| 摘要: | 設計工程師在設計齒輪箱時一般除要確認承載能力外，同時還需考慮空間限制、重量、造價成本等限制條件，由於牽涉到各種繁雜的計算，通常無法快速地找到最佳解。在電腦計算能力已經大幅進步的現在，若是能在給定設定參數及設計要求，利用程式將複雜的計算交由電腦執行，將會減少在設計開發上的時間成本。
本論文以Sendzimir滾軋機兩速減速齒輪箱之換檔齒輪段為案例進行研究。此段利用換檔機構可形成直驅及減速兩種速比。在設計上，有兩對相同中心距但速比不同的齒輪對。因此本研究將會以此為案例，使用齒輪計算軟體KISSsoft開發腳本程式，加快分析效率。
在研究中使用KISSsoft之模組整合軟體KISSsys，利用其中的腳本程式撰寫功能，針對案例之兩同中心距但不同速比的齒輪對，求得最佳扭矩重量比的齒輪參數組合，以及最小齒面負載係數KHβ之齒面修整量。在研究中會分析KISSsys中能夠使用的各項模組，接著根據齒輪對的邊界條件建立計算齒輪參數的數學模型，並且透過數學模型建立KISSsys腳本程式，以設定範圍內之參數使用KISSsoft螺旋齒輪對模組進行重複計算，並從中選出最佳扭力重量比之參數組合。
隨後以兩齒輪對之齒輪參數在KISSsys齒輪對模型的基礎下，加入齒輪箱體、軸件、軸承等零件，以分析計算齒輪對在各種不同情況下的接觸特性。首先利用腳本程式，計算最佳齒線螺旋角修整之修整量，以解決需反覆手動試誤之耗時過久的問題。同時藉此探討齒面修整對齒面接觸特性影響。最後將箱體剛性導入KISSsys，探討箱體變形對齒輪接觸及修整量的影響。分析結果顯示軸、軸承與箱體變形對齒面接觸有明顯影響，同時箱體鎖固螺栓力會改變齒面接觸特性。透過修整可將KHβ從1.1~1.3降至1.02~1.04。
;When designing a gearbox, engineers usually need not only to confirm the load capacity, but also to consider space, weight, cost and other constraints, which usually cannot be solved quickly due to the various complex calculations involved. Nowadays, because the computation technology been greatly improved, the time cost in design development can be reduced, if the program is used to execute the complicated calculations with the given design parameters and requirements.
This paper is based on the study case of the switching stage of a two-speed gear reducer of Sendzimir rolling mill. Two speed ratios are formed due to gear shifting mechanism direct drive with ratio as one and speed reduction. There are two gear pairs with the same center distance but different speed ratios. In this study, script programs are developed by using software KISSsoft for gear calculation to speed up the analysis of this study case.
In the analysis, KISSsys, a module integration software of KISSsoft for gear transmission system, is used to establish the model of the two gears pairs of this study case. A script program is developed to find the maximal combination of gearing parameters for the torque to weight ratio and the minimum face load factor KHβ. In the study, a mathematical model is created according to the boundary conditions of the gear pairs base on the available modules in KISSsys. With aid of the developed KISSsys script program, the gearing parameters in the given range are repeatedly calculated using the KISSsoft helical gear pair module. The combination of parameters for the best torque to weight ratio is selected from the calculated results.
Then, in order to analyze and calculate the contact characteristics of the gear pairs under various conditions, the gearbox housing, the shafts, and the bearings are added to the KISSsys gear pairs model with the selected gearing parameters. Firstly, a script is used to calculate the optimal modification amount of the helix angle modification of the gear flank to solve the time consuming problem of manually repeated trial and error process. At the same time, the effect of modification on tooth contact characteristics is also investigated. Finally, the housing stiffness form FEM is also imported into KISSsys to investigate the influence of housing deformation on the tooth contact and modification amount of gears. The analysis results of the analysis show that the deformation of the shaft, bearing and housing has a significant effect on the tooth contact, and the locking bolts of the housing also changes the tooth contact characteristics. The face load factor KHβ can be reduced from 1.1~1.3 to 1.02~1.04 by applying flank modification. |
