Ildar Ilgizarovich Salaehov 4.Pmd
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BIOSCIENCES BIOTECHNOLOGY RESEARCH ASIA, June 2016. Vol. 13(2), 859-864 Development of a Gear Box of the Truck Ildar Ilgizarovich Salakhov*, Ildus Rifovich Mavleev, Ildar Rafisovich Shamsutdinov, Damir Imamutdinovich Nuretdinov and Niyaz Ilgizarovich Salakhov Naberezhnochelninsky Institute (branch) «Kazan Federal University», Russian Federation, 423812, Naberezhnye Chelny, pr.Syuyumbike, 10A, http://dx.doi.org/10.13005/bbra/2107 (Received: 14 February 2016; accepted: 13 April 2016) The kinematic scheme hydromechanical differential high-torque CVT. Developed the design of the continuously variable transmission of the truck with a high-torque differential hydromechanical CVT. Key words: hydra-mechanical gear train, continuously variable transmission, differential hydra- mechanical variator, mechanical diagram, high-torque differential hydra-mechanical variator. Continuous variable transmission to operate at high pressure values enables to combine effectively the engine * Provide automatic torque control on the performance with different modes of the vehicle output shaft, without control systems, operation. However, the existing mechanical depending on the changes in the external continuous variable transmissions have a load and the control range of trucks1. significant disadvantage - the maximum transmittable torque of 300 ÷ 350 H-M, which 2 High torque differential hydro-mechanical prevents their use in trucks transmissions. The variator (HTHMV) continuous variable transmissions are still not High torque differential hydro-mechanical widely used in trucks transmissions also due to variator is designed for the continuous automatic their existing significant shortcomings as converting of rotary motion between the motor compared to mechanical speed transmission shaft and the shaft of the working body of the gearbox (size, weight, efficiency, production costs, machinery in order to ensure the optimal mode of etc.). the joint operation of the engine and the variator at High torque differential hydro-mechanical an arbitrarily changing value of the external load variator used in the construction of the continuous on the working body. Kinematic HTHMV diagram variable transmission allows to meet the following shown in Figure1 is applicable to the trucks tasks: transmission; it has a large transformation ratio and * Increase the maximum value of the can operate at high fluid pressure values of above transmitted torque; 20 MPa. * Increase the mechanism efficiency and The housing 12 of the differential high- reduce the dimensions due to the possibility torque hydro-mechanical variator rests on the bearings installed in the oil-filled crankcase 20. The crankcase has an expansion tank 21 to compensate * To whom all correspondence should be addressed. for thermal expansion of the oil. The first differential E-mail: [email protected] stage of the variator is a mechanical differential 860 SALAEHOV et al., Biosci., Biotech. Res. Asia, Vol. 13(2), 859-864 (2016) mechanism consisting of the input shaft 1, F is directed perpendicular to the direct line AB satellites 2, the output unit 3 and the carrier 4. The and creates an unbalanced hydrostatic torque on second differential stage is a hydro-mechanical the carrier. differential transducer having two planetary gear М = FH ...(2) sets, one of which is formed by kinematic units of ГС the multiple gear hydro-pump 9 consisting of a where H – the shoulder of the force F, m. crown wheel 4’ coupled by the internal engagement At the same time, the moment resultant with satellites 5, and the second – by kinematic of the pressure forces on the crown wheel is equal units of the multiple gear hydro-motor 10 with two to zero, because the resultant vector of the pressure crown satellites 7-7’, the internal engagement gears forces comes through the crown wheel rotation thereof 7 are connected with the crown wheel 6, axis4, 5. and those of the outer engagement 7’ - with the In general case, the magnitude of the force central sun gear 8. The hydraulic pump and the F is equal to motor have input 15 and 18, output 14 and 19 ports, ...(3) their number being equal to the number of satellites where p – fluid pressure, ÌPà; L – the length of the at the hydraulic pump and the motor2, 3. í The hydraulic annular channel 22 is chord passing through the points À and Â, m; b – equipped with an automatic bypass valve 16 and the width of the tooth, m. the controlled valve 17. Between the carrier 12 and The final value of the hydrostatic moment the crankcase 20 there is a free-wheel clutch 11, on the input ports of the pump there is a filter 13, and there is a heat exchanger 23 mounted at the bottom of the crankcase 20. At a fixed carrier 12, the torque Ì1 from an external power source is transmitted to the input unit 1of the differential mechanism À1, which F = р н S = p н Lb rotates at a speed of n1 and is transmitted through satellites2 to the carrier of the differential 4 of the kinematic unit 4-4'. Herewith, the unit 4-4' rotates in the same direction as the input unit 1. Rotation of the unit 4-4' and satellites 5 creates a flow of the working fluid determined by the parameters of the equation pнVГН M 4−4' = M ГН = ...(1) À 1 – mechanical differential mechanism; À2 – 2π hydromechanical differential Converter; 1 – the input element of the differential mechanism, the input shaft of where M 4−4' = M ГН – the torque on the variator; 2 – satellites; 3 – crown wheel differential the input shaft of the hydraulic pump, N’”m; mechanism À1; 4 – drove A1 of the differential mechanism, ρ – fluid pressure, ÌPà; the input link of the differential hydromechanical í Converter; 4’ – a leading crown wheel pump; 5 – the VΠH – the working volume of the hydraulic pump, satellites pump; 6 – crown wheel hydraulic motor; 7-7’ – m3. dvuhventsovye satellite; 8 – the Central sun gear shaft; 9 A hydrostatic moment on the carrier is a – hydraulic pump; 10 – hydraulic motor; 11 – freewheel distinctive feature of the hydraulic machines with clutch; 12 – led (housing) of the variator; 13 – filter; 14 and 19 – respectively, the outlet port of the hydraulic internal engagement gears. Figure 2 presents the motor and hydraulic pump; 15 and 18 – respectively, inlet diagram for determining of the hydrostatic moment. ports of the hydraulic motor and hydraulic pump; 16 – Projections of curved surfaces of gear crowns, automatic by-pass valve; 17 – operated valve; 20 – Carter which are pressed by the liquid stream, are reduced variator; 21 – expansion tank; 22 – annular channel; 23 – heat exchanger to a rectangular area of the length L and the width b. The resultant of the pressure forces of the liquid Fig. 1. The kinematic diagram of the variator SALAEHOV et al., Biosci., Biotech. Res. Asia, Vol. 13(2), 859-864 (2016) 861 on the carrier is equal to The working fluid flow through the output ports of the hydraulic pump 19 enters the annular Rw4' channel 22 and through the input ports of the М ГС = M ГН = M ГН i54' ...(4) Rw5 hydraulic motor 18 in its working cavity formed by the troughs of the gear wheels 6 and 7. The torque where i – gear ratio hydraulic pump. 54’ on the output shaft of the motor is equal to At the driving crown gear p V М M = Н ГМ = M i = −М (1− i )i = М = II М = M . ГМ ГН г 1 13 г 7−7' , ГС ГН 2π i7'8 The carrier 12 receives the reactive ...(5) moment from the mechanical differential mechanism where ρH – fluid pressure, ÌPà; V – the working volume of the hydraulic A1 equal to , directed opposite ÃÌ motor, m3; of the input unit 1 rotation When using a gear pump with internal M V i = ГМ = ГМ engagement gears with two or more driven wheels, г M V – hydraulic gear ratio; a moment let to the gear 4' (the pump moment) is ГН ГН received by the resistance moments acting at the М – the torque at the output shaft of the hydraulic pump gears 4' and 5. In this case, the 7−7' resistance moment on the unit 5 defines the value motor, N·m; of the reaction moment on a carrier 12 which is М II – the torque at the output shaft of the equal variator, N·m; M ' i – the gear ratio of the gearing between the M = − 5 (r − r ) = M ' (i −1) 7'8 12 А2 4' 5 5 54' gears 7’ è 8. r5 The reactive moments occur on the carrier The carrier 12 is influenced by an Мat 12presenceА1 = − Mof 1thei13 resistance on the output shaft unbalanced hydrostatic moment resulting from the of the hydraulic motor in the direction opposite to pressure of the working fluid flow equal the rotation of the input shaft. When a working M ГСА2 = М ГН = −М1(1− i13 ) . fluid is fed in the working spaces of a gear hydraulic The value of the resistance moment at motor with internal engagement gears and with the unit 5 is determined from the equation two or more satellites the same as in hydraulic pumps, there occur moments of the resistance on ' ' M ГН = М 4' + M 5i54' and moments’ redistribution M ' λ = 4' ratio in the hydraulic pump Н ' . That is M 5 M M ' = ГН 5 . The moments М12А1 , M λН + i54' 12А2 and M ГСА2 M1 ∑ М12 = М12 А1 + М12А2 + M ГСА2 = ()λН + i54' − (1− i13 )(1− i54' ) λН + i54' sum is equal to and has the same direction as the one of the input unit 1 rotation. This moment is the reference point, it determines the maximum transformation rate basing on the equilibrium conditions of the carrier 12, under the action of the total reactive moment from the hydraulic motor [3, 6].