机器人柔性关节准椭球面齿轮传动—节曲面的优化设计

本文针对“东方”喷漆机器人柔性关节上装用的球面齿轮传动装置存在的问题,研制出了一种新型的可实现精密全方位变传动比的准椭球面齿轮传动.本篇依据空间双自由度啮合条件,对准椭球面齿轮的传动比函数及节曲面有关参数进行了优化设计.     

谐波齿轮精确间隙分析可视化仿真

研究谐波齿轮传动优化问题,渐开线齿廓代替齿轮共轭齿廓时,存在齿轮重叠干涉影响精度问题。为保证齿轮既不发生干涉又能实现精确传动,且提高计算精度与收敛速度,提出根据齿顶干涉检验法的自动优化算法。通过图形界面参数化设计进行迭代计算,快速精确计算出最小啮合间隙,并对齿廓啮合过程进行了可视化仿真。结果表明,优化结果啮合状况良好,明显提高了计算精度与收敛速度。最后,通过大量实例分析,得到齿轮啮合过程中最容易发生干涉的转角,并采用变位修正法进行修正。为谐波齿轮加工与检验提供参考依据。     

求解面齿轮啮合轨迹的新方法

根据面齿轮传动的点接触原理,提出一种求解面齿轮啮合轨迹的新方法,假设小齿轮、刀具、面齿轮三齿面同时啮合,通过求解小齿轮一刀具接触线和面齿轮一刀具接触线的交点,以确定它们在固定坐标系下的啮合线,从而反求面齿轮和小齿轮齿面上的啮合轨迹;通过MATLAB的数值计算功能,利用新方法求解了面齿轮传动的啮合轨迹,并与轮齿接触方法(TCA)求得的面齿轮啮合轨迹进行对比,发现结果一致,证明了方法的可行性;对安装误差下的面齿轮传动进行了分析,研究了不同安装误差对面齿轮啮合轨迹的影响.     

基于传动误差数据的齿轮误差检测方法与系统

齿轮传动误差影响齿轮传动精度和平稳性,传动误差与齿距和齿廓偏差等齿轮误差数据有直接关系.利用单面啮合测试和虚拟仪器原理,构建了传动误差检测系统,研究了传动误差与齿距与齿廓偏差数据的关系,找到一种将齿距与齿廓偏差计算出来的方法.经过试验分析,验证了本方法和系统的准确性.     

人字齿轮啮合刚度计算与齿面载荷分布研究

为了精确地进行人字齿轮的强度计算和动态特性分析,首先建立了渐开线真实齿廓的人字齿轮三维模型,提出了一种基于有限元方法和齿轮啮合原理的准确计算人字齿轮啮合刚度和齿面载荷分布的有效方法.方法利用有限元方法计算齿面柔度系数,考虑了齿轮的动态啮合过程.运用该方法计算了一对人字齿轮模型,最后分析了斜齿轮和人字齿轮啮合刚度的关系,得出了斜齿轮和人字齿轮啮合刚度近似相等的结论,为后续的动力学分析提供了准确的刚度激励.     

直线共轭少齿差行星齿轮传动仿真及实验研究

为了研究直线共轭齿廓在少齿差行星齿轮传动领域的性能特点,展开推导了直线共轭少齿差行星齿轮传动的数学模型,对其动态啮合力及振动特性进行仿真分析并进行了振动测试实验验证。结果表明,减速器性能表现良好,几种典型工况下啮合力最大误差值为7.01%,分析固定内齿轮第310,580节点的振动加速度值在齿轮副进入啮合瞬间达到峰值。结论验证了减速器的振动加速度与输入转速、负载转矩呈正相关性,为直线共轭齿廓在少齿差行星齿轮传动领域的后续应用发展提供了理论基础与实例支撑。     

机器人腕关节所用球面齿轮传动

提出了凹齿齿形为圆锥形的球面齿轮传动原理及加 工方法,并对相应凸齿齿形作了分析计算．由于该种球面齿轮的凹齿齿形采用圆锥形,使得 该种球面齿轮在加工制造方面容易得多,从而可进一步提高加工精度和简化加工工艺．     

连续共轭啮合的双圆弧谐波齿轮齿廓设计及运动仿真验证

基于分段函数表达的参数化公切线双圆弧齿廓,利用柔轮装配变形的包络精确算法研究双圆弧齿廓原始齿廓参数对包络存在区间大小的影响及其共轭齿廓的可用性,提出使二次共轭现象成为可用齿廓的设计方法.首先按照柔轮中性层周向位移引起的转角及其轮齿对称线相对于径矢转角的精确计算方法,确定变形后柔轮轮齿的位置和方位,获得一系列柔轮齿廓相对于刚轮齿槽的啮合运动轨迹;然后从计算机图形学角度获得用柔轮齿廓外包络表达的刚轮齿廓,验证二次共轭现象及其可用共轭齿廓的存在性.实例结果表明,双圆弧齿廓谐波齿轮可以通过合理的参数设计实现在整个啮合区间上的连续共轭传动,使更多齿对同时参与共轭啮合,从而提高谐波齿轮的承载能力和传动精度.     

圆柱斜齿轮动态强度与疲劳损伤仿真

为更好满足使用要求,对圆柱斜齿轮进行精确设计与加工,利用非线性有限元仿真软件MSC Marc对圆柱斜齿轮动态啮合过程齿面接触应力和齿根弯曲应力变化规律进行研究,利用疲劳分析软件MSC Fatigue对轮齿齿根弯曲疲劳寿命进行仿真计算,并根据设计寿命计算出安全寿命系数,为齿轮设计提供理论依据.     

考虑摩擦剥落故障的直齿轮副啮合刚度研究

针对直齿轮副从动轮轮齿由于受到交变与热应力载荷而发生点蚀剥落故障时齿轮副时变啮合刚度变化问题,本文选取矩形剥落区域简化计算,建立齿轮副齿面剥落的物理模型,以势能法推导当发生非对称剥落故障时齿轮副传动任意时刻的啮合刚度;同时通过建立齿面摩擦模型,研究了基于定摩擦因数下和时变摩擦因数下齿面摩擦和点蚀剥落故障对齿轮副啮合刚度的综合影响,推导考虑齿面摩擦的剥落故障齿轮副啮合刚度计算解析式。研究结果表明,当齿轮发生非对称齿面剥落故障时,轮齿因发生扭转变形而产生扭转刚度,齿轮副啮合刚度减小;齿面摩擦对啮合刚度影响较为复杂,其会增加直齿轮副双齿啮合区间和单齿啮合区间啮入阶段的啮合刚度,减小单齿啮合区间啮出阶段的啮合刚度。     

Static contact stress analysis of a spur gear tooth using the finite element method, including frictional effects

The literature available on gear tooth contact stress problems is not very extensive and that available does not explain the method by which analysis was carried out. In this paper an attempt has been made to study the contact stresses of a pair of mating gear teeth, under static conditions, by using a two-dimensional finite element method and the Lagrangian multiplier technique. The contact condition at the neighbouring node pair, namely, the contact existing over a number of node pairs in the contact zone, has been considered. To study the effect of friction between the mating gear teeth a range of average static friction coefficients, from 0.0 to 0.3, has been considered. The actual length of contact against the calculated length of contact is discussed. The variation of contact stress along the contact surface in a direction normal to the mating surfaces, which will give an idea about the depth of hardening required, is also presented.     

CAD of worms and their machining tools

To develop high-quality products, geometric modeling is needed in gear engineering to calculate the workpiece and tool geometry of worms, threads, or similar mechanical elements that can be described by helical or rotatory surfaces and that are to be generated by milling, grinding, or whirling. A survey will be given on the theoretical background, corresponding procedures, and illustrating examples of application concerning: (a) design of gear or worm profiles by means of curve primitives, their motion and manipulation; (b) calculation of conjugate gear profiles subjected to trochoidal motion; (c) calculation of arbitrary plane intersections of helicoids; and (d) calculation of the rotatory machining tool surface for a given worm and the inverse problem, including the solution of the undercut problem. Basic to the achieved integrated approach to CAD/CAM in this field is a discrete curve representation as sequence of points, tangent lines, and osculating circles providing higher geometrical information about curve and surface shape, which is also of high functional and economical importance for technological decisions.     

Dual-edge robotic gear chamfering with registration error compensation

This paper describes a novel method for robotic gear chamfering called dual-edge chamfering which can facilitate simultaneous chamfering of the two edges of adjacent gear teeth and overcome typical registration errors arising due to the placement of the workpiece in the robot workspace. Deviations of the robot end-effector trajectory when compared to the nominal trajectory due to registration errors are discussed first; such trajectory deviations caused by typical registration errors due to gear center translation and rotation are quantified. Dual-edge chamfering process is described and an efficient trajectory design strategy is developed by considering the kinematic constraints imposed by the profiles of the gear edge and the abrasive tool. The dual-edge chamfering robot trajectory is facilitated by a simple procedure for identifying the gear and gear root centers by employing the robot. To execute the dual-edge chamfering trajectory, an efficient motion/force control strategy that includes active compliance from the tool mounted on the robot is proposed. A number of real-time experiments are conducted to evaluate the proposed method by employing a commercial six degree-of-freedom robot. Two types of large cylindrical metal gears are utilized for testing, an external gear with teeth on the outside and an internal gear with teeth on the inside. In addition to these, two different robotic compliant tools with axial and radial compliance are tested. A representative sample of the experimental results are presented and discussed.     

Rigid-elastic modeling of meshing gear wheels in multibody systems

In many applications in mechanical engineering, gear wheels are used to transmit power between rotating shafts and, therefore, the ability to incorporate them into multibody systems and to simulate contact between them has become an essential topic in multibody dynamics.However, in some applications gear wheels may not be considered as being perfectly rigid. Due to the effect of contact forces there occur relevant deformations in meshing teeth and it is required for a high quality of the analysis to introduce some elasticities in the model of meshing gear wheels. Therefore, in this work elastic elements between the teeth and the body of each gear wheel are considered. This approach is especially well suited for multibody systems since it is a compromise between a totally rigid model and a fully elastic model allowing the simulation of large motions with many revolutions while still important elasticities are considered. The teeth and the body of each gear wheel are still modelled as being rigid but they are connected to each other by elastic elements. In doing so, an efficient and physically motivated algorithm is described and implemented in order to find the effects of multi-tooth contact as well as backlash and left and right hand side contact of the meshing teeth. Some examples compare the simulation results of rigid, partially elastic and fully elastic models.     

Computerized design of modified helical gears finished by plunge shaving

Among the several types of gear shaving operations, plunge shaving is used for finishing gears in mass-production due to the low cost and short machining time. Plunge shaving may be used to apply surface modifications with the purpose of reducing noise and vibration by the predesign of favorable functions of transmission errors, and modify gear tooth surfaces to avoid edge contacts and increase gear endurance, safety, and service life. A new geometry for helical gear tooth surfaces that combine the advantages of gear drives with lineal and localized contacts is proposed and obtained by plunge shaving. The shaver tooth surfaces are conjugated to those of an ideal helical gear with surface modifications. In this way, the to-be-shaved gear and the shaving cutter will be in line contact, and only a radial feed motion of the shaver is needed to generate the required pressure for the shaver to cut the excess of material on the gear tooth surfaces. A numerical example of design illustrates the advantages of the proposed geometry.     

A micro gearing system based on a ratchet mechanism and electrostatic actuation

This paper presents the design and fabrication of a silicon micro gearing system (MGS) that utilizes electrostatic comb-drive actuators to rotate a gear ring through a ratchet mechanism. The rotational comb-drive actuator is engaged with the gear ring through a spring system and ratchet teeth at one end, reciprocally rotates around an elastic point at the other end based on the electrostatic force. Rotational motion and torque from the driving gear ring are transmitted smoothly to driven gears through involute-shaped gear teeth. Smart design of anti-gap structures helps to overcome the unavoidable gap problem occurred in deep reactive ion etching (deep-RIE) process of silicon. The MGS has been fabricated and tested successfully by using SOI (silicon-on-insulator) wafer and one mask only. The angular velocity of the gear ring is proportional to the driving frequency up to 40 Hz.     

Fabrication of micro gear by micro powder injection molding

Micro components made from polymers can be easily processed but they may not be suitable for all applications. One example is where good mechanical properties are required. Thus, the fabrication of micro components from non-polymeric materials such as metals and ceramics is essential. In this paper, the fabrication of 316L stainless steel micro gear by micro powder injection molding is reported. The specifications of the green micro gear were: 10 teeth, module of 0.08, outer diameter of 1 mm and a length of 1 mm. Injection molding was conducted on a conventional injection molding machine with a small screw diameter of 14 mm. The green micro gear was well replicated. The debound micro gear retained its shape and the teeth were well defined. After sintering, the shape was also retained but with some surface irregularities. The process differences between μPIM and PIM, such as the use of smaller particle size and higher mold temperature are also highlighted.     

圆锥齿轮实体参数化逆向造型设计

提出实体参数化逆向造型设计的方法，介绍应用该方法开发圆锥齿轮三维实体参数化造型设计系统的过程。采用小型CAD软件的基本造型功能对圆锥齿轮三维基体作造型设计，再利用其宏记录自动生成程序的功能将宏文件和齿形生成程序结合，在Visual Basic环境下实现圆锥齿轮基体与齿形三维实体参数化逆向造型设计。旨在提供一种对CAD软件二次开发的新方法，使设计者掌握运用该方法对复杂三维实体进行参数化设计，从而提高开发小型CAD软件的能力。     

基于几何方程的齿轮GUI模拟

从几何学原理将齿轮轮齿分解为若干曲线段,以这些曲线段为基本图元,应用图形用户界面(GUI)技术,改变齿数、模数后可以直接模拟出齿轮,并能显示变位系数、齿顶圆直径等数据。实际测试表明：齿轮模拟的速度快、效率高,此方法对于机械工程技术人员、教师和出版商均具实用价值。