基于动态传动误差的弧齿锥齿轮形性耦合机理与啮合精度主动控制研究

The dynamic meshing performance of spiral bevel gear is closely related with its manufacturing and assembling methods. The traditional design and processing technologies cannot meet the demands of the transmission stability. It is not enough to study the relationships of the meshing performance with the design parameters and the transmission error, and lacks theoretical researches of the meshing accuracy improved by controlling the locating distance error. This project takes the dynamic meshing performance of spiral bevel gear as research object, established a mathematical vibration model which contains comprehensive meshing error. As a main line of dynamic transmission error, it is researching on the coupling degree of gear meshing characteristics with tooth surface error, adjustment error and locating distance error, and will obtain the influence weights of some parameters from the spectrum of dynamic transmission error. Through the geometric model derivation, the virtual driven model simulation, the kinetic model solution, the decoupling of dynamic transmission error, and the validating of the combined testing, the coupling effect between the tooth morphology and the transmission performance is analyzed. With the integrated constraints of transmission error and the tooth contact area, the evaluation mechanism driven by the both is established, to explore the active control strategy of meshing accuracy and to seek optimum balance between performance and locating distance error. The research results will improve the meshing accuracy and the transmission performance of spiral bevel gear, and provide technical supports for other high quality gear processing and testing.

弧齿锥齿轮的动态啮合性能与其制造和装配方法密切相关，传统的设计加工技术已不能满足高品质弧齿锥齿轮传动平稳性的需求，对设计参数、传动误差与啮合性能之间的关系研究不够深入，在通过控制装配误差提高啮合精度方面缺乏系统的理论研究。本项目以弧齿锥齿轮动态啮合性能为研究对象，建立含综合啮合误差的齿轮振动数学模型；以动态传动误差为主线，研究齿面几何、调整误差和装配误差对齿轮动态啮合特性量的耦合度，获取传动误差谱系中相关参数的影响权重。通过几何模型推演、虚拟传动模型仿真、动力学模型求解、传动误差谱系解耦和综合试验验证，分析轮齿形貌与啮合性能之间的耦合效应；以传动误差和啮合接触区综合最优为约束条件，构建动态传动误差和齿面接触区双驱动的啮合精度评估机制，探索啮合精度的主动控制优化策略，寻求啮合性能与装配误差间的最佳平衡。研究成果将改善弧齿锥齿轮啮合精度和传动性能，也为其他高品质齿轮的加工和检测提供技术支撑。

弧齿锥齿轮是汽车运输、工程机械、航空航海等领域复杂动力机械的关键传动部件，其轮齿精加工质量、齿面匹配精度与装配误差直接影响弧齿锥齿轮的啮合精度、传动平稳性和振动噪声等主要性能，其动态啮合性能与齿轮的制造和装配方法密切相关。传统的设计加工技术已不能满足高品质弧齿锥齿轮传动平稳性的需求，对设计参数、传动误差与啮合性能之间的关系研究不够深入，在通过控制装配误差提高啮合精度方面缺乏系统的理论研究。本项目以弧齿锥齿轮动态啮合性能为研究对象，建立弧齿锥齿轮副啮合数学模型，确定装配误差与传动误差之间的函数关系，研究装配误差对接触区及传动误差的影响；以几何数字模型为基础，建立有限元加载接触基本方程组，得到加载条件下单项装配误差及制造误差对齿面接触椭圆、应力分布及传动误差曲线的影响；以传动误差和啮合接触区综合最优为约束条件，构建动态传动误差和齿面接触区双驱动的啮合精度评估机制，在弧齿锥齿轮动态传动性能测试平台上开展齿轮啮合性能试验，探索啮合精度的主动控制优化策略，提出一种确定最佳安装距的方法，寻求啮合性能与装配误差间的最佳平衡。利用本项目研究成果，可以在数控滚动检查机上进行齿轮齿面接触区检查、齿轮副运动时的动态传动误差检测、齿轮副啮合振动检测、齿轮副齿侧间隙及变动量测量、以及运转噪声测定，使之能够在生产现场快速地对成品锥齿轮进行快速检测与评估，推进了弧齿锥齿轮动态传动性能的测试装备与智能评估技术研究，对于提高我国锥齿轮测试装备的水平和实现锥齿轮的全闭环制造具有较高的理论意义和应用价值。