【作者】 刘润爱；

【导师】 张根保；

【作者基本信息】 重庆大学 ， 机械制造及其自动化， 2006， 博士

【摘要】 “零传动”又称直接驱动,在一般加工机床上用“电主轴”实现机床的主运动,可以较好地解决“外联”传动链长的问题,随着直线电机技术的逐渐成熟,直线运动也开始实现零传动。但对传动原理异常复杂、“内联”传动精度要求非常高的齿轮加工机床而言,由于缺乏理论作指导,在20世纪90年代以前国内外一直没有见到“零传动”技术在齿轮加工机床中成功应用的先例,齿轮加工机床一直沿用传统的传动方式,造成机床的传动结构异常复杂、传动效率低、传动精度差、磨损严重、切削速度低。一直到进入二十一世纪,“干切削”、“高速切削”、“高精度切削”、“硬齿面切削”等现代加工工艺进入齿轮加工领域,基于传统机械传动链的机床难于满足这些需求,因此国外的部分厂家才开始研制“零传动”齿轮加工机床,但机床的售价很高,设计原理和技术资料严格保密,形成了技术垄断的局面。为了打破国外的技术垄断,尽快提高我国齿轮加工机床的设计/制造水平,本文提出以“零传动”功能部件为核心,对机床设计/制造中关键的理论和技术进行深入系统的研究,研制成功一台基于零传动功能部件的高速、高精度滚齿机原型,为我国机床行业赶超世界先进水平打下坚实的基础。零传动滚齿机的滚刀主轴回转运动和工件主轴回转运动均去掉一般数控滚齿机中的高精度齿轮副和蜗轮副,采用内置主轴电机(电主轴,用于滚刀主轴)、内置力矩电机(DDR电机,用于工件主轴)分别驱动,这样就消除了由于传动装置而产生的误差,提高了滚齿机的加工精度。零传动滚齿机突破了传统齿轮加工机床的结构设计原理,研究和开发高速、高精度零传动滚齿机是齿轮机床的重大变革。针对零传动高速滚齿机的六项关键设计技术:总体布局设计技术、速度匹配性设计技术、传动系统设计技术、床身及排屑系统设计技术、滚刀主轴及工件主轴直接驱动结构设计技术、直驱滚刀主轴及工件主轴编码器选取技术进行了详细的分析与研究。将多体系统理论与齿轮啮合原理结合起来,根据数控滚齿机运动的实际情况,在比较全面地考虑了由于制造误差、安装误差、运动控制不精确以及其它原因引起的机床部件初始位置误差与运动误差等因素后,对数控滚齿机的滚齿啮合进行了分析,推导出包含误差影响因素在内的工件齿面方程,建立了工件齿面误差模型。该模型包含了由于制造、安装、运动控制不精确和刀具、床身、工件热变形更多还原

【Abstract】 “Motorized spindle”is used to drive tool spindle in general machine tool to realize“direct-drive”, which can solve the problem of long external driving chain well. As the linear motor technology is becoming more and more mature, straight-line motion has been realized direct-drive too. But for the machine tool which has complex drive principle and higher demand for internal drive precision, there is no successful case that direct-drive technology been used in gear cutting machine until 1990s. Gear cutting machine always adopts traditional drive way, which causes the unusual complication of drive structure, the low drive efficiency, the bad drive precision, the serious wears and tears and the low cutting speed. As 21st century’s coming, some modern processing technologies such as“dry cutting”,“high speed cutting”,“high precision cutting”,“hard gear cutting”, etc. have entered gear cutting filed. These new technologies cause the machine tool based on traditional machinery driving chain is difficult to meet demand, so some producers abroad have begun to develop“direct-drive”gear cutting machine. This machine’s cost is very high, and the design principle and technical data are kept secret strictly, which has formed the situation of technology monopoly.In order to break the technology monopoly and improve the level of designing/manufacturing rapidly in our country’s gear cutting machine, the paper focusd on the“direct-drive”function parts, deeply researched on the key theories and technologies of the machine designing/manufacturing, and succeed in developing a gear hobbing machine prototype at high-speed and high-precision, which built a solid foundation for the machine tool trade of our country to catch up with and surpass the advanced international level. Both the rotary motions of hob spindle and workpiece spindle in direct-drive gear hobbing machine remove high precision gears and wormwheel-worm in general NC gear hobbing machine. They are drived individually by internal spindle motor (motorized spindle, which is used in the hob spindle) and internal torque motor (DDR motor, which is used in the workpiece spindle). The change in structure can remove the error caused by drive device, and improve the precision of the gear hobbing machine.The direct-drive gear hobbing machine breaks through the traditional structure更多还原