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Gearbox for Cold Aluminum Rolling Machine

Gearboxes have a wide range of applications, such as in wind turbines. Gearboxes are an important mechanical component that is widely used in wind turbines. Its main function is to transmit the power generated by the wind wheel under the action of the wind to the generator and make it get the corresponding speed.
Generally, the rotation speed of the wind wheel is very low, far less than the rotation speed required by the generator to generate electricity. It must be realized by the speed increasing effect of the gear pair of the gear box.

Introduction:
The gear box bears the force from the wind wheel and the reaction force generated during gear transmission, and must have sufficient rigidity to withstand the force and torque, prevent deformation, and ensure the transmission quality. The design of the gear box body should be carried out in accordance with the requirements of the layout of the wind turbine power transmission, processing and assembly conditions, and ease of inspection and maintenance. With the continuous rapid development of the gearbox industry, more and more industries and different companies have used gearboxes, and more and more companies have developed and grown in the gearbox industry.
The gearbox is based on the modular design principle of the unit structure, which greatly reduces the types of parts and is suitable for mass production and flexible selection. The spiral bevel gears and helical gears of the reducer are all carburized and quenched with high-quality alloy steel. The tooth surface hardness is as high as 60±2HRC, and the tooth surface grinding accuracy is as high as 5-6.

Gearbox for cold aluminum rolling machine
The bearings of the transmission parts are all domestic well-known brand bearings or imported bearings, and the seals are skeleton oil seals; the structure of the suction box, the larger surface area of ​​the cabinet and the large fan; reduce the temperature rise and noise of the whole machine, and improve the reliability of operation , The transmission power increases. It can realize parallel shaft, right-angle shaft, vertical and horizontal general box. The input methods include motor connection flange and shaft input; the output shaft can be output at right angles or horizontally, and solid shaft and hollow shaft, flange type output shaft are available . The gearbox can meet the installation requirements of small spaces, and can also be supplied according to customer needs. Its volume is 1/2 smaller than that of the soft gear reducer, the weight is reduced by half, the service life is increased by 3 to 4 times, and the carrying capacity is increased by 8 to 10 times. Widely used in printing and packaging machinery, three-dimensional garage equipment, environmental protection machinery, conveying equipment, chemical equipment, metallurgical mining equipment, iron and steel power equipment, mixing equipment, road construction machinery, sugar industry, wind power generation, escalator and elevator drives, shipbuilding, light High-power, high-speed ratio, high-torque occasions such as industrial field, papermaking field, metallurgical industry, sewage treatment, building materials industry, lifting machinery, conveyor line, assembly line, etc. It has a good cost performance and is conducive to the matching of localized equipment.

effect:
The gearbox has the following functions:
1. Accelerating and decelerating is the so-called variable speed gearbox.
2. Change the transmission direction. For example, we can use two sector gears to transmit the force vertically to the other rotating shaft.
3. Change the rotating torque. Under the same power condition, the faster the gear rotates, the smaller the torque on the shaft, and vice versa.
4. Clutch function: We can achieve the purpose of separating the engine from the load by separating the two originally meshed gears. Such as brake clutch and so on.
5. Distribution of power. For example, we can use an engine to drive multiple slave shafts through a gearbox main shaft, so as to realize the function of one engine driving multiple loads.

Gearbox for cold aluminum rolling machine

Design:
Compared with other industrial gearboxes, since wind turbine gearboxes are installed in a narrow nacelle tens of meters or even more than a hundred meters above the ground, their volume and weight affect the nacelle, tower, foundation, wind load, installation and maintenance of the unit. Costs have an important impact, so reducing the size and weight is particularly important. At the same time, due to inconvenient maintenance and high maintenance costs, the design life of the gearbox is usually required to be 20 years, and the requirements for reliability are extremely harsh. Because size, weight and reliability are often an irreconcilable contradiction, the design and manufacture of wind power gearboxes are often caught in a dilemma. In the overall design stage, under the premise of meeting the requirements of reliability and working life, the transmission schemes should be compared and optimized with the goal of minimum size and weight; the structural design should meet the transmission power and space constraints as the premise, and try to consider simple structure, Reliable operation and convenient maintenance; product quality should be ensured in every link of the manufacturing process; the gearbox operating state (bearing temperature, vibration, oil temperature, quality change, etc.) should be monitored in real time during operation and routine maintenance should be carried out according to specifications.
Since the linear speed of the blade tip cannot be too high, the rated input speed of the gearbox gradually decreases with the increase of the single machine capacity, and the rated speed of the unit above MW generally does not exceed 20r/min. On the other hand, the rated speed of the generator is generally 1500 or 1800r/min, so the speed ratio of the large-scale wind power speed-increasing gearbox is generally around 75-100. In order to reduce the volume of the gearbox, wind power gearboxes above 500kw usually use power split planetary transmission; 500kw~1000kw common structures have two types of parallel shaft + 1 planet and 1 parallel shaft + 2 planetary transmission. ;Megawatt gearboxes mostly adopt the structure of 2-stage parallel shaft+1-stage planetary transmission. Because the planetary transmission structure is relatively complicated, and the large-scale internal gear ring is difficult to process and the cost is high, even if the 2-stage planetary transmission is adopted, the NW transmission is the most common form.

Gearbox for cold aluminum rolling machine

Manufacturing Technology
The external gears of wind power gearboxes generally adopt the carburizing quenching gear grinding process. The introduction of a large number of high-efficiency and high-precision CNC forming gear grinding machines has made China's foreign gear finishing level not too far behind foreign countries, and there is no technical difficulty in reaching the level 5 precision specified by the 19073 and 6006 standards. However, there is still a gap between China and foreign advanced technologies in terms of heat treatment deformation control, effective layer depth control, tooth surface grinding and tempering control, and gear tooth shaping technology.
Due to the large size of the ring gear of the wind power gearbox and the high machining accuracy requirements, the manufacturing technology of the internal gear of our country is far behind the international advanced level, which is mainly reflected in the processing of helical internal gears and the deformation control of heat treatment.
The machining accuracy of the box, planet carrier, input shaft and other structural parts has a very important influence on the meshing quality of the gear transmission and the life of the bearing. The quality of the assembly also determines the life and reliability of the wind power gearbox. . In terms of the processing and assembly precision of structural parts, my country recognizes that the equipment level is far behind the advanced level of foreign countries. The acquisition of high-quality and high-reliability wind power gearboxes, in addition to advanced design technology and necessary manufacturing equipment support, is inseparable from strict quality control in every link of the manufacturing process. The 6006 standard provides strict and detailed regulations on the quality assurance of gearboxes.

Lubricating
Commonly used gearbox lubrication methods include gear oil lubrication, semi-fluid grease lubrication, and solid lubricant lubrication. For better sealing, high speed, high load, and good sealing performance, you can use gear oil for lubrication; for poor sealing performance and low speed, you can use semi-fluid grease for lubrication; for oil-free occasions or high temperature occasions, you can use two Molybdenum sulfide ultrafine powder lubrication.

Gearbox for cold aluminum rolling machine
The lubrication system of the gearbox is of great significance to the normal operation of the gearbox. Large-scale wind power gearboxes must be equipped with a reliable forced lubrication system to spray lubrication on gear meshing areas and bearings. Insufficient lubrication accounts for more than half of the causes of gearbox failure. Lubricating oil temperature is related to component fatigue and the life of the entire system. Generally speaking, the maximum oil temperature of the gearbox during normal operation should not exceed 80℃, and the temperature difference between different bearings should not exceed 15℃. When the oil temperature is higher than 65°C, the cooling system starts to work; when the oil temperature is lower than 10°C, the lubricating oil should be heated to a predetermined temperature before starting up.
In summer, due to wind turbines being in full power for a long time, coupled with high-altitude direct sunlight, etc., the operating temperature of the oil rises above the set value; while in winter in the northeast cold region, the lowest temperature often reaches below -30℃, lubrication Lubricating oil flowing in the pipeline is not smooth, gears and bearings are not sufficiently lubricated, resulting in high temperature shutdown of the gear box, tooth surface and bearing wear, and low temperature will also increase the viscosity of the gear box oil, heavy load when the oil pump starts, and overload of the oil pump motor .
Gearbox lubricating oil has an optimal temperature range for working. It is recommended to design a lubricating oil thermal management system on the gearbox lubrication system: when the temperature exceeds a certain value, the cooling system starts to work, and when the temperature falls below a certain value, the heating system starts to work , Always control the temperature within the optimal range. In addition, improving the quality of lubricating oil is also an important aspect of the lubrication system. Lubricant products must have excellent low-temperature fluidity and high-temperature stability, and research on high-performance lubricating oil must be strengthened.

Gearbox for cold aluminum rolling machine

Features
1.Accelerate and decelerate, which is often referred to as a variable speed gearbox.
2. Change the transmission direction, for example, we can use two sector gears to transmit the force to the other rotating shaft vertically.
3. Change the rotating torque. Under the same power condition, the faster the gear rotates, the smaller the torque on the shaft, and vice versa.
4. Clutch function: We can separate the engine from the load by separating the two originally meshed gears, such as the brake clutch.
5. Power distribution. For example, we can use one engine to drive multiple slave shafts through the gearbox main shaft, so as to realize the function of one engine driving multiple loads.

Gearbox for cold aluminum rolling machine

Noise treatment
Gearbox is an important component widely used in mechanical transmission. When a pair of gears mesh, due to the inevitable error of tooth pitch and tooth profile, meshing shock will occur during operation and noise corresponding to the gear meshing frequency will occur. , Friction noise also occurs due to relative sliding between the tooth surfaces. Since gears are the basic parts of gearbox transmission, reducing gear noise is necessary to control gearbox noise. Generally speaking, the main causes of gear system noise are as follows:
1. Gear design. Improper parameter selection, too small overlap, improper or no modification of tooth profile, unreasonable gear box structure, etc. In gear processing, the base pitch error and tooth profile error are too large, the tooth side clearance is too large, and the surface roughness is too large.
2. Gear train and gear box. The assembly is eccentric, the contact accuracy is low, the parallelism of the shaft is poor, the rigidity of the shaft, bearing, support is insufficient, the rotation accuracy of the bearing is not high, and the clearance is improper.
3. Other input torque. The fluctuation of load torque, the torsional vibration of the shaft system, the balance of the motor and other transmission pairs, etc.

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