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44吨混合式焊接滚轮架的设计目录
1、焊接滚轮架分析·······································2 2、方案的选择与确定·····································3 2.1驱动方案的拟定·······································3 2.2传动方案的确定·······································3 2.3滚轮的直径确定·······································3 2.4偏心系数的确定·······································4 3、计算与校核············································5 3.1焊接滚轮架的设计计算·································8 3.2电机型号的确定······································10 3.3传动比分配及减速器选择······························10 3.4滚轮架滚轮设计······································11 3.5主动滚轮轴的设计计算································12 3.6蜗杆轴的设计计算····································12 3.7蜗轮蜗杆传动设计计算································13 3.8 V带设计计算·······································15 4、滚轮架零部件结构设计选择·····························15 4.1轴承端盖的设计·····································16 4.2键及联轴器的选择····································16 4.3机架的设计·········································17 4.4表面粗糙度·········································18 5、小结及参考资料·······································19
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44吨混合式焊接滚轮架的设计
1 焊接滚轮架分析
1.1课程设计题目分析
焊接滚轮架是借助主动滚轮与焊件之间的摩接力带动焊接旋转的变位机械。焊接滚轮架主要用于筒形焊件的装配与焊接。焊接滚轮架按结构形式分为两类：第一类是长轴式滚轮架，第二类是组合式滚轮架。本次设计的就是组合式滚轮架，它的主动滚轮架，从动滚轮架，混合式滚轮架都是独立的，使用时可根据焊件的重量和长度进行任意组合，其组合比例也不是1与1的组合。因此，使用方便灵活，对焊件的适应性很强。本次课程设计即是组合式滚轮架，草图如下
图1-1组合滚轮架草图
1.2 给定参数
吨位：44T
G=44×103×9.8=4.31×105N
焊接滚轮的圆周速度：V=6~60m/h范围内无级可调。 中心角：??45?~110?
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主要计算
结果及参数
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2 方案的选择与确定
2.1滚轮驱动方案的拟定
为使焊接滚轮架的滚轮间距调节方便可靠，组合便利，采用主动轮单独驱动的设计方案，即每个主动轮单独利用一台电动机和减速机构驱动。不过要注意解决好各主动轮的同步问题，在选用电动机和减速机结构上要尽量选用特性一致且经过实测的使用。
2.2 传动方案的确定
整个传动过程实质上是一个减速过程，且总的传动比比较大，可以采用三级减速：一级皮带轮减速；一级摆线针轮减速器减速；一级蜗轮蜗杆减速。传动方案简图如下图所示
图2-1 传动方案简图
2.3滚轮的直径的确定
由表1可知本次设计的44t滚轮架选取滚轮直径Dr=500mm；工件筒体直径Dmin=500mm，Dmxa=4000mm。
当中心角的?>130时支反力和圆周力急剧增大，相反，当?角太小时，滚轮架上的筒体焊件放置有可能不稳定。因此在实际应用中为使焊件在滚轮架上获得可靠的稳定性，并保证焊件可以平稳的转动?应小于40度我国制定的焊接滚轮架行业标准（ZBJ/T33003-1990）中规定中心角?应在45度到110度之间。
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滚轮直径 Dr= 500mm
工件筒体直径 Dmin= 500mm
Dmxa= 4000mm