渐开线水液压内啮合齿轮泵研究
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摘要
目前柱塞泵是水液压动力元件最为常见的结构形式,虽然部分水液压柱塞泵产品的工作性能已经达到甚至超过油压产品,但仍无法避免其结构形式所带来的结构复杂、对污染物敏感、自吸性能差、流量/压力脉动大和振动噪声等级高等固有弊端,这在一定程度上限制了水液压传动技术的应用和发展。水液压内啮合齿轮泵是将绿色水液压技术和高压内啮合齿轮泵技术结合的产物,该泵能够克服已有水液压泵存在上述缺点,符合液压动力元件“高压化”、“高速化”、“集成化”和“绿色化”的发展趋势。
本文选取了新型渐开线内啮合齿轮副(简称“渐开线内啮合齿轮副”)作为水液压内啮合齿轮泵的核心关键元件,该种齿轮副能够减小齿轮泵的无用死体积和困油体积,因而使内啮合齿轮泵具有更好的工作特性；研究了渐开线内啮合齿轮副的参数化数学建模方法及图形化建模方法,分析了渐开线内啮合齿轮副的啮合特性,推导了渐开线内啮合齿轮副避免根切的极限条件；推导了渐开线内啮合齿轮副的参数化瞬时流量方程以及相关流体输运特性评价指标,分析了齿轮设计参数对泵流体输运特性的影响规律；分析了渐开线内啮合齿轮副运动特性对困油特性的影响,提出了基于内啮合齿轮副图形模型的困油特性图形化求解方法,研究了齿轮设计参数对泵困油特性的影响,并给出了困油消除结构设计方法；提出了基于内啮合齿轮副图形模型的不平衡径向力精确求解方法,获得了内啮合齿轮副不平衡径向力的周期性变化数值,设计了水润滑环境下齿轮轴滑动轴承和内齿轮壳体两对关键摩擦副的静压支承结构；设计了水液压内啮合齿轮泵轴向和径向间隙自动补偿控制元件,结合有限元分析软件分析了间隙补偿元件在工作过程中的应力和变形分布状况,计算了间隙自动补偿控制过程中的内泄漏量；确定了水液压内啮合齿轮泵的主要技术指标及内啮合齿轮副的设计参数,基于关键零部件的工况特点选定了其材料及对应加工工艺；参考油压齿轮泵相关标准设计了水液压内啮合齿轮泵样机试验系统,试验研究了水液压内啮合齿轮泵样机的工作性能,分析了其主要失效形式及原因。
第一章概述了水液压动力元件的发展现状及所存在的固有缺点,介绍了本课题的来源、研究目的和意义,简述了现代水液压技术和内啮合齿轮泵技术的发展现状,指出了水液压内啮合齿轮泵的优势所在,介绍了本课题的关键问题和主要研究内容。
第二章运用二次展成法建立了渐开线内啮合齿轮副的参数化数学模型,基于所获得的数学模型,建立了内啮合齿轮副的图形模型,分析了该种齿轮副独特的啮合运动特性,结合齿轮啮合理论推导了渐开线内啮合齿轮副避免根切的极限条件。
第三章推导了渐开线内啮合齿轮副的参数化瞬时流量公式,提出了考核内啮合齿轮副流体输运特性的三个性能指标,分析了模数、变位系数、齿数、压力角和过渡圆角半径等齿轮设计参数对内啮合齿轮副流体输运特性的影响。
第四章分析了渐开线内啮合齿轮副运动特性对其困油特性的影响,提出了基于内啮合齿轮副图形模型的困油特性求解方法,分析了模数、变位系数、齿数、压力角和过渡圆角半径等齿轮设计参数对内啮合齿轮副困油特性的影响,设计了对应困油消除结构。
第五章提出了求解渐开线内啮合齿轮副不平衡径向力的图形化求解方法,获得了不平衡径向力随齿轮旋转的周期时变特性,确定了水润滑条件下、承受周期变负载的齿轮轴滑动轴承和内齿轮壳体两对关键摩擦副静压支承结构形式,分析了静压支承结构参数对其承载力和泄漏量的影响,确定了减摩耐磨、泄漏小的静压支承结构参数。
第六章分析了水液压内啮合齿轮泵利用浮动侧板和月牙块实现轴向和径向间隙自动补偿控制的原理,基于浮动侧板反推力时变特性设计了其背压腔结构,利用有限元方法获得了浮动侧板和月牙块的应力和变形分布,计算了间隙自动补偿过程中的泄漏量。
第七章确定了水液压内啮合齿轮泵的主要技术指标及对应的齿轮设计参数,确定了内啮合齿轮副高精度加工成形方法以及浮动侧板、月牙块和滑动轴承等复合塑料零件的加工工艺,搭建了水液压内啮合齿轮泵样机试验系统,试验研究了水液压内啮合齿轮泵样机的工作性能、失效形式。
第八章总结了本文的研究工作,并对进一步研究做了展望。
At present, piston pumps are the most common structure forms in water hydraulic pumps. Although performances of some water hydraulic piston pumps have reached or even over those of oil hydraulic ones, they still have shortcomings which are caused by their structure forms, such like complicated structures, sensitive to contaminants, bad suction performance, large flowrate and pressure pulsation, high level of vibration and noise and so on. To a certain extent, these shortcomings have restricted the application and development of water hydraulic technologies. Water hydraulic internal gear pumps have combined the advantages of green water hydraulic technologies and high-pressure internal gear pump technologies, which makes they overcome the shortcomings of traditional water hydraulic pumps and consistent with the development trend of hydraulic pumps, such as higher operation pressure, higher operation speed, more compact and more greener.
In this dissertation, a new kind of involute internal gear pairs, short for "involute internal gear pairs" are chosen as the key components of water hydraulic internal gear pumps. Compared to the conventional involute gear pairs, these new gear pairs can decrease the useless dead volumes and trapped volumes, which can improve the performances of internal gear pumps. Firstly, a parametric mathematical modeling method of conjugated involute internal gear pairs is proposed and then the graphical modeling method is presented. With the mathematical models, meshing characteristics of the gear pairs are discussed and the limiting conditions to avoid overcutting are derived. Then, the parametric instantaneous flow equation of the internal gear pumps is obtained. And, some indexes are proposed to evaluate the influences of gear parameters on fluid transport performance. Also, the influences of meshing characteristics on trapped volumes are discussed and a graphical method is presented to investigate influences of gear parameters on trapped oil characteristics, based on which the structure for eliminating trapped oil is designed. With the help of graphical model of gear pairs, the unbalance radial forces acting on internal gear pairs can be accurately solved, which are periodically changing with gear rotation. According to the unbalance radial forces, the hydrostatic bearing forms are determined for the two key friction pairs, which are gear shaft-sliding bearing and internal gear-pump case, under water lubrication conditions. Components are designed to compensate gaps and make axial and radial gaps always at a lower level. With the help of FEA tool, results of stress and deformation of these components during the operation process are obtained. And, the deformation-resulting leakages are analyzed. The main technical specifications of water hydraulic internal gear pumps are determined, which help to determine the parameters of internal gear pairs. Based on the operation conditions, materials for key components are chosen and so are the machining methods. Finally, referring to the standards of oil gear pumps, an experiment system for water hydraulic internal gear pumps is designed, which lays the foundation for the experiment researches and the following optimization and improvement of the pumps.
In Chapter1, the development status and shortcoming of existing water hydraulic pumps are briefly described. The source, purpose and significance of this dissertation are introduced. With descriptions of development statuses of modern water hydraulic technologies and internal gear pump technologies, the advantages of water hydraulic internal gear pumps are pointed out. The key problems and main research contents are listed.
In Chapter2, the mathematical models of involute internal gear pairs are built based on double generating method. With the obtained mathematical models, the graphical models of the gear pairs are built. Then, the meshing characteristics of internal gear pairs are analyzed. Moreover, the limiting conditions to avoid overcutting are derived according to the gear meshing principles.
In Chapter3, the parametric instantaneous flowrate formula of involute internal gear pairs is derived. Three indexes are proposed to evaluate the fluid transport performances. And, the influences of module, shifting coefficient, tooth number, pressure angle and fillet radius are discussed.
In Chapter4, the influence of meshing characteristics on trapped oil is discussed. A solving method for trapped oil characteristics is presented, which is based on the graphical models of internal gear pairs. Then, the influences of module, shifting coefficient, tooth number, pressure angle and fillet radius are discussed. With the obtained trapped oil characteristics, structures for eliminating trapped oil are designed.
In Chapter5, based on the graphical models, a method for solving unbalance radical forces, which are acting on the internal gear pairs, are proposed. And then, the unbalance radical forces are obtained, which are periodically changing with gear rotation. With these results, the hydrostatic bearing forms are determined for the two key friction pairs, which are gear shaft-sliding bearing and internal gear-pump case, under water lubrication conditions. Also, the influences of hydrostatic bearing parameters on bearing capacity and leakage are discussed, which helps to optimize the hydrostatic bearing parameters with larger bearing capacity and smaller leakage.
In Chapter6, the operation principles of compensating axial and radial gaps are presented, which are achieved by using floating plates and crescent plates. According to the characteristics of reverse pushing forces, the back-pressure chamber of floating plates is designed. With the help of FEA tools, the results of stress and deformation of floating plates and crescent plates are obtained, which help to calculate the leakage occurring during the gap-compensating process.
In Chapter7, the main technical specifications of water hydraulic internal gear pumps are determined and so are the design parameters of internal gear pairs. Then, the machining methods with higher accuracy are chosen for the internal gear pairs and so are the machining methods for floating plates, crescent plates and sliding bearings, whose material is composite plastic. Finally, an experiment system for water hydraulic internal gear pumps is built and based on experiments analyses on operation performances and failure modes are carried on.
In Chapter8, conclusions of this dissertation are made and so are some outlooks for the further research of water hydraulic internal gear pumps.
本文选取了新型渐开线内啮合齿轮副(简称“渐开线内啮合齿轮副”)作为水液压内啮合齿轮泵的核心关键元件,该种齿轮副能够减小齿轮泵的无用死体积和困油体积,因而使内啮合齿轮泵具有更好的工作特性；研究了渐开线内啮合齿轮副的参数化数学建模方法及图形化建模方法,分析了渐开线内啮合齿轮副的啮合特性,推导了渐开线内啮合齿轮副避免根切的极限条件；推导了渐开线内啮合齿轮副的参数化瞬时流量方程以及相关流体输运特性评价指标,分析了齿轮设计参数对泵流体输运特性的影响规律；分析了渐开线内啮合齿轮副运动特性对困油特性的影响,提出了基于内啮合齿轮副图形模型的困油特性图形化求解方法,研究了齿轮设计参数对泵困油特性的影响,并给出了困油消除结构设计方法；提出了基于内啮合齿轮副图形模型的不平衡径向力精确求解方法,获得了内啮合齿轮副不平衡径向力的周期性变化数值,设计了水润滑环境下齿轮轴滑动轴承和内齿轮壳体两对关键摩擦副的静压支承结构；设计了水液压内啮合齿轮泵轴向和径向间隙自动补偿控制元件,结合有限元分析软件分析了间隙补偿元件在工作过程中的应力和变形分布状况,计算了间隙自动补偿控制过程中的内泄漏量；确定了水液压内啮合齿轮泵的主要技术指标及内啮合齿轮副的设计参数,基于关键零部件的工况特点选定了其材料及对应加工工艺；参考油压齿轮泵相关标准设计了水液压内啮合齿轮泵样机试验系统,试验研究了水液压内啮合齿轮泵样机的工作性能,分析了其主要失效形式及原因。
第一章概述了水液压动力元件的发展现状及所存在的固有缺点,介绍了本课题的来源、研究目的和意义,简述了现代水液压技术和内啮合齿轮泵技术的发展现状,指出了水液压内啮合齿轮泵的优势所在,介绍了本课题的关键问题和主要研究内容。
第二章运用二次展成法建立了渐开线内啮合齿轮副的参数化数学模型,基于所获得的数学模型,建立了内啮合齿轮副的图形模型,分析了该种齿轮副独特的啮合运动特性,结合齿轮啮合理论推导了渐开线内啮合齿轮副避免根切的极限条件。
第三章推导了渐开线内啮合齿轮副的参数化瞬时流量公式,提出了考核内啮合齿轮副流体输运特性的三个性能指标,分析了模数、变位系数、齿数、压力角和过渡圆角半径等齿轮设计参数对内啮合齿轮副流体输运特性的影响。
第四章分析了渐开线内啮合齿轮副运动特性对其困油特性的影响,提出了基于内啮合齿轮副图形模型的困油特性求解方法,分析了模数、变位系数、齿数、压力角和过渡圆角半径等齿轮设计参数对内啮合齿轮副困油特性的影响,设计了对应困油消除结构。
第五章提出了求解渐开线内啮合齿轮副不平衡径向力的图形化求解方法,获得了不平衡径向力随齿轮旋转的周期时变特性,确定了水润滑条件下、承受周期变负载的齿轮轴滑动轴承和内齿轮壳体两对关键摩擦副静压支承结构形式,分析了静压支承结构参数对其承载力和泄漏量的影响,确定了减摩耐磨、泄漏小的静压支承结构参数。
第六章分析了水液压内啮合齿轮泵利用浮动侧板和月牙块实现轴向和径向间隙自动补偿控制的原理,基于浮动侧板反推力时变特性设计了其背压腔结构,利用有限元方法获得了浮动侧板和月牙块的应力和变形分布,计算了间隙自动补偿过程中的泄漏量。
第七章确定了水液压内啮合齿轮泵的主要技术指标及对应的齿轮设计参数,确定了内啮合齿轮副高精度加工成形方法以及浮动侧板、月牙块和滑动轴承等复合塑料零件的加工工艺,搭建了水液压内啮合齿轮泵样机试验系统,试验研究了水液压内啮合齿轮泵样机的工作性能、失效形式。
第八章总结了本文的研究工作,并对进一步研究做了展望。
At present, piston pumps are the most common structure forms in water hydraulic pumps. Although performances of some water hydraulic piston pumps have reached or even over those of oil hydraulic ones, they still have shortcomings which are caused by their structure forms, such like complicated structures, sensitive to contaminants, bad suction performance, large flowrate and pressure pulsation, high level of vibration and noise and so on. To a certain extent, these shortcomings have restricted the application and development of water hydraulic technologies. Water hydraulic internal gear pumps have combined the advantages of green water hydraulic technologies and high-pressure internal gear pump technologies, which makes they overcome the shortcomings of traditional water hydraulic pumps and consistent with the development trend of hydraulic pumps, such as higher operation pressure, higher operation speed, more compact and more greener.
In this dissertation, a new kind of involute internal gear pairs, short for "involute internal gear pairs" are chosen as the key components of water hydraulic internal gear pumps. Compared to the conventional involute gear pairs, these new gear pairs can decrease the useless dead volumes and trapped volumes, which can improve the performances of internal gear pumps. Firstly, a parametric mathematical modeling method of conjugated involute internal gear pairs is proposed and then the graphical modeling method is presented. With the mathematical models, meshing characteristics of the gear pairs are discussed and the limiting conditions to avoid overcutting are derived. Then, the parametric instantaneous flow equation of the internal gear pumps is obtained. And, some indexes are proposed to evaluate the influences of gear parameters on fluid transport performance. Also, the influences of meshing characteristics on trapped volumes are discussed and a graphical method is presented to investigate influences of gear parameters on trapped oil characteristics, based on which the structure for eliminating trapped oil is designed. With the help of graphical model of gear pairs, the unbalance radial forces acting on internal gear pairs can be accurately solved, which are periodically changing with gear rotation. According to the unbalance radial forces, the hydrostatic bearing forms are determined for the two key friction pairs, which are gear shaft-sliding bearing and internal gear-pump case, under water lubrication conditions. Components are designed to compensate gaps and make axial and radial gaps always at a lower level. With the help of FEA tool, results of stress and deformation of these components during the operation process are obtained. And, the deformation-resulting leakages are analyzed. The main technical specifications of water hydraulic internal gear pumps are determined, which help to determine the parameters of internal gear pairs. Based on the operation conditions, materials for key components are chosen and so are the machining methods. Finally, referring to the standards of oil gear pumps, an experiment system for water hydraulic internal gear pumps is designed, which lays the foundation for the experiment researches and the following optimization and improvement of the pumps.
In Chapter1, the development status and shortcoming of existing water hydraulic pumps are briefly described. The source, purpose and significance of this dissertation are introduced. With descriptions of development statuses of modern water hydraulic technologies and internal gear pump technologies, the advantages of water hydraulic internal gear pumps are pointed out. The key problems and main research contents are listed.
In Chapter2, the mathematical models of involute internal gear pairs are built based on double generating method. With the obtained mathematical models, the graphical models of the gear pairs are built. Then, the meshing characteristics of internal gear pairs are analyzed. Moreover, the limiting conditions to avoid overcutting are derived according to the gear meshing principles.
In Chapter3, the parametric instantaneous flowrate formula of involute internal gear pairs is derived. Three indexes are proposed to evaluate the fluid transport performances. And, the influences of module, shifting coefficient, tooth number, pressure angle and fillet radius are discussed.
In Chapter4, the influence of meshing characteristics on trapped oil is discussed. A solving method for trapped oil characteristics is presented, which is based on the graphical models of internal gear pairs. Then, the influences of module, shifting coefficient, tooth number, pressure angle and fillet radius are discussed. With the obtained trapped oil characteristics, structures for eliminating trapped oil are designed.
In Chapter5, based on the graphical models, a method for solving unbalance radical forces, which are acting on the internal gear pairs, are proposed. And then, the unbalance radical forces are obtained, which are periodically changing with gear rotation. With these results, the hydrostatic bearing forms are determined for the two key friction pairs, which are gear shaft-sliding bearing and internal gear-pump case, under water lubrication conditions. Also, the influences of hydrostatic bearing parameters on bearing capacity and leakage are discussed, which helps to optimize the hydrostatic bearing parameters with larger bearing capacity and smaller leakage.
In Chapter6, the operation principles of compensating axial and radial gaps are presented, which are achieved by using floating plates and crescent plates. According to the characteristics of reverse pushing forces, the back-pressure chamber of floating plates is designed. With the help of FEA tools, the results of stress and deformation of floating plates and crescent plates are obtained, which help to calculate the leakage occurring during the gap-compensating process.
In Chapter7, the main technical specifications of water hydraulic internal gear pumps are determined and so are the design parameters of internal gear pairs. Then, the machining methods with higher accuracy are chosen for the internal gear pairs and so are the machining methods for floating plates, crescent plates and sliding bearings, whose material is composite plastic. Finally, an experiment system for water hydraulic internal gear pumps is built and based on experiments analyses on operation performances and failure modes are carried on.
In Chapter8, conclusions of this dissertation are made and so are some outlooks for the further research of water hydraulic internal gear pumps.
引文
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