1.Gear trimming

Gear modification includes crown modification and root modification. When the gears mesh, the tooth profile is elastically deformed. When cutting or withdrawing the gear, the top and root of the driving gear interfere with each other, and the mesh stiffness changes drastically, resulting in gravitational excitation. Improvements in gear tooth profiles not only avoid thousands of waves, reduce excitation and dynamic loads, but also reduce the effects of additional dynamic loads caused by base circle pitch errors.

2. Improve the contact degree of gear meshing

The greater the gear meshing, the more stable the gear transmission, the smaller the meshing impact and the lower the noise.

3.Reasonable design of gear teeth and modules

The reduction ratio of the gear reducer is determined by the number of gear teeth, and the bearing capacity of the gear reducer is determined by the number of gear teeth and the gear module. In the reducer, the working conditions of the sun gear are very poor, so in the design stage, the number of teeth and modules must be selected according to the actual use of the reducer, and the force of the sun gear must be checked.

At the same time, in order to reduce possible errors in gear manufacturing, when selecting the number of gear teeth, the transmission ratio is a non-integer and a prime number. This number of teeth prevents periodic manufacturing errors of the gears, which can cause vibration or abnormal noise.

4.Manufacturing accuracy

The accuracy of any machine will directly affect the mechanical performance of the machine, especially the performance of high-precision machinery. The accuracy of planetary reducer in general engineering is 7 and above.

Gear surface roughness is one of the important factors affecting the machining accuracy of gears. Because the gear pair transmits torque through contact with the tooth surface and slides during the transmission process, the smaller surface roughness can reduce the wear between the gears, reduce the heat of the gears, and improve the life of the gear transmission and the bearing capacity of the gears. In order to obtain a higher surface topography, the gears need to be ground.

The manufacturing accuracy of the gear is also related to the cumulative error of the pitch. The radial runout deviation and gear profile deviation are used to measure the deviation between the actual tooth profile and the ideal tooth profile. If the actual machining tooth profile deviation is large, it will cause uneven force on the gear, resulting in vibration and noise.

5.Reasonable load-balancing mechanism

In fact, manufacturing errors of gears always exist. The gear transmission adopts a load distribution mechanism, which can automatically compensate for various manufacturing and installation errors between the gear and the planet carrier to achieve load balance. Planetary gear reducers are usually divided into one part that floats and two parts that float at the same time. Single-component floating, sun gear floating, internal gear floating, planetary rack floating, two-part floating, sun gear and internal gear floating at the same time, sun gear and planet carrier floating at the same time. Two components float better than one.

6.Gear material and surface treatment

The bearing capacity of the reducer is not only related to the modulus of teeth, but also to the selection of gear and planetary rack materials. To further increase the load-carrying capacity of gears and planet carriers, heat treatment, such as carburizing or nitriding, is usually required depending on the selected material. After heat treatment, the gear tooth surface has a constant hardened layer. The hardness of the gear can reach HRC60, the bearing capacity is high, and the hardness of the center of the gear is low, so that the gear has a certain toughness.

7.Set a reasonable backlash

Gear gap meshing can avoid inter-tooth interference caused by manufacturing errors and thermal deformation, and facilitate lubricating oil storage. However, it is clear that excessive clearance can cause shock to the meshing gears, thereby increasing vibration and noise.

The failure types and causes of planetary gear reducer are analyzed, and measures to improve the performance of the reducer are proposed from the design and manufacturing level. As can be seen from the analysis, in order to improve the performance of the reducer, it is necessary to combine all aspects of design and manufacture. In addition to the necessary design calculations, the excellent performance of the gear reducer relies more on mature manufacturing processes and rich product experience.

Founded in 2008, Wangchi specialized in the manufacturing of engine gears and camshafts, and has obtained reputation in the motorcycle industry in China after 14 years of operation.

In 2020, Wangchi started to develop gearboxes for construction machinery. As a new player in the transmission industry, Wangchi aims to break down technical barriers and build its name with advanced technologies.

Wangchi is always focusing on innovation and spending a lot in research and development every year. Its gearbox series are much smaller and lighter than the equivalent standard transmissions in the global market.

With outstanding R&D capabilities, Wangchi is able to offer integrated solutions to clients in the fields of mobility.

Wangchi, a dynamic innovator, is shaping the future of transmission system.

For more information, please contact:
No. 10 Factory, Huxiao Village, Nanquan Street, Banan Disctrict, Chongqing, China

Telephone. (+86) 17353225540. Email: [email protected]
Website: https://www.wangchigear.com/en-US/