Modular design and its application in gear reducers
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Modular design and its application in gear reducer Wang Yunxiang, Department of Mechanical Engineering, Gao Hong Anhui Mechanical and Electrical College, Wuhu, Anhui. The deficiencies of the traditional gear reducer design method are analyzed. The modular design theory and its main features are introduced. The application of modular design in the gear reducer is described. The modular design not only enables the gear reducer to have great adaptability and flexibility, but also plays an important role in improving the transmission quality of the gear reducer and prolonging the service life.
Gear reducers are widely used because of their high efficiency, long working life and convenient maintenance. However, the traditional gear reducer design is often oriented to a specific product, starting from the part design, and gradually complete the design of the whole machine, except for a small number of standard parts, it is almost brand new, the inheritance of production and technology is very poor, and new products The design cycle is long, the process equipment and production preparation workload are large, and the production line needs to be adjusted. With the development of science and technology and the national economy, the demand for gear reducers is increasing, and higher requirements are placed on quality. If the traditional single product design method is still used, it will not meet the needs of market diversification. It cannot adapt to fierce market competition, and it is difficult to improve the comprehensive technical and economic benefits of products and ensure product quality. In order to solve these problems, a modular design can be adopted. Modular design is a standardized modular design. It is not for a specific product, but for adjacent product systems of a certain kind of product system and similar functions. It does not have to be designed separately for each product, but is designed carefully. A variety of modules, in a smart and flexible way to combine a variety of new product development cycle, and can greatly enrich the product specifications and varieties, improve product responsiveness and adaptability to the user, so that the product structure is flexible.
1 Modular design and its main features Modular design is an advanced design method commonly used in developed countries in recent years. Its core idea is to decompose the system into a common module and a dedicated module for diversifying effects, and combine these two parts to form a new product or diversify the product.
The so-called module in the mechanical product is a single unit in which the group has the same function and the combination element refers to the shape and size of the joint portion and the fitting or twisting parameters between the joint members, but the performance and structure are different, but can be interchanged.
The modular design is to design the same functional unit on the product into different performance, interchangeable modules, and different modules can be used to form different types and different specifications. The principle of modular design is to strive to make up more products with a few modules, and to make the products have high precision, stable performance, simple structure and low cost on the basis of satisfying the requirements of users.
The main way of modular design is the horizontal series modular design. That is, using the module to develop a variant product without changing the main parameters of the product. The horizontal series modular design method is the most common and simple. It is often replaced or added to the base variety to form a new variant.
The vertical series modular design refers to the modular design of the basic products with different main parameters, and the design is more complicated.
In the vertical series module system, the product functions and principle schemes are the same, the structure is similar, but with the change of the main parameters, not only the dimensional specifications change, but also the dynamic parameters change accordingly. Therefore, when the main parameters change greatly, the vertical series products must be divided into reasonable sections, which are common to the modules in the same section.
Full range of modular design. The full range of modular designs includes modular designs for vertical and horizontal series.
Cross-series modular design. Different types of products with similar dynamic parameters in the series of modular systems, there are two modular ways to use different modules to form a cross-series product on the same basic component structure; the other is the same across the series of products with different basic components. Functional components use the same functional modules.
The modular design product has the following advantages, and the product composition is flexible and updated quickly. The development of new products is usually a partial improvement. If advanced technology is introduced into the corresponding modules, it is easier to implement, which speeds up the upgrading of products.
cut costs. After modularization, the same module can be used for several products, increasing the production quantity of the module, facilitating the use of advanced technology grouping technology, etc., and shortening the design time, thereby reducing product cost and improving product quality.
Easy to repair, expand, and diversify. Easy to maintain, only replace modules if necessary. For modular products, the elimination of an old product, but the modules that make up the product are not eliminated, these modules can also be used to combine other products. The modular structure also facilitates the rapid development of product varieties to meet diverse needs.
2 Modular design in gear reducer 2.1 Market research analysis and parameter range determination An important prerequisite for modular design is that the product variety and specifications and the market demand for similar products must be fully understood. In order to carry out the division of modules to create a combination. According to market research, in order to meet the needs of metallurgical mine construction, chemical industry, light industry and other industries, it is proposed to design a series of medium and small power universal gear reducers, which are required to meet the transmission of parallel and intersecting axes. The series parameters are single stage center distance 80560, transmission ratio 2.35. .6; level center distance from 200560, transmission ratio 820; level center distance 200500, transmission ratio 25100.
2.2 Proposed product assembly form and center distance determination Gear reducer mainly has cylindrical gear reducer conical gear reducer cylindrical bevel gear reducer type structure, in order to make the gear reducer through the unit module combination, realize the series of internal transmission parts exchange There are 12 kinds of assembly forms for the proposed product, 1.
Determining the gear center distance of each stage of the reducer mainly considers two factors: to achieve the contact strength of all levels of gears as much as possible. The number of gears is realized by each series of gears, and the drop of the heat is also fixed. Whether it is a grade drive or a grade drive, the value of the final center is the box number, and each box can achieve a variety of fixed speed ratios. In order to make the gear reducer of each series of various speed ratios of the series reducer reach the equal contact strength, the ratio of the adjacent two center distances in each box number 3132 should be constant or fixed ratio. The value of the value can be selected by referring to the technical data of the reducer catalogue at home and abroad.
2.3 Module division reducer The whole structure of the reducer has obvious grading characteristics. When the modular design is carried out, based on the functional analysis of the product, the total function of the product is decomposed into several levels of comprehensive functional units, 2. Then According to different needs, these comprehensive functional units are respectively refined into several lower-level interchangeable independent basic units, such as the hierarchical decomposition of gear bearings.
Decomposition of the basic unit of the bearing 2.4 Module design Since the module has many possible combinations, the design should take into account the more joints of the modules, and the reasonable assembly should be reasonable; the standardized structure should be used as much as possible; The module should be guaranteed to have the same life and easy maintenance and replacement. The main module design features of the gear reducer, the center distance of the box module is the same and the speed ratio is different. The same box module can be used for the level. However, when the stage drive is used, the high-speed hole of the original box does not need to be cut out or sealed with a cover. . When the input shaft and the output shaft need to be perpendicular, and the high-speed stage is driven by a bevel gear, the original basic box can also be used, and only the side cover needs to be added at the input end. In order to increase the flexibility of the installation of the reducer, in order to adapt to various installation occasions, the installation plane and the mounting hole are respectively arranged on the four upper and lower axial end faces of the box body, and the box body can realize the installation manner of four kinds of orientations. Both horizontal and vertical.
When specifically determining the technical parameters of the transmission gears of the gears, the gear module should increase the interchangeability of the gears between the series of boxes as much as possible, except for the transmission gears of the same center distance and speed ratio, different center distances and The transmission gear of the speed ratio should also be able to achieve a fixed interchange ratio. In order to achieve the standard center distance, the gear should be angularly displaced, and the specific geometrical parameters need to be optimized. In addition, the single-stage gear is used as the base module, and the grade drive gear is selected from the single-stage gear module to minimize the variety of gears and improve the generalization degree.
The design of the shaft module shaft module is mainly determined according to the assembly relationship between the shaft and other components such as bearing seals. For different gear ratios, the shafts with the same structural dimensions are used as much as possible, even if the other dimensions of the shaft are different, the diameter of the bearing is installed. And the preparation of 2.5 technical documents Because the modular design of the modules is often not directly related to the product, it is necessary to pay attention to the preparation of its technical documents, in order to organically link the modules of different functions. The preparation of technical documents mainly includes the following contents: the relationship between the module combination and the preparation of the reducer products. The full range of module types and various reducers use the module group and module catalogue for all products, indicating the composition of each product and module group.
Prepare a series of general manufacturing and acceptance conditions, certificate of conformity and packing list.
Develop modular instructions to suit the needs of different modules in different products.
3 Conclusion Modular gear reducer is composed of general-purpose modules such as box gear shaft bearing end cover and a small number of special-purpose modules. The general-purpose modules can be planned in advance and can be manufactured in batches. When users need a new gear reducer, they only need to design and manufacture the special parts, and then assemble them with existing common modules and purchased standard parts. This modular reducer product has the advantages of great adaptability and flexibility, short design cycle and low manufacturing cost, making it competitive in the market.
In addition, modular design is a process of repeated practice and continuous improvement. Through a large number of modular product design practices, the variety of gear reducer modules is gradually increasing, and the modular system is also undergoing metabolism. Some excellent new modules are continuously added, and some poorly designed modules are continuously replaced and eliminated, thus enriching And the development module series dedicated modules are converted into general-purpose modules to improve the versatility of modularity.
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