阅读说明：本技术 一种可以安装在潜水搅拌机壳体内的齿轮减速器 (Gear reducer capable of being installed in submersible mixer shell ) 是由 黄林 于 2019-03-04 设计创作，主要内容包括：本发明的目的在于通过改进产品结构,将原采用(6P、8P、12P)等多P电机直连式驱动结构形式的传统型潜水搅拌机设计成4P电机驱动,在潜水搅拌机机壳内增加一个齿轮减速器,利用4P电机综合性能较优以及斜齿圆柱齿轮传动效率可达99％的优点,同时利用齿轮减速增加扭矩的机械原理,实现4P电机驱动齿轮减速器后使输出轴上的叶轮转速达到12P、8P、6P直连式传统型潜水搅拌机叶轮的基本相同的转速,经过机电一体化组合设计成新型结构的具有节电功能的新型潜水搅拌机。(The invention aims to design the traditional submersible mixer which originally adopts a multi-P motor direct-connected driving structural form such as (6P, 8P and 12P) and the like into 4P motor driving by improving the product structure, and a gear reducer is added in the submersible mixer shell, so that the rotation speed of an impeller on an output shaft reaches the basically same rotation speed of the impeller of the traditional submersible mixer with 12P, 8P and 6P direct-connected modes by utilizing the advantages of better comprehensive performance of the 4P motor and 99 percent of transmission efficiency of a helical cylindrical gear and simultaneously utilizing the mechanical principle of gear reduction and torque increase, and the novel submersible mixer with the novel structure and the power saving function is designed by mechanical and electrical integration combination.)

1. A gear reducer capable of being installed in a submersible mixer shell is characterized in that the transmission structure of the gear reducer is a three-shaft type, an input shaft and an output shaft are the same axis, and a parallel shaft helical gear cylindrical gear is adopted for secondary speed reduction.

2. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the gear reducer box body is made of aluminum alloy, the box body is cylindrical, a front wall, a middle wall and a rear wall are arranged on the axial section of the box body, the box body is divided into a front box chamber and a rear box chamber, the lower sides of the front box chamber and the rear box chamber are in a closed state, and a window for mounting a gear and a bearing is arranged on the upper side of the box body; three groups of hole systems with parallel axes are arranged on the front wall, the middle wall and the rear wall of the box body, one group of central axes of the three groups of axes is coaxial with the central line of the cylindrical box body, and the other two groups of axes are eccentrically and symmetrically arranged on the axial section of the central line of the box body; the radial section of the box body is similar to a deformed sub-character geometric shape, the outer cylinders of the radial section views of the front wall and the middle wall of the box body are symmetrically provided with notches which are V-shaped at four positions, the outer circle of the box body is positioned in the shell of the novel submersible mixer, and the box walls at two sides of the box body are provided with a plurality of oil return holes; a bearing positioning step hole is formed in the front end of a central hole in the front wall of the box body; the center of the middle wall of the box body is provided with a bearing hole, an elastic retainer ring groove is arranged in the bearing hole, and a guide step hole convenient for bearing installation is arranged at the orifice; a step hole for positioning a front bearing seat of the motor is arranged at the rear end of a central hole on the rear wall of the box body; the axial section of the box body is provided with bearing holes which are parallel to the central line of the box body and are symmetrically arranged up and down, the bearing holes are arranged on the front wall and the rear wall of the box body, and the middle wall of the box body is provided with round holes for the middle shafts to pass through; in general, the product uses a group of intermediate shafts; the other group of bearing holes are used as a product for a double-intermediate shaft structure; an elastic retainer ring groove is arranged in a bearing hole of the intermediate shaft on the front wall of the box body, and a guide step hole convenient for mounting a bearing is arranged in the hole; the rear end of a middle shaft bearing hole in the rear wall of the box body is processed into a threaded hole, a bearing gland is arranged in the threaded hole, and a positioning screw hole is formed in the bearing gland.

3. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the front bearing seat of the speed reducer is made of aluminum alloy, the axial appearance of the body of the front bearing seat is in a shape like a Chinese character 'ya', a bearing hole is formed in the central axis, and a bearing shell protruding out of the bearing shell is radially and axially positioned with the speed reducer box body after the bearing in the hole is assembled and is connected with the speed reducer box body through screws.

4. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the rear end of the reducer box body is connected with a motor front bearing seat by screws, the motor front bearing seat is made of aluminum alloy, the axial appearance of the body is cylindrical, the front end of a central hole is provided with an annular positioning boss and a step hole for installing a mechanical sealing assembly, an elastic retaining ring groove is arranged in a hole in the rear end of the bearing hole, and a guide step hole convenient for bearing installation is arranged in a hole opening of the bearing hole.

5. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the motor gear is used as power input and is tightly installed on a front end shaft neck of a motor rotor shaft in a cylindrical hole and flat key connection mode, the tooth shape of the motor gear is a helical gear which is formed by grinding, the motor gear is inserted into a rear box chamber of a reducer box body and is meshed with a primary reduction gear pair on an intermediate gear shaft of which two ends are provided with tapered roller bearings, and then primary reduction of the gear reducer is formed.

6. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the right side of the intermediate gear shaft is provided with a primary reduction gear in sleeved connection with an involute spline, and the left end journal and the right end journal are both provided with tapered roller bearings; the gear on the intermediate shaft body is a secondary speed reduction driving gear, the tooth shape of the gear is a helical gear which is formed by grinding, the right end of an involute spline tooth of the intermediate shaft is provided with a guide step which is convenient for mounting a fitting, the tooth shape of the primary speed reduction gear is a helical gear which is formed by grinding, and an inner hole is an involute spline; and a thrust retainer ring is arranged between the first-stage reduction gear and the right tapered roller bearing.

7. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the front end of the power output shaft is provided with a double-row angular contact ball bearing with sealing rings on two sides, and the right side of the power output shaft is provided with a secondary reduction gear in sleeved connection with an involute spline; the right end of the involute spline tooth of the power output shaft is provided with a guide step convenient for mounting a fitting, the secondary reduction gear is a helical gear which is formed by grinding, and a thrust retainer ring is arranged between the rear end of the secondary reduction gear and the cylindrical roller bearing; the secondary reduction gear pair is arranged in a front box chamber of the gear reducer box body.

8. A gear reducer mountable in a submersible mixer housing as claimed in claim 1, wherein: the gear adopts a hard tooth surface helical gear with high transmission efficiency and strong bearing capacity; the gear parameters are repeatedly screened and matched and optimally designed by a computer, so that the gear strength minimum safety factor requirement recommended by relevant standards at home and abroad is met, and the gear strength minimum safety factor successfully passes BS ISO 6336: computer review of spur and helical gear load capacity by standard 2006; the gear parameters of the gear have unique occupation.

Technical Field

The invention belongs to the field of water treatment equipment, and particularly relates to a gear reducer which can be arranged in a submersible mixer shell;

background

The submersible mixer is a device which is used in a large amount in municipal and industrial sewage treatment process flows, and the submersible mixer needs to continuously run for a long time due to the requirement of continuity of the water treatment process flows, so that the power consumption is extremely high.

At present, most of traditional submersible mixers in China are in a structural form of directly connecting an alternating current asynchronous motor (hereinafter, the alternating current asynchronous motor is simply referred to as a motor) with an impeller, in order to ensure that the impeller generates enough water flow thrust at a certain rotating speed, the traditional submersible mixer selects a multi-pole (hereinafter, poles are replaced by P) motor mode in a grading mode according to the diameter of the matched impeller to realize the purpose that the rated rotating speed provides a torque power source for the impeller of the mixer, the motor of the traditional submersible mixer (with the impeller diameter of 320 and 400) with low power (4Kw and below) is generally designed according to the 8P standard, and the motor of the traditional submersible mixer (with the impeller diameter of 620) with high power (5Kw and above) is generally designed according to the 12P standard. The more P number of the motor with the same nominal power, the larger current in the working process, the extremely large power consumption and the low power factor caused by the much consumed useless work of the motor are calculated by taking a 7.5Kw/12P traditional submersible mixer as an example: the rated current is 28A, the actual current of a plurality of tests on a certain water treatment site is between 26.4 and 30.4, the average power consumption per hour is 11.6 degrees, and the motor power factor is about 0.51 to 0.61.

Disclosure of Invention

The invention aims to design the traditional submersible mixer which originally adopts a multi-P motor direct-connected driving structural form such as (6P, 8P, 12P) and the like into 4P motor driving by improving the product structure, and a gear reducer is added in the submersible mixer shell, so that the impeller rotating speed on an output shaft reaches the basically same rotating speed of the impeller of the traditional submersible mixer with 12P, 8P or 6P direct-connected type after the gear reducer is driven by the 4P motor by utilizing the advantages that the comprehensive performance of the 4P motor is better and the transmission efficiency of a helical cylindrical gear can reach 99 percent, and simultaneously, the mechanical principle of increasing torque by gear reduction is utilized, and the novel submersible mixer with the power saving function is designed by electromechanical integration combination; actually, taking a 7.5Kw4P novel submersible mixer motor as an example, the current A is 11.9-12.5A, the average power consumption is 6.34 degrees per hour, 5.25 degrees per hour can be saved, the power can be saved by over 45000 degrees per year, and the power saving effect can reach 45 percent; the weight of the novel submersible mixer provided with the gear reducer is reduced by about 30 percent compared with the traditional submersible mixer. The novel improved submersible mixer has the same basic overall dimension as the traditional submersible mixer, and has no influence on an installation system, so that water treatment enterprises using the traditional submersible mixer are very favorable for updating products; is more suitable for the model selection of the newly-built water treatment project.

In order to achieve the purpose of the invention, the following technical scheme is adopted:

a gear reducer capable of being installed in a submersible mixer shell is of a three-shaft type, an input shaft and an output shaft are of the same axis, and a parallel-shaft helical gear cylindrical gear is adopted for secondary speed reduction; the gear reducer is assembled in the front space of the inner cavity of the shell of the novel submersible mixer; the power transmission route is as follows: motor → motor gear → primary reduction gear on the right side of the middle shaft (the axis motor is parallel to the axis) below the motor axis → secondary driving gear on the middle shaft body → secondary reduction gear on the power take-off shaft (same as the motor axis) → stirrer impeller; the rotating speed of the decelerated power output shaft is basically consistent with the rated rotating speed of the original multi-P motor; the length and the size of the improved novel submersible mixer are slightly increased, the product weight is greatly reduced, and the original submersible mixer installation system is not influenced, so that the novel submersible mixer is very favorable for water treatment enterprises using traditional submersible mixer products to update the products; is more suitable for the selection of newly-built water treatment project.

Drawings

Fig. 1 is a schematic structural diagram of a gear reducer assembled in a novel submersible mixer casing, and a main body structure of the gear reducer is shown in the range of a dotted line square frame.

Fig. 2 is a schematic sectional view of the gear reducer a-a of fig. 1, in which the elliptical hole-shaped sectional position is a schematic partial sectional view in the radial direction of a first reduction gear pair, and the part number (b) is an assembly of a double-countershaft series (after the gear structure is changed) when the double-countershaft series is applied.

Detailed Description

The invention will be more fully described with reference to the following examples and the accompanying drawings.

A gear reducer capable of being installed in a submersible mixer shell is characterized in that the transmission structure form of the gear reducer is a three-shaft type; the input shaft and the output shaft are the same axis; the parallel shaft helical gear carries out two-stage speed reduction.

The gear reducer box body is made of aluminum alloy, the box body is cylindrical, a front wall, a middle wall and a rear wall are arranged on the axial section of the box body, the box body is divided into a front box chamber and a rear box chamber, the lower sides of the front box chamber and the rear box chamber are in a closed state, and a window for mounting a gear and a bearing is arranged on the upper side of the box body; three groups of hole systems with parallel axes are arranged on the front wall, the middle wall and the rear wall of the box body, one group of central axes of the three groups of axes is coaxial with the central line of the cylindrical box body, and the other two groups of central axes are eccentrically and symmetrically arranged on the axial section of the central line of the box body; in general, the product uses a group of intermediate shafts; the other group of bearing holes are used as a product for a double-intermediate shaft structure; the radial section of the box body is similar to a deformed herringbone geometric shape, the outer cylinders of the radial section views of the front wall and the middle wall of the box body are symmetrically distributed with notches in V shapes at four positions, the outer circle of the box body is positioned in a novel submersible mixer shell II, and two symmetrical crescent spaces are arranged on two sides of the box body; the box walls on the two sides of the box body are provided with a plurality of oil return holes, so that the function of the lubricating oil which is stirred by the rotation of the gear and then repeatedly flows between the inner oil chamber and the outer oil chamber of the box body in a circulating manner can be realized, and the lubricating oil can be favorably cooled by the heat dissipation of the submersible mixer shell; a bearing positioning step hole is formed in the front end of a central hole in the front wall of the box body; the center of the middle wall of the box body is provided with a bearing hole, an elastic retainer ring groove is arranged in the bearing hole, and a guide step hole convenient for bearing installation is arranged at the orifice; a central hole on the rear wall of the box body is provided with a step hole for positioning a front bearing seat of the motor; two groups of intermediate gear shaft bearing holes are symmetrically arranged up and down on the axial section of the box body in parallel with the central line of the box body, the bearing holes are arranged on the front wall and the rear wall of the box body, and the middle wall of the box body is provided with a round hole for the intermediate gear shaft to pass through; an elastic retainer ring groove is arranged in a bearing hole of a middle gear shaft on the front wall of the box body, and a guide step hole convenient for bearing installation is arranged at the hole opening of the bearing; the rear end of a bearing hole of the intermediate gear shaft on the rear wall of the box body is processed into a threaded hole, a bearing gland is arranged in the threaded hole, threads on the bearing gland are matched with threads of the shell, a threaded hole for a positioning screw is formed in the bearing gland, pre-tightening force is applied to a tapered roller bearing shell of the intermediate shaft through the rotating bearing cover, and after the pre-tightening force is adjusted, the rotating bearing cover is locked through the setting screw.

The front bearing seat of the gear reducer is made of aluminum alloy, the axial appearance of the front bearing seat is in a shape of a Chinese character ya, a bearing hole is arranged on a central axis, a double-row angular contact ball bearing with sealing rings on two sides is arranged in the bearing hole, and a convex bearing shell and a reducer box body are used for radial and axial positioning and are connected through screws.

The rear end of the gear reducer box body is connected with a motor front bearing seat by screws, the motor front bearing seat is made of aluminum alloy materials, the axial appearance of the motor front bearing seat is a cylinder, the front end of a shaft hole in the center of the box body is provided with an annular positioning boss and a positioning seat hole for installing a mechanical sealing assembly, an elastic retaining ring groove is arranged in a hole in the bearing hole at the rear end, and a guide step hole convenient for bearing installation is arranged in a hole opening of the bearing hole.

A hole elastic retainer ring clamped in a shell hole of the submersible mixer is shared between a bearing seat at the front end of the motor and a gear reducer box body to axially position the motor and the gear reducer.

The motor rotor shaft extends into the rear box chamber of the reducer box body from a hole in the center of the motor front bearing seat, and the motor gear is fixedly arranged on a front end shaft neck of the motor rotor shaft in a cylindrical hole and flat key connection mode; a mechanical seal assembly is arranged between the motor gear and the motor front bearing seat; the tooth shape of the motor gear is a helical gear which is formed by grinding, and the motor gear which extends into the rear box chamber of the reducer box body is meshed with a primary reduction gear pair on an intermediate gear shaft which is provided with tapered roller bearings at two ends to form primary reduction of the gear reducer.

The right side of the intermediate gear shaft is provided with a first-stage reduction gear (IV) in sleeved connection with an involute spline, and the left end shaft neck and the right end shaft neck are provided with tapered roller bearings; the gear on the intermediate gear shaft body is a secondary reduction driving gear, the tooth shape of the gear is a milled helical gear, the right end of the excircle of the involute spline of the intermediate gear shaft is provided with a guiding and positioning step for mounting a fitting, the tooth shape of the primary reduction gear is a milled helical gear, and the inner hole is an involute spline; and a thrust retainer ring is arranged between the first-stage reduction gear and the right tapered roller bearing.

The front end of the power output shaft is provided with a double-row angular contact ball bearing, and the right side of the power output shaft is provided with a secondary reduction gear sixth in sleeved connection with an involute spline; the right end of the outer circle of the involute spline shaft of the power output shaft is provided with a guide positioning step for mounting a corresponding part, the secondary reduction gear is a helical gear which is formed by grinding, and a thrust retaining ring is arranged between the rear end of the secondary reduction gear and the cylindrical roller bearing; the secondary reduction gear pair is arranged in a front box chamber of the gear reducer box body. The impeller of the stirring machine is sleeved and fastened on a shaft neck at the front end of the power output shaft in a cylindrical hole flat key connection mode.

The gear reducer box body and the bearing seat blank are produced by adopting a casting process; the main parts are machined by adopting precise numerical control machining process equipment; the gear is a helical gear with parallel shaft angle deflection; the gear parts adopt high-quality alloy steel forgings and a nitriding heat treatment process, and the final processing of the tooth-shaped surface adopts a precise grinding process; the design standards in the product are all adopted by advanced new standards at home and abroad; the gear parameters are optimized and designed by using computer software, and are calculated according to the following steps of BS ISO 6336: 2006 standard performs computational rechecking of spur and helical gear load capacities; the product structure, the gear, the shaft part and the bearing are analyzed and evaluated by SABR series software. Can meet the requirement of the product on long-time continuous safe operation working condition. The product design has the characteristics of modularization, serialization, specialization and batch.

The above is only one embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be covered by the claims of the present invention, as long as the person is capable of changing the specific geometric dimension, the tooth shape parameters and other insubstantial structural modifications within the scope of the present invention.