Reductor cu o treapta

8/10/2019 Reductor cu o treapta

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1. STRUCURAL SCHEME, TORQUES AND ROTATION FOR

EACH SHAFT

1.1 Structural scheme

Figure 1

M - the electric engine

P - the power of the electric motor n - the rotation spead of the motor shaft

Mtn - the nominal torque at the motor shaft

Li - the ratial af the chain

I - the imput shaft

I T

- the torque of the imput shaft

I n - the rotation spead of the imput shaft

II - the output shaft

II

T

- the torque of the output shaft II n - the rotation spead of the output shaft

1 - the pinion

2 – the driver wheel

!"!#!$ – the %earings

r i - the spead redurer ratio

&.M. - the wor'ing machine

1



1.2 (orque and rotations for each shaft

)ngine

Nmmn

P M

rot n

t *!+,-,1,*

/100!,100!,

min,*

**=⋅⋅=⋅=

=

Input shaft I3

Nmmi M M

rot i

nn

l ct tI

l c

I

,,2!/--/,2!1*!+,-,1

min42!1

,*

=⋅=⋅=

===

5utput shaft II3

Nmmi M M

rot i

nn

r tI tII

r

I II

/-!1*,01200!+,,2!/--/,

min+0!22000!+

4

=⋅=⋅=

===

2



2. PROJECT PARAMETERS

INPUT DATA

2.1 Pinion speed n1! rotmin

n1 6 4 rotmin2.2 (he torsion torque at the pinion of the gearing (1! 7mm

(1 6 //,!,,2 7mm

2.+ 8earing ratio udat

udat 6 +!00

2./ Minimum functioning time of the gearing 9h! hours

9h 6 40 hours

2.0 Functioning conditions of the gearing

$river machine: electrical motor

$riven machine: fans

(;pe of load: uniform

2.* (he loading c;cles for the teeth

contact load : pulsator; c;cle

%ending load : pulsator; c;cle

2. 7um%er of load c;cles of the tooth flan'! at a full rotation χ1 for the pinion! χ2

for the driven wheel

χ1!2 6 1

2.4 (he reference rac' profile

For inclined teeth

αn 6 2< h=an 6 1!< c=

u 6 .20< ρ=fn 6 .+4

+



3. CHOOSING THE MATERIALS, HEAT TREATMENTS AND THE

LIMIT STRESSES

+.1 #hoosing materials and treatments

&e choose /#r1 from S(S ,1

>ardness - e?ternal 0 >@#

- internal 2* >"

σr 6 , MPa

σ2 6 * Mpa

+.2 9imit stresses! σ>lim1!2! at contact and σFlim1!2 at %ending! MPa

σ>lim1!2 6 MPa

σFlim1!2 6 +2 MPa

/



4. PRE-DIMENSIONING CALCULUS

/.1 7um%er of teeth A1! of the pinion! respectivel; A2 of the driven wheel.

12

-0

2/!+212cos100!+

2-0cos1

2ma?1

=

=

=°+

⋅=+

=

β

β

n

w

dat n

w

m

a

uma z

&e choose: +1 = z

0!1*00!++12 =⋅=⋅= dat u z z &e choose 1-2 = z

/.2 @eal gearing ratio u

+.24.

1

0*!++

1-

1

2

≤

∆≤−

===

uu

u

z

z u

dat

/.+ (he contact calculus factors B21!*C

/.+.1 (he elasticit; factor of the wheels material A)! MPa

MPa Z

MPa E E

E E

z

E

E

4!14,

1*!2

+!

11

1

021

21

2

2

2

1

2

1

=

⋅==

==

−+

−=

ν ν

ν ν π

/.+.2 (he contact area factor A>

/*.212cos/,!2cos/,!2 === β H z

/.+.+ (he covering factor Aε

0



/.1

4/./.1

11

=

===

α

α

ε

ε ε

Z

/.+./ Inclining factor of the teeth Aβ

1!112cos

1

cos

1===

β β Z

/./ (he factor for the %ending calculus

/./.1 7um%er of teeth for the equivalent wheels

++2!11/12cos

1-

cos

00!+212cos

+

cos

++

22

++

11

===

===

β

β z

z

z z

n

n

/./.2 (he displacement coefficient of the profile in the normal plane ?n1!2

2!1 =n x

/./.+ Shape factor of the teeth DFa 1!2

14!23<++2!11/3!

0!23<00!+23!

222

111

===

===

Fann Fa Fa

Fann Fa Fa

Y x zY Y

Y x zY Y

/././ #orrection factor of stress DSa 1!2

--!13<++2!11/3!

*+!13<00!+23!

222

111

===

===

SannSaSa

SannSaSa

Y x zY Y

Y x zY Y

/./.0 #overing factor Dε

/.1

-*.12cos/.1

-0.20.cos

-0.20. 22

=

=+=+≈

α

α

ε

ε

β ε

Y

/./.* Inclined factor for the teeth Dβ

,.12

121

121 =

°

°−=

°

°−= β

β Y

/.0 9oad correction factor

/.0.1 (he functioning regime factor ' a

+0!1= Ak

/.0.2 $;namic factor ' v

1!1=vk

/.0.+ $istri%ution uneven3 factor for load on the width of the teeth ' >β for

contact and ' Fβ for %ending

*



0!1

/0!1

=

=

β

β

F

H

k

k

/.0./ (he uneven distri%ution factor of the frontal plane ' >α at contact and

' Fα for %ending

/.1/*.112cos

/.1

cos 22 >====

β ε α

α α F H k k

/.* (he allowa%le resistances σ>P1!2 at contact and σFP1!2 for %ending BMPaC

-

222

4

111

1/,!11140+0!220**

14!/1404**

,2!

⋅=⋅⋅⋅==

⋅=⋅⋅⋅==

=

χ

χ

H L

H L

RV L

Ln N

Ln N

Z Z Z

MPaY Y Y S

Y Y

MPaY Y Y S

Y Y

MPa Z Z Z Z Z S

z

MPa Z Z Z Z Z S

z

S

z

z

z

z

x R

F

N ST F

FP

x R

F

N ST F FP

HP

! RV L

H

N H

HP

HP HP HP

! RV L

H

N H

HP

H

N

N

x

w

++!40+0!1

11122+2

**!/2*0!1

11112+2

+1!*13+0!*0,<+1!*1min

+0!*0,11,2.2.1

21!1--

3!min

+1!*111,2.2.1

12!1--

+!1

21!1

12!1

1

.1

22

min

22lim

2

11

min

11lim1

min

2lim

2

21

min

1lim

1

min

2

1

=⋅⋅⋅⋅⋅

==

=⋅⋅⋅⋅⋅==

==

=⋅⋅⋅⋅

==

=

=⋅⋅⋅⋅

==

=

=

=

==

δ

δ

σ σ

σ

σ

σ

σ σ

σ σ σ

σ

σ



/. (he distance %etween the a?is at pre-dimensioning

/..1 &ide coefficient ψ a! ψ d

+!=aψ

ψ d 6 *4/!+!2

10*!+

2

1=

+=

+a

uψ

/..2 $istance %etween the a?is from the strength condition at contact aw>!mm

Z Z Z Z u

k k k k T ua H E

HP a

H H V A

wH

+!1+,31!14/./*.24.14,3+1!*10*!++!2

/*!1/0!11!1+0!1/*310*!+

32

31

+2

2

+ 2

2

1

=⋅⋅⋅⋅⋅⋅

⋅⋅⋅⋅+=

=Ψ

+= β ε

α β

σ

/..+ $istance %etween a?is from the strength condition at %ending a wF! mm

( )

/0.3!ma?

02!/-

/0!,!-*!/*!10!11!1+0!112cos+!2

10*!++/*

cos2

31

2

22

1

11

+

+

2

11

=

⋅⋅

=

⋅

=

=⋅⋅⋅⋅⋅⋅°⋅⋅

+⋅=

=+

=

FP

Sa Fa

FP

Sa Fa

FP

Sa Fa

FP

Sa Fa F F va

a

wF

Y Y Y Y Y Y mm

Y Y Y Y k k k k

u z T a

σ σ σ

σ β ψ β ε α β

/../ dopting the distance %etween the a?is at predimensioning aw! mm

aw 6 ma? aw>!awF3 6 ma? 1+,!+4</!023 6 1+,!+4mm <

&e adopt from S(S *00 the following aw 6 1/ mm.

/..0 (he preliminar; lengths of the wheels mma" ! a -,!/1+4!1+,+.2 =⋅==ψ

mm""" -,!/+2-,!/121 =+=∆+=

2<+...1 =∆=∆ ""

KINEMATIC SCHEME OF THE SPEAD REDUCER

4



5. GEARING FORCES CALCULUS

0.1 Forces calculus

0.1.1 (angential force Ft! 7<

Figure. 0.1

N F F

N d

T F

t t

w

t

1,!10/*

1,!10/*-*/-1!*1

,,2!/--/,22

21

1

11

==

=⋅

==

0.1.2 @adial force Fr ! 7<

,



N F F

N t# t# F

F

r r

wnt

r

1+!*-

1+!*-1+!2112cos

1,!10/*

cos

12

11

==

=⋅=⋅= α β

0.1.+ ?ial force Fa! 7<

Figure. 0.2

N F F

N t# t# F F

aa

t a

*0!+24

*0+!+24121,!10/*

21

11

==

=°⋅=⋅= β

0.2 #hoosing the sense of rotation and appl;ing forces

Figure. 0.+

1



6. CALCULUS OF THE SHAFTS

*.1 Pre-dimensioning calculus:

mm

T

d atI

I

I +1.20101/!+

,,2!/--/,1*1*++ =⋅

⋅

=⋅

⋅

= τ π

mmT

d atII

II

II 4/!2-/2/!+

/-!1*,0121*1*++ =

⋅

⋅=

⋅

⋅=

τ π

*.2 #hoose of %earing mounting for input and output shafts:

Figure. *.1

d%3I!II 6 dI!II – 2E43mm

11



(a%le *.1

d

BmmC

$ " r sBminC

Masa

B'gC

Sim%ol Sarcina radiala

$inamica Statica

dI 2 / 1/ 1 !114 *2/ 12! 0!

dII 20 02 10 1 !1/2 *20 1/ *!,0

*.+ #hec' of the input shaft for composed stresses.

*.+.1 >oriAontal plane

Figure *.2

"

@ > @ ">

Fr1

Fa1

[H

12



N R F R

N l l

d F l F

R

d F l F l l R

M

AH r $H

w

ar

AH

w

ar AH

$

+!2/*!+*-1+!*-

*!+*-*101

2

-*/-1!*1*0!+24011+!*-

32

2

3

1

21

1

121

1

12121

=−=−=

=+

⋅+⋅=

+

⋅+⋅=

=⋅−−+

=Σ

*.+.2 ertical plane

Figure *.+

N R F R

N l l

l F R

l F l l R

M

AV t $V

t

AV

t AV

$

1+!4/2*!-/1,!10/*

*!-/01*1

011,!10/*

3

1

21

21

2121

=−=−=

=+

⋅=

+⋅

=

=⋅−+

=Σ

*./ $etermining of the reactions in the 2 %earings

@

l1

"

@ "

Ft1

[!

1+



Figure *./

Nmml R M

Nmml R M

AH iH

AV iV

**!22+,*1*!+*-

**!/2,/-*1*!-/

1ma?

1ma?

=⋅=⋅=

=⋅=⋅=

*.0 Stresses identification

*.0.1 (orsion

MPad

T

%

t +*!1

3+///!0*1/!+

,,2!/--/,1*1*++

1

1=

⋅

⋅=

⋅

⋅=π

τ

*.0.2 "ending

MPad

M M

%

iV iH

i 2,!13+///!0*1/!+

3**!/2,-3**!22+,+2+2+

22

+

1

22

=⋅

+⋅=

⋅

+⋅=

π σ

*.* )quivalent stress

( ) aiIII &' σ τ α σ σ ≤⋅+= 22 /

( ) aiIII &' σ σ ≤=⋅+= -0!1+*!12-!/3/2!1 22

MPaict /2!12,!11+!3 =+=+= σ σ σ

MPad

F

%

act 1+!

3+///!0*1/!+

*0+!+24//22

1

13 =

⋅

⋅=

⋅

⋅=π

σ

°== 2-.aiI

aiIII

σ

σ α MPaaiIII ,=σ MPaaiI ++=σ

l1

"

Mih

Miv

Mt

(

1/



". DESIGN OF THE ASSEM#LE #ET$EEN THE ENHECE AND

THE OUTPUT SHAFT

F%&'() ".1

&e choose from S(S 1/-41: %64< h6

,1!11-20

,,2./--/,//=

⋅⋅

⋅=

⋅⋅=

a(

t

c)d

M l

σ

MPaa( 1...*0=σ B1+C(o fi? the wheel 2 on the intermediate shaft is chosen to parallel t;pe G4G20 S(S

1/ – 41.

l 6 lc H % 6 1!,1 H 4 614!,1 mm

l62 mm S(S 1/-41

(a%le .1d % h

I 1/ 0 0

II 2 * *

II 20 4

10



*. CHECH OF THE #EARING MONTINGS FOR THE IMPUT SHAFT

F%&'() *.1

02.*+

*0!+24==

o

A

*

F 6J e6!//

G61D6

& R R

F

F

F

AV AH

A

R

A≤=

+

=

+

= 1-.*!-/*!+*-

*0!+24

2222

1

+0!1,++2==⇒≤ R

R

A F P & F F

A R

R

A F Y F P & F

F ⋅+⋅=⇒≥

+

+2!1/++40/4+0!1,++2 +

=

=⋅=≤=

+

* L P * r

+

n&c

rot mil L)n

L I /41

404*

1

***

=⋅⋅

=⋅⋅

=

1*



+. COOSING AND JUSTIFING THE OILING SSTEM AND

SEALING SSTEM

Oiling the gearings:

(he gears from speed reducers are grease through splashing in the oil %ath.

For this aim in which a gear from the gearing mechanism is introduce in the oil %ath until a tooth is covered with oil! not more than 1 mm! and without passingsi? time the modulus.

In case of speed reducers with more steps when the wheels dont reach the

%ath3! the grease is made with a parasite gear! or with the help of some discs or

splashing spoons which are creating am oil fog.

(he grease through splashing is applied on gearing mechanisms that are

wor'ing periodicall;! with speeds up to 10ms. For greater peripheral speeds! thegrease is done with oil inKectors. (he oil pressure is a%out .1-.4at. For greasing!

mineral oils are use with the viscosit; of +-* degrees )0L#.

$% /0 ' ) )(%)( ))7 % )(, ) /8 ()'()87 ) (/'&8) () %&)(, 87 /() 9%/' /% () ')7.

5n speed reducers with more gears! the oil is choused with a viscosit;

corresponding to the steps that transmit the %iggest torque. For the oil %ath

volume are considered .20-.0l of oil over a horsepower. (he period of oil change

is a%out 1-0 hours of functioning for the case when the gearing

mechanism is sealed and the oil is filtrate ever; 20 hours3. For filtering can %e

used magnetic filters. &hen the speed reducer is new! the oil must %e changed

after 2-+hours.

Oiling the ball-bearings:

(he choose of lu%ricants for %all %earings and esta%lishing the grease

intervals! is done considering the dimension! num%er of revolutions! load and wor'

temperature of the %earing.

8enerall;! the liquid lu%ricants have more advantages then the consistent

ones: higher ph;sical-chemical sta%ilit;! can %e used at high speeds and

temperatures! and also at ver; low temperatures! easier evacuation of heat

produced in the %earing! smaller resistance sported %; the rolling %odies.

$isadvantages: difficult %earing sealing! loses through lea'ages in time! etc.

8rease lu%rication is more advantageous %ecause leads to: simpler %earings

construction! eas; to seal! with a lower cost! %etter protection of the %alls to

e?ternal impurities! lower lu%ricant looses.

8as'ets: due to high levels of revolutions trees cuffs sealing is

accomplished %; rotation.

1



1:.GHOOSING THE MATERIALA AND MANUFACTURING

SSTEM

It is choosen 14Mn#r11 steel hardening and tempering to achieve the shaft

and gear wheel transmission %ecause this steel has good resistance to %ending and

also has a high resistance to fatigue.

Materials used for speed reducer construction.

Materials used for gears:

Steel

It is used great steel: steel with car%on./-.* # and steel with .+0-./0#

low allo;ed with Mn! #r! #r-Mo! #r-7i etc. Steel non allo;ed with #r! #r6Mo! #r- 7i! with c;aniding

#ast irons

#ast irons are used at gearing which has a eas; wor'ing! change wheels which

dosent functioning ever; time.&hen it is as'ing a silent condition ma; %e usednormal iron ash.

Nsed material for a?els e?ecution:

8enerall; the a?el which don t have a heat treatment are made %; normall; steel

car%on: 59 0! 59 *! Stas 0-4For a?el which a %ig lifting power we can use car%on steel of qualit;: 59# +0!59# /0! 59# *! according to S(S 44-**.

In case of a?el which have a strong load and are required small dimension are used

steel allo;ed with crom! #r-7i or #r-Mn.

Marerials used for producing the body.

(he %od; %ecause of the stiffness are made %; cast irons or %; casting steel. Most

of the %od; are made %; cast iron with average resistance Fc 2! Fc 20.

14



11.TECHNICAL SECURIT RULES $ORK

@educer %; definition in a speed reduction mechanism while increasing torque

transmition. 9i'e an; reducer mechanism involves compliance with specific

emplo;ment securit; tehmicaOs grave. It is a%solutel; mandator;:

-9ocation reducer in the vertical position< - 9u%ricant oil changes to term limits<

- @eplace %earings after the num%er of operating hours provided<

- n immediate replacement of an; assem%l; or su%assem%l; as soon as it

has found its damage<

- Fi?ing a reducer on the pedestal %efore putting it into operation<

- )?panding the level of lu%ricant if ;ou have found a fall %elow its

minimum<

- Periodic verification of the status reducer<

In prohi%its:

- Introducing lu%ricating oil other than reducing the limit<

- Introducing the reducing of an; material that could damage the gears<

- #hanging the oil or lu%ricant of an; assem%l; or su%assem%l; sin reducer

component during its operation<

- #logging ventilation holes<

1,

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