三齿轮联动环板式针摆行星传动虚拟样机及其试验研究
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摘要
本文结合国家自然科学基金《双曲柄环板式针摆行星传动动态响应优化设计及试验研究》，以三齿轮联动双曲柄四环板式针摆行星减速器为研究对象进行研究，环板式针摆行星传动这种新型传动形式，是在深入分析传统针摆行星传动减速器和三环式渐开线减速器的优缺点的基础上提出的一种新型传动形式。通过前期的科研准备，目前该研究方向已取得了大量的科研成果，先后制造生产了四台不同型式的样机进行实验室性能测试和试验，为产品的定型提供了丰富的理论支持。结合已取得的科研成果，本文在数字化设计、模型的动力学分析和仿真计算以及样机的实验室测试等几个方面进行了系统深入的研究。
1、结合数字化设计原则，参考传统针摆行星传动设计方法，并充分考虑环板式针摆行星传动的结构特点，分别采用渐开线齿轮传动设计计算理论和摆线传动参数设计方法编制软件，对传动结构中传动零件和轴承的基本参数进行分析计算；推导并编制了参数优化设计和受力分析计算软件系统；结合该计算软件对环板式针摆行星传动进行了系列化设计，并在保证主要传动件强度和轴承寿命条件基础上进行了参数优化。
2、关于零件的准确建模，为使摆线轮在工作过程中具有合理的同时受力齿数和较高的传动效率，采用等距修形和移距修形的组合修形方法进行摆线齿形的加工，因此，在Pro/E软件中建立了符合实际摆线齿形的参数化模型，可以方便灵活的获得设计计算所需的摆线轮齿形，实现交互式的参数化设计；同时，研究了准确的渐开线齿形建模方法，并结合齿轮刀具参数化包络原理实现整个齿廓形状的参数化建模，实现存在齿侧间隙的齿形条件下准确的虚拟仿真；最后，结合已有的样机尺寸参数构建了四种不同型式的样机装配模型，为后续的有限元分析和动力学虚拟样机建模和仿真计算奠定了基础。
3、结合物理样机实验室验证，在获得了减速器整机装配模型的基础上，将模型导入ADAMS软件中进行了各种工况条件下的动力学虚拟仿真分析，通过仿真分析不但获得了运动、动力学仿真结果，还通过提取影响整机动力学特性的主要零部件的质心加速度、角加速度等计算数据，并进行对应的时域频域变换，获得了反映减速器各构件动力学特性的频谱图，代替实验室振动测试，获得了影响整机振动特性的主要频率响应区间，为改善样机的动力学性能提供了依据。4、理论分析的根本目的是为产品服务，因此，在完成全面系统的有关减速器设计的理论分析后，结合样机的有限元模态分析和虚拟动力学仿真结果指导完成物理样机的实验室性能试验，获得包括振动、噪声等测试数据，并与前述获得的有限元模态分析结果和动力学虚拟样机仿真结果进行了对比分析，分析了影响整机振动响应特性的主要频率范围，并验证了虚拟模型的正确性。以此为基础进行整机动力学分析，并进行模型的改进设计与虚拟仿真在渐开线三环式传动装置中也目前有应用在建筑施工、矿山机械设备上的双电机驱动三环式打桩机，结构如图1.3所示。其左右两侧可以安装两台同型号电动机同时驱动曲柄轴转动，而输出轴为中空的结构，可以让钻杆通过。
The researchs that are supported by National Natural Science Foundation of China aboutthe double cranks ring-plate-type pin-cycloidal gear planetary drvie with three gears weredone, this kind of new drive was proposed by analyzing and comparing the characteristics ofclassical pin-cycloid planetary drive and three rings involute gear reducer, which obtain theadvantages and overcome the disadvantages of the above two kinds of tranmission, so it is akind of developing industry product. The project has got large research achievements, whichinclude four prototypes and tests of propotypes in laborary, all that works proviod richtheoretical support for product. The researchs about series design and dynamics simulationand analysis of virtual prototypes and test of prototypes in laborary are done in this paper onthe base of researches have been made.
1. Under the guidance of the digital design theory, the software system of parametersdesign and force analysis were derived and written referring to the design method of classicalpin cycloid planetray drive combining the structure characteristics of ring plate type pincycloidal planetary drive, which include the basic parameters design method of involute gearsand cycloidal gears. So the series designs of products were done and the opimaztion designsthat guarantee the main strength indexs and life requirements of bearings are done also.
2. For the purpose of completing the virtual analysis of prototypes, the modeling ofaccurate3D models of key parts is necessary, so analyzing the forming principle andstructural characteristics and modeling method of cycloidal gears and involute gears is one ofthe main jobs of this thesis. In order to getting reasonable number of working teeth thatmeshing at the same time and high transmission efficience during work process of cycloidalgear, the equidistance and displacement modifications are adopted in manufacturing processof cycloidal gears, so the parametrical models of real cycloidal gears are built in Pro/Esoftware. At the same time the accurancy models of modified helical involute gears are builtalso, the simulations of virtual models that have gear clearances can be achieved. Finally, fourkinds of prototypes are built, and the base of virtual prototype simulation and FEM analysis isbuilt.
3. The new prototype test in laboratory is a kind of good method of getting theperformance index of prototype, but the dynamic characteristics of inner parts of prototypesare hard to getting by laboratory test condition, and the purposes of test are limited, and largecost of time and energy during test is not beneficial for stereotypes and seriation design. Toovercome the above shortcomings, the dynamic virtual simulation of virtual prototypes usingsoftware is a good choice. After achieving the assembly3D models of prototypes, inputtingthe models into ADAMS software and defining the dynamic settgings, the dynamic simulations of serious working conditions are done. The simulation resultes not only includethe kinematics and dynamics results, but can attain the spectral characteristics of key parts ofprototypes by data processing. Such as extracting the simulation data of velocity andacceleration of centroid of main parts and attaining the spectral diagrams by fast Fouriertransform, which as the work base of improving the dynamic performance of products by hardworks.
4. The purpose of principle research is to provide better products for society requirement.After completing the systematic theory calculations about the design methods of reduce, thelaboratory test of real prototype is done combined with the finite element analysis of parts ofreduce and dynamic simulation of virtual prototypes. By compared the test data of realprototype with the simulation results of reduce, such as vibration and noise test results, themain frequency ranges that affect the dynamics performance of reduce are confirmed. On thebase of above works, defined the dynamics model and redesign and simulations of virtualpropotype is done.
1、结合数字化设计原则，参考传统针摆行星传动设计方法，并充分考虑环板式针摆行星传动的结构特点，分别采用渐开线齿轮传动设计计算理论和摆线传动参数设计方法编制软件，对传动结构中传动零件和轴承的基本参数进行分析计算；推导并编制了参数优化设计和受力分析计算软件系统；结合该计算软件对环板式针摆行星传动进行了系列化设计，并在保证主要传动件强度和轴承寿命条件基础上进行了参数优化。
2、关于零件的准确建模，为使摆线轮在工作过程中具有合理的同时受力齿数和较高的传动效率，采用等距修形和移距修形的组合修形方法进行摆线齿形的加工，因此，在Pro/E软件中建立了符合实际摆线齿形的参数化模型，可以方便灵活的获得设计计算所需的摆线轮齿形，实现交互式的参数化设计；同时，研究了准确的渐开线齿形建模方法，并结合齿轮刀具参数化包络原理实现整个齿廓形状的参数化建模，实现存在齿侧间隙的齿形条件下准确的虚拟仿真；最后，结合已有的样机尺寸参数构建了四种不同型式的样机装配模型，为后续的有限元分析和动力学虚拟样机建模和仿真计算奠定了基础。
3、结合物理样机实验室验证，在获得了减速器整机装配模型的基础上，将模型导入ADAMS软件中进行了各种工况条件下的动力学虚拟仿真分析，通过仿真分析不但获得了运动、动力学仿真结果，还通过提取影响整机动力学特性的主要零部件的质心加速度、角加速度等计算数据，并进行对应的时域频域变换，获得了反映减速器各构件动力学特性的频谱图，代替实验室振动测试，获得了影响整机振动特性的主要频率响应区间，为改善样机的动力学性能提供了依据。4、理论分析的根本目的是为产品服务，因此，在完成全面系统的有关减速器设计的理论分析后，结合样机的有限元模态分析和虚拟动力学仿真结果指导完成物理样机的实验室性能试验，获得包括振动、噪声等测试数据，并与前述获得的有限元模态分析结果和动力学虚拟样机仿真结果进行了对比分析，分析了影响整机振动响应特性的主要频率范围，并验证了虚拟模型的正确性。以此为基础进行整机动力学分析，并进行模型的改进设计与虚拟仿真在渐开线三环式传动装置中也目前有应用在建筑施工、矿山机械设备上的双电机驱动三环式打桩机，结构如图1.3所示。其左右两侧可以安装两台同型号电动机同时驱动曲柄轴转动，而输出轴为中空的结构，可以让钻杆通过。
The researchs that are supported by National Natural Science Foundation of China aboutthe double cranks ring-plate-type pin-cycloidal gear planetary drvie with three gears weredone, this kind of new drive was proposed by analyzing and comparing the characteristics ofclassical pin-cycloid planetary drive and three rings involute gear reducer, which obtain theadvantages and overcome the disadvantages of the above two kinds of tranmission, so it is akind of developing industry product. The project has got large research achievements, whichinclude four prototypes and tests of propotypes in laborary, all that works proviod richtheoretical support for product. The researchs about series design and dynamics simulationand analysis of virtual prototypes and test of prototypes in laborary are done in this paper onthe base of researches have been made.
1. Under the guidance of the digital design theory, the software system of parametersdesign and force analysis were derived and written referring to the design method of classicalpin cycloid planetray drive combining the structure characteristics of ring plate type pincycloidal planetary drive, which include the basic parameters design method of involute gearsand cycloidal gears. So the series designs of products were done and the opimaztion designsthat guarantee the main strength indexs and life requirements of bearings are done also.
2. For the purpose of completing the virtual analysis of prototypes, the modeling ofaccurate3D models of key parts is necessary, so analyzing the forming principle andstructural characteristics and modeling method of cycloidal gears and involute gears is one ofthe main jobs of this thesis. In order to getting reasonable number of working teeth thatmeshing at the same time and high transmission efficience during work process of cycloidalgear, the equidistance and displacement modifications are adopted in manufacturing processof cycloidal gears, so the parametrical models of real cycloidal gears are built in Pro/Esoftware. At the same time the accurancy models of modified helical involute gears are builtalso, the simulations of virtual models that have gear clearances can be achieved. Finally, fourkinds of prototypes are built, and the base of virtual prototype simulation and FEM analysis isbuilt.
3. The new prototype test in laboratory is a kind of good method of getting theperformance index of prototype, but the dynamic characteristics of inner parts of prototypesare hard to getting by laboratory test condition, and the purposes of test are limited, and largecost of time and energy during test is not beneficial for stereotypes and seriation design. Toovercome the above shortcomings, the dynamic virtual simulation of virtual prototypes usingsoftware is a good choice. After achieving the assembly3D models of prototypes, inputtingthe models into ADAMS software and defining the dynamic settgings, the dynamic simulations of serious working conditions are done. The simulation resultes not only includethe kinematics and dynamics results, but can attain the spectral characteristics of key parts ofprototypes by data processing. Such as extracting the simulation data of velocity andacceleration of centroid of main parts and attaining the spectral diagrams by fast Fouriertransform, which as the work base of improving the dynamic performance of products by hardworks.
4. The purpose of principle research is to provide better products for society requirement.After completing the systematic theory calculations about the design methods of reduce, thelaboratory test of real prototype is done combined with the finite element analysis of parts ofreduce and dynamic simulation of virtual prototypes. By compared the test data of realprototype with the simulation results of reduce, such as vibration and noise test results, themain frequency ranges that affect the dynamics performance of reduce are confirmed. On thebase of above works, defined the dynamics model and redesign and simulations of virtualpropotype is done.
引文
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