Parametric Analysis of the End Face Engagement Worm Gear

A novel specific type of worm drive, so-called end face engagement worm gear（EFEWD）, is originally presented to minimize or overcome the gear backlash. Different factors, including the three different types, contact curves, tooth profile, lubrication angle and the induced normal curvature are taken into account to investigate the meshing characteristics and create the profile of a novel specific type of worm drive through mathematical models and theoretical analysis. The tooth of the worm wheel is very specific with the sine-shaped tooth which is located at the alveolus of the worm and the tooth profile of a worm is generated by the meshing movement of the worm wheel with the sine-shaped tooth, but just the end face of the worm（with three different typical meshing types） is adapted to meshing, and therefore an extraordinary manufacturing methods is used to generate the profile of the end face engagement worm. The research results indicates that the bearing contacts of the generated conjugate hourglass worm gear set are in line contacts, with certain advantages of no-backlash, high precision and high operating efficiency over other gears and gear systems besides the end face engagement worm gear drive may improve bearing contact, reduce the level of transmission errors and lessen the sensitivity to errors of alignment. Also, the end face engagement worm can be easily made with superior meshing and lubrication performance compared with the conventional techniques. In particular, the meshing and lubrication performance of the end face engagement worm gear by using the end face to meshing can be increased over 10% and 7%, respectively. This investigate is expect to provide a new insight on the design of the future no-backlash worm drive for industry.

Optimal Design for an End Face Engagement Worm Gear with Multiple Worm-wheel Meshing

To solve the problem for lacking a special mechanical transmission that could provide multiple outputs with high transmission efficiency and good lubrication in the modem industrial, a novel worm gear, named end face engagement worm gear, with multiple worm-wheel meshing is proposed for the first time. The essential parameters for the worm gear are optimized to enhance lubrication and meshing properties. Moreover, analysis of variance（ANOVA） is applied to determine the optimum levels and to determine the influence of parameters. The ANOVA results show that the novel end face engagement worm gear with multiple worm wheels provides high lubrication（the lubrication angle is more than 89~） and meshing performance（the induce normal curvature is less than 0.0002 mm ＇）. The interaction between center distance and roller slant distance most strongly influences the lubrication angle（contributed 51.6%）, followed by the parameters of center distance（contributed 25.0%）, roller slant distance（contributed 16.4%）, tooth angle of gear, gear ratio, and roller radius. In addition, roller radius most strongly influences the induced normal curvature（contributed 39.4%）, followed by roller slant distance（contributed 15.2%）, tooth angle of the gear（contributed 9.0%）, center distance, and gear ratio. The proposed worm gear helps to enrich the no-backlash high precision worm drive and the optimal design method can provide a useful reference on performance improvement of other worm gear.

STUDY ON THE STABILITY OF IMMEDIATE ROOF BLOCKS AT THE END FACE

Using vector-analysis, three kinds of roof blocks at the end face of fully mechanized long wall faces have been studied. Tbe result indicates that with face advancing, the three kinds of blocks may all become key blocks. It is put forward that the key blocks can reach into the scope of angle of fracture through supporting, and the fomulas for calculating supporting force needed for the three key blocks to maintain stadility have been derived.

Research on Vane End Face of Cam-Rotor Vane Servo Motor Based on Disturbing Torque

Cam-rotor vane motor(CRVM) is one of the new continuous hydraulic servo motors with the characteristics of no pulsation of instantaneous flow rate and output torque,small volume and rotating inertia.It is one of the appropriate actuators for hydraulic servo system which has good dynamic and steady-state performance requirements.The ideal output torque of CRVM is pulseless,but the actual output torque of CRVM is pulsating.This is caused by the disturbing torque of contact components,especially the friction between vane and cam-rotor.In order to get better performance of CRVM,which means more stable output torque and smaller disturbing torque,we discuss four kinds of vane end faces(VEFs).Analytic formulae of the normal contact force and the disturbing torque caused by the vane are derived from systematical force analysis.The normal contact force and the disturbing torque vary through a period under different VEF,and the reduced oil pressure is simulated in this paper.The simulation shows that the VEF with the proper round and reduced oil pressure can significantly decrease the disturbing torque and get better servo performance.The experiment results verify the correctness of the theoretical analysis and simulation.

Suitable retention and recovery technology of floor coal at ends of fully mechanized face with great mining heights

Gateways at faces of great mining heights are mostly driven along the roof of coal seams.For gateway height restrictions,a 1-3 m floor coal is retained,leaving a triangular floor coal at the face ends,causing a loss of coal.In order to improve coal recovery rates and to ensure efficiency of equipment at coal mining faces,we investigated suitable retention methods and recovery technology of floor coal at face ends.The upper floor coal can directly be recovered by a shearer with floor dinting.The lower floor coal is recovered by shearer with floor dinting after advanced floor dinting and retaining a step for protecting coal sides in a haulage gateway.Field practice shows that this method can improve the coal recovery rates at fully mechanized working faces with great mining heights.

Improvement of 2.79-μm laser performance on laser diode side-pumped GYSGG/Er,Pr:GYSGG bonding rod with concave end-faces

A comparative study on the laser performance between bonding and non-bonding Er,Pr:GYSGG rods side-pumped by 970-nm laser diodes(LDs) is conducted for the thermal lensing compensation. The analyses of the thermal distribution and thermal focal length show that the bonding rod possesses a high cooling efficiency and weak thermal lensing effect compared with the conventional Er,Pr:GYSGG rod. Moreover, the laser characteristics of maximum output power, slope efficiency, and laser beam quality of the bonding rod with concave end-faces operated at 2.79 μm are improved under the high-repetition-rate operation. A maximum output power of 13.96 W is achieved at 150-Hz and 200-μs pulse width,corresponding to a slope efficiency of 17.7% and an electrical-to-optical efficiency of 12.9%. All results suggest that the combination of thermal bonding and concave end-face is a suitable structure for thermal lensing compensation.

多头双向螺旋面的加工方案研究

在介绍活齿端面谐波齿轮的传动原理及多头双向螺旋面含义的基础上,提出了2种加工多头双向螺旋面的方案,并进行了分析、比较。方案一:先采用三维建模软件(如NX等)对具有不同参数的多头双向螺旋面的零件进行建模,再利用数控立式加工中心进行加工;方案二:利用数控电火花线切割机床与数控回转工作台互相配合,按照多头双向螺旋面形成的原理进行加工。

核主泵用机械密封摩擦学性能研究进展

核主泵是核电厂的核心元件,核主泵机械密封在其中起到防止介质泄漏的作用。当前,我国核主泵密封装置相关技术和产品受到国外垄断限制,核主泵摩擦副在运行状态下泄漏严重破坏核电系统的稳定运行和长周期服役,其摩擦学性能直接影响核主泵的运行性能。对于动压式核主泵机械密封,若没有处于完全液膜润滑状态,密封装置会出现异常磨损和泄漏率增大导致核主泵故障。针对核主泵摩擦副的液膜特性,从数学模型计算和软件仿真两方面分析。对温度场、速度场和应力场等进行分析,总结了密封环及副密封材料、端面热变形对摩擦学性能的影响,概述了端面形状的动压润滑机理及波度面、槽型结构和加工方法等因素对摩擦磨损的影响,为核主泵密封性能的提高和可靠运行提供理论基础。

双端面机械密封在双螺杆原油泵上的应用

基于原油库拆建工程项目,对双螺杆原油泵原采用的单端面金属波纹管机械密封改造为新型的带泵效环的背靠背双端面机械密封,并配套冷却循环辅助系统,经现场工业考核,背靠背双端面机械密封在双螺杆原油泵上得到良好应用。结果表明,新改造的双端面机械密封彻底解决了原密封存在的摩擦副磨损严重、泄漏量大、使用寿命短等问题,实现了工艺介质的零泄漏并确保设备长周期安全稳定运行。

密封端面声发射信号降噪处理技术研究

针对利用声发射技术监测密封端面摩擦状态,受到轴承、电机等部件摩擦产生背景噪声对密封端面摩擦信号的干扰,导致获取密封端面声发射信号信噪比不高的问题,文章提出的基于经验小波变换和相对熵(EWT-KLD)的滤波降噪方法,对采集到的原始信号进行滤波降噪处理,以提高密封端面摩擦产生声发射信号的信噪比。通过试验验证,该方法可适用于不同工况、不同介质、不同摩擦状态的声发射信号进行降噪,提高50 kHz以上声发射信号的信噪比,尤其是密封端面微弱摩擦产生信号的信噪比,有效地提高了密封端面摩擦声发射检测的精度和灵敏度,对于早期密封端面摩擦监测的作用尤为明显,使得密封端面摩擦状态累积变化过程的监测更准确。

综放面采空区漏风规律及防治技术研究

综放工作面采空区漏风易导致遗煤自燃,危及矿井安全。以大南湖一矿1305综放工作面为研究背景,采用数值模拟和现场试验的方法,研究了综放工作面采空区漏风规律,提出了综放工作面端头封堵采空区防漏风技术方案,并在现场进行了试验。结果表明,工作面端头是综放工作面采空区漏风的主要通道,其中进风巷侧端头漏风率达19%;风流在采空区内渗透深度约160 m;工作面端头封堵后,风流在采空区内渗透深度缩减至100 m左右;1305综放工作面端头封堵后,采空区漏风率降低17个百分点。

空间最优投影平面的斜口圆截面管路端头位姿测量

船舶、飞机等发动机为减小体积,采用斜口管路焊接代替弯头连接,管路系统中端头位姿是焊接对齐的前提。针对斜口管路端头位姿的高效高精度测量难题,提出了一种通过重建管路轴线以及管路端面进行端头位姿精确测量的方法。通过获取种子圆柱并设计非线性寻优算法提高圆柱拟合精度,通过高精度种子圆柱扩散重建得到管路轴线。通过双曲率阈值搜索方法对管路边缘进行搜索,得到管路端面边缘点整像素坐标。通过对端面提取得到的整像素坐标进行椭圆拟合结合射线求交方法求解端面边缘亚像素坐标,从而避免插值方法计算亚像素坐标受环境光源影响大的问题。最后,使用逐点最小二乘法重建空间投影平面并在平面上得到残差最小空间椭圆,空间椭圆中心即为管路端点,该投影平面即为端面所在平面,实现了对端头位姿的精确测量。实验结果表明,该方法的测量精度达到0.05 mm,角度测量误差小于0.1°,基本满足斜口管路端头的位姿测量精度要求,对管路的装配具有良好的指导意义。

热键合、凹端面及晶体棒直径对Er∶YSGG中红外激光性能的影响

对热键合、凹端面及不同直径Er∶YSGG晶体棒的中红外激光性能进行了系统对比研究。晶体经高温退火、定向切割、端面精密抛光后,测量得到其平面度和表面粗糙度分别小于0.1λ@633 nm和0.5 nm。通过精密加工实现了YSGG与Er∶YSGG室温光胶,然后进行了高温热键合,透过谱表明键合界面基本无损耗,达到了一体化。热焦距结果表明,热键合、凹端面能够有效改善和补偿高功率泵浦条件下晶体的热透镜效应,有利于提高晶体的激光性能。对比未键合、热键合及凹面热键合Er∶YSGG晶体在968 nm LD侧面泵浦条件下的激光性能发现,低频150 Hz以下,键合与凹面并未表现出优势,三种棒的最大输出功率和斜效率分别均在24 W和28%附近;但随重频增加,热效应逐渐加重,键合晶体良好散热能力和凹面热补偿效应使激光性能得到提高。在重频300 Hz下,未键合、热键合及凹面热键合三种棒的最大输出功率分别为15.54,17.85和18.33 W、斜效率分别为16.6%,18.3%和18.4%;重频600 Hz条件下,三种棒的最大输出功率分别为9.4,13.32和13.18 W、斜效率分别为6.7%,8.6%和9%。此外,对比研究了不同直径Er∶YSGG晶体的激光性能,在低于100 Hz的低频下,三种晶体的激光性能接近。但相比于3和4 mm键合凹面棒,直径2 mm棒有大的比表面积,拥有更好的热管理能力,使其在高重频条件下具有更好的激光性能。如在150 Hz条件下,2 mm凹面键合Er∶YSGG晶体棒获得了功率23.82 W、斜效率27.7%的中红外激光输出,大大高于直径3和4 mm棒的18 W和23%。在600 Hz,直径2 mm键合凹面棒中实现了功率13.18 W,斜效率9%的激光输出,相比于直径3和4 mm键合凹面棒的9 W,7%具有较大的改善。测量得到2 mm凹面键合Er∶YSGG晶体棒在150 Hz,200μs条件下的光束质量因子M_(x)^(2)/M_(y)^(2)=6.28/6.30,表明该激光具有良好的光束质量。综上,选择合适晶体棒直径,并将键合与凹面相结合是实现高性能2.79μm激光的有效方法。

不同剪切端面和围压下损伤煤体孔渗特性实验研究

煤体损伤是影响渗透率变化和瓦斯流动的重要因素;采用多剪切端面损伤渗流测试系统和核磁共振仪,分析了不同剪切端面和围压下损伤煤体孔渗特性变化规律。结果表明:损伤煤体内中大孔增多,吸附空间向渗流空间转化,孔隙间连通性变好;50%剪切端面情况下,渗流空间(驰豫时间T_(2)>10 ms)平均面积百分比由9.89%增大为14.94%;剪切应力作用下,煤体轴向变形量不断增大,50%剪切端面比30%剪切端面导致的轴向变形量大,而围压值越大,轴向变形量越小;随着剪切应力的增大,煤体渗透率先降低后缓慢增加,当应力达到煤体强度阈值时,损伤煤体渗透率以指数形式增大,50%剪切端面对应的渗透率值普遍比30%剪切端面的大,前者是后者的7倍左右。

一种移动式端面钻孔攻丝机的研制

自动化设备生产需要加工很多螺孔用于连接安装板,加工较长安装板的螺孔多选用立式加工中心垂直装夹,由于零件伸的太高造成装夹刚性太差;而采用卧式加工中心,设备昂贵成本太高。本文研制一款简易的端面钻孔攻丝装置,设计可移动式的工作台以降低设备占地空间,设计快速钻孔装置以提高钻孔攻丝的便捷性,增加一组工作台调节装置以扩大加工行程,改装一套攻丝系统以实现钻孔与自动攻丝功能,加装数显装置以提高孔坐标位置的精度,经过样机试制与切削实验,解决了较长安装板螺孔加工工艺问题,节约了生产成本。

任意端面螺栓的转矩系数理论计算

螺栓连接是工程建设中常用的连接方式,工业现场常采用紧固力矩值控制螺栓预紧力的方式以保证其可靠性。转矩系数是螺栓紧固力矩与预紧力之间的比例系数,对确定合适的紧固力矩范围至关重要。目前关于转矩系数的研究主要集中在圆环端面螺栓,对其他端面螺栓的研究较少。根据螺栓紧固受力分析,构建了螺栓预紧的力学模型,以极坐标描述螺栓端面内外轮廓的方式,推导出了任意端面螺栓转矩系数的精确计算公式。通过搭建简易转矩系数测量系统,对圆环端面、六角端面、T型端面螺栓进行实验验证。实验结果与理论计算一致,证明了转矩系数理论计算公式的准确性。

光纤端面耦合周期极化铌酸锂(PPLN)薄膜波导器件的研究

通过有限元模拟器从理论上分析了在理想光学系统中实现光纤与周期性极化铌酸锂(PPLN)波导之间高效耦合的可行性。仿真模拟了单模保偏光纤和透镜光纤在空间中的发散情况。针对截面尺寸为10μm×10μm、长度为20 mm的PPLN脊形波导,进行了与两种不同光纤的直接端面耦合模拟分析。分析发现,尽管透镜光纤的耦合效率高达95%,但其基模占比却不足5%。鉴于PPLN倍频器件主要依赖于激光的基模进行工作,这使透镜光纤的耦合效率在实际应用中显得相对较低。相比之下,单模保偏光纤的基模占比高达93.8%,显示出更为优越的性能。因此,本文选择了单模保偏光纤与PPLN脊形波导进行封装测试。实验结果表明:当温度为24.8℃,从光纤放大器输出的泵浦功率最大为1.6 W时,计算扣除输入端光纤与波导的耦合损耗后的输入泵浦功率为1.2 W,光纤到波导的耦合效率为75%,略高于当前已知的最高效率72%。1 560 nm基频光的输入功率为1.2 W时,最大输出653 mW的倍频光,光光转换效率达到了54.4%,归一化转换效率为20.2%/(W·cm^(2))。

采用点云分区统计的成捆棒材端面定位方法

针对成捆棒材端面贴标过程中出现的端面中心位姿测量难度大、效率低等问题,提出一种基于点云分区统计的成捆棒材端面定位方法.首先对端面点云进行预处理操作;然后使用改进的聚类分割算法对端面点云进行分割,并以分区统计为依据提出完整单根棒材端面中心定位方法和残缺单根棒材端面中心定位方法,实现端面中心定位;最后以端面法向量表征端面中心姿态重建端面中心位姿.采集200组不同姿态的单根棒材端面点云进行实验的结果表明,单根棒材端面定位时间不超过0.5 s,位置误差小于3 mm,姿态误差小于2°;所提方法是高效的,可准确地定位棒材端面中心.

新型偏心双螺杆挤出机流域混合特性

基于非对称流场的混沌混合理论,设计了一种新型的偏心双螺杆挤出机。通过对比传统普通螺杆元件与新型偏心螺杆元件,偏心距不仅决定了螺杆的端面形状,也改变了螺槽形状,使同一导程内的2个独立的C型室螺槽形成一个ω型室螺槽。利用Polyflow软件分别对传统双螺杆挤出机与3种不同偏心距螺杆元件的新型双螺杆挤出机进行模拟仿真,分析了压力场、速度场与混合指数分布规律,计算了4种双螺杆挤出机流场的停留时间分布、分离尺度、最大剪切应力等混合表征系数。结果表明,与传统双螺杆挤出机相比,偏心双螺杆挤出机压力分布不均匀,正负压压力值增大,因此,压力差增大,使熔体回流速度增大,混合效果更佳;拉伸流区域增大,混合能力增强;熔体在流体域内的总体停留时间缩短,混合效果更佳;分离尺度数值下降较快,混合效率较高;偏心螺杆元件对流体的剪切应力增大,分散混合能力增强。

轻质铸造铝合金轮毂热处理变形测试分析

目的精准建立铸造铝合金轮毂各区域的T6热处理变形状态及其最佳检测方法,对热处理态轮毂进行表征研究,探讨铝合金轮毂热处理过程的变形规律,为轮毂工业生产和变形研究提供精确和适宜的变形测试方法。方法根据轮毂的结构特征,将变形检测区域分为外轮缘端面、轮辋、轮辐-轮心3个区域,分别使用三坐标测量机、手持三维激光扫描仪和轮缘轴向高度检测装置对4种不同结构的热处理态轮毂进行变形测试,并对测量结果进行分析。结果铝合金轮毂的热处理变形程度与其自身的结构、尺寸密切相关;外轮缘端面轴向变形主要表现为翘曲变形,呈双波峰波谷的变形规律;距离外轮缘越远的环状轮辋,受轮辐结构影响的凹凸程度逐渐减小,椭圆形趋势增大;轮辐-轮心为轴向凹陷变形;轮缘轴向高度检测装置的测量结果与三坐标测量结果基本一致,误差为±5μm。结论手持扫描仪适用于轮辋/轮辐等平坦曲面的变形测试及整体变形云图化;轮缘轴向高度检测装置适用于工业化在线测试。所使用的测试工具和建立的测试方法可以较好地测试轮毂变形,阐明铝合金轮毂热处理变形规律,为后续轮毂的变形控制和变形测试提供测试基础。