Developmental Investigation into Low-Noise High-Performance Hybrid Reducers Consisting of Gear and Traction Drives

齿轮传动因其传动效率高、齿轮箱结构紧凑而得到广泛应用。然而，在许多情况下，当齿轮传动装置在高速运行时，齿轮噪声会引起麻烦。与此相反，牵引传动几乎不会产生噪音问题，因为动力是在没有牙齿的帮助下传递的。为了最大限度地减少减速机的噪音，我们设计并制造了一种新的混合减速机，它有两个减速级，包括齿轮和牵引传动。第一阶段（高速）采用一个驱动辊和三个跟随辊的牵引传动，第二阶段采用一个齿轮和三个小齿轮集成到跟随辊轴的齿轮传动。推导了混合动力减速器的理论减速比和动力传递效率的计算公式，并对实验结果进行了分析。设计并制造了两种混合式减速器，对其传动效率和运行噪声进行了测试。带有总减速比约为20的外部齿轮的试验混合减速机被旋转到2000 rpm输入轴转速。当采用低粘度矿物油作为牵引油时，减速机的总效率可达90%左右。在采用内齿轮减速器的情况下，在相同尺寸的减速器箱的情况下，减速比提高到28左右，但总效率没有降低。从减速机运行噪音是极低的预期。通过实验和理论分析，阐明了不同牵引油和滚动体接触压力对总效率和减速比变化的影响。

Gear drives have been widely used because of their high power transmission efficiency and the compactness of the gear box. However, gear noise causes trouble in many cases when gear drives are operated at high speed. In contrast to this, traction drives hardly cause noise problems because power is transmitted without help of teeth.In order to minimize noise from speed reducers, we designed and made a new hybrid speed-reducer with two reduction stages consisting of gear and traction drives. A traction drive with one driving roller and three following rollers was used in the first (high speed) stage, and a gear drive with one gear and three pinion integrated to the following-roller shafts was used in the second stage.Equations for calculating the theoretical reduction ratio and power transmission efficiency of the hybrid speed reducer were derived, and they were used for the analyses of the experimental results.Two types of the hybrid speed reducers were designed and made to examine the power transmission efficiency and running noise. The trial hybrid reducer with external gears having a total reduction ratio of about 20 was rotated up to 2000 rpm input shaft speed. the total efficiency of the speed reducer reached to about 90 % when a low viscosity mineral oil was used as traction oil. In the case of the reducer with an internal gear, the reduction ratio was increased to about 28 with the same size of reducer box, but the total efficiency did not decrease. Running noise from the speed reducers was extremely low as expected.Effects of kinds of traction oils and contact pressure between rolling elements on the total efficiency and changes in the reduction ratio were clarified by experiments with the help of theory.