Gears and Shafts
Analysis of the core structure of mechanical transmission
What are Gears and Shafts?
Gears and Shafts are the most important basic components of a mechanical transmission system. Mechanical power is a process of transmitting motion to each other through the meshing of the tooth surfaces of gears, and the gear shaft is a key component that spatially supports the rotating part and transmits torque. Shafts and gears form the “bones” and “joints” of modern mechanical equipment and are widely used in various fields from miniature precision instruments to large-scale industrial equipment.
2. Functional analysis and motion principle of Gears and Shafts:
2.1 Power transmission: The power of the engine/electric energy is efficiently transmitted to the actuator. When the drive gear rotates, its tooth surface pushes the tooth surface of the driven gear, thereby transmitting motion and power.
2.2 Variable speed adjustment: By switching different gear combinations, speed and torque conversion can be achieved due to the coordination of different tooth numbers, so as to achieve torque amplification or speed improvement.
2.3 Steering adjustment: the linear motion is converted into rotating motion, and the differential motion of the car wheel is realized in the drive shaft and the disk Angle teeth.
2.4 Power distribution: The rotation of the sun gear drives the movement of planetary wheels at all levels to achieve power distribution.
2.5 Accurate control: In the need for accurate flow control (valve), the flow distribution can be controlled by accurate speed and position.
3.the role of the tooth ring and typical application scenarios
3.1 As a special Gear structure, the Gear Ring plays a key role in the following scenarios:
3.2 Power transmission of large rotary equipment: rotary power generation of wind power.
Precise Angle positioning control to achieve the perfect position of the clamp, such as excavator and tower crane rotation.
3.3 Power distribution under heavy load condition: driving gear ring of mining machinery.
3.4 Typical Application Scenarios:
Wind turbine: the diameter of the rotating gear ring can reach more than 10 meters
Construction machinery: rotary bearing gear ring bearing huge torque
Military equipment: precision gear ring of turret rotating mechanism
Steel rolling machinery: driving gear ring of steel rolling equipment
Automatic production line: precision indexing positioning mechanism
4. the core value of helical gear:
4.1 Transmission smoothness breakthrough
Progressive meshing features allow smooth transition of contact lines
The vibration amplitude is reduced by 60-70% compared to spur gear
Ideal for high-speed applications (line speeds up to 50m/s)
4.2 Leap in carrying capacity
Increased contact area by 25-35%
Reduction of pressure per unit area by 20-25%
Transfer torque can be increased by more than 50%
Typical application: Wind power gearbox (power > 8MW)
4.3 Noise control Revolution
Meshing impact noise is reduced by 8-12dB
Precision helical fit can reach AGMA level 13 accuracy
4.4 Life extension technology
Wear uniform distribution mechanism
Increase the life of heavy duty by more than 30%
5. Hot forging process brings significant advantages to gears and shafts:
5.1 Improved material performance and strong density
5.2 Prepare for heat treatment, improve granular grain structure and improve mechanical strength
5.3 Eliminate the original defects and thinning of the material, and enhance the fatigue life
5.4 Optimize metal flow lines to improve load carrying capacity
5.5 Reduce the amount of subsequent processing, reduce the cost, and the material utilization rate is as high as 80%
Typical hot-forged gears include: various mechanical transmission gears, wind power spindle gears, construction machinery mining transmission gears, etc.
6. The industrial significance of Gears and Shafts
The cornerstone of modern industry: more than 90% of mechanical equipment relies on gear transmission and hydraulic transmission systems
The application of gear is ubiquitous, the precision control of gear lies in the CNC process, but the performance of the gear depends on the choice of materials, the forging process, the way of heat treatment, which is the fundamental performance of the gear. High-end gear must be selected according to the working conditions of the material, in the form of hot die forging prefabricated gear billet after precision machining.
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