AGMA 11FTM19-2011 Convoloid Gearing Technology - The Shape Of The Future.pdf
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1、11FTM19AGMA Technical PaperConvoloid GearingTechnology - TheShape Of The FutureBy B.E. Berlinger Jr., andJ.R. Colbourne, GenesisPartners, LPConvoloid Gearing Technology - The Shape Of The FutureBernard E. Berlinger Jr., and Dr. John R. Colbourne, Genesis Partners, LPThe statements and opinions conta
2、ined herein are those of the author and should not be construed as anofficial action or opinion of the American Gear Manufacturers Association.AbstractSincethe1694inventionoftheinvolutecurvebytheFrenchscientist,PhilippedelaHire,andtheapplicationthereoftogearingbytheprolificSwissmathematicianLeonardE
3、uler,theworldhasembracedanddevelopedthis type of gear tooth form to a very high degree of engineering and manufacturing excellence.Improvements in recent years have been relatively modest, since this form has been so rigorously studiedandapplied. Thelong-termadoptionoftheinvoluteisrootedinlargepartt
4、othesimplicityofitstoolsandfieldoperation. Straightsidedtoolsandconjugacy,evenwithlimitedchangesincenterdistance,wereconsistentwith the industrial revolution of the 18th,19th, and 20thcenturies, and the mechanically based machine toolsand tolerance capabilities of these ages. The recent ubiquitous n
5、ature of computers and CNC machineryenhances the cost-effective freedom to optimize many parameters affecting our everyday life including geartooth forms.Convoloidisanewgeartoothformcapableofincreasingtorques20%to35%overthoseofconventionallydesignedinvolutepairs.Theformiscomputeroptimized,iscompatib
6、lewiththeworldsexistingcapitalassetinfrastructure, and mirrors the manufacturing sequences, processes and basic production costs of involutegears. The result is a major enhancement in gear drive system power density and cost reduction for a givenpower requirement. Convoloid gearing is totally scalab
7、le and is used in parallel axis helical, planetary, andother configurations.Copyright 2011American Gear Manufacturers Association1001 N. Fairfax Street, 5thFloorAlexandria, Virginia 22314October 2011ISBN: 978-1-61481-018-63 11FTM19Convoloid Gearing Technology - The Shape Of The FutureBernard E. Berl
8、inger Jr., and Dr. John R. Colbourne, Genesis Partners, LPIntroductionSincethe1694inventionof theinvolutecurveby theFrenchscientist, PhilippedelaHire, andtheapplicationthereoftogearingbytheprolificSwissmathematicianLeonardEuler,theworldhasembracedanddevelopedthis type of gear tooth form to a very hi
9、gh degree of engineering and manufacturing excellence. Improve-mentsinrecentyearshavebeenrelativelymodest,sincethisformhasbeensorigorouslystudiedandapplied.The long-term adoption of the involute is rooted in large part to the simplicity of its tools and field operation.Straight sided tools and conju
10、gacy, even with limited changes in center distance, were consistent with theindustrialrevolutionofthe18th,19th,and20thcenturies,andthemechanicallybasedmachinetools andtoler-ance capabilities of these ages. The recent ubiquitous nature of computers and CNC machinery enhancesthe cost-effective freedom
11、 to optimize many parameters affecting our everyday life including gear toothforms.Convoloidis anewgear toothform capableof increasingtorques 20% to35% over those of conventionallydesignedinvolutepairs. Theformis computeroptimized, iscompatiblewiththeworldsexistingcapitalassetinfrastructure, and mir
12、rors the manufacturing sequences, processes and basic production costs of involutegears. The result is amajor enhancement ingear drivesystem power density andcost reductionfor agivenpower requirement. Convoloid gearing is totally scalable and is used in parallel axis helical, planetary, andother con
13、figurations. See Figure 1.Primary objectives of the power transmission industryThe major quest of power transmission system designers and manufacturers today is twofold:S Increasing power (torque) density, i.e., maximum power through the smallest possible enclosedvolume.S Maintaining lowest cost per
14、 unit torque or power.Figure 1. 12 tooth, 10.4 module (2.44 NDP) Convoloid pinion4 11FTM19These two parameters are heavily interdependent for general economic viability.Convoloid gearing technology can provide these advantages. Convoloid gear tooth forms are computeroptimized and characterized by co
15、ncave/convex meshing surfaces. Involute tooth forms are, in contrast,convex/convex resulting in surface stresses on involute forms considerably higher than those of Convoloidforms. Theconcavetoothform intheConvoloidgear dedendum(lower partof thetooth) isconducivetohightooth beam strength which adds
16、to the Convoloid advantages.S Increases torque density from 20% to 35% over equivalent involute forms.S Is totally scalable for gearing from a few millimeters to several meters in diameter.S Is compatible with todays capital asset infrastructure so that the existing world gearing facilities canmanuf
17、acture and inspect this gearing.S Reflects the same manufacturing sequences and processes as now commonly practiced.S Is easily retrofitted intoexisting housings or other support structures by matchinggear center distances,ratios, and face widths.S Has manufacturing cost structures closely approxima
18、ting those of involute gears.S Can be designed into various configurations of parallel axis helicals including planetaries and otherepicyclics.Economic implicationsThereis asignificant potentialimprovement inthe cost and performanceof gear drive systems in many gearmarkets through the use of Convolo
19、id technology. Primary advantages of this new gearing concept are:RetrofittingA balanced gear drive design retrofitted to a given involute pairs center distance, with the same face width,sameratio, material, andheat treatment, yet canrateat 20-35%higher torqueandpower ratingat thesameorlowerstressle
20、velsinbothbendingandsurfacedurability. Here,assumingadequatebearingdesign,hous-ingstrength, etc., thegear system canbeupratedwithinacost indexat, orclosetothat benchmarkedbytheinvolute pair.Higher gear pair ratiosSinceConvoloidgeardesignsarenotdependentonthebasecircletheory,butarecraftedfromtheConvo
21、loidparameters free from involute-related constraints, smaller numbers of teeth in pinions can be designedwithout undercut to provide single pair ratios considerably higher than that commonly found with involutedesigns, and yet, are considered “balanced” viz-a-viz bending strength and surface durabi
22、lity stress levels.Result - potentially fewer gear pairs in a multistage transmission of given overall ratio, with the associatedreduction in gears themselves, bearings, housing machining, enclosed volume, etc.Process conversionLower stress characteristics of Convoloidgearingcanincreasethe opportuni
23、ty for process conversion inthemanufactureof thegears themselves. Dependingonstress levels, life, andother parameters, wrought steelgears can now be substituted with powdered metal, ground gears with hobbed gears, and other lower costconversions. Result - lower cost, higher productivity for a given
24、gear system of specified performancecapability.General power density increasesConvoloid designs that are specifically calculated to achieve a given performance level can be up to 20%smaller in enclosed volume compared to their involute stress level “equivalent.” Result - lower costs, lessenclosed vo
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