滤波减速器的设计与分析
摘要
本文的研究内容来源于梁锡昌、王家序教授的专利,是在谐波减速器的基础上改进的减速器,它具有运动精度高、传动效率高、刚度大、传动比大、承载能力大和回差小、体积小、高精度、寿命长等一系列优点,正好符合机器人传动装置的要求,而且克服了谐波传动难以克服的缺点,在国内外市场中的潜力是很大的。对这种新型传动的优化设计理论与方法进行研究,不仅有重要的理论意义,还有重要的实用价值。
本文研究工作的主要内容可概括如下:
1、在谐波减速器的基础上本文设计了一种新型减速器,即滤波减速器,它具有谐波减速器结构简单,重量轻、体积小等优点,可克服谐波减速器的缺点如柔轮椭圆变形,容易引起材料的疲劳破坏,空耗功率消耗大,柔轮存在薄壁,存在不稳定。对滤波减速器进行运动学计算和重要零部件的结构设计,并对内啮合的齿轮进行干涉验算。用I-DEAS软件对滤波减速器结构进行三维实体建模并完成零件的装配,生成机构的装配模型,并在此基础上对该传动装置进行机构分析。
2、对滤波减速器从刚度、强度和平衡几方面分析,用当量齿形法和ISO方法分别进行刚度分析并对两结果进行比较。接触强度首先进行分析计算,然后根据弹性接触分析理论,应用I-DEAS软件进行有限元接触分析,包括有限元分析模型的自动生成,应力应变分析,及分析结果的后处理。对轮齿弯曲强度进行分析计算,并对轮齿工作面进行耐磨计算。对滤波减速器结构上存在的不平衡质量进行平衡分析。
3、对滤波减速器传动装置各部件从改进结构和使用新型材料两个方面进行节约材料的研究,提出了四种结构改进方案,并依靠先进的结构设计技术及广泛使用轻质金属复合材料和非金属复合材料等措施,有效地降低了滤波减速器的重量,节约了材料。
4、对滤波减速器进行试验研究。加工出实验平台,进行运动精度测试和噪声测试,确定其声强的大小和传动比是否满足要求,以验证其各种数学模型的正确性。
This paper comes from the national patent for Professor Liangxichang and Professor Wangjiaxu . The lvbo speed reducer used in robot is a new type drive , which is developed on the basis of harmonic drive .It has a serial advantage ,such as wide range of transmission ratio ,high transmission accuracy, little backlash ,high rigidity ,high capacity of impact resistance ,small volume, compact structure and high transmission efficiency etc. So it will be widely paid attention to at home and abroad . Study on the optimization design theory and method of this new type lvbo drive is not only of theoretical significance,but also of practical value. The main work of this paper includes:
1.This paper presents an improved new design of harmonic reducer , based upon the established one . With the help of I-DEAS, the solid modeling is firstiy carried out . Then the assembly simulations were also carried out and generated the assembly models.
2.The paper analyses the every main factor which affects the transmission accuracy of lvbo speed reducer. on the above basis, the analysis of intensity, rigidity , balance must be done in order to design this speed reducer .The rigidity analysis is calculation quantitatively with routine method and ISO method. Finite element analysis by means of I-DEAS software, including auto-modeling of finite element analysis model, stress and deformation analysis, contact stress analysis and post processing. According to the contact theory of Hertz , verified the strength and rigidity for gear wheel of lvbo speed reducer.
3.In order to economize material of lvbo speed reducer, we have researched the two aspects of the lvbo speed reducer, which have improved the solid modeling and have bringed the new material into use.
4.The third sets of advanced sample machine is successfully manufactured by cooperating with the factory . Because the lvbo speed reducer used in robot requires high accuracy of transmission accuracy , static state test of measuring of transmission accuracy is conducted to prove all the mathematical models are correct.
本文研究工作的主要内容可概括如下:
1、在谐波减速器的基础上本文设计了一种新型减速器,即滤波减速器,它具有谐波减速器结构简单,重量轻、体积小等优点,可克服谐波减速器的缺点如柔轮椭圆变形,容易引起材料的疲劳破坏,空耗功率消耗大,柔轮存在薄壁,存在不稳定。对滤波减速器进行运动学计算和重要零部件的结构设计,并对内啮合的齿轮进行干涉验算。用I-DEAS软件对滤波减速器结构进行三维实体建模并完成零件的装配,生成机构的装配模型,并在此基础上对该传动装置进行机构分析。
2、对滤波减速器从刚度、强度和平衡几方面分析,用当量齿形法和ISO方法分别进行刚度分析并对两结果进行比较。接触强度首先进行分析计算,然后根据弹性接触分析理论,应用I-DEAS软件进行有限元接触分析,包括有限元分析模型的自动生成,应力应变分析,及分析结果的后处理。对轮齿弯曲强度进行分析计算,并对轮齿工作面进行耐磨计算。对滤波减速器结构上存在的不平衡质量进行平衡分析。
3、对滤波减速器传动装置各部件从改进结构和使用新型材料两个方面进行节约材料的研究,提出了四种结构改进方案,并依靠先进的结构设计技术及广泛使用轻质金属复合材料和非金属复合材料等措施,有效地降低了滤波减速器的重量,节约了材料。
4、对滤波减速器进行试验研究。加工出实验平台,进行运动精度测试和噪声测试,确定其声强的大小和传动比是否满足要求,以验证其各种数学模型的正确性。
This paper comes from the national patent for Professor Liangxichang and Professor Wangjiaxu . The lvbo speed reducer used in robot is a new type drive , which is developed on the basis of harmonic drive .It has a serial advantage ,such as wide range of transmission ratio ,high transmission accuracy, little backlash ,high rigidity ,high capacity of impact resistance ,small volume, compact structure and high transmission efficiency etc. So it will be widely paid attention to at home and abroad . Study on the optimization design theory and method of this new type lvbo drive is not only of theoretical significance,but also of practical value. The main work of this paper includes:
1.This paper presents an improved new design of harmonic reducer , based upon the established one . With the help of I-DEAS, the solid modeling is firstiy carried out . Then the assembly simulations were also carried out and generated the assembly models.
2.The paper analyses the every main factor which affects the transmission accuracy of lvbo speed reducer. on the above basis, the analysis of intensity, rigidity , balance must be done in order to design this speed reducer .The rigidity analysis is calculation quantitatively with routine method and ISO method. Finite element analysis by means of I-DEAS software, including auto-modeling of finite element analysis model, stress and deformation analysis, contact stress analysis and post processing. According to the contact theory of Hertz , verified the strength and rigidity for gear wheel of lvbo speed reducer.
3.In order to economize material of lvbo speed reducer, we have researched the two aspects of the lvbo speed reducer, which have improved the solid modeling and have bringed the new material into use.
4.The third sets of advanced sample machine is successfully manufactured by cooperating with the factory . Because the lvbo speed reducer used in robot requires high accuracy of transmission accuracy , static state test of measuring of transmission accuracy is conducted to prove all the mathematical models are correct.
引文
[1]梁锡昌,王家序.中国专利.专利号 CN200510057123.X.重庆.2005
[2]成大先.机械设计手册<减速器电机与电器>.化学工业出版社.北京.2004 年 4 月
[3]周明衡.减速器选用手册. 化学工业出版社.2002 年 6 月
[4]张展.减速器设计选用手册.上海科学技术出版社.2002 年 5 月
[5]李佳.计算机辅助设计与制造(CAD/CAM) .天津大学出版社.2002
[6]李骏.六大机械CADCAMCAE软件公司产品简介.电脑学习.2000
[7]马萍等.Ⅰ-DEAS软件及其在机械设计制造中的应用.机械与电子.1994
[8]方新.I-DEAS产品三维设计指南.机械工业出版社.2001
[9]崔风奎.I-DEAS机械设计.机械工业出版社,2004年3月
[10]杨建新,魏海燕.I-DEAS 入门与提高.清华大学出版社.2002 年 6 月
[11]Lawry , Mark H.. I-DEAS.EDS PLM Solutions.c.2004 年
[12]方新.I-DEAS 产品创成式加工指南.机械工业出版社.2002 年 4 月
[13]张简坤正,柯孜升,曹智雄.I-DEAS 入门.科学出版社.2001 年
[14]朱孝录.齿轮传动设计手册.化学工业出版社.2005 年 [15 王树人.齿轮啮合理论简明教程.天津大学出版社.2005 年
[16]许洪基.齿轮手册.机械工业出版社.2001 年 1 月
[17]商向东.齿轮加工精度机械工业出版社.2000 年 1 月
[18]ISO/DP6336/Ⅰ-Ⅲ,Basic Principles for the Calculation of Load Capacity of Spur and Helical Gear,1980.
[19] ISO/DP6336/ Ⅳ , Calculation of Load Capacity of Spur and Helical Gear,Part4;Calculation of Scuffing Load Capacity,1985
[20]ISO/TC60/WG6 N242E ,Load Carrying Capacity Calculations for High Speed Gear Drives ,1982.
[21] ISO/TC60/WG6 N291E, Calculation of Load Capacity of Cylindrical Involut: Gears; Application Standard for Industrial Gears; Detailed Method,1984.
[21] ISO/TC60/WG6 N290E, Calculation of Load Capacity of Cylindrical Involut: Gears; Application Standard for Industrial Gears;Simplified Method,1984.
[23] ISO/TC60/WG6 N283E, Calculation of Load Capacity of Cylindrical Gears; Application Standard for Vehicle Gears,1983.
[24] ISO/TC60/WG6 N264E, Calculation of Load Capacity of Cylindrical Gears;Application , Detailed Method for Industrial Gears; 1982.
[25]ISO/TC60/WG6 N265D, Tragfahigkeitsberechnung fur Stirnrader- Anwendung fur Schiffs-Hauptgetriebe,1982.
[26] ISO/TC60/WG6 N268E, Basic Principles for the Calculation of Load Capacity of Cylindrical Gears, Endurance Limits and Material Qualities,1984.
[27] 朱孝录.齿轮承载能力分析.高等教育出版社.1992 年 8 月
[28] 张耀良.航空材料学.哈尔滨工程大学
[29] 廖日东.I-DEAS实例教程-有限元分析.北京理工大学出版社
[30] 吴宗泽,刘莹.机械设计教程.机械工业出版社.2003年
[31] 成大先.机械设计手册(机械传动).化学工业出版社.2001年
[32] 李润方.齿轮传动的刚度分析和修行方法.重庆大学出版社.1998年
[33] 余跃庆,李哲.现代机械动力学.北京工业大学出版社.1998年
[34] 李润方,王建军.结构分析程序SAP5原理及其应用.重庆大学出版社.1992年
[35] 王勖成,邵敏.有限元法基本原理和数值方法 .清华大学出版社.2002年
[36] 赵均海,汪梦甫.弹性力学及有限元.武汉理工大学出版社.2003
[37]B M Iron. Engineering Applications of Numerical Integration in Stiffness Methods. AIAAJ. 1966, 4(11):378~392
[38]B M Irons, A Frontal Solution Program. Int. J. Num. Mech. Engng. 1970, 2:456~473
[39]E A Wilson, B Parsons. Finite Element Analysis of Elastic Contact Problems using Differential Displacements. Int. J. Num. Mech. Engng. 1970, 2:248~256
[40]S K Chan, I S Tuba. A Finite Element Method for Contact Problems of Solid Bodies, II, Application to Turbine Blade Fastening. Int. J. Mech. Sci. 1971, 13:132~145
[41]S Ohte. Finite Element Analysis of Elastic Contact Problems. Bull. JSME 16, 1973
[42]A Francavilla, O C Zienkiewicz. A Note on Numerical Computation of Elastic Contact Problem. Int. J. Num. Mech. Engng. 1975, 19:913-924
[43]B Fredriksson. Finite Element Solution of Surface Nonlinearities in Structural Mechanics with Special Emphasis to Contact and Fracture Mechanics Problem. Computer and structure. 1976, 6:514~530
[44]冈本纪明.有限要素法たょゐ非线性接触问题の解析. 日本机械学会论文. 1977, 372~386
[45]茑纪夫.有限要素法の接触问题への应用.机械の研究. 1978, 2(8):28~43
[46]J T Stadter, R O Weiss. Analysis of Contact through Finite Element Gaps. Computer and structure. 1979, 10(6): 867-873
[47]陈万吉.用有限元混合法分析弹性接触问题.大连工学院学报.1979, (2):12~15
[48]R F Li. Finite Element Analysis for Elastic-plastic Contact Problems with Friction. C/R/523/85.1985
[49]李锡夔. 蠕变-弹塑性-损伤耦合响应的有限元分析. 计算结构力学及其应用. 1995,12(1):26~38
[50]倪强,王乘,黄玉盈,张标标. 焊接过程的耦合三维热弹塑性有限元分析. 华中理工大学学报. 1997,25(1):84~86
[51]孙秦,徐晓飞. 弹塑性耦合张量的宏细观对偶形式. 应用力学学报. 1998,15(4):19~21
[52]张军,吴昌华. 轮轨接触问题的弹塑性分析. 铁道学报. 2000,22(3):16~21
[53]王勖成.有限单元法.清华大学出版社.2003
[54]O.C.Zienkiewicz . The Finite Element Method . McGraw-Hill.1990
[55]卓家寿.弹性力学中的有限元法.高等教育出版社.1987
[56]朱伯芳 .有限元法原理与应用.中国水利电力出版社.1987
[57]日本机械学会.齿轮强度设计资料.机械工业出版社.1979
[58]渐开线圆柱齿轮承载能力计算方法.中国标准出版社.1998
[59]齿轮手册编委会.齿轮手册(上下册).机械工业出版社.1990
[60]中国机械工程学会.中国机械设计大典.江西科学技术出版社.2002
[61] www.lw999.cn/lunwen 步进电机的选用
[62] www.cdxhw.com 步进电机的原理
[63]周希章,周全.如何正确选用电动机.机械工业出版社.2004
[2]成大先.机械设计手册<减速器电机与电器>.化学工业出版社.北京.2004 年 4 月
[3]周明衡.减速器选用手册. 化学工业出版社.2002 年 6 月
[4]张展.减速器设计选用手册.上海科学技术出版社.2002 年 5 月
[5]李佳.计算机辅助设计与制造(CAD/CAM) .天津大学出版社.2002
[6]李骏.六大机械CADCAMCAE软件公司产品简介.电脑学习.2000
[7]马萍等.Ⅰ-DEAS软件及其在机械设计制造中的应用.机械与电子.1994
[8]方新.I-DEAS产品三维设计指南.机械工业出版社.2001
[9]崔风奎.I-DEAS机械设计.机械工业出版社,2004年3月
[10]杨建新,魏海燕.I-DEAS 入门与提高.清华大学出版社.2002 年 6 月
[11]Lawry , Mark H.. I-DEAS.EDS PLM Solutions.c.2004 年
[12]方新.I-DEAS 产品创成式加工指南.机械工业出版社.2002 年 4 月
[13]张简坤正,柯孜升,曹智雄.I-DEAS 入门.科学出版社.2001 年
[14]朱孝录.齿轮传动设计手册.化学工业出版社.2005 年 [15 王树人.齿轮啮合理论简明教程.天津大学出版社.2005 年
[16]许洪基.齿轮手册.机械工业出版社.2001 年 1 月
[17]商向东.齿轮加工精度机械工业出版社.2000 年 1 月
[18]ISO/DP6336/Ⅰ-Ⅲ,Basic Principles for the Calculation of Load Capacity of Spur and Helical Gear,1980.
[19] ISO/DP6336/ Ⅳ , Calculation of Load Capacity of Spur and Helical Gear,Part4;Calculation of Scuffing Load Capacity,1985
[20]ISO/TC60/WG6 N242E ,Load Carrying Capacity Calculations for High Speed Gear Drives ,1982.
[21] ISO/TC60/WG6 N291E, Calculation of Load Capacity of Cylindrical Involut: Gears; Application Standard for Industrial Gears; Detailed Method,1984.
[21] ISO/TC60/WG6 N290E, Calculation of Load Capacity of Cylindrical Involut: Gears; Application Standard for Industrial Gears;Simplified Method,1984.
[23] ISO/TC60/WG6 N283E, Calculation of Load Capacity of Cylindrical Gears; Application Standard for Vehicle Gears,1983.
[24] ISO/TC60/WG6 N264E, Calculation of Load Capacity of Cylindrical Gears;Application , Detailed Method for Industrial Gears; 1982.
[25]ISO/TC60/WG6 N265D, Tragfahigkeitsberechnung fur Stirnrader- Anwendung fur Schiffs-Hauptgetriebe,1982.
[26] ISO/TC60/WG6 N268E, Basic Principles for the Calculation of Load Capacity of Cylindrical Gears, Endurance Limits and Material Qualities,1984.
[27] 朱孝录.齿轮承载能力分析.高等教育出版社.1992 年 8 月
[28] 张耀良.航空材料学.哈尔滨工程大学
[29] 廖日东.I-DEAS实例教程-有限元分析.北京理工大学出版社
[30] 吴宗泽,刘莹.机械设计教程.机械工业出版社.2003年
[31] 成大先.机械设计手册(机械传动).化学工业出版社.2001年
[32] 李润方.齿轮传动的刚度分析和修行方法.重庆大学出版社.1998年
[33] 余跃庆,李哲.现代机械动力学.北京工业大学出版社.1998年
[34] 李润方,王建军.结构分析程序SAP5原理及其应用.重庆大学出版社.1992年
[35] 王勖成,邵敏.有限元法基本原理和数值方法 .清华大学出版社.2002年
[36] 赵均海,汪梦甫.弹性力学及有限元.武汉理工大学出版社.2003
[37]B M Iron. Engineering Applications of Numerical Integration in Stiffness Methods. AIAAJ. 1966, 4(11):378~392
[38]B M Irons, A Frontal Solution Program. Int. J. Num. Mech. Engng. 1970, 2:456~473
[39]E A Wilson, B Parsons. Finite Element Analysis of Elastic Contact Problems using Differential Displacements. Int. J. Num. Mech. Engng. 1970, 2:248~256
[40]S K Chan, I S Tuba. A Finite Element Method for Contact Problems of Solid Bodies, II, Application to Turbine Blade Fastening. Int. J. Mech. Sci. 1971, 13:132~145
[41]S Ohte. Finite Element Analysis of Elastic Contact Problems. Bull. JSME 16, 1973
[42]A Francavilla, O C Zienkiewicz. A Note on Numerical Computation of Elastic Contact Problem. Int. J. Num. Mech. Engng. 1975, 19:913-924
[43]B Fredriksson. Finite Element Solution of Surface Nonlinearities in Structural Mechanics with Special Emphasis to Contact and Fracture Mechanics Problem. Computer and structure. 1976, 6:514~530
[44]冈本纪明.有限要素法たょゐ非线性接触问题の解析. 日本机械学会论文. 1977, 372~386
[45]茑纪夫.有限要素法の接触问题への应用.机械の研究. 1978, 2(8):28~43
[46]J T Stadter, R O Weiss. Analysis of Contact through Finite Element Gaps. Computer and structure. 1979, 10(6): 867-873
[47]陈万吉.用有限元混合法分析弹性接触问题.大连工学院学报.1979, (2):12~15
[48]R F Li. Finite Element Analysis for Elastic-plastic Contact Problems with Friction. C/R/523/85.1985
[49]李锡夔. 蠕变-弹塑性-损伤耦合响应的有限元分析. 计算结构力学及其应用. 1995,12(1):26~38
[50]倪强,王乘,黄玉盈,张标标. 焊接过程的耦合三维热弹塑性有限元分析. 华中理工大学学报. 1997,25(1):84~86
[51]孙秦,徐晓飞. 弹塑性耦合张量的宏细观对偶形式. 应用力学学报. 1998,15(4):19~21
[52]张军,吴昌华. 轮轨接触问题的弹塑性分析. 铁道学报. 2000,22(3):16~21
[53]王勖成.有限单元法.清华大学出版社.2003
[54]O.C.Zienkiewicz . The Finite Element Method . McGraw-Hill.1990
[55]卓家寿.弹性力学中的有限元法.高等教育出版社.1987
[56]朱伯芳 .有限元法原理与应用.中国水利电力出版社.1987
[57]日本机械学会.齿轮强度设计资料.机械工业出版社.1979
[58]渐开线圆柱齿轮承载能力计算方法.中国标准出版社.1998
[59]齿轮手册编委会.齿轮手册(上下册).机械工业出版社.1990
[60]中国机械工程学会.中国机械设计大典.江西科学技术出版社.2002
[61] www.lw999.cn/lunwen 步进电机的选用
[62] www.cdxhw.com 步进电机的原理
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