带式输送机使用的V带传动或链传动及直齿圆柱齿轮.doc
带式输送机使用的V带传动或链传动及直齿圆柱齿轮减速器设计
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带式输送机使用的V带传动或链传动及直齿圆柱齿轮减速器设计,输送,使用,传动,链传动,圆柱齿轮,减速器,设计
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目录1. 题目12. 传动方案的分析23. 电动机选择，传动系统运动和动力参数计算24. 传动零件的设计计算55. 轴的设计计算166. 轴承的选择和校核267. 键联接的选择和校核278. 联轴器的选择289. 减速器的润滑、密封和润滑牌号的选择2810. 减速器箱体设计及附件的选择和说明2911. 设计总结3112. 参考文献31 广东技术师范学院机电系机械设计课程设计设 计 任 务 书题目：设计一带式输送机使用的V带传动或链传动及直齿圆柱齿轮减速器。设计参数如下表所示。1、基本数据数据编号QB-5运输带工作拉力F/N2000运输带工作速度v/(m/s)1.4卷筒直径D/mm340滚筒效率0.962.工作情况 两班制，连续单向运转，载荷平稳；3.工作环境 室内 ，灰尘较大 ，环境最高温度35度左右。4.工作寿命15年，每年300个工作日，每日工作16小时5.制作条件及生产批量: 一般机械厂制造，可加工78级齿轮；加工条件：小批量生产。生产30台6.部件：1.电动机，2.V带传动或链传动,3.减速器,4.联轴器,5.输送带6.输送带鼓轮7.工作条件：连续单向运转，工作时有轻微振动，室内工作； 运输带速度允许误差5%； 两班制工作，3年大修，使用期限15年。(卷筒支承及卷筒与运输带间的摩擦影响在运输带工作拉力F中已考虑。)8.设计工作量：1、减速器装配图1张(A0或sA1)； 2、零件图13张； 3、设计说明书一份。 2传动方案的分析 1电动机，2弹性联轴器，3两级圆柱齿轮减速器，4高速级齿轮，5低速级齿轮 6刚性联轴器 7卷筒方案分析:由计算(下页)可知电机的转速的范围为: 674.4103372.04r/min由经济上考虑可选择常用电机为1500r/min .功率为4kw.又可知总传动比为17.082.如果用带传动,刚减速器的传动比为510,用二级圆柱齿轮减速器则传动比太小,而用一级则有点过大,从而齿轮过大,箱体就随着大.因而不用带传动直接用联轴器,因有轻微振动,因而用弹性联轴器与电机相连.两级展开式圆柱齿轮减速器的特点及应用：结构简单，但齿轮相对于轴承的位置不对称，因此要求轴有较大的刚度。高速级齿轮布置在远离转矩输入端，这样，轴在转矩作用下产生的扭转变形和轴在弯矩作用下产生的弯曲变形可部分地互相抵消，以减缓沿齿宽载荷分布不均匀的现象。高速级一般做成斜齿，低速级可做成直齿。两级同轴式圆柱齿轮减速: 特点及应用：减速器横向尺寸较小，两对齿轮浸入油中深度大致相同。但轴向尺寸大和重量较大，且中间轴较长、刚度差，使载荷沿齿宽分布不均匀，高速级齿轮的承载能力难于充分利用。从性能和尺寸以及经济性上考虑选择两级展开式圆柱齿轮减速.卷筒同输出轴直接同联轴器相连就可以,因为这样可以减少能量的损耗.3电动机选择，传动系统运动和动力参数计算一、电动机的选择1.确定电动机类型 按工作要求和条件,选用y系列三相交流异步电动机。2.确定电动机的容量（1）工作机卷筒上所需功率PwPw = Fv/1000 =2000 X 1.4/1000 =2.8kw(2)电动机所需的输出功率为了计算电动机的所需的输出功率Pd，先要确定从电动机到工作机之间的总功率总。设1、2、3、4、分别为弹性联轴器、闭式齿轮传动（设齿轮精度为7级）、滚动轴承、弹性联轴器、工作机的效率，由2表2-2 P6查得1 = 0.99，2 = 0.98，3 = 0.99，4 = 0.99，5 = 0.96，则传动装置的总效率为总=1222334 = 0.992 x 0.982 x 0.993 x 0.96=0.877 2.8/0.877=3.193kw3.选择电动机转速由2表2-3推荐的传动副传动比合理范围 联轴器传动 i联=1 两级减速器传动 i减=840(i齿=36)则传动装置总传动比的合理范围为 i总= i联i齿1i齿2 i总=1（840）=（840）电动机转速的可选范围为nw=60x1000x1.4/3.14x34078.68r/minnd=i总nw=（840）nw=8nw40nw=629.343147.2r/min根据电动机所需功率和同步转速，查机械设计手册(软件版)R2.0-电器设备-常用电动机规格，符合这一范围的常用同步加速有3000、1500、1000。选用同步转速为1500r/min，输出轴直径为28j6mm选定电动机型号为Y112M-4。二、传动装置总传动比的确定及各级传动比的分配1.传动装置总传动比 i总= nm / nw=1440/78.6818.30式中nm-电动机满载转速，1440 r/min; nw-工作机的转速，78.68 r/min。2.分配传动装置各级传动比 i总=i联i齿1i齿2 分配原则：（1） i齿=36 i齿1=（1.31.4）i齿2 减速器的总传动比为 i = i总/ i联=18.30 双级圆柱齿轮减速器高速级的传动比为 i齿1 = = 4.877 低速级的传动比 i齿2 = i/i齿1 = 8.30/4.877 =3.752 三、运动参数和动力参数计算 1.各轴转速计算 n0= nm =1440 r/min n= nm / i联 =1440 r/min n= n / i齿1 = 1440/4.877=295.26 r/minn= n / i齿2 =295.26/3.752=78.69r/min2.各轴输入功率 P0= Pd=3.193kwP= Pd4 = 3.193x0.99=3.163kw P= P23 =3.163x0.98x0.99=3.067kwP= P23 =3.067x0.98x0.99=2.976kw3.各轴输入转矩T0 = 9550Pd/n0 =9550x3.193/1440=21.176T = 9550P/n=9550x3.161/1440=20.964T = 9550P/n = 9550x3.067/295.26=99.20T = 9550P/n = 9550x2.9767/78.69=361.174表1 传动装置各轴运动参数和动力参数表 项目轴号功率转速转矩传动比 0轴3.193144021.1761 轴3.161144020.9644.877 轴3.067295.2699.2003.752轴2.9767 78.69361.174 4传动零件的设计计算一、渐开线斜齿圆柱齿轮设计（一）高速级直齿圆柱齿轮设计计算表项目计算（或选择）依据计算过程单位计算（或确定）结果1选齿轮精度等级查1P208 表10-8传输机为一般工作机速度不高级72材料选择查1P180 表10-1小齿轮40Cr(调质)大齿轮45钢(调质)小齿轮280HBS,大齿轮240HBS3选择齿数ZZ1=24Z2=4.877x24=117.3U=117/24=4.875个24117U4.8755按齿面接触疲劳强度设计（1）试选Kt试选1.3Kt=1.3(2)计算小齿轮传递的转矩T1T=9550XP1/n1T=9550x3161/1440=2.0963X10NmmT1=2.096x 10(3)齿宽系数d由1P201表10-7d=0.71.15d=1(4)材料的弹性影响系数ZE由1 P198表10-6锻钢MP1/2ZE=189.8(5) 齿轮接触疲劳强度极限由1P207图 600550600550（6）应力循环次数N由1式N1=60n1jLh=60X1440X16X300X156.2208X109 =6.22X109/4.877=1.275X109N1=6.22X109N2=1.28X109（7）接触疲劳强度寿命系数KHN由1P203图10-19KHN1 = 0.90KHN2 = 0.95 KHN1 = 0.90KHN2 = 0.95（8）计算接触疲劳强度许用应力H取失效概率为，安全系数为S=1，由1式得H1= =0.90X600/1=540 H2= =0.95X550/1=522.5 H1= 540H2= 522.5（9）试算小齿轮分度圆直径按1式（1021）试算37.8225mm37.823（10）计算圆周速度vV=3.14X37.823X1440/60X1000=2.85034m/sV=2.85（11）计算齿宽Bb = dd1tB1=137.823mmB1=37.823（12）模数37.823/241.576h = 2.25mnt =3.546b/h =37.823/3.546=10.5769度=1.576h =3.546b/h= 10.577（13）计算载荷系数K由1表10-2查得使用系数根据v= 2.85级精度，由1P190图10-8查得动载荷系数1.10由1表P194查得KH=1.12+0.18(1+0.6d2) d2+0.2310-3b=1.12+0.18(1+0.6X)+0.23X10-3X37.823=1.417由1图P195查得KF=1.34假定，由1P193表10-3查得1.2故载荷系数K=KAKVKHKH=1X1.10X1.2X1.417=1.870K=1.870（14）按实际的载荷系数校正分度圆直径由1式10-10d1=d1t=42.696d1=42.70（15）计算模数42.70/24=1.779mmmn=1.786按齿根弯曲疲劳强度设计（1）计算载荷系数KK=KAKVKFKFK1x1.10x1.2X1.34=1.7688K1.769(2)齿形系数Fsa由1P197 表10-5Fsa1=2.65Fsa2=2.18+(2.14-2.18)(117-100)/(150-100)=2.1664Fsa1=2.65Fsa2=2.166（3）应力校正系数YSa由1 P197 表YSa1=1.58YSa2=1.79+(1.83-1.79)(117-100)/(150-100)=1.8036YSa1=1.58YSa2=1.804（4）齿轮的弯曲疲劳强度极限由1P204 图500380500380（5）弯曲疲劳强度寿命系数由1P202 图0.840.880.840.88（6）计算弯曲疲劳许用应力F取弯曲疲劳安全系数S1.35，由式10-12得F1= 0.85X500/1.35=314.8148F2= 0.88X380/1.35=247.7037F1=314.815F2=247.704（7）计算大小齿轮的并加以比较2.65x1.58/314.815=0.0132992.166x1.804/247.704=0.01577499结论：取0.015770.01330=0.01577大齿轮值大（8）齿根弯曲强度设计计算由1式5=1.10298mm1.103结论：对比计算结果，由齿面接触疲劳强度计算的法面模数大于由齿根弯曲疲劳强度计算的法面模数，取 2mm，已可满足弯曲强度。但为了同时满足接触疲劳强度，须按接触疲劳强度算得的分度圆直径d1= 42.70应有的齿数。于是由=42.70/2 =21.35，取Z1=21,Z2 = Z1i齿1 =21x4.877=102.417取Z2 =1023几何尺寸计算（1）计算中心距aA=(21+102)2/2=123mma=123（2）计算齿轮的分度圆直径dd=zmnd1=2x21=42d2=2x102=204mmd1=42d2=2043）计算齿轮的齿根圆直径df=42-5=37=204-5=199mmdf1=37df2=199（4）计算齿轮宽度Bb = dd1圆整后取：B1 = 50B2 = 45mm B1 = 50B2 = 45（5）验算=2x20960/42N =998.10N=1x998.10/45N/mm = 22.18N/mm100N/mm合适（二）低速级直齿圆柱齿轮设计计算表项目计算（或选择）依据计算过程单位计算（或确定）结果1选齿轮精度等级查1表10-8传输机为一般工作机速度不高级72材料选择小齿轮40Cr(调质)大齿轮45钢(调质)小齿轮280HBS,大齿轮240HBS）3选择齿数Z=23=3.752x23=86.3U=86/23=3.7391个=23=86U=3.7395按齿面接触强度设计（1）试选KtKt=1.3(2)计算小齿轮传递的转矩TT=9550P/nT=9550x3067/295.26=99200.2NmmT=99.20X103(3)齿宽系数d由1P203表10-7d=0.70.115d=1(4)材料的弹性影响系数ZE由1P198表10-6锻钢MPa1/2ZE=189.8(5) 齿轮接触疲劳强度极限由1P207图10-21600550600550（6）应力循环次数N由1式10-13 N3=60n3jLh=60x295.26x16x300x15=1.2755x109N4 = N3/ i齿2 =1.28x109/3.752=0.34x109N3=1.28X109N4=0.34x109（7）接触疲劳强度寿命系数KHN由1P203图10-19KHN3 = 0.90 KHN4 = 0.95KHN3 = 0.90 KHN4 = 0.95（8）计算接触疲劳强度许用应力H取失效概率为，安全系数为S=1，由1式得H3= =600X0.90/1540H4= 0.95x550/1522.5 H3=540H4=522.5（9）试算小齿轮分度圆直径按1式（1021）试算64.5788mm64.579（10）计算圆周速度vv=3.14x64.579x295.26/60x1000=0.99787m/sv=0.998（11）计算齿宽Bb = dd3t B=1X64.579=64.579mmB=64.579（12）模数mnt=64.579/23=2.808h=2.25mnt =6.318b/h =64.579/6.318=10.221度mnt=2.808h=6.318b/h =10.221（13）计算载荷系数K由1P190表10-2查得使用系数根据v= 0.998级精度，由1P192图10-8查得动载荷系数1.06由1表P194查得KH=1.12+0.18(1+0.6d2)d2+0.23103b=1.12+0.18(1+0.6X)+0.23X103X64.579=1.42由1图10-13P195查得KF=1.35假定，由1P193表查得1.2故载荷系数K=KAKVKHKH=1X1.06X1.2X1.42=1.806K=1.806（14）按实际的载荷系数校正分度圆直径d3由1式10-10D3=d3t=72.058D3=72.058（15）计算模数=72.058/23=3.133mm=3.1336按齿根弯曲强度设计（1）计算载荷系数KK=KAKVKFKFK=1X1.06X1.2X1.35=1.7172K=1.717（2）齿形系数YFa由1P197表YFa3=2.69YFa4=2.22+(2.20-2.22)(86-80)/(90-80)=2.208YFa3=2.69YFa4=2.208（3）应力校正系数YSa由1P197表10-5YSa3=1.575YSa4=1.77+(1.78-1.77)(86-80)/(90-80)=1.776YSa3=1.575YSa4=1.776（4）齿轮的弯曲疲劳强度极限由1P204图10-20500380500380（5）弯曲疲劳强度寿命系数由1P202图10-180.850.880.850.88（6）计算弯曲疲劳许用应力F取弯曲疲劳安全系数S1.35，由式10-2得F3= =0.85x500/1.35=314.8148F4= =0.88x380/1.35=247.7037F3=314.815F3=247.704（7）计算大小齿轮的并加以比较=(2.69+1.575)/314.815=0.013547=2.208+1.776/247.704=0.016083结论：大齿轮值大大齿轮值大（8）齿根弯曲强度设计计算由1式=2.17962.18结论：对比计算结果，由齿面接触疲劳强度计算的法面模数大于由齿根弯曲疲劳强度计算的法面模数，取2.5mm，已可满足弯曲强度。但为了同时满足接触疲劳强度，须按接触疲劳强度算得的分度圆直径d3= 72.058mm来计算应有的齿数。于是由=72.058/2.5= 28.8 取29，则Z4 = Z3i齿2 = 29x3.752=108.8 取Z4 = 1093几何尺寸计算（1）计算中心距aA=(29+109)2.5/2=172.5将中心距圆整为173mma=173（2）计算齿轮的分度圆直径dd3=29x2.5=72.5d4=109x2.5=272.5mmd3=72.5d4=272.5（3）计算齿轮的齿根圆直径df=72.5-6.25=66.25=272.5-6.25=266.25mmdf1=66.25df2=266.25（4）计算齿轮宽度Bb = dd3圆整后取：B3 =80B4 = 75mm B3 =80B4 = 75（5）验算=2x99.2x103 /72.5 N = 2.7366x103N=1x2.7366x103 /75N/mm = 36.488N/mm100N/mm 合适（三）直齿轮设计参数表传动类型模数齿数中心距齿宽高速级直齿圆柱齿轮2211021235045低速级直齿圆柱齿轮2.52910917380755联轴器的选择轴的联轴器:由于电机的输出轴轴径为28mm查1表14-1由于转矩变化很小可取KA=1.31.320.964=27.253N.m又由于电机的输出轴轴径为28mm查2p128表13-5，选用弹性套柱销联轴器:TL4(钢性),其许用转矩n=63N.m,许用最大转速为5700r/min,轴径为2028之间，由于电机的轴径固定为28mm,而由估算可得1轴的轴径为20mm。故联轴器合用:的联轴器:查1表14-1转矩变化很小可取KA=1.31.3361.174=469.52 N.m查2p128表13-5，选用弹性套柱销联轴器:TL7,其许用转矩n=500N.m,许用最大转速为3600r/min, 轴径为4048之间,由估算可选两边的轴径为40mm.联轴器合用.5轴的设计计算减速器轴的结构草图一、轴的结构设计1选择轴的材料及热处理方法查1表15-1选择轴的材料为40Cr；根据齿轮直径，热处理方法为正火。2确定轴的最小直径查1式15-2的扭转强度估算轴的最小直径的公式：=14.296mm再查 1表15-3，A0=(112 97)D13.546mm考虑键：有一个键槽，D14.296（1+5）=15.01mm3确定各轴段直径并填于下表内名称依据单位确定结果大于轴的最小直径15.01且考虑与联轴器内孔标准直径配合20大带轮定位d2= d1+2（0.070.1）d1=20+2.84=22.824考虑密封圈查2表15-8 P143得d=2525考虑轴承d3 d2选用6206轴承从机械设计手册软件（R2.0）B=16mm， da=36mm，d3=30mm,D=6230考虑轴承定位查表2 9-7da3636考虑到齿轮分度圆与轴径相差不大齿跟查表2 9-736（同一对轴承） 304选择轴承润滑方式，确定与轴长有关的参数。查 2（2）“润滑方式”，及说明书“（12）计算齿轮圆周速度” =3.467 ，故选用油润滑。将与轴长度有关的各参数填入下表名称依据单位确定结果箱体壁厚查3表3P26 小于8选88地脚螺栓直径及数目n查3表3P26df=0.036a+12a,考虑联轴器定位查,并考虑与密封垫配合查附表：158接触式密封d=4545考虑与轴承公称直径配合 ，轴承代号：6210B20 da5750d4=da5757考虑到齿轮定位, d5=d4+(510)=63查63= 57= 504选择轴承润滑方式，确定与轴长有关的参数。查 2（二）“滚动轴承的润滑”，及说明书“六、计算齿轮速度” ，由于第一轴选用了油润滑,故也用油润滑, 名称依据单位确定结果轴承支点距轴承宽边端面距离a从机械手册软件版105.计算各轴段长度名称计算公式单位计算结果与联轴器配合长度短23mm84-（23）82828+22+20+5+8+29-20-4.567.567.520204.5+10+2.5+45+10+2.5-1262.562.5轴肩1275-27373 20-2+4.5+10+2.5+23737L（总长）L 82+67.5+20+62.5+12+73+37354354L(支点距离)L 354-82-67.5-20+2186.5mm186.5四、校核轴的强度齿轮的受力分析：齿轮2上的圆周力小齿轮上的经向力小齿轮上的轴向力=N972.549*=353.979N0齿轮3上的圆周力小齿轮上的经向力小齿轮上的轴向力=N2736.552*=996.023N01求支反力、绘弯矩、扭矩图轴的跨度和齿轮在轴上的位置的受力如上图。AC=8.5+17+=48 CD=+10+=72.5BD=8.5+4.5+10+40=63在XAY平面上：X48+X（72.5+48）=（48+72.5+63）972.549X48+2736.552X120.5=183.5所以，=2051.427N =+=1657.674N所以，C断面 =48=79.568X D断面 =63=129.24X在XAZ平面上：x48+X183.5=x（48+72.5）353.979x48+x183.5=996.023x120.5 所以，=561.47N =80.574N所以，C断面 =X48=3.868X =X63=35.373X合成弯矩C断面 =79.662X合成弯矩D断面 =133.99X因为 , 所以D断面为危险截面。=22.91MPa查表15-1得=60mpa,因为(1630015)h=72000h结论：所选的轴承满足寿命要求。7键联接的选择和校核一、轴大齿轮键1键的选择选用普通 圆头平键 A型,轴径d=40mm ,查1表6-1，得宽度b=12mm,高度h=8mm, 2键的校核键长度小于轮毂长度且键长不宜超过，前面算得大齿轮宽度 45 ,根据键的长度系列选键长L=36mm 。(查1表6-1)键，轴，轮毂的材料都为钢，查16-2得许用挤压应力p=100120Mpa,取p=100Mpa.键的工作长度 =Lb=3612=24mm,键与轮毂键槽的接触高度k=0.5h=0.58=4mm由式16-1得p=51.67Mpa所以所选用的平键强度足够。9减速器的润滑、密封和润滑牌号的选择一、传动零件的润滑1齿轮传动润滑因为齿轮圆周速度，故选择浸油润滑。2滚动轴承的润滑因为I轴II轴齿轮圆周速度v2m/s,滚动轴承采用油润滑而III轴的齿轮圆周速度v2m/s,由于第一轴选用了油润滑,故也用油润滑,但由于齿轮不能飞溅润滑,故要用刮油板把油从三轴大齿轮边引到槽从而达到润滑轴承目的。二、减速器密封1.轴外伸端密封I轴：与之组合的轴的直径是25mm，查2表15-8P143，选d=25mm毡圈油封II轴：无需密封圈III轴：与之配合的轴的直径是45mm，查2表15-8P143，选d=45mm 选毡圈油封2.箱体结合面的密封软钢纸板10减速器箱体设计及附件的选择和说明一、箱体主要设计尺寸名称计算依据计算过程计算结果箱座壁厚0.025*123+36.0758箱盖壁厚8=0.8x8=6.48箱座凸缘厚度1.5812箱盖凸缘厚度1.5812箱座底凸缘厚度2.5820地脚螺栓直径0.036a+12=0.036x123+12=16.428查3表3P2620地脚螺钉数目4轴承旁联接螺栓直径0.7520=1516箱盖与箱座联接螺栓直径0.5x20=1010联接螺栓d2的间距查3表3P26150200160轴承端盖螺钉直径查3表3P26(0.4-0.5)df0.4x20=88定位销直径（0.70.8）108、至外箱壁距离查3表4262216、至凸缘边缘距离查3表42414轴承旁凸台半径10凸台高度作图得到h=54轴承座宽度8+22+20+555大齿轮顶圆与内箱壁距离1.28=9.610齿轮端面与内箱壁距离101510箱盖、箱昨筋厚、0.8586.86.8轴承端盖外径62+58=10272+58=112100+58=130102112130轴承旁联接螺栓距离102112130二、附属零件设计1窥视孔和窥视孔盖其结构见2表14-4 p133,其尺寸选择为：2.通气塞和通气器通气器结构见2表14-9,p136 主要尺寸：M16x1.5,D=22,D1=19.8,S=17,L=23,l=12,a=2,d1=53.油标、油尺由于杆式油标结构简单，应用广泛，选择杆式油标尺，其结构见2表14-8p135其尺寸选择为:M124.油塞、封油垫其结构见2表14-14 p139其尺寸选择为:M20X1.55.起吊装置选择吊耳环和吊钩结构见2表14-12 p1376.轴承端盖、调整垫片查2表14-1 p13211设计小结 我们这次机械设计课程设计是做带式运输机用的二级圆柱齿轮减速器。在两个星期的设计过程中，让我明白一个简单机械设计的过程，知道一个设计所必须要准备些什么，要怎样去安排工作，并学习机械设计的一般方法，掌握机械设计的一般规律；也通过课程设计实践，培养了我综合运用机械设计课程和其他先修课程的理论与生产实际知识来分析和解决机械设计问题的能力；学会怎样去进行机械设计计算、绘图、查阅资料和手册、运用标准和规范。还有就是激发了我的学习兴趣，能起到一种激励奋斗的作用，让我更加对课堂所学内容的更加理解和掌握。 这次机械课程设计中，我遇到了很多问题，但同学讨论和老师 指导起到了很大的作用，这就是团队的精神。自己在设计中所遇到的困难，让我明白要做好一个机械设计是一件不容易的事，必须有丰富的知识面和实践经验，还必须有一个好的导师。设计让我感到学习设计的紧张，能看到同学间的奋斗努力，能让大家很好地回顾以前所学习的理论知识，也明白只有在学习理论基础上才能做设计，让我以后更加注重理论的学习并回到实践中去。还这次自己没有很好地把握设计时间的分配，前面传动方案设计和传动件设计时间太长，而在装配草图设计、装配工作图设计时间太紧，还有就是在装配草图设计中遇到一些尺寸不是很确定，而减慢了AutoCAD工程制图的速度，这也很好让我们更加掌握AutoCAD工程制图的操作。这是自己设计思维不太严谨，没有很好地熟悉一些理论知识，没有过此类设计的经验；在设计过程中自己也做了一些重复的计数，很多往往是一个参数所取不正确或没有太在意一些计数，而在尺寸计算校核才发现问题，而白白花了重复工作的时间，但也能让我更加深刻一些设计的过程，积累了一些设计的经验。 这次机械设计课程设计是我们一次进行的较长时间、较系统、 较全面的工程设计能力训练，很好地提高了我们实践能力和运用综合能力的水平。我们可以通过设计，明白到学习的内容的目的，更加明确大学学习的目标方向，能激起学生学习激情，也让我们有学习的成就感，希望以后有更多合适实训教学安排。12参考资料1 濮良贵主编. 1997.机械设计（第七版）.高等教育出版社2 唐增宝；何永然；刘安俊主编.1998.机械设计课程设计.华中科技大学出版社3 龚溎义 罗圣国 李平林 张立乃 黄少颜编， 龚溎义主编机械设计课程设计指导书第二版，高等教育出版社 4机械设计手册软件版R2.0,42长春理工大学光电信息学院毕业设计Introduction to the common speed reducerDevice 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 ofReducer is mainly composed of transmission parts (gear or worm), shaft, bearing, box and its accessories. Its basic structure has three parts:1gear, shaft and bearing combinationPinion 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 bodyEnclosure 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 fittingsIn 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 dont 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 loadMachine 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 programA, the original design information and data1 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.3the prime mover for machine and connection way of the reducer, shaft and if there is a radial force and axial force.4installation type (reducer and prime mover, the relative position of working machine, vertical and horizontal).5transmission ratio and its error is allowed.6the size and weight requirements.7to the degree of service life, safety and reliability requirements.8environmental 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.9to the requirements of operation and control.10 the source of material, blank, standard parts and inventory.11factory manufacturing capabilities.12on 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 typeThree, set at the beginning of each process methods and parametersSelected 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 seriesAccording to the total transmission ratio, to determine the transmission series and all levels of the transmission ratio.Five, the initial geometry parametersEarly calculate gear transmission center distance (or pitch diameter), modulus and other geometric parameters.Six, the overall design schemeDetermine the structure of the reducer, shaft size, span and the bearing model, etc.Seven, checkCheck the strength of the gear, shaft, key load, calculation of bearing life.Eight, lubrication cooling calculationTo determine the speed reducer and accessoryTen, gear carburized depth is determinedWhen necessary for tooth form and tooth to fix quantity calculation process data.Eleven, drawing construction drawingIn the design should implement national and industry related standards.Using the classification1 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.2general 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 reducerSingle stage level 2, level 2, level 2 above. Decorate a form: expansion, shunt type, coaxial type.2) cone gear reducerUsed for the input shaft and output shaft position into the intersection.3) worm gear reducerIs 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 reducerIf gear drive level at high speed, the structure is compact;If worm transmission at high speed, high efficiency.5) planetary gear reducerWith a range of high transmission efficiency, transmission ratio, transmission power is 12 w 50000 kw, small volume and weight3common types of reducer1) 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, dont 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 principle1 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;3minimize the reducer for the shape of the size or weight, etcModel selectionAs far as possible choose close to ideal reduction ratio:Reduction ratio = / servo motor speed reducer output shaft speedTorque 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 superMaximum 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 methodThe 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 maintenanceDifferent 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 checkCut 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 oilCut 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 screw3the oil replacementAfter 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 solveSpeed reducer leakage oil cause analysis and solutionAnalysis of the causes1the pressure inside the tankIn 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.2the structure of the speed reducer design is not reasonable cause oil leakageSuch as design of reducer without ventilation hood, pressure reducer can not be achieved, in the pressure more and more high, oil leakage occurs.3amount to muchReducer 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.4improper maintenance technologyIn 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 schemeGovernance 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 trend1high 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.2modular 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.3style 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 for expanding the scope of the use.Prompt reducer levels to increase the main factors are: (1) the theoretical knowledge of increasingly perfect, the closer to the actual, such as gear strength calculation method, modification technology and deformation calculation and optimization design method, the tooth root transition smooth, the new structure, etc.). (2) adopts good material, widely used in a variety of high quality alloy steel forgings, materials and heat treatment quality control level. 3. The structure design more reasonable. (4) increase machining accuracy to ISO5 - level 6. (5) bearing quality and improve service life. 6. Lubricating oil quality improvement.8常用减速器简介装置概述：减速器是原动机和工作机之间的独立的闭式传动装置，用来降低转速和增大转矩，以满足工作需要，在某些场合也用来增速，称为增速器。选用减速器时应根据工作机的选用条件，技术参数，动力机的性能，经济性等因素，比较不同类型、品种减速器的外廓尺寸、传动效率、承载能力、质量、价格等，选择最适合的减速器。减速器是一种相对精密的机械，使用它的目的是降低转速，增加转矩。结构特点减速器主要由传动零件(齿轮或蜗杆)、轴、轴承、箱体及其附件所组成。其基本结构有三大部分：1、齿轮、轴及轴承组合小齿轮与轴制成一体，称齿轮轴，这种结构用于齿轮直径与轴的直径相关不大的情况下，如果轴的直径为d，齿轮齿根圆的直径为df，则当df-d67mn时，应采用这种结构。而当df-d67mn时，采用齿轮与轴分开为两个零件的结构，如低速轴与大齿轮。此时齿轮与轴的周向固定平键联接，轴上零件利用轴肩、轴套和轴承盖作轴向固定。两轴均采用了深沟球轴承。这种组合，用于承受径向载荷和不大的轴向载荷的情况。当轴向载荷较大时，应采用角接触球轴承、圆锥滚子轴承或深沟球轴承与推力轴承的组合结构。轴承是利用齿轮旋转时溅起的稀油，进行润滑。箱座中油池的润滑油，被旋转的齿轮溅起飞溅到箱盖的内壁上，沿内壁流到分箱面坡口后，通过导油槽流入轴承。当浸油齿轮圆周速度2m/s时，应采用润滑脂润滑轴承，为避免可能溅起的稀油冲掉润滑脂，可采用挡油环将其分开。为防止润滑油流失和外界灰尘进入箱内，在轴承端盖和外伸轴之间装有密封元件。2、箱体箱体是减速器的重要组成部件。它是传动零件的基座，应具有足够的强度和刚度。箱体通常用灰铸铁制造，对于重载或有冲击载荷的减速器也可以采用铸钢箱体。单体生产的减速器，为了简化工艺、降低成本，可采用钢板焊接的箱体。灰铸铁具有很好的铸造性能和减振性能。为了便于轴系部件的安装和拆卸，箱体制成沿轴心线水平剖分式。上箱盖和下箱体用螺栓联接成一体。轴承座的联接螺栓应尽量靠近轴承座孔，而轴承座旁的凸台，应具有足够的承托面，以便放置联接螺栓，并保证旋紧螺栓时需要的扳手空间。为保证箱体具有足够的刚度，在轴承孔附近加支撑肋。为保证减速器安置在基础上的稳定性并尽可能减少箱体底座平面的机械加工面积，箱体底座一般不采用完整的平面。3、减速器附件为了保证减速器的正常工作，除了对齿轮、轴、轴承组合和箱体的结构设计给予足够的重视外，还应考虑到为减速器润滑油池注油、排油、检查油面高度、加工及拆装检修时箱盖与箱座的精确定位、吊装等辅助零件和部件的合理选择和设计。1）检查孔为检查传动零件的啮合情况，并向箱内注入润滑油，应在箱体的适当位置设置检查孔。检查孔设在上箱盖顶部能直接观察到齿轮啮合部位处。平时，检查孔的盖板用螺钉固定在箱盖上。2)通气器减速器工作时，箱体内温度升高，气体膨胀，压力增大，为使箱内热胀空气能自由排出，以保持箱内外压力平衡，不致使润滑油沿分箱面或轴伸密封件等其他缝隙渗漏，通常在箱体顶部装设通气器。3)轴承盖为固定轴系部件的轴向位置并承受轴向载荷，轴承座孔两端用轴承盖封闭。轴承盖有凸缘式和嵌入式两种。利用六角螺栓固定在箱体上，外伸轴处的轴承盖是通孔，其中装有密封装置。凸缘式轴承盖的优点是拆装、调整轴承方便，但和嵌入式轴承盖相比，零件数目较多，尺寸较大，外观不平整。4)定位销为保证每次拆装箱盖时，仍保持轴承座孔制造加工时的精度，应在精加工轴承孔前，在箱盖与箱座的联接凸缘上配装定位销。安置在箱体纵向两侧联接凸缘上，对称箱体应呈对称布置，以免错装。5)油面指示器检查减速器内油池油面的高度，经常保持油池内有适量的油，一般在箱体便于观察、油面较稳定的部位，装设油面指示器。6)放油螺塞换油时，排放污油和清洗剂，应在箱座底部，油池的最低位置处开设放油孔，平时用螺塞将放油孔堵住，放油螺塞和箱体接合面间应加防漏用的垫圈。7)启箱螺钉为加强密封效果，通常在装配时于箱体剖分面上
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