-freedomfrom the result in Fig. 3. Once the known mass is set on the toolFig. 1 Schematic view of developed CNC latheFig. 2 Typical measurement result of compliance transferfunction by conventional impulse excitation method on a repre-sentative pointFig. 3 Transfer function between input force and relative dis-placement (tool post and spindle)Fig. 4 Mode shape vector (top view)Table 2 Identified modal parameterItems Value UnitMass, m 214 kgDamping factor, c 8.01 N/(m/s)Spring constant, k 1.62C21007N/mKv3.66C21003N/m/sKd5.73C21002N/(m/s)Table 1 Specifications of CNC latheItems SpecificationsHead stock Chuck Collet chuckMaximum speed 10000 minC01Tool post type Horizontal linearMinimum resolution 0.0001 mmSize 440 WC21450 LC21050 H mmMachine weight 525 kgCNC controller Mitsubishi Electric Co., Ltd. M700V044502-2 / Vol. 136, AUGUST 2014 Transactions of the ASMEDownloaded From: / on 05/26/2014 Terms of Use: /termsntspost, the change in the resonant frequency is measured, and themodal parameters are obtained, as shown in Table 2. These aresubstituted into Eq. (7), and the feedback gain K is calculatedaccording to linear-quadratic (LQ) control theory.Vibration Control SystemLead zirconate titanate (PZT) devices are used in the vibrationcontrol system as the actuator source. Structural vibration controland motion control for machine tools use this device because ofits large generated force and high-frequency response 811.We developed an actuator that consists of a PZT, a fluid cham-ber with two different cross-sectional areas, and connecting rods,as shown in Fig. 5. The fluid chamber is used to transform thegenerated force from the PZT. Although the longitudinal displace-ment of the PZT is short enough, the displacement is reduced bythe chamber area. This effect makes the generated displacementless than a submicron order. Two actuators are set between theconnecting blocks as brace bars. The dynamic characteristics areevaluated using the impulse response method, and the result isshown in Fig. 6. This actuator can be used below 200 Hz. Theeffects of the vibration control are evaluated in Effects of ActiveVibration Control section. Although the thermal elongation of thebrace bars has to be considered when the long run operation, wedo not consider the thermal deformation of the frame because ofthe short-time machining.Effects of Active Vibration ControlThe relative vibration between the spindle and the tool post iscontrolled by two actuators. In this case, according to LQ controltheory, we have developed the control system to realize thecontrol method represented by the block diagram in Fig. 7 and inTable 3. This system runs with a sampling speed of 3000 Hz. Therelative vibration is generated by the unbalance of the spindleunit. Since the maximum displacement is observed at around2725 minC01(45.4 Hz), the target frequency is set to 45 Hz.The experimental procedure has been executed during air cut-ting and during cutting. From the experimental result and fre-quency response of the actuator, the target-controlled frequencyrange is set from 10 to 100 Hz. A band-pass real-time filter isadapted to obtain the vibration signal and to suppress the disturb-ance noise and high-frequency signals.To evaluate the effect of the active vibration control, two accel-eration sensors due to the limitation of the installation space areused for the control. The relative vibration is numerically inte-grated to obtain the relative velocity and the relative displace-ment. The relative displacement itself during motion is measuredby a laser displacement sensor that is set on the tool post anddetects the relative displacement of the spindle unit.The control result during finish cutting is shown in Fig. 8. Thecontrol parameters have been determined previously during aircutting. This condition is not always applicable to the conditionduring cutting because the workpiece and the tool contact eachother, and the cutting force acts on the contact point. Although themodal parameters are not always constant, our control system isapplied using the same conditions as air cutting, and the effect ofthe vibration control is evaluated during cutting.When the control is started, the relative displacement decreasesits amplitude. FFT analysis is used to determine the difference inthe frequency element between with control and without control,as shown in Fig. 9. The solid line shows the result with control,and the dotted line shows the result without control. Almost 50%of the vibration amplitude around the target frequency of 45 Hz issuppressed by our developed system. The effect of an increase inrigidity by the actuator installed as a brace can be seen in thelower frequency range. On the other hand, the effect above100 Hz cannot be seen because of the filter effect of the controlFig. 5 Schematic diagram of PZTactuator for vibration controlFig. 6 Transfer function between input voltage of actuator andtable displacement by impulse responseFig. 7 Block diagram for vibration controlTable 3 Experimental setup for vibration controlItems Value UnitSpindle speed 2700 minC01Target frequency 45 HzSampling frequency 3000 HzDepth of cut 0.1 MmFeed 0.02 mm/revWorkpiece material C3604BDFig. 8 Comparison of relative motion during cuttingJournal of Manufacturing Science and Engineering AUGUST 2014, Vol. 136 / 044502-3Downloaded From: / on 05/26/2014 Terms of Use: /termsntssystem. These results demonstrate that this vibration control sys-tem used during finish cutting is suitable for our pipe frame CNClathe. To improve the effect of the vibration control, the layout(including the direction of the actuator) should be considered, andfurther improvement of this actuator system is needed to suppressthe vibration amplitude more efficiently.Evaluation of Workpiece by Vibration ControlSince it has been confirmed that the vibration control is effec-tive even during cutting, we evaluated the accuracy of themachined workpiece. Because the target control frequency wasset to 45 Hz, the effect of the control result appears as surfacewaviness. Then, the surface profile was measured by the surfaceroughness tester without a high-pass filter. Figure 10 shows themeasured results. The upper figure shows the profile withoutvibration control, and the lower figure shows the result with vibra-tion control. The surface waviness is remarkably improved. Theimprovement of the waviness at this frequency range is related tothe relative vibration mode that appears in this frequency range.Figure 11 shows the harmonic analysis of the measured round-ness result. Since the target frequency is set to the spindle rota-tional frequency, the effect of the vibration control generallyappears on the roundness with two undulations per round. Themeasured result shows this tendency well. The amplitude of theundulations per round decreased by 50% from the amplitude with-out control.These results show the effectiveness of our control system atsuppressing the relative vibration mode between the spindle andthe tool post and the improvement in the accuracy of the machinedworkpiece.ConclusionsIn this paper, the effectiveness of the real-time vibration controlfor the developed CNC lathe by a single degrees of freedommodel has been evaluated using the differential signal between thespindle and the tool post. The main results obtained as follows:(1) Almost 50% of the vibration amplitude around the targetfrequency of 45 Hz is suppressed by our developed system.(2) The roundness amplitude of the undulations per rounddecreased by 50% from the amplitude without control.(3) Results obtained show the effectiveness of the applied con-trol system at suppressing the relative vibration modebetween the spindle and the tool post.Further investigations are required to improve the vibrationcontrol system, including the layout (the direction of the actuator)and actuator performance to suppress the vibration amplitudemore efficiently.AcknowledgmentThe authors express their gratitude for the assistance of Kazu-hiro Shimizu, who has supported our experiments. This study waspartially supported by grant funding from the New Energy andIndustrial Technology Development Organization.References1 Suzuki, N., 2010, “Development of Ultra Small Size CNC Lathe by Pipe FrameStructure,” Proceedings of 4th CIRP International Conference on High Per-formance Cutting, Nagoya, Japan, Vol. 2, p. 183.2 Claesson, I., 1998, “Adaptive Active Control of Machine-Tool Vibration in aLathe,” Int. J. Acoust. Vib., 3(4), pp. 155162.3 Choudhury, S. K., 1997, “On-Line Control of Machine Tool Vibration in Turn-ing,” Int. J. M

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