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1、 Introduction 介绍 Function Overview 功能概述 Gearbox Types 壳体类型 Design Guidelines 设计 指南 Gears Shafts Bearings Fasteners Flanges Flange Sealing Ribs Joints Radii Wall thickness Corrosion Surface treatment NVH 齿轮 轴 轴承 紧固件 凸缘 凸缘密封 筋 过渡连接 倒圆角 壁厚 腐蚀 表面处理 噪音 Materials Options 材料选择 Material Weight 材料重量 Suitable
2、 Casting Options 铸造类型 Sand Casting 砂型铸造 Gravity Die重力铸造 Die Casting压铸 Low Pressure低压 High Pressure高压 Casting Tolerance Comparison铸造公差比较 Material Comparison材料比较 Heat Treatment Comparison热处 理 比较 Material Machinability材料可加工性能 Typical Transmission case materials 传统变 速箱壳体材料 Pro E Casing Modelling Process
3、 Pro E的建模 过程 Typical Design Process典型的设计过 程 Casing Design Summary外壳设计 总结 Case Study Mg vs Aluminium 案例分析 镁合金与铝合金比较 The aim of this guide is to help the designer to make an informed choice when designing a transmission case or casings The choices taken will depend on many factors such as 本指南的目的是帮助设计人
4、员在设计变速箱外壳时 作出正确的选择 需要考虑的因素如下 Time时间 Available time to design and or manufacture 设计和制造所用时间 Cost成本 Cost Targets Of design Materials Manufacturing and Processes 成本目标 设计 材料 制造 Number of units 组件数量 Small medium of large volumes 小件 中件 大件 Function功能 Structural Non structural Loaded vs Non Loaded 结构性或者非结构性功
5、能 承载或者非承载结构 Size尺寸 Overall size of transmission Castability Machinability 变速器外形尺寸 铸造性能 机械加工 性能 Complexity 复杂性 Influenced by Size and Function compromised by Castability machinability 受尺寸 功能 铸造性能 可加工性的影 响 Material材料 Iron Aluminum or Magnesium Alloys 铁 铝合金或镁合金 Environment 环境 External Regime package as
6、 well as recyclability of materials 外部政策 包装以及材料可回收性 Duty 工况 Life Duty Cycle Load regime Torque and Power 路谱 负载 扭矩和动力 Weight重量 Target Vehicle weight Transmission target weight see materials 目标车辆的重量 变速箱的目标重量 由变速箱材料决定 Vehicle Type车辆类型 Transverse Longitudinal FWD RWD 2WD 4WD 横置 纵置 前轮驱动 后轮驱动 两轮驱动 四轮驱动 To
7、 provide a suitable housing so that speed and torque can be transmitted from the input via shafts gears or pulleys to the output These speeds and torque s can be 一个结构合理的壳体 可以使速度和扭矩从发动机经过输入 轴 齿轮或滑套传到输出轴 使速度和扭矩达到如下变化 Continuous 连续 Stepped 阶梯 Constantly changing 不断变化的 Speeds and torque s impart loads a
8、s a result of the gears shaft and differentials The housing react these loads and forces 齿轮 轴和差速器的速度和转矩最终以力的形式作用到壳体 Provide an Oil reservoir for cooling and lubrication 为变速箱冷却和润滑提供油路系统 In addition mount or support other sub systems such as为其他子系统提供安 装支撑 如下 Drive Clutches 驱动离合器 CSC Engine Starter Moto
9、rs 发动机起动马达 Manual Shifter Systems 手动换档系统 Shift mechanisms Rails Forks Cable Brackets 换挡机构 手柄 拨叉 拉线支架 Hydraulic Shifter Systems 液压换挡系统 Automated Manual Shift Mechanisms 自动换挡系统 Wet Clutches Powershift etc Pumps Accumulators Coolers Filters etc 湿式离合器 动力换档原件 如泵 蓄能器 冷却器 过滤器等 Park Brakes 驻车制动 Depending on
10、 the type of Loads and installation casings can be divided into two types 根据载荷的不同 可将壳体分为两类 Non Structural the loads the casing sees are from the shafts and gears only with the casing hanging off the engine and the vehicle side member 非结构性壳体 齿轮和轴作用到壳体上的作用力最 后作用到发动机和车辆侧梁 private vehicles 乘用车 commercia
11、l vehicles 商用车 Structural 结构性壳体 Tractor chassis Transaxles 牵引车底盘 驱 动桥 The transmission case is an integral part of the chassis 变速箱是底盘的一个组成部分 Motor sport applications 赛车的应用 Transaxle designs Vehicle loads going through the casing such as Tractor Transaxle suspension hard points located on them 驱动桥设计
12、车辆荷载通过变速箱壳体悬 置部位传递到它们 Non Structural Motor sport Transaxle Tractor Transaxle牵引车驱动桥 These are the main components for transferring speed and torque in a transmission 在变速箱结构中 这些是用于传递速度和扭矩主要组件 As a result they impart the following type of loads on the casing 齿轮和轴从下面几个方面影响作用到壳体上的作用力 Separating Loads are
13、 effectively trying to push the each shaft and gear apart 分离载荷 径向力 有效地将每个轴和齿轮推开 Tangential Loads act normal to the base circle are a result of the gears reacting against each other 垂直于基圆的切向力是齿轮之间相互作用的结果 Axial Loads act along the rotating axis of the gear and shaft 轴向载荷沿齿轮和轴的轴向传递 Helical gears over s
14、pur gears will result in having to consider axial load effects The larger the helix angle the larger the load Other gear forms that impart axial loads include bevel and hypoid gearing 斜齿轮与直齿轮相比 必须考虑轴向载荷的影响 螺旋角越大轴向载荷越大 锥齿轮和准双曲 面齿轮也必须考虑轴线载荷的影响 The bearings are the elements that actually interact with
15、the casing It is here that the gearing loads pass through the rolling elements into the casing The size and type are very much dependant on the loads anticipated as well as the layout of the rotating parts within it 轴承是直接与外壳相互作用的元件 齿轮力最终通过轴承内部的 旋转件传递到外壳 轴承尺寸和类型的选择依赖于受力大小以及内部 旋转件的布局 Deep Groove Ball
16、深沟球轴承 Cylindrical Roller圆柱滚子轴承 Taper Roller圆锥滚 子轴承 The seating mounting of the bearings in the casings needs careful consideration 壳体轴承的安装需要进行充分的考虑 Bore 轴承孔 This will ensure that the bearing retains it shape when loaded 这将确保轴承在受力时形状保持不变 Needs to be manufactured to tight tolerances to ensure the bore is round and concentric to the shaft axis 需要严格按照公差加工 以确保该孔的圆度并且于轴的轴线同心 The amount of interference clearance depends on the type of bearing and load 轴承与轴承孔之间的配合间隙取决于轴承类型和轴承力 Typical transmission appli
