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中英文文献翻译-Fuller双中间轴变速器结构特点分析

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2021-01-26 09:48
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2021年1月26日发(作者:chuang)







A

The Analysis of Fuller Twin Countershafts Transmission

Structure Sharacteristics

Fulham
(Fuller)
because
American
Eaton
is
twin
countershafts
transmission

Eaton
company
of
the
60's
original
products,
in
1965
patent
application,
and
then
put
into
production,
supply
market.
It
is
aimed
at
the
condition
of
design:
when
the
U.S.
has
gradually built
highway
system, in
order to
improve the economic benefit to
freight
cars,
trucks, and fast pace to large, specialty direction. In the United States more prevalent mode
of transportation is by the saddle type tractor trailer and car pulled the tractor is the train, the
main road with heavy car models, its characteristic is short wheelbase, in addition to the U.S.
highway law caps the car before hanging must not be more than 800
mm
, and consequently
make
twin
countershafts
transmission
shaft
to
size
is
very
limited.
The
needs
of
the
development
of
surface
but
repeated
requests
to
improve
the
car
engine
power,
and
corresponding enlarges the bearing capacity of the transmission, this to the traditional single
axis
twin
countershafts
transmission
for,
its
axial
dimensions
must
increase
thus
had
a
contradiction, double the axis is that the twin countershafts transmission in such a situation
of
The
Times
looks
unfamiliar.
It
greatly
improve
the
twin
countershafts
transmission
torque
capacity
(Fuller
products
has
reached
2240
N
×
m
),
largest
and
decreases
the
axial
dimensions. It supply market in the United States, after the heavy car gradually replaced the
traditional
single
axis
transmission.
Eighty
s
it
almost
exclusive
American
heavy
vehicle
twin
countershafts transmission
market
(including
Eaton
company products
accounted
for
about 75%). Since the mid seventy s, Eaton products in reducing noise and improve life and
reliability
have
increased
significantly.
And
in
the
twin
countershafts
transmission
basic
structure
under
the
condition
of
invariable,
and
has
successfully
developed
series
presentation
of
a
new
generation
transmission.
At
the
same
time,
adjusted
the
original,
redesign
the
product
series
and
realize
standardization.
Eighty
s
has
the
new
series
production.
This
paper
is
based
on
the
original
900
series
(namely
the
new
series
11600,


both
the
same
basic
structure
of
RT-915)
type
group
structure
of
the
desktop
twin
countershafts transmission for an example cent fold.

Figure A1 Fuller Twin Countershafts Transmission

-The first shaft


-Lord box box axial



-The second Lord box in the axis
R-Lord box in reverse



Thaft axis



-vice Box-vice box output shaft
①②③
-Bhift joints set



-Vice box high low synchronizer joints sets

-Vice box super cheap synchronizer joints set of
ZR2-Lord box in reverse presence wheel
Attached A1 RT-915 type the basic structure of transmission

Figure
A1
shows
is
the
RT-915
type
twin
countershafts
transmission

structure
diagram, it consists of a main five gear box and a rear times of three gear shift combination
to vice box, it has 15 forward gears and three in reverse. The Lord box and vice gearbox
which
is
148.43
mm
center
distance
they
each
have
two
sets
of
intermediate
bearing
assembly, all the gear for spur gear, often meshing type
transmission , both on the output
shaft
gear
are
floating,
Lord
box
output
shaft
also
float.
The
box
without
the
file
synchronizer, vice box with high cheap locking pin type synchronizer, ultra low inertia by


outer
profile
of
mating
type
shift
device.
The
box
for
each
file
mechanical
hand
manipulation,
vice
box
every
file
adopted
the
pneumatic
control
shift.
When
vice
box
synchronizer joints set with mating set of

(

) are moved to the mating position when the
left

and
the
twin
countershafts
transmission
were
at
high
speed
area,
low
speed
area,
super-low speed area, equipped with five ratio for selection.
Attached A2 Structure analysis
Attached A2.1 Dual axis power diversion

Figure A1 shows twin countershafts transmission box and vice box the Lord had two
sets of the axis assembly, input power points to two road axis assembly, again by the output
shaft
assembly will be two road after mixing power output.
Input
and output shaft
of the
gear has at the same time two teeth on the axis of the two respectively with gear, work by
load
per
tooth
structure
is
concerned,
because
the
relative
single
reduced
1/2,
in
fact,
in
theory, the tooth shape error, the tooth thickness error, the center distance, the error on the
axis gear and corresponding mesh loading not even, make the actual reduce the value of less
than
1/2.
This
situation
than
single
axis
transmission
double
the
axis
has
obvious
advantages.
Attached A2.1.1 Dual axis gears life

In view of the fatigue life of gear with its load of three times about square of inverse
ratio, the formula is as follows:
P
3
?
N
C

(constant)






type (A1)
Type:

P-
Gear load
;
N-Fatigue damage of gear tooth cycles.
The
type
that
a
single
tooth,
A1
power
twin
countershafts
transmission
cases,
gear
load
P
1
,
the
corresponding
fatigue
damage
cycle
times
N
1
.
When
double
teeth
power
transmission, every single tooth load
P
2
, a former theory, that is
P
2
=
P
1
/
2
, the lower half of
the corresponding fatigue damage at this time
N
2
=
2
3

N
1
, that same cyclic number transfer
torque, double teeth power transmission , the fatigue life of gear can be increased greatly. If
keep gear fatigue life, that is
N
2
=
N
1
, the constant
P
2
=
P
1
,, this shows that the fatigue life
of gear equal, double teeth power transmission , every single tooth can be increased by
P
1
/
2



the load to
P
1
, can improve a times. If the worst of the actual situation, according to consider,
two
teeth
load
distribution
non-uniform
coefficient
for
0.6,
by
calculating
know
that
the
torque capacity still can be increased by 67%. This is double the axis on the basis of which
the design principle of the twin countershafts transmission facts.
Attached A2.1.2 Double the axis center distance transmission

The
axis
of
gear
twin
countershafts
transmission
of
center
distance
to
the
following
formula
A
=
K
A
3
BT
e
max
i
g
1< br>h
g






Type (A2)
Type:

B-the load distribution non-uniform coefficient (for 0.52 ~ 0.60);
By typeA2, it is known that the center distance gear is single axis structure reduce 15 to
20%, this to improve the twin countershafts transmission efficiency and lightweight has the
important meaning, we know that gear center distance is reduced, quality can reduce a lot.
Therefore, the center distance gear is gear twin countershafts transmission in the design
the
most
basic
parameters,
it
affects
the
twin
countershafts
transmission

many
of
the
important
performance
index,
and
direct
and
gear
twin
countershafts
transmission

and
structure design of carrying capacity has close relationship. For a long time, to reduce the
twin
countershafts
transmission

of the domestic and foreign traditional gear from center
made unremitting efforts, eventually because of bearing, material by technological level and
shift the design and manufacture of synchronizer into the technical level of the check and
little progress. The axis of the structure of the double appear, because power diversion has
greatly improved the gears, bearings and the axis, the loading condition, and may reduce the
processing
accuracy
requirement,
and
can
therefore
do
not
only
ensure
the
twin
countershafts transmission

performance, and reduced the gear from the center.
Due to the stress of gear twin countershafts transmission gear with a more traditional
nearly half, it can be reduced to about 40% of the reduced width, already reduced the twin
countershafts
transmission
shaft
to
size,
and
keep
the
bearing
capacity
of
the
gear,
with
improved load of the tooth, and to improve the distribution of gear life.
Attached A2.2 Gear floating
The box on the output shaft gear at the same time and the two symmetrically arranged
on
the
axis
of
gear
engagement,
it
in
two
gears
can
be
along
radial
direction
between


floating, rely on meshing round self- centering, vice box also is such. This is because of the
structure of the double Fuller twin countershafts transmission characteristics, its advantage
is: (1) to make the output shaft gear and two on the axis gear meshing, and correct evenly
distributed
load.
(2)
tell
the
traditional
twin
countershafts
transmission
output
shaft
in
all
often mesh in the needle bearing. The needle bearing is the weaknesses in traditional twin
countershafts
transmission
structure,
cancel
it,
to
improve
the
twin
countershafts
transmission of life and the working reliability have obvious function. (3) on gear precision,
accuracy
and the shaft bearing hole position precision can reduce requirements. (4) make
tooth shape by the error of dynamic load less of an effect. (5) test shows that the meshing
can reduce the floating strong resonance noise intensity.
Attached A2.3The arrangement of the shaft and stress
The second shaft for the box floating structure, two axis back end and vice box drive
gear spline connection, and through the bearing can support on the enclosure;
Shaft front
shaft
neck
and
oil
bearing
radial
clearance
of
the
big
(shaanxi
automobile
wheel
factory
measurement for the 0.9
mm
), the shaft
is
the fulcrum, front
after floating.
Therefore, the
second shaft gear are floating, shift, in the second shaft of the outer profile of engagement
with floating, facilitate change gear shaft.
Figure A1 shows, the axis of the centre of the attachment and the Angle
a

between
horizontal, Fuller 19°
Angle, this is too small, if will make the width dimension increase,
stir
oil
loss
increases,
the
loss
is
the
main
factors
of
influence
twin
countershafts
transmission efficiency; If too much, is the size, and increase the height above bearing bad
lubrication condition.
Symmetrical arrangement of the axis make first shaft, double the second shaft gear by
radial force balance each other, make this second shaft under bending moment, and are not
only bear torque, put can make the first axis, the second shaft diameter. 2 the axis also this
by
bending
moment,
can
make
the
shaft
decrease
1/2
ensure
enough
(this
is
intermediate
bearing stiffness design should be the main consideration question), to improve the working
conditions of the gear and bearing, this to raises gear and bearing life and reduce the noise is
favorable.
Attached A2.4 Solve the bearings use life problem
By that, input shaft and the output shaft bearings by composition of radial force to zero,


twin countershafts transmission gears for straight teeth, no axial force, bearing under gravity
only;
The
axis
of
the
bearing
by
radial
force
nearly
1/2,
reduce
without
axial
force.
All
bearing load conditions have been great improvement, this is caused such twin countershafts
transmission
bearing
life
long
basic
factors.
In
addition,
the
one
end
of
the
intermediate
bearing
vice
box
still
used
bearing
capacity
of
strong
roller
bearing,
already
won
the
benefits
of
large
capacity,
but
also
because
of
the
axis
must
be
adopted
to
support,
and
separate swimming type type bearings with convenient fold to. The box is a common type
though bearing the rest, but compared with the traditional twin countershafts transmission
coefficient of its life, but many high.
Deputy
box
output
shaft
is
made
up
of
two the outfit's
circular
cone
roller
bearings,
according to the analysis of the main support is to enhance the cantilevered shaft stiffness
and stability, and increase the bearing capacity.
In bearing load is small, as far as possible increase bearing capacity, can rise already
bearing life, to that of the twin countershafts transmission adapt to life always; And enhance
the stiffness, strengthen the functioning of the shaft rigidity, ensure gear meshing, improve
the correct life and reduce noise. The new series of products to reduce noise, and the new
design, so as to improve the bearing the bearing quality. The actual application result: Fuller
double central axis in the twin countershafts transmission within 480000 kilometers, the life
without
changing
bearing
the
same
level
in
the
value
of
the
world's
best
level
in
transmission.
AttachedA2.5
The
Lord
without
synchronizer
and
the
box,
type
clutch
cooperate
with
shifted gears
Fuller
double
the
axis
twin
countershafts
transmission
box
has
not
adopted
the
synchronizer, but the outer profile of mating type shift device. Normally, for large capacity
for
the
twin
countershafts
transmission
torque,
due
to
the
large
inertia
gear,
big,
shift
in
entering
when
the
speed
of
the
difference
of
the
larger
meshing
between
gear
from
the
impact
is
big
also,
cause
shift
difficult.
Therefore,
we
should
add
synchronizer.
But
the
synchronizer,
to
solve
the
current
problem
of
its
service
life.
Big
torque
capacity
of
the
single axis twin countershafts transmission is west Germany government is world famous
products,
there
are
still
a
synchronizer
early
damage,
the
problem
in
the
world
each
production manufacturer also
have been solved.
Fuller double the axis
twin
countershafts


transmission box has not adopted the synchronizer, but from a device with pull model, with
a simultaneous shift. It is in the box on the first shaft installed a friction brake disc, when
shift separation clutch, separate fork pulled back bearings, will friction brake disc pressure
to
the
first
axis,
brake
first
shaft
cover,
to
speed
up
the
process,
according
to
the
gear
synchronous this, it can only make the first shaft for, so can only slow movement in place
the start up and use, and can't shift in downward shift when used.
In the design principle, structure and calculation on the practice of exploratory, from
the principle and structure can be done on the up and down when shift all can use.
According to the analysis, the device in the simplified operation, shorten the time shift,
a simultaneous shift on can be as effective as synchronizer similar role, but for this structure
does not have synchronizer is the lock function, to realize no impact shift, but also depends
on
the
driver
of
the
operation
of
proficiency.
Eaton
company
claimed
that
the
shift
in
institutions of the engagement of the set, the spline tooth ends and the corresponding spline
gears between a big hole are design Angle pouring in shift, it can play a certain process lock
up
the
role.
This
kind
of
unique
shift
agencies
from
the
United
States,
heavy
duty
truck
generally use the situation, is successful, if via improved. Expected to completely replace
the synchronizer function, to cancel synchronizer purpose. So the benefits of the obvious, it
avoided
the
synchronizer
this
difficult
problem,
and
transmission
,
improve
the
life
the
weaknesses
in
the
work
of
transmission
,
simplify
the
structure
reliability
transmission
,
make its axial dimensions cut short, quality, reduce the ease of technology and materials to
demand higher parts, make the twin countershafts transmission cost reduced.
Attached A2.6 The straight teeth gear transmission

Fuller double the axis
twin
countershafts transmission
box and
Lord of all
gear vice
box
USES
the
straight
teeth
gear
meshing
twin
countershafts
transmission
at
home
and
abroad, often torque capacity is rare in transmission. In addition to deputy box drive gear is
the
single
diameter
temperance
gear
outside,
are
more
than
double
diameter
temperance
short gears, Lord box and vice box of each shift gears are one from each kind of the festival,
6/7
and
5/7
respectively,
converted
to
4.32/3.63
and
5.08/3.63
module
(new
series
of
the
products, the modulus gear presentation is less than 1.27 the tooth shape, easy to form more
slender gear meshing). The Lord all gear pair of gear box for 22 to 23 of gear teeth, all gear
tooth
shape
by
small
Angle
and
deflection
is
fixed.
In
order
to
achieve
the
new
traffic


regulations
for
noise
limit,
Eaton
for
new
products
to
take
the
following
measures:
(1)
improve tooth shape structure; (2) improve the superposition coefficient; vice (3) improve
the precision (presentation than thick tooth gear series precision high level, is make series
load distribution among gear teeth uniform); (4) improve bearing quality; (5) improve the
rigidity. Good results have been achieved, new series product is old products to reduce noise
intensity by 5 ~ 7
dB
.
Analysis the characteristics of structure above (1) all adopt the straight teeth gear, to
the
double
integral
of
the
intermediate
bearing
structure,
easy
to
assembly
assembly
and
collapse (2) using short teeth gear system can enhance the gear bending strength, but at the
same
time,
they
have
also
made
the
straight
teeth
gear
coincidence,
the
defects
of
small
coefficient by small teeth shape Angle and more to the teeth mesh areas, it can make up the
defects, new series of products to the superposition coefficient reaches 2.2 (the traditional
design
superposition
coefficient
around
1.5)
only.
Sweden
Scania
company
produces
the
GR860 main twin countershafts transmission adopts full inclined gear meshing transmission,
its
often
heavy
machine,
coefficient
of
1.45
to
1.68.
The
improvement
of
superposition
coefficient
can
improve
the
gearing
mesh
performance,
test
shows
that:
(1)
to
reduce
the
noise; (2) make is the influence of surface fatigue life of gear was obviously improved (for
tooth
face
pressure
decrease);
(3)
the
coincidence
degree
coefficient
of
large
gear
impact
resistant ability than superposition coefficient low gear (by the former load distribution is
more homogeneous), this ability is heavy auto twin countershafts transmission is required.
(3) with small teeth shape Angle will reduce the strength, the root is adopted deflection is
modified, in order to enhance strength of tooth root gear. (4) in order to guarantee the box
on the axis with the first two gear shaft,
the second shaft
gear can at the same time, also
make
the
second
shaft
meshing
gears
can
will
load
on
evenly
distributed
to
two
axis,
so
should guarantee the first axis, the second shaft
gear the number of teeth are even on the
gear axis all have a tooth is located in the same longitudinal plane inside, and all of the same
modulus gear. (7) for gear teeth smaller diameter, wide is narrower, facilitate the pull teeth
and shaving teeth and other high efficient processing method production.
The road test
results
show that:
the average operation 640000 kilometers of the new
series products, the reliability coefficient was 92%, 90% at 800000 km. Not only that such
twin countershafts transmission of simple structure, good technology, and reliable work, life

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