QJR-D起重机减速器设计

QJ起重机减速机一、概述QJ系列减速机适用于起重机各种运行机构，也广泛用于运输、冶金、矿山、化工、轻工等各种机械设备的传动机构中。1.特点1)减速比范围宽，公称速比10200；2)机械传动效率高，二级达96，三级达94；3)运转平稳，噪音低；4)由于采用了42CrMo、35CrMo经锻造调制处理，分别制作齿轮轴和齿轮，所以使用寿命长，承载能力高。5)易于拆检，易于安装。2.使用条件1)齿轮圆周速度不大于16m/s；2)高速轴转速不大于1000r/min；3)工作环境温度为4045；4)可正反两方向运转3.型号及速比型号速比QJR/QJR-D1012.516202531.5QJS/QJRSQJS-D/QJRS-D405063801001251602004.标记标记示例：起重机减速机三级传动，名义中心距a1=560mm，公称传动比50，装配型式第III种，输出轴端为齿轮轴端，卧式安装则标记为：减速机QJS560-50IIICW标记示例：起重机带底座的二级减速机，名义中心距a1=560mm，公称传动比i20，装配型式第IV种，轴端型式为P型，则标记为：减速机QJR-D560-20-IVP二、装配型式及安装型式QJR、QJS、QJRS型安装型式：卧式W或立式L(V)在偏转角范围内为卧式安装，L范围内为立式安装。注：角的度数与传动比有关，当减速机倾斜角时，应保证使中间级大齿轮沾油12个齿高深度。QJR、QJS、QJRS型为三支点支承型式。综上，本设计拟研究的减速器定为：QJR-D450-16-IP，即中心距为450mm，速比16，安装形式为第一种，轴端型式为P型。四、QJR-D(QJB-D)减速机外型及安装尺寸外型尺寸输入轴端地脚安装尺寸名义中心距a1a2a02LHB中心高hNd2l2SS1S2S3CP孔数(个)AB1nG1e1重量(kg)1401002404943052201401202250175380190221864301902517211511017011828857736525017013528602054602302518651321527197138170200140340664425270200180328023055027525186600250252221652302361704067964973302362103880280660330282367163003026519531028020048092558536028023548110310780390302368453403330323041533523657111006954303352555511037094045035276100640035362280840400280680138083051040028565140450110055040276119549050422325101445031576514629305904503108017049012401000600403381350550554813701360500355855162210306405003509017054013901120670453381510620605314152250560400960182211607105603851002106001550125075050398169069070596460332563045010802037130077063042511021065017501410850553981905770806665204370710500121022781460860710450120210740196015809506045821308688574458561408005601360253816409808004901302508302195177010606545823909801008246507840900630153028601840110090054015025095024802000120070528270011301109307401128010007101710320020401200100061017030010502750222013207552830201220135104081516380QJR-D450-16-IP的安装尺寸为按照上述尺寸，在solidworks中建立的QJR-D450-16-IP减速器的安装模型如下：外型尺寸输入轴端地脚安装尺寸名义中心距a1a2a02LHB中心高hNd2l2SS1S2S3CP孔数(个)AB1nG1e1重量(kg)45031576514629305904503108017049012401000600403381350550554813701360QJR-D减速器输出轴端型式及尺寸表P型C型H型名义中心距a1d0(r6)L0b0t0mxzDD1(F1)D2D3B1B2BEL1L2mxzh6daLad5Md6(k6)L6L753x154835256402312150170558216593x1857353065027121602006510518693x2269404086030162152368013022853x561749040135279.5253252545603x278445508703016245QJR-D450-16-IP减速器输出轴端的相关尺寸如下高速轴轴端采用圆柱轴伸，平键联接，如图所示。QJ型和QJ-D型减速器高速轴轴伸尺寸(mm)高速轴端RS或RS名义中心距a1NL2d2b2l2L2d2b2l21401205022624.5401851817013560288315022620.52809013025954x5623212040170302.5271352550755x189555608803516285335110165281164x5623212040170339.5308352550755x221156070101004020315400130(140)20032(36)137(148)6x56348170452604023704032761005x261357590101204520375450150200361586x56348170452604293974032761005x3015580100121405025400500170(180)24040(45)179(190)8x544482001052604824425032781005x3417590120121605525445560190(220)28045(50)200(231)10x485002001052805705056035781105x381951001401218055254806302202805023110x545602501403806205506540801208x26216110160121906025530710250(260)33056262(272)12x486002701504207006207545881308x302481251801622060326008002803806329212x546722901704807766967545951308x342801402001625060326509003203807033412x5872031018056085077085601051408x3831215522020280704070510003604508037512x64792380230620970895100801401808x44360175250203207540775P型名义中心距a1d0(r6)L0b0t045015020036158236210803210356028624.5280235110481451.590381035335255110551659110451041400285140651869110501451.5450310170802285110551453.55003501709023951406016595603852101002610614070186963042521011028116170802285710450210120321271709022908004902501303212721010025100900540260150361582101102511610006103001704017925013032137本设计所取数据为450310170802285QJR、QJS、QJRS与QJR-D、QJS-D、QJRS-D型K值对比表QJR、QJR-D减速机的承载能力表工作级别M5型号/K/中心距1401702002362803354004505005606307108009001000R、RS、S130140195225250280340365410445495565615670740R-D、RS-D、S-D130150175200220260310335370410450510570640700公称传动比1012.516202531.5输入轴速度r/min名义中心距a1mm输出扭矩N.m高速轴许用功率KW1408205.34.33.42.72.11.617013609.07.25.74.53.52.8200265015.512.49.77.86.24.9236450026.021.016.513.210.58.4600280750044.035.027.022.017.613.93351250073.059.046.037.029.023.040021200124.099.078.062.050.039.045030000176.0141.0110.088.070.056.050042500249.0199.0155.0124.0100.079.056060000351.0281.0220.0176.0141.0112.063085000497.0398.0311.0249.0199.0159.0710118000691.0552.0432.0345.0276.0219.0800170000995.0796.0622.0497.0398.0316.09002360001381.01105.0863.0691.0552.0438.010003350001961.01568.01225.0980.0784.0622.01408206.45.24.13.32.62.0170136010.78.87.05.74.53.4200265019.315.512.19.77.76.1236450033.020.021.016.413.110.4280750055.044.034.027.022.017.43351250091.073.057.046.036.029.040021200155.0124.097.077.062.049.045030000219.0175.0137.0109.088.069.050042500310.0248.0194.0155.0124.098.056060000437.0350.0274.0219.0175.0139.063085000620.0496.0387.0310.0248.0197.0710118000860.0688.0538.0430.0344.0273.08001700001239.0991.0775.0620.0496.0393.09002360001720.01376.01075.0860.0688.0546.071010003350002442.01954.01526.01221.0977.0775.01408207.96.55.24.23.32.6170136013.210.98.77.15.74.4200265026.021.016.212.910.38.2236450044.035.027.022.017.613.9950280750073.059.046.037.029.023.0连续工作型33512500122.098.076.061.049.039.040021200207.0165.0129.0103.083.066.045030000293.0234.0183.0146.0117.093.050042500415.0332.0259.0207.0166.0132.056060000585.0468.0366.0293.0234.0186.063085000829.0663.0518.0415.0332.0263.07101180001151.0921.0719.0576.0460.0365.08001700001658.01327.01036.0829.0663.0526.09002360002302.01842.01439.01151.0921.0731.010003350003268.02641.02012.21634.01307.01037.0公称传动比1012.516202531.5输入轴速度r/min名义中心距a1mm输出扭矩N.m高速轴许用功率KW1404102.72.21.71.41.10.81706804.53.62.92.31.81.420013257.86.24.93.93.12.5236225013.010.58.36.65.34.2280375022.017.513.511.08.87.0335625036.529.523.018.514.511.54001060062.049.539.031.025.019.54501500088.070.555.044.035.028.050021250124.599.577.562.050.039.556030000175.5140.5110.088.070.556.063042500248.5199.0155.5124.599.579.071059000345.5276.0216.0172.5138.5109.580085000497.5398.0311.0248.5199.0158.0900118000690.5552.5431.5345.5276.0219.06001000167500980.5784.0612.5490.0392.0311.01404103.22.62.11.71.31.01706805.44.43.52.92.31.720013259.77.86.14.93.93.1236225016.513.010.58.26.65.2280375027.522.017.013.511.08.7335625045.536.528.523.018.014.54001060077.562.048.538.531.024.545015000109.587.568.554.544.034.550021250155.0124.097.077.562.049.056030000218.5175.0136.5109.587.569.563042500310.0298.0198.5155.0124.098.071059000430.0344.0269.0215.0172.0136.580085000619.5495.5387.5310.0248.0196.5900118000860.0688.0537.0430.0344.0273.071010001675001221.0977.0763.0610.5488.5387.51404103.93.22.62.11.61.31706806.65.44.33.52.82.2200132513.010.58.16.45.14.1236225022.017.513.511.08.86.9280375036.529.523.018.514.511.5335625061.049.038.030.524.519.540010600103.582.564.551.541.511.545015000146.5117.091.573.058.546.550021250207.5166.0129.5103.583.066.056030000292.5234.0183.0146.0117.093.063042500414.5331.5259.0207.5166.0131.571059000575.5460.5359.5288.0230.0182.580085000829.0663.5518.0414.5331.5263.09001180001151.0921.0719.5575.5460.5365.595010001675001634.01307.01021.0817.0653.5518.5本设计的减速器的工作级别为M5，相关参数由表可知：公称传动比16输入轴速度r/min名义中心距a1mm输出扭矩N.m高速轴许用功率KW60045030000110.0QJR-D减速器的设计计算过程一、传动装置的总体设计4、传动比分配（1）、两级齿轮传动比公式22(.34).ii（2）、减速器传动比减速器的传动比16i取减速器的高速传动比为=1.3ii.164.5则低速轴的传动比为21.084.56i5、运动条件及运动参数分析计算1轴：减速器的高速轴，也是输入轴。功率，转速0pkw160/minnr则转矩为119.57.8PTN2轴：减速器的中间轴功率1,20.6.pkwA转速2/6/45138/minnir则转矩为22907.PTNn3轴：减速器的低速轴功率2,316.9103.5pkwA转速32/1.58/307.51/minnir则转矩为33926PTNn查表可知，低速轴的许用输出转矩为，故符合条件。30运动和动力参数结果如下表功率PKW转矩TNm轴名输入输出输入输出转速r/min1轴110106.71750.87744.26002轴106.7103.57744.226351131.583轴103.5102.5263512716637.5（二）、高速轴齿轮的设计与校核1、选材根据文献【1】表12.7知选小齿轮：40Cr，调质处理2601=HB选大齿轮：45钢，调质处理42、初步计算（1）、转矩为119.570.8PTNmn（2）、尺宽系数.4d（3）、接触疲劳极限由文献【1】图12.17cMPaHlin580712=MPaH52809.06342lim211=由表可知，高速级的中心距1m1()2dia代入数据计算可得13.m由文献【1】由表12.16，取90=dA1331221750.8461905.drbTuAm所以符合条件3、确定大小齿轮齿数214.56Zi取，则13021304.561.8Zi取，则27Z17.i0%.i合适（1）、核算21351.7.6admZ1.73.0tmz由文献【1】表12.3取；nm3arcos1458.ntm之间，合适介于58120;40coscosnnzzdd取13bmb932=4、接触强度校核（1）、圆周速度V1062.84/601dnvms（2）、精度等级由表12.6知：选8级精度（3）、使用系数由表12.9知：AK35.1=AK（4）、动载系数由图12.9知：=1.12vv（5）、齿间载荷分配系数由表12.10知，先求：HK12750.849tTFNdmNbFKtA/10/7.693405.1）（，故，取，因、由式Z（11）、螺旋角系数9354cos（12）、接触最小安全系数minHS0.12minHS，取、由表（13）、总工作时间hth908360（14）、应力循环次数LN9291103.,10.295841602(601=iNtrNlLhnL）、式（15）、接触寿命系数由文献【1】图12、18NZ5.;.21NZ（16）、许用接触应力及验算H542375.493108.265.0428.190.56391.7222111minlilHaiEHaNHMpbdKYZMpS=+=计算结果表明，接触疲劳强度足够5、弯曲疲劳强度验算123333017;45coscosVVZZ（1）、齿数系数FaY8.25.11=AAFFY；知：、】图由文献【（2）、应力修正系数S70.1cos)4531(2.8.cos)(2.38.2.6.212=+=+VvZaa；，、由图（3）、重合度系数Y69.0.52.=+v（4）、螺旋角系数minmin897.01241201(5.5.YY=计算）时，按当（5）齿间载荷分配系数FK78.124.378.124.368.07.193=9.0coss124tanr703.265.1;0.tsi.1cos)93(.cos)(2.8.412=+=tnbtrdHzmbZ（6）、齿向载荷分布系数由文献【1】表12、11HK51.37106.16.071)(.22=+=bCdbBAH(7)、载荷系数K14.35.135.=HVAK（8）、弹性系数由文献【1】表12、12EZMPaZE8.19（9）、节点区域系数由文献【1】图12、16H462=H（10）、重合度系数76.03.11342=+=）（，故，取，因、由式Z（11）、螺旋角系数98.0cos（12）、接触最小安全系数minHS0.412minHS，取、由表（13）、总工作时间hth365（14）、应力循环次数LN9291107.,103.2913602(601=iNtrNlLhnL）、式（15）、接触寿命系数由文献【1】图12、18NZ5.;.21NZ（16）、许用接触应力及验算H573241.317804.3276.0428.1920.56391.7222111minlilHaiEHaNHMpbdKYZMpS=+=计算结果表明，接触疲劳强度足够5、弯曲疲劳强度验算104cos97;32cos0332311=ZZVV（1）、齿数系数FaY8.5.21AAFFY；知：、】图由文献【（2）、应力修正系数SaY69.1cos)97301(2.8.1cos)1(2.38.2.22=+=+VvZaa；，、由图（3）、重合度系数Y694.0.1752.05=+v（4）、螺旋角系数75.09.1201(5.minmin=YY计算）时，按当（5）齿间载荷分配系数FK4.113.413.694.073.13=+=+=（六）、中间轴的设计与强度校核1、选材MP360650;2517HB40SB，由手册：钢，调质CrC=1122、初估直径圆整d=50mnPd.49138.31=3、结构设计由文献【1】得初估轴得尺寸如下：.49,1,0,47,5,27506650543216=llllmlldd4、强度校核（1）、确定力点与支反力与求轴上作用力（图示附后）（2）、齿轮上作用力mNnpT802713.05.9105.96262=NFNdtt4097382=NFFntrtrtaa1542cos31095n,6=（3）、水平支反力从上到下第二幅图NFFFMRttR6842;8920132;012=+=（4）、垂直面内的支反力从上到下第四幅图NFRrRrara379251435975980210)(4.212=+=+（5）、绘水平弯矩图第三幅图；（如下所示）（6）、求垂直弯矩并绘垂直弯矩图第五幅图（如下所示）（7）、合成弯矩图第六幅图（如下所示）（8）、绘扭矩图第七幅图（如下所示）mNT8027=（9）、求当量弯矩BAM、mNmNMPBA62941,1096745.503.,)(22=+得由表（10）、确定危险截面校核轴径尺寸，危险截面A，危险截面B符合要求符合要求601.4760.291.05.8.33331mMdbBBbAA=合强度要求弯矩法校核说得结果符由此得出结论，用当量（七）、中间轴轴承校核1、选轴承根据文献【1】表18.1可得轴承的型号为：6310。D110mmB27mm；Cr61.8KN；Cor38KN所以轴承符合强度要求比较危险轴承则得冲击载荷系数】表则由文献【取；则得】表由文献【轴轴轴hPCnLIRNYFXffeReCNFRIharddaoraaR29034)96810.(3601)(1.)(0.18.0,14.96372036.8174F7.8;691860221221=+=+（十）、键联接的选择与计算1、电动机小带轮端的键电动机DE=42110mm,E=110mm,由文献【2】表2.4-30得键为128GB1096-90即圆头普通平键（A型），键的参数为：b=12mm;h=8mm;l=100mm(1)、键校核键的接触长度；则键联接所能传递的转矩mbl8120=为：由文献【1】表7.1得mNdhlTp871204814=120MP；强度符合要求pNT3.02、高速轴大带轮端的键高速轴带轮端尺寸：30101；由文献【2】表2.4-30得键为108GB1096-90即圆头普通平键（A型），键的参数为：b=10mm;h=8mm;l=80mm(1)、键校核键的接触长度；则键联接所能传递的扭矩为：mbl7018=由文献【1】表7.1得NdhlTp6320714=120MP；强度符合要求pT35.93、中间轴的键轴的尺寸为：6593；由文献【2】表2.4-30得键为：1811GB1096-90即圆头普通平键（A型），键的参数为：b=18mm;h=11mm;l=70mm(1)、键校核键的接触长度；则键联接所能传递的扭矩为：mbl521870=由文献【1】表7.1得NdhlTp.26514=120MP；强度符合要求pT.802小齿轮处轴的尺寸为：65147；由文献【2】表2.4-30得键为：2012GB1096-90即圆头普通平键（A型），键的参数为:b=20mm;h=12mm;l=125mm(2)、键校核键的接触长度；则键联接所能传递的扭矩为：mbl1052=由文献【1】表7.1得NdhlTp471056241=120MP；强度符合要求pT7.84、低速轴键大齿轮处轴的尺寸为：95135；由文献【2】表2.4-30得键为：2816GB1096-90即圆头普通平键（A型），键的参数为：b=28mm;h=16mml=125mm(1)、键的校核键的接触长度为：；则键联接所能传递的扭mbl972815=矩为：由文献【1】表NdhlTp.430971641=7.1得120MP；强度符合要求pT3.253联轴器处的轴的尺寸为：75140；由文献【2】表2.4-30得键为：2012GB1096-90单圆头普通平键（C型），键的参数为：b=20mm;h=12mmL=125mm(2)、键的校核键的接触长度为：;则键联接所能传递的扭mbl1052=矩为：由文献【1】表7.1得NdhlTp837501241=120MP；强度符合要求pmNT63.2501=（十一）、对中间轴进行安全系数法校核安全系数法校核轴强度符号单位截面A截面B1、扭矩2、合成弯矩3、轴径4、抗弯截面模量5、抗扭截面模量6、弯曲应力副7、扭转应力副8、弯曲平均应力9、扭转平均应力TNmm802770802770MNmm989204565633dmm6565W231333m2313350080T35008042.762/N24.4516.032/m16.030m2/N08.0152/m8.01510、强度极限bMPB650=11、弯曲疲劳极限1012、扭转疲劳极限0MP312950=13、等效系数25.018=符号截面A截面B14、弯曲有效应力集中系数K1.681.6815、扭转有效应力集中系数1.241.2416、表面状态系数0.920.9217、尺寸系数0.880.880.810.8118、弯曲综合影响系数K2.082.0819、扭转综合影响系数1.661.6620、弯曲配合影响系数DK)(2.643.5121、扭转配合影响系数1.982.5122、弯曲配合影响系数D)(2.643.5123、扭转配合影响系数K2.192.5124、寿命系数N1125、弯曲安全系数S3.225.6226、扭转安全系数6.816.8127、许用安全系数1.51.5由安全系数法可以得到安全系数如下：（A）截面5.1928.62.32=+=SA（B截面）5.1348.62.522=+=SB完全符合强度要求综合当量弯矩法和安全系数法得出：该轴体的尺寸完全符合强度要求，符合生产所需的强度，所以无需将原尺寸修改。（十二）、润滑密封设计对于二级圆柱齿轮减速器，因为传动装置属于轻型的，且传速较低，所以其速度远远小于，所以采用脂润滑，箱体内选用5(1.