A. The core advantage of helical gear design: from "meshing impact" to "smooth transmission"
The instantaneous single-tooth meshing characteristics of spur planetary gears lead to two fatal problems:
1. Vibration noise: The load suddenly changes at the moment of meshing, causing high-frequency vibration (measured data: the vibration acceleration of the spur gearbox at 3000rpm is 47% higher than that of the helical gear);
2. Life decay: periodic impact loads accelerate tooth surface fatigue (case: a certain brand of spur joints on the automotive welding line has a life of only 8000 hours, while the helical gear solution can reach 20000 hours).
Helical gears achieve the following through progressive multi-tooth meshing (helix angle 15°-30°):
1. Load distribution optimization: the number of teeth participating in meshing increases by 30%-50%, and the unit tooth surface pressure decreases;
2. Transmission continuity improvement: there is no instantaneous disengagement during meshing, and the vibration energy decreases by more than 60% (Figure 1: Comparison of vibration spectrum of a certain model);
Axial force utilization: angular contact bearings are used to offset the axial force component and improve system rigidity (torque rigidity increases by 22%).
B. Manufacturing process breakthrough: from "precision compromise" to "micron-level control"
The production difficulties of helical planetary gearboxes are concentrated on tooth profile accuracy and assembly consistency. We have achieved breakthroughs in mass production through the following technologies:
1. Precision spiral grinding: using a five-axis linkage CNC gear grinding machine (such as KAPP NILES), the tooth surface profile error is ≤3μm, and the tooth direction deviation is ≤5μm;
2. Phase synchronization assembly: planetary gear load adjustment based on laser alignment instrument to ensure that the load deviation of each planetary gear is less than 5%;
3. Thermal deformation compensation: the gearbox housing is made of low expansion coefficient aluminum alloy (such as AlSi10Mg), with a temperature-controlled assembly workshop from -30℃ to 80℃.
C. Future evolution direction: helical gear + intelligent fusion innovation
As a manufacturer, we are promoting:
1. Dynamic meshing adaptation: piezoelectric ceramic sensors are integrated in the gearbox to monitor the tooth surface contact stress in real time and adjust the preload;
2. Lightweight topology: hollow helical gear design based on AI algorithm (weight reduction of 30%, torque density remains unchanged);
3. Self-healing coating technology: spraying a composite coating containing nano-molybdenum disulfide on the helical tooth surface, reducing the wear rate by 90%.
If you need customized development of helical planetary gearbox solutions suitable for different robot arms, please contact us!
Ningbo Zhongda Leader Intelligent Transmission Co., Ltd. is professional planetary gearbox manufacturers, established in 2006, we have more than 1500 employees, 66666m2 area and we have got 676 million sales on 2019.
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