鋼絲校直機(jī)傳動控制設(shè)計(jì)說明書

1、長江大學(xué)畢業(yè)設(shè)計(jì)（論文）題 目： 鋼絲校直機(jī)傳動及控制設(shè)計(jì) 專 業(yè)： 姓 名： 指導(dǎo)教師： 院系站點(diǎn)：長江大學(xué)繼續(xù)教育學(xué)院2010年5月鋼絲校直機(jī)傳動及控制設(shè)計(jì)學(xué) 生:班 級：指導(dǎo)老師:評 閱 人: 完成日期：王 世 春 2010年1月7日 至 2010年5月20日畢業(yè)設(shè)計(jì)任務(wù)書一、 設(shè)計(jì)題目鋼絲校直機(jī)傳動及控制設(shè)計(jì)二、 設(shè)計(jì)條件本機(jī)采用兩臺三相異步電動機(jī)傳動，普通電器元件控制，具有校直、拖動、定長切斷、落料等功能。本機(jī)可切斷鋼絲直徑1.52 mm ；校直、切斷最大速度為25m/min ；校直軸轉(zhuǎn)速為4568 m/min ；拉輪轉(zhuǎn)速為227.5 m/min ；校直長度為：蒸發(fā)器 300500

2、mm ； 冷凝器 5001000 mm 切斷長度誤差 0.3 mm ；最大切斷行程 8 mm ；氣源壓力 0.40.6 MPa ；工作電源 AC 380V 50HZ ；三聯(lián)體工作壓力 4.55Kg ；三、 設(shè)計(jì)內(nèi)容1、 設(shè)計(jì)計(jì)算說明書一份2、 校直箱裝配圖一張 1號圖3、 傳動箱裝配圖一張 1號圖4、 電氣控制原理圖一張 1號圖摘 要本本鋼絲校直、切斷機(jī)是為了適應(yīng)社會主義市場經(jīng)濟(jì)的需要， 針對目前制冷行業(yè)的發(fā)展?fàn)顩r采用絲管式冷凝器取代散熱效果差的百葉窗式冷凝器后，結(jié)合工廠的實(shí)際生產(chǎn)要求而設(shè)計(jì)、研制的。本機(jī)采用兩臺三相異步電動機(jī)傳動，普通電器元件控制，具有校直、拖動、定長切斷、落料等功能。設(shè)備穩(wěn)

3、定性好、生產(chǎn)效率高、成本低廉、應(yīng)用范圍廣。本設(shè)計(jì)中，包括：總體方案的設(shè)計(jì)，校直箱部分的設(shè)計(jì)，傳動箱部分的設(shè)計(jì)，定長、切斷、落料部分的設(shè)計(jì)，機(jī)架，絲架，電氣控制部分的設(shè)計(jì)。同時(shí)也對帶輪、齒輪、軸承、鍵等零件的強(qiáng)度進(jìn)行了分析計(jì)算。關(guān)鍵詞：鋼絲校直部分 鋼絲拖動部分 電氣控制部分 設(shè)備的操作使用與維修 交流接觸器 三聯(lián)體 繼電器 熔斷器 三相異步電動機(jī)前 言現(xiàn)代科技技術(shù)的不斷發(fā)展，極大地推動了不同學(xué)科的交叉與滲透，導(dǎo)致了工程領(lǐng)域的技術(shù)革命與改造。在機(jī)械工程領(lǐng)域，由于微電子技術(shù)、單片機(jī)技術(shù)和計(jì)算機(jī)技術(shù)的迅速發(fā)展，使機(jī)械工業(yè)的技術(shù)結(jié)構(gòu)、產(chǎn)品機(jī)構(gòu)、功能與構(gòu)成、生產(chǎn)方式及管理體系發(fā)生了巨大變化，使工業(yè)產(chǎn)業(yè)由

4、“機(jī)械電氣化”邁入了“機(jī)電一體化”為特征的發(fā)展階段。機(jī)電一體化是許多科學(xué)技術(shù)發(fā)展的結(jié)晶，是社會生產(chǎn)力發(fā)展到一定階段的必然要求。當(dāng)然，與機(jī)電一體化技術(shù)相關(guān)的技術(shù)還有很多，并且隨著科學(xué)技術(shù)的發(fā)展，各種技術(shù)相互融合的趨勢越來越明顯，機(jī)電一體化技術(shù)的廣闊發(fā)展前景也將越來越光明。設(shè)計(jì)者2010年5月目 錄1. 引 言 ························&

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7、#183;···· 12. 鋼絲校直機(jī)總體方案設(shè)計(jì) ··········································&#

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11、183;·········· 33.1校直部分的組成 ·····································&

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13、#183;············· 4 3.1.1 電動機(jī) ··································

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15、······························ 43.1.2皮帶傳動 ··················

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17、·········································· 43.1.2.1 皮帶傳動的設(shè)計(jì)計(jì)算 ····

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19、3;························· 43.1.2.2帶傳動的張緊 ······················

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23、3;································· 83.1.校直箱 ···············

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27、································ 9 3.1.3.2鍵的強(qiáng)度校核 ···············&

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29、#183;····················· 10 .2 校直部分的工作原理 ·························&#

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31、183;········ 11 .鋼絲拖動部分 ·······································&#

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33、183;······················· 12.1拖動部分的組成.1.1電動機(jī).1.2皮帶傳動 ·····················

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39、183;········ 134.1.2.1 皮帶傳動的設(shè)計(jì)計(jì)算 ······································

40、;··································· 134.1.2.2帶傳動的張緊 ············

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42、························· 174.1.2.3 結(jié)論 ······················

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46、#183;···························· 174.1.3.1滾動軸承壽命計(jì)算 ··················

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48、········ 184.1.3.2齒輪傳動的設(shè)計(jì)計(jì)算 ······································

49、3;································· 194.1.3.3 鍵的強(qiáng)度校核 ·············

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53、;··································· 23 .2拖動部分的工作原理 ············&

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55、#183;·················· 235.定長、切斷、落料部分 ····························

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57、83;············ 245.1定長 ····································

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67、3;········································ 257.絲 架 ········&

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82、83;········································ 288.1電氣控制方案 ·······&#

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89、83;··············· 318.2.2停止按鈕(TA1) ·······························

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91、83;·············· 318.2.3電源指示燈(XD2) ································&#

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93、183;········ 318.2.4手動切斷按鈕(QA2) ······································

94、················································ 318.2.5旋轉(zhuǎn)組合

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96、83;················································ 318.3交流接

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105、;·························· 329.鋼絲校直、切斷機(jī)的技術(shù)規(guī)范 ····················

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108、;··········································· 34 10.1 校直滑塊偏心的調(diào)整 ···

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110、3;··································· 34 10.2 拉輪的調(diào)整 ············&

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112、#183;·············································· 34 10.3切斷、落料機(jī)構(gòu)的調(diào)整

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116、;· 3511.設(shè)備的操作使用與維護(hù) ··············································

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124、;·············································· 37 致 謝 ··

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127、83;································ 38 參考文獻(xiàn)················&

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133、1. 引 言機(jī)械工業(yè)是重要的基礎(chǔ)工業(yè)，是國民經(jīng)濟(jì)發(fā)展的先導(dǎo)部門。由于科學(xué)技術(shù)的發(fā)展，世界機(jī)械產(chǎn)品的結(jié)構(gòu)越來越合理，其性能、精度和效率日趨提高，因此，為了和世界先進(jìn)技術(shù)接軌，我國對機(jī)械產(chǎn)品零件也相應(yīng)的提出了高性能、高精度與高自動化的要求。隨著現(xiàn)代科學(xué)技術(shù)的不斷發(fā)展，促進(jìn)了各學(xué)科多種技術(shù)間的有機(jī)結(jié)合，從而產(chǎn)生了許多綜合性的邊緣學(xué)科，極大地推動了不同學(xué)科的交叉與滲透，導(dǎo)致了工程領(lǐng)域的技術(shù)革命與改造。在機(jī)械工程領(lǐng)域，由于微電子技術(shù)和計(jì)算機(jī)技術(shù)的迅速發(fā)展及其向機(jī)械工業(yè)的滲透所形成的機(jī)電一體化，使機(jī)械工業(yè)的技術(shù)結(jié)構(gòu)、產(chǎn)品機(jī)構(gòu)、功能與構(gòu)成、生產(chǎn)方式及管理體系發(fā)生了巨大變化，使工業(yè)生產(chǎn)由“機(jī)械電氣化”邁入了“

134、機(jī)電一體化”為特征的發(fā)展階段。機(jī)電一體化是集機(jī)械、電子、光學(xué)、控制、計(jì)算機(jī)、信息等多學(xué)科的交叉綜合，它的發(fā)展和進(jìn)步依賴并促進(jìn)相關(guān)技術(shù)的發(fā)展和進(jìn)步。因此，機(jī)電一體化正向著智能化、模塊化、網(wǎng)絡(luò)化、微型化、綠色化、系統(tǒng)化的方向發(fā)展。為了適應(yīng)社會發(fā)展的需要和推動社會發(fā)展，我們的畢業(yè)設(shè)計(jì)課題，在對工廠進(jìn)行實(shí)地考查之后，從生產(chǎn)實(shí)際出發(fā)，對設(shè)備的工作原理和具體結(jié)構(gòu)進(jìn)行了詳細(xì)的分析論證，從而制定出了下面的設(shè)計(jì)方案。圖一 方案設(shè)計(jì)簡圖12. 鋼絲校直機(jī)總體方案設(shè)計(jì)本鋼絲校直、切斷機(jī)是為了適應(yīng)社會主義市場經(jīng)濟(jì)的需要，針對目前制冷行業(yè)的發(fā)展?fàn)顩r，結(jié)合工廠的實(shí)際生產(chǎn)要求而研制的，它適用于電風(fēng)扇、電冰箱冷凝器、冰柜、雞

135、籠、傘骨、焊條等各種鋼絲的校直和切斷。本機(jī)主要由鋼絲校直箱、齒輪傳動（牽引）箱、定長切斷落料、機(jī)架、絲架、電器控制六部分組成。絲架 圖二 總體結(jié)構(gòu)示意圖23. 鋼絲校直部分3.1校直部分的組成鋼絲校直部分由電動機(jī)、皮帶輪、V帶、和校直箱組成。圖三 校直箱裝配圖 33.1.1電動機(jī)鋼絲校直部分的傳動電機(jī)采用Y802 2型三相異步電動機(jī)，額定功率1.1KW, 額定電流2.5A, 同步轉(zhuǎn)速為3000 r/min , 滿載轉(zhuǎn)速為 2825 r/min 。電動機(jī)輸出軸的直徑為，軸上用鍵為。3.1.2皮帶傳動3.1.2.1 皮帶傳動的設(shè)計(jì)計(jì)算根據(jù)電動機(jī)額定功率P=1.1KW,，滿載轉(zhuǎn)速為nm = 2825

136、 r/min，從電動機(jī)到校直箱的動力擬采用2根普通V帶傳動，主、從動輪的傳動比為i=1，屬于增2速傳動。要求兩帶輪軸的中心距不大于500mm ,每天工作時(shí)間按16小時(shí)計(jì)算。1. 選擇V帶型號根據(jù)所給條件，選取工況系數(shù)KA=1.2。由此可計(jì)算出V帶傳動的設(shè)計(jì)功率Pd為：Pd=KAP= 1.2 X1.1= 1.32 KW依據(jù)設(shè)計(jì)功率Pd和大帶輪轉(zhuǎn)速n 查表，選A型帶。2. 確定帶輪的基準(zhǔn)直徑 dd1、dd2（1）選取大帶輪的基準(zhǔn)直徑dd1根據(jù)設(shè)計(jì)功率Pd和大帶輪轉(zhuǎn)速n 查表，選取大帶輪的基準(zhǔn)直徑dd1=140。（）驗(yàn)算帶的速度v根據(jù)公式 v=6010004 dd1n3.141402825 6010

137、00 . 速度，沒有超出范圍 。 （）確定大帶輪的基準(zhǔn)直徑 dd2取=0.015 ，則dd2=idd1(1-).（.） .根據(jù)普通帶帶輪基準(zhǔn)直徑系列，型帶帶輪的最小直徑不應(yīng)小于，故取 dd2 。. 確定中心距a和帶的基準(zhǔn)長度Ld （）初定中心距 a0根據(jù)已知條件，初步確定a0 。 （）確定帶的基準(zhǔn)長度Ld根據(jù)選定的帶輪的基準(zhǔn)直徑 dd1、dd2和初定的中心距 a0，可初步計(jì)算出皮帶所需的長度Ld0Ld0(dd2-dd1)2 =2a0+(dd1+dd2)+24a0(75-140)22450+(140+75)+24450 . .查表取 Ld 。 5（）確定中心距aaa0+Ld-Ld0 21250-

138、1239.85 2 450+安裝時(shí)所需的最小中心距amin=a-0.015Ld. .安裝時(shí)所需的最大中心距amax=a+0.03Ld. （）驗(yàn)算小帶輪包角11=180-57.3180-57.3000000dd2-dd1 a140-75 450.5 171.7120 （合適）.確定帶的根數(shù)查表得 單根帶的基本額定功率P0=.，P0=， Ka=.， KL=. 。 根據(jù)公式 z=PdPd =P0(P0+P0)KaKL 61.32 (1.25+0)0.9850.93.取 計(jì)算初拉力F0查表知 型帶的單位長度質(zhì)量 q=0.10Kg。 根據(jù)公式 F0=500500(2.5-Ka)Pd+qv2 Kazv(2

139、.5-0.985)1.32+0.1020.72 0.985220.7. .計(jì)算帶作用在軸上的力 FQFQ=2ZF0sin12171.702267.37sin 2 .帶輪結(jié)構(gòu)設(shè)計(jì)根據(jù)大帶輪的基準(zhǔn)直徑dd1=140，小帶輪的基準(zhǔn)直徑dd2，大、小帶輪均采用實(shí)心式結(jié)構(gòu)，用45鋼鍛造加工而成。取兩個(gè)帶輪的輪緣寬度，小帶輪的軸孔直徑d2，大帶輪的軸孔直徑d1mm。73.1.2.2帶傳動的張緊為了保證帶傳動的正常工作，應(yīng)定期檢查初拉力F0，當(dāng)發(fā)現(xiàn)初拉力小于允許值范圍時(shí)，須重新張緊。校直部分的電動機(jī)安裝在可以活動的擺架上面，依靠調(diào)節(jié)螺釘定期調(diào)整中心距，以恢復(fù)初拉力。圖四 校直箱傳動皮帶張緊裝置3.1.2.3

140、 結(jié)論從電動機(jī)到校直箱的動力采用2根長度為1mm的普通A型V帶傳 動，安裝中心距為.。大、小帶輪均用45鋼鍛造加工而成，采用實(shí)心式結(jié)構(gòu)。主、從動輪的傳動比為1：2，屬于增速傳動。3.1.校直箱本機(jī)校直箱采用密閉式，從而減少了噪音，有效地了高速運(yùn)轉(zhuǎn)部件對人體的 傷害，校直結(jié)構(gòu)先進(jìn)、精度高，可校各種長度規(guī)格的鋼絲。主要由箱體、箱蓋、校直軸、校直模、滾動軸承組成。箱體、箱蓋均采用HT200 鑄造而成，箱體和箱蓋采用自制鉸鏈連接，為了防止校直軸高速運(yùn)轉(zhuǎn)時(shí)因振動產(chǎn)生噪音，箱體和箱蓋之間需加橡膠軟墊。箱體兩端的軸承孔須在鏜床上加工，以保證兩孔的同軸度，避免高速運(yùn)轉(zhuǎn)時(shí)產(chǎn)生噪音。軸承的間隙依靠端蓋進(jìn)行調(diào)整，松

141、緊要適當(dāng)。8校直軸上裝有偏心調(diào)整滑塊，滑塊內(nèi)嵌有硬質(zhì)合金校直模，可校直徑為1.52mm的鋼絲。硬質(zhì)合金校直模的耐磨性好，可延長設(shè)備的使用壽命。但校直模的內(nèi)孔必須進(jìn)行研磨，以防劃傷鋼絲，影響焊接質(zhì)量和美觀。由于校直軸轉(zhuǎn)速高達(dá)r/min，校直切斷最大速度為25m/min,為使運(yùn)行平穩(wěn)，必要時(shí)需對校直軸進(jìn)行動平衡。校直軸上帶輪安裝處用鍵為 8X7X25 GB109679 。支承校直軸的兩個(gè)滾動軸承型號為6206(GB276-89)，基本額定動載荷為19500N，極限轉(zhuǎn)速為950013000r/min 。3.1.3.1滾動軸承壽命校核106fTC根據(jù)公式 Lh=() 60nfPP式中，Lh工作小時(shí)數(shù)（

142、h）n軸承轉(zhuǎn)速（r/min）fP載荷系數(shù)fT溫度系數(shù)P當(dāng)量動載荷（N）C基本額定動載荷（N）壽命系數(shù) 球軸承軸承的轉(zhuǎn)速 n=(1-)dd1nm dd21402825 75 (1-0.015) r/min查表 fP. ，fT ， ，當(dāng)量動載荷以皮帶作用在軸上力代入，取P91061195003() 則 Lh=6051941.2269（h）如果按設(shè)備每天工作小時(shí)，每月工作天，一年工作的時(shí)間為 （小時(shí)）那麼軸承可使用的年限為 ÷.年，壽命足夠。3.1.3.2鍵的強(qiáng)度校核軸上鍵的部位在帶輪連接處，只需校核此處的強(qiáng)度即可。 根據(jù)公式 p=4Tp dhl式中 p鍵工作面的最大擠壓應(yīng)力（MPa）,

143、P鍵連接的許用擠壓應(yīng)力（MPa）,d軸的直徑（mm）, d=24 mmh鍵的高度（mm）, h=7 mm l鍵的工作長度（mm）, l=25 mm T傳動軸的轉(zhuǎn)矩（N.mm）. T=9.55106P n其中 P=Pd=1.10.96=1.056KW n=(1-)dd1nm1402825 =(1-0.015)dd275=5194 r/min因此 T=9.55106=2135.8 N.mm 1.11.056 519410將以上數(shù)據(jù)代人公式得 p=42135.8=2.034MPa P 24725鍵連接的強(qiáng)度足夠。.2 校直部分的工作原理工作時(shí)，根據(jù)鋼絲的軟硬程度，通過調(diào)整傳動軸上的偏心滑塊，使鋼絲產(chǎn)

144、生波狀彎曲，各段具有不同的曲率，然后由電動機(jī)依靠2根普通V帶帶動校直軸高速旋轉(zhuǎn)，校直軸高速旋轉(zhuǎn)時(shí)，使鋼絲形成多次連續(xù)反復(fù)彎曲，以達(dá)到校直的目的。在校直軸內(nèi)，等距離的位置上，安裝著5個(gè)有中心孔的滑塊（內(nèi)部嵌有校直模），通過調(diào)節(jié)滑塊上的兩個(gè)螺母來控制偏心的大小。調(diào)整時(shí)必須保證鋼絲校直時(shí)產(chǎn)生的彎曲應(yīng)力大小于材料的屈服極限，否則鋼絲將會斷裂。在鋼絲能校直的情況下，偏心量應(yīng)盡量小，這樣同時(shí)也可減少功率消耗。11.鋼絲拖動部分.1 拖動部分的組成鋼絲拖動部分由電動機(jī)、皮帶輪、V帶、齒輪傳動箱和拉輪組成。圖五 齒輪傳動箱裝配圖121.1 電動機(jī)拖動電機(jī)采用Y90S6型三相異步電動機(jī)，額定功率為0.75KW,

145、滿載轉(zhuǎn)速為910r/min ，額定電流為2.3A .電動機(jī)輸出軸直徑為，軸上用鍵為。 .1.2皮帶傳動4.1.2.1 皮帶傳動的設(shè)計(jì)計(jì)算根據(jù)電動機(jī)額定功率P=.KW,，滿載轉(zhuǎn)速為nm = r/min，從電動機(jī)到校直箱的動力擬采用根普通V帶傳動，主、從動輪的傳動比為i=3，屬于減速傳動。要求兩帶輪軸的中心距不大于50mm ,每天工作時(shí)間按16小時(shí)計(jì)算。.選擇V帶型號根據(jù)所給條件，選取工況系數(shù)KA=1.2。由此可計(jì)算出V帶傳動的設(shè)計(jì)功率Pd為：Pd=KAP= 1.2 X.= . KW依據(jù)設(shè)計(jì)功率Pd和大帶輪轉(zhuǎn)速n 查表，選A型帶。2. 確定帶輪的基準(zhǔn)直徑 dd1、dd2（1）選取大帶輪的基準(zhǔn)直徑d

146、d1根據(jù)設(shè)計(jì)功率Pd和大帶輪轉(zhuǎn)速n 查表，選取大帶輪的基準(zhǔn)直徑dd1=0。（）驗(yàn)算帶的速度v根據(jù)公式 v=60100013 dd1n3.1480910 601000 . 速度，沒有超出范圍 。 （）確定大帶輪的基準(zhǔn)直徑 dd2 取=0.015 ，則dd2=idd1(1-)（.） . 取dd2 。. 確定中心距a和帶的基準(zhǔn)長度Ld （）初定中心距 a0根據(jù)已知條件，初步確定a0 。 （）確定帶的基準(zhǔn)長度Ld根據(jù)選定的帶輪的基準(zhǔn)直徑 dd1、dd2和初定的中心距a0，可初步計(jì)算出皮帶所需的長度Ld0Ld0(dd2-dd1)2 =2a0+(dd1+dd2)+24a0(236-80)22400+(80

147、+236)+24400 . . 查表取 Ld 。 （）確定中心距a14aa0+Ld-Ld0 21400-1311.33 2 400+.安裝時(shí)所需的最小中心距amin=a-0.015Ld. .安裝時(shí)所需的最大中心距amax=a+0.03Ld. .（）驗(yàn)算小帶輪包角11=180-57.3180-57.3000000dd2-dd1 a236-80 444.35 160120 （合適）.確定帶的根數(shù)查表得 單根帶的基本額定功率P0=.，P0=.， Ka=.， KL=. 。根據(jù)公式 z=PdPd =P0(P0+P0)KaKL0.84 (0.79+0.11)0.950.96 15.取 計(jì)算初拉力F0查表知

148、 型帶的單位長度質(zhì)量 q=0.10Kg。 根據(jù)公式 F0=500500(2.5-Ka)Pd+qv2 Kazv(2.5-0.95)0.84+0.103.82 0.9513.8. .計(jì)算帶作用在軸上的力 FQFQ=2ZF0sin12160021194.77sin 2. .帶輪結(jié)構(gòu)設(shè)計(jì)根據(jù)小帶輪的基準(zhǔn)直徑dd1=0，大帶輪的基準(zhǔn)直徑小帶輪均采用實(shí)心式結(jié)構(gòu)，用45鋼鍛造加工而成， 小 dd2，帶輪的軸孔直徑d1。大帶輪均采用輪輻式結(jié)構(gòu)，用 鑄造加工而成，大帶輪的軸孔直徑 d2 。取兩個(gè)帶輪的輪緣 寬度，164.1.2.2帶傳動的張緊為了保證帶傳動的正常工作，應(yīng)定期檢查初拉力F0，當(dāng)發(fā)現(xiàn)初拉力小于允許值范圍時(shí)，須重新張緊。拖動部分的傳動電機(jī)安裝在可以活動的擺架上面，依靠調(diào)節(jié)螺釘定期調(diào)整中心距，以恢復(fù)初拉力。圖六 齒輪傳動箱皮帶張緊裝置4.1.2.3 結(jié)論從電動機(jī)到校直箱的動力采用1根長度為10mm的普通A型V帶傳， 小帶輪用45鋼鍛造加工而成，采用實(shí)心式結(jié)構(gòu)；大帶輪用鑄造加工而成，采用輪輻式結(jié)構(gòu)。主、從動輪的傳動比為：1，屬于減速傳動。4.1.3齒輪傳動箱齒輪傳動箱由箱體、箱蓋、前滑塊、傳動軸、軸承、齒輪、調(diào)節(jié)手輪、彈簧等組成。箱體采用鋼板焊接加工而成。17蓋板用鋼板