Lightweight Design Of Two-stage Planetary Gear Reducer

Large-scale hoist muti-stage planetary gear reducer was widely used in mine production. As an important part of reducer, reducer box’s performance also has a great influence on reducer. However, in the past, the shortage of technological capability compelled designers to increase the thickness of the reducer box based on traditional design experience when they wanted to ensure the intensity of the box, which would increase the weight, waste materials and increase the cost at the meantime. To solve this problem, the lightweight design of reducer becomes more and more necessary.With the support of the National Science and Technology Support Project ‘key technology research of lightweight and noise reduction of large-scale mine and hoisting transmission’(Project Number: 2013BAF01B05), the following studies were carried out:①Build a FEA model of the reducer with finite element method aimed at the performance characteristics of the multi-stage planetary gear reducer. On this basis,a dynamic finite element analysis of the reducer box is taken, the load of limit condition is obtained. Next, author takes topology optimization pre-treatment of box model, and then a static finite element analysis of the reducer box’s topology optimization model is taken, stress and displacement distribution under the limit condition are obtained.②Based on static finite element analysis results, a topology optimization is taken by using of the variable density method, which sets minimum volume fraction for optimal object, maximum displacement, minimum and maximum members’ dimension for optimal constraints, then the optimal design is taken according to density contours, the weight of optimized reducer box is reduced by 9.12%. Then a dynamic finite element analysis and a static finite element analysis of the optimized reducer box are taken, the stress and displacement distribution under the static analysis, the stress and vibration velocity under the dynamic analysis,the natural characteristics analysis are obtained. Compare all these analysis results with the original reducer box’s analysis results, the results show that performance of the optimized box accords with operating requirement, the lightweight design is realized.③ Take natural characteristics analysis of the gear transmission combined with Mesh Phasing theory. The results takes out that the method of optimize the vibration of gear transmission system with Mesh Phasing.