Composite gear, gear processing method, reduction transmission assembly and aircraft

Abstract

The present invention discloses a composite gear, a gear processing method, a reduction transmission assembly and an aircraft, and relates to the field of transmission devices of aircraft. The composite gear comprises: a web having a center hole in the center and periodic hollow holes on the web; a hub fitted at the center hole; a gear ring connected to the web, the gear ring and the hub being coaxially arranged, and the gear ring is provided with meshing teeth spaced circumferentially. The hub and the gear ring are metal parts. The web is made by continuous printing of carbon fiber by a 3D printer. According to the composite gear of an embodiment of the present invention, the web is formed by 3D printing of continuous carbon fiber, which can reduce the weight while maintaining high strength and durability, and can reduce the burden of flight.

Description

Technical Field

[0001] The present invention relates to the field of transmission devices for aircraft, and in particular to a composite gear, a gear processing method, a reduction transmission assembly and an aircraft. Background Art

[0002] The performance requirements of the aircraft's transmission system are relatively high. For example, the main task of the helicopter transmission system is to transfer the power of the power system to the rotor system. At present, the main load-bearing components in the transmission system of the helicopter, the components with complex forces, and the components that bear dynamic loads and impact loads are still mainly made of metal materials, resulting in a large weight share, which affects the performance of the helicopter and the goal of lightweighting. Therefore, the structure of the aircraft's transmission system has room for improvement. Summary of the invention

[0003] The purpose of the first aspect of the present invention is to provide a continuous fiber 3D printed composite material-metal material mixed composite gear.

[0004] A second aspect of the present invention aims to provide a gear machining method for machining the above-mentioned composite gear.

[0005] A third aspect of the present invention is to provide a reduction transmission assembly having the above-mentioned composite gear.

[0006] A fourth aspect of the present invention aims to provide an aircraft having the above-mentioned reduction transmission assembly.

[0007] According to the first aspect of the present invention, a composite gear of a continuous fiber 3D printed composite material and a mixed metal material includes: a web, which is a continuous carbon fiber 3D printed molded part, has periodic hollow holes on the web, and has a center hole in the center of the web; a hub, which is fitted at the center hole, and is a metal part; a gear ring, which is connected to the web, is coaxially arranged with the hub, is provided with meshing teeth spaced circumferentially, and is a metal part.

[0008] The composite gear according to the embodiment of the present invention uses a continuous carbon fiber 3D printed molded part as the web between the gear ring and the wheel hub to achieve the goal of lightweight. At the same time, the metal gear ring provides high hardness and wear resistance to ensure reliability during high torque transmission. This composite gear can reduce the flight burden and reduce flight energy consumption.

[0009] The present invention provides a composite gear of a mixture of continuous fiber 3D printed composite materials and metal materials, which is a composite gear formed by physically connecting a continuous carbon fiber 3D printed composite material structural element and a metal material structural element into a functional whole, achieving the high performance, lightweight and low cost attributes of the components, and can achieve a weight reduction of more than 50% at the component level while maintaining equivalent performance and cost, solving the problems of performance improvement and lightweight design of gear parts in traditional helicopter transmission systems.

[0010] According to some embodiments of the composite gear of the present invention, the web includes at least two layers of sub-plates stacked in the axial direction, each layer of the sub-plates is made by continuous printing of carbon fiber by a 3D printer, each layer of the sub-plates has periodic hollow holes, and all layers of the sub-plates are formed by printing layer by layer. The web is made by continuous printing of carbon fiber by a 3D printer, the thickness of the web is at least 18 mm, and the torsional strength of the web is in the range of 100 MPa-150 MPa, and the bending strength is in the range of 170 MPa-220 MPa.

[0011] The gear processing method according to the second aspect of the present invention is used to process the composite gear according to the first aspect of the present invention, and includes the following processing method:

[0012] S1: Using the wheel hub as a printing reference for positioning;

[0013] S3: using a 3D printer to continuously print carbon fibers into a first sub-plate, wherein the first sub-plate takes the wheel hub as a center and the first sub-plate takes the outer circumference of the wheel hub as an inner constraint;

[0014] S5: placing the gear ring on the first sub-plate, the gear ring surrounding the radial outer side of the hub, wherein the gear ring is provided with a flange extending radially inward;

[0015] S7: Using a 3D printer, continuously printing the carbon fiber to form a second sub-plate, wherein the second sub-plate is located on the first sub-plate, the second sub-plate takes the wheel hub as the center, the second sub-plate takes the outer circumference of the wheel hub as the inner constraint, and the second sub-plate takes the inner circumference of the flange as the outer constraint;

[0016] S9: Continue to use the 3D printer to continuously print the carbon fiber to form a third sub-plate, wherein the third sub-plate is located on the flange and the second sub-plate, the third sub-plate takes the wheel hub as the center, the third sub-plate takes the outer circumference of the wheel hub as the inner constraint, and the third sub-plate takes the inner circumference of the gear ring as the outer constraint.

[0017] In some embodiments, in step S7, the thickness of the second sub-plate is equal to the thickness of the flange.

[0018] In some embodiments, in step S7, in step S3, the outer circumferential shape of the first sub-plate is the same as the outer circumferential shape of the ring gear, and in step S5, the outer circumferential surface of the first sub-plate is flush with the outer circumferential surface of the ring gear.

[0019] In some embodiments, step S4 is further included between step S3 and step S5: an adhesive layer is applied on at least one of the ring gear and the first sub-plate, so that after the ring gear is placed on the first sub-plate in step S5, the ring gear is glued to the first sub-plate.

[0020] In some embodiments, the inner circumference of the flange is a non-cylindrical surface; in step S7, when printing the second sub-plate, the outer circumference of the second sub-plate is brought into contact and connected with the inner circumference of the flange.

[0021] In some embodiments, the flange includes a plurality of triangular areas sequentially arranged along the circumferential direction, the top angle of each triangular area is arranged toward the hub and is rounded, and the sides of two adjacent triangular areas are connected by an arc transition.

[0022] According to an embodiment of the third aspect of the present invention, the reduction transmission assembly comprises: a casing, wherein an assembly cavity is defined in the casing, and an input shaft hole and an output shaft hole are provided on the casing; an input gear, wherein the input gear is assembled at the input shaft hole; an output gear, wherein the output gear is assembled at the output shaft hole, and the output gear is meshed with the input gear in the assembly cavity; wherein at least one of the input gear and the output gear is the composite gear described in the embodiment of the first aspect of the present invention.

[0023] The aircraft according to the fourth aspect of the present invention comprises: a power system; a reduction transmission assembly, wherein the reduction transmission assembly is the reduction transmission assembly according to the third aspect of the present invention, wherein the input gear is connected to the power system; and a rotor system, wherein the rotor system is connected to the output gear. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is an isometric view of a compound gear according to some embodiments of the present invention;

[0025] Figure 2 An exploded view of a composite gear according to some embodiments of the present invention;

[0026] Figure 3 Schematic cross-sectional views of compound gears according to some embodiments of the present invention;

[0027] Figure 4 A front view of a gear ring according to some embodiments of the present invention;

[0028] Figure 5 for Figure 4 Sectional view along AA;

[0029] Figure 6 A front view of a web according to some embodiments of the present invention;

[0030] Figure 7 for Figure 6 a side view of the web shown;

[0031] Figure 8 for Figure 7 A cross-sectional view along BB of the web shown;

[0032] Fig. 9 for Figure 6 The middle circle shows the enlarged view of point C;

[0033] Fig.10 for Figure 6 a cross-sectional view of the web shown;

[0034] Fig.11 for Fig.10 The middle circle shows the enlarged view of point D;

[0035] Fig.12 A front view of a wheel hub according to some embodiments of the present invention;

[0036] Fig.13 for Fig.12 a side view of the hub shown;

[0037] Fig.14 for Fig.12 a cross-sectional view of the hub shown;

[0038] Fig.15 for Fig.12 a perspective view of the hub shown;

[0039] Fig.16 An adhesive layer between the gear ring and the web in some embodiments of the present invention;

[0040] Fig.17 A gear processing flow chart of some embodiments of the present invention;

[0041] Fig.18 A schematic structural diagram of a casing in some embodiments of the present invention;

[0042] Fig.19 An exploded view of a casing according to some embodiments of the present invention;

[0043] Fig. 20 It is a schematic diagram of the structure of a reduction transmission assembly in some embodiments of the present invention;

[0044] Fig.21Schematic diagram of the internal structure of a reduction transmission assembly according to some embodiments of the present invention;

[0045] Fig. 22 A schematic diagram of the structure of an aircraft according to some embodiments of the present invention;

[0046] Fig.23 A schematic diagram of the coordination of a reduction transmission assembly, a power system, and a rotor system of an aircraft according to some embodiments of the present invention;

[0047] Fig.24 The present invention is a schematic diagram of the connection structure of the reduction transmission assembly, the power system and the rotor system of an aircraft in some embodiments of the present invention.

[0048] Reference numerals:

[0049] Aircraft 10,000;

[0050] Reduction transmission assembly 1000;

[0051] Compound gear 100;

[0052] Web 13, center hole 13-10, first center hole 13-1, second center hole 13-2, third center hole 13-3;

[0053] Sub-board 130, first sub-board 1301, second sub-board 1302, third sub-board 1303;

[0054] Wheel hub 15;

[0055] Ring gear 40, meshing teeth 41, ring gear end face 42, flange 44, triangular area 441;

[0056] Adhesive layer 60;

[0057] Casing 200, input shaft hole 201, output shaft hole 202, assembly cavity 203;

[0058] Input gear 300, output gear 400;

[0059] Power system 2000, rotor system 3000. DETAILED DESCRIPTION

[0060] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0061] In the description of the present invention, it should be understood that the terms "upper", "lower", "inner", "outer", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation and be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0062] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0063] Reference below Figure 1 - Fig.17 A composite gear 100 made of a continuous fiber 3D printed composite material and a metal material hybrid is described according to an embodiment of the first aspect of the present invention.

[0064] According to the composite gear 100 of the first embodiment of the present invention, the application field of the composite gear 100 is not limited, and it can be used in a variety of equipment and machinery that require gear transmission, such as in an aircraft 10000. For ease of description, the composite gear 100 is used in the aircraft 10000 for illustration in this application.

[0065] like Figure 1 - Figure 2 As shown, the composite gear 100 according to the first embodiment of the present invention includes: a web 13 , a hub 15 and a ring gear 40 .

[0066] The web 13 is a continuous carbon fiber 3D printed part, and therefore has periodic hollow holes, which can significantly reduce weight.

[0067] The use of continuous carbon fiber 3D printed molded parts as the web 13 of the composite gear 100 has the following advantages compared to traditional metal materials:

[0068] First, the density of continuous carbon fiber 3D printed parts is lower than that of general metal parts, which means that continuous carbon fiber 3D printed parts can reduce the weight of the composite gear 100. For weight-sensitive aircraft 10000 such as helicopters, weight reduction can directly translate into higher payload, longer range or better fuel economy.

[0069] Secondly, the continuous carbon fiber 3D printed molded parts provide relatively excellent specific strength (i.e. strength / weight ratio) and specific stiffness (i.e. stiffness / weight ratio), which enables the web 13 to maintain good mechanical properties even under high-intensity load conditions.

[0070] Furthermore, the continuous carbon fiber 3D printed molded parts also have good fatigue resistance, which is very important for the transmission system of the helicopter that needs to run for a long time and withstand periodic loads. Having high fatigue resistance can enhance the reliability and durability of the composite gear 100, thereby ensuring that the aircraft 10000 has a longer service life and lower maintenance frequency.

[0071] In addition, the continuous carbon fiber 3D printed molded parts also have a certain corrosion resistance, which helps to increase the service life of the web 13, reduce the probability of its corrosion, and correspondingly extend the service life of the composite gear 100 and reduce maintenance costs.

[0072] The center of the web 13 has a center hole 13-10, and the hub 15 is fitted in the center hole 13-10. The ring gear 40 is connected to the web 13, and the ring gear 40 is coaxially arranged with the hub 15. The ring gear 40 is provided with meshing teeth 41 distributed at intervals along the circumferential direction. The hub 15 is a metal part, and the ring gear 40 is also a metal part.

[0073] It can be known that the axis of the ring gear 40 coincides with that of the wheel hub 15, which can ensure the accuracy and stability of the transmission.

[0074] The gear ring 40 is provided with meshing teeth 41 spaced apart along the circumferential direction. The meshing teeth 41 are the parts that mesh with other gears or transmission components. The transmission of power and torque can be achieved through the meshing teeth 41 .

[0075] The gear ring 40 is a metal part. Specifically, when the metal gear ring 40 is used in the transmission system of the aircraft 10000, the metal gear ring 40 has high strength, high hardness and good wear resistance. Therefore, it can withstand the friction generated by high load and high-speed operation, thereby ensuring the long-term stable operation of the transmission system.

[0076] Optionally, the hub 15, the gear ring 40 and the web 13 may be connected by welding, bolting or adhesive connection, or a combination thereof. For example, in some solutions, the gear ring 40 and the web 13 are connected by bolts. Alternatively, in some other solutions, the gear ring 40 and the web 13 are connected by a combination of bolting and adhesive connection.

[0077] The web 13 is a continuous carbon fiber 3D printed molded part, which means that the web 13 is made by continuously printing carbon fiber with a 3D printer. The web 13 can be a single board or include a multi-layer sub-board 130. The so-called "continuous carbon fiber 3D printing" means that during the single board printing process, the carbon fiber material ejected by the 3D printer is continuous and has no broken lines. For example, a Markforged brand printer can be selected for continuous carbon fiber 3D printing.

[0078] Specifically, the carbon fiber selected by the 3D printer can be continuous carbon fiber such as T300-1K and T700-1K produced by Toray Industries, Japan.

[0079] Here, T300 and T700 are the models of carbon fiber. Carbon fiber is a new type of fiber material with high strength and high modulus fiber with a carbon content of more than 90%. The "T" in T300 and T700 represents the tensile strength classification of carbon fiber, and the numbers "300" and "700" indicate that the tensile strength of carbon fiber is about 300MPa and 700MPa respectively. T300 fiber cloth has high strength and can withstand large tensile forces. Its modulus is high, which means that the material has a strong ability to resist deformation when subjected to force.

[0080] In the field of fiber cloth such as carbon fiber cloth, "K" is a unit that represents the number of filaments in a fiber bundle. "1K" means that a bundle of fibers in the fiber cloth is composed of 1,000 filaments. For example, in the production process of carbon fiber cloth, these filaments are bundled together to form a fiber bundle with certain properties.

[0081] The thickness of the web 13 is at least 18 mm, and the web 13 has a torsional strength in the range of 100 MPa-150 MPa and a bending strength in the range of 170 MPa-220 MPa.

[0082] Specifically, the continuous carbon fiber 3D printing process belongs to the molten deposition molding process. The print head of the 3D printer can achieve synchronous and real-time heating, continuous wire feeding, and solidification molding. The print head continuously deposits and molds according to the programmed path.

[0083] Through the design of the printing path, the 3D printer can control the print nozzle to complete the continuous carbon fiber additive manufacturing of complex hollow structures; for example, by printing at equal intervals along the straight path of +60°, 0°, and -60°, a periodic hollow structure with an isosceles triangle hollow space can be obtained; its performance is comparable to that of the structure prepared by the laminate process, but it is lighter, more flexible to prepare, and can be printed in situ, simplifying the subsequent assembly steps. Of course, more complex printing paths can also be designed to prepare more complex structures through the continuous carbon fiber 3D printing process.

[0084] In this way, the web 13 required for this application can be obtained.

[0085] The present invention overcomes the deficiencies in the prior art and provides a composite gear 100 of a continuous fiber 3D printed composite material and a metal material mixed therein, wherein the composite gear 100 is formed by physically connecting a continuous carbon fiber 3D printed composite material structural element and a metal material structural element to form a functional whole, thereby achieving high performance, light weight, and low cost properties of the components, and achieving a weight reduction of more than 50% at the component level while maintaining equivalent performance and cost, thereby solving the problem of performance improvement and lightweight design of gear parts of traditional helicopter transmission systems.

[0086] In some embodiments, the web 13 may be an integral plate. In other embodiments, such as Figure 2 and Figure 3 As shown, the web 13 includes at least two layers of sub-plates 130 stacked in the axial direction, and each layer of sub-plates 130 is made by continuously printing carbon fibers using a 3D printer.

[0087] Specifically, each layer of the sub-board 130 has periodic hollow holes, and all layers of the sub-boards 130 are formed by printing layer by layer. Fig. 9 The figure shows triangular hollow holes, and the entire sub-board 130 is covered with hollow holes and arranged regularly. The periodicity here means that the hollow holes are arranged regularly, and the arrangement regularity is not limited.

[0088] Optionally, the thickness of each layer of sub-plate 130 is at least 6 mm. In this way, after the web 13 is layered, the thickness of the single-layer sub-plate 130 is reduced, which is convenient for installation and connection with the hub 15 and the ring gear 40, and convenient for the web 13 to be physically connected to the hub 15 and the ring gear 40.

[0089] For example, in some specific embodiments, Figure 2-Figure 5As shown, a flange 44 extending radially inward is provided on the gear ring 40. The web 13 includes: a first sub-plate 1301, a second sub-plate 1302 and a third sub-plate 1303, wherein the first sub-plate 1301 is located on one axial side of the flange 44. The second sub-plate 1302 is located in the space surrounded by the flange 44, and the third sub-plate 1303 is located on the other axial side of the flange 44.

[0090] The flange 44 is sandwiched between the first sub-board 1301 and the third sub-board 1303 , and the second sub-board 1302 is also sandwiched between the first sub-board 1301 and the third sub-board 1303 .

[0091] With such arrangement, the flange 44 is clamped between the first sub-plate 1301 and the third sub-plate 1303, the contact area between the web 13 and the gear ring 40 is large, and the two can be strictly limited in the axial, circumferential and radial directions, which is beneficial to improve the structural strength and rigidity of the connection between the two and reduce the probability of disengagement between the two.

[0092] Figure 4-Figure 5 The structure of the gear ring 40 in some embodiments of the present invention is shown. Figure 6-Figure 11 The structure of the web 13 of some embodiments of the present invention is shown. Figure 12-Figure 15 The structure of the hub 15 according to some embodiments of the present invention is shown.

[0093] Specifically, Figure 2 and Figure 6 As shown, the inner peripheral surface of the flange 44 is a non-cylindrical surface. Figure 2 and Figure 3 , Figure 8 As shown, the outer circumference of the second sub-plate 1302 is consistent in shape with the inner circumference of the flange 44 , and the outer circumference of the second sub-plate 1302 is in contact with the inner circumference of the flange 44 .

[0094] The non-cylindrical surface setting can provide a larger contact area, thereby improving the uniformity and stability of torque transmission.

[0095] In this way, when one of the ring gear 40 and the wheel hub 15 rotates, the outer circumference of the second sub-plate 1302 and the inner circumference of the flange 44 are in surface contact, driving the other of the ring gear 40 and the wheel hub 15 to rotate. The transmission of the driving force between the two can be at least partially transmitted through the surface contact between the outer circumference of the second sub-plate 1302 and the inner circumference of the flange 44. The large circumference of the contact surface can disperse the driving force in the circumferential direction, thereby reducing the force per unit area, reducing the concentrated stress, and improving the transmission reliability.

[0096] Here, the shape of the inner circumference of the flange 44 may not be limited, and the projection of the inner circumference of the flange 44 on the end surface of the flange 44 may be an ellipse, a polygon, etc., which is not limited here.

[0097] In some specific embodiments, Figure 4 and Figure 2 As shown, the flange 44 includes a plurality of triangular areas 441 arranged in sequence along the circumferential direction, so that the circumference of the contact surface is longer. Optionally, the top of each triangular area 441 is an arc angle, and optionally, adjacent triangular areas 441 are connected by arc transition. In this way, the concentrated stress on the flange 44 can be further reduced and its load capacity can be increased.

[0098] In some specific embodiments, the inner circumference of the flange 44 is a sinusoidal directrix cylinder, that is, the inner circumference of the flange 44 is a sinusoidal curve surface after being unfolded.

[0099] Alternatively, the inner circumferential surface of the flange 44 may also adopt other centrally symmetrical but non-cylindrical shapes.

[0100] It is understandable that the central symmetric pattern can make the two contact surfaces have a more uniform stress distribution when connected. Due to the characteristics of the central symmetric pattern, they can evenly distribute the stress to the entire contact surface when subjected to the same external force, thereby avoiding local wear or damage caused by stress concentration at one or several points.

[0101] Since the stress distribution is more uniform, the design of the central symmetrical pattern can improve the connection strength between the web 13 and the ring gear 40. This uniform stress distribution reduces material fatigue caused by stress concentration, thereby extending the service life of the composite gear 100. In addition, the uniform stress distribution also helps to reduce vibration and noise caused by unbalanced forces, thereby helping to improve the running smoothness of the transmission system of the aircraft 10000.

[0102] In the present application, the outer circumference of the second sub-plate 1302 and the inner circumference of the flange 44 may have the same shape or may have a slight difference, as long as the two are compatible.

[0103] Specifically, in the web 13 of the composite gear 100, each sub-plate 130 is manufactured by continuous carbon fiber 3D printing in one piece. The printing process uses the ring gear 40 of the composite gear 100 as the outer constraint, the hub 15 of the composite gear 100 as the inner constraint, and the plane parallel to the ring gear end face 42 of the ring gear 40 of the composite gear 100 as the printing plane.

[0104] When the sub-plate 130 of the composite gear 100 is manufactured by 3D printing, the thickness of the sub-plate 130 increases along the axis of the hub 15 of the composite gear 100 and points to the side of the meshing teeth 41 at the top of the gear ring 40 of the composite gear 100. The continuous carbon fiber printed by 3D printing is printed layer by layer along the printing path in the printing plane, such as Fig.11As shown, the first thickness h1 of the first sub-plate 1301, the second thickness h2 of the second sub-plate 1302, and the third thickness h3 of the third sub-plate 1303 are printed in sequence, and the following is formed: Fig. 9 The periodic hollow structure shown.

[0105] The web 13 of the composite gear 100 is a periodic hollow structure made of continuous carbon fiber by 3D printing layer by layer, which can completely cover the ring gear end face 42 at the bottom of the ring gear 40 of the composite gear 100 and the sinusoidal flange 44 inside the ring gear 40 of the composite gear 100, and the second thickness h2 part of the second sub-plate 1302. The second sub-plate 1302 can fit with the flange 44 to form a profile connection structure. The inner side of the third sub-plate 1303 is a curved surface with a sine curve as the directrix, and can fit with the sinusoidal directrix cylinder outside the hub 15 to form a profile connection structure.

[0106] In some embodiments, Figure 6 As shown, the center hole 13-10 of the web 13 is a non-circular hole. Figure 12-Figure 15 As shown, the shape of the outer circumference of the hub 15 is consistent with the shape of the inner circumference of the center hole 13-10. The outer circumference of the hub 15 is in contact with the inner circumference of the center hole 13-10.

[0107] Here, when the web 13 is a multi-layer sub-board 130, as shown in FIG. Fig.10 As shown, the center of each layer of sub-plate 130 is provided with a hole corresponding to the hub 15. For example, a first center hole 13-1 is provided at the center of the first sub-plate 1301, a second center hole 13-2 is provided at the center of the second sub-plate 1302, and a third center hole 13-3 is provided at the center of the third sub-plate 1303. The shapes of the first center hole 13-1, the second center hole 13-2, and the third center hole 13-3 all match the shape of the outer circumference of the hub 15.

[0108] like Figure 12-Figure 15 As shown, the middle section of the hub 15 forms a spline to assemble the first sub-plate 1301, the second sub-plate 1302, and the third sub-plate 1303. Shoulders are formed on the two layers of the spline to assemble bearings and the like.

[0109] In some embodiments, Fig.16 As shown, the composite gear 100 further includes an adhesive layer 60 , which is bonded between the ring gear 40 and the web 13 .

[0110] The adhesive layer 60 is located between the gear ring 40 and the web 13. The adhesive layer 60 serves to firmly bond the two components together.

[0111] On the one hand, by adding the adhesive layer 60, the connection strength between the ring gear 40 and the web 13 is enhanced to a certain extent. The adhesive can fill the tiny gap and eliminate some potential looseness, thereby improving the reliability of the composite gear 100. Especially under some high torque transmission and vibration conditions, the adhesive layer 60 can prevent the relative displacement or looseness between the ring gear 40 and the web 13, and improve the connection strength between the two.

[0112] On the other hand, the adhesive layer 60 can play a role in uniform stress distribution. Since the adhesive can fill the irregularities that may occur on the contact surface, the stress is more evenly distributed on the contact surface, thereby reducing local stress concentration.

[0113] Furthermore, the adhesive layer 60 can also provide a certain sealing effect to prevent foreign matter from entering between the contact surfaces, protect the internal structure from being polluted, and further extend the service life of the composite gear 100.

[0114] In some optional embodiments, the thickness of the adhesive layer 60 is 0.1 mm-0.2 mm.

[0115] For example, the thickness of the adhesive layer 60 is 0.1 mm, 0.12 mm, 0.15 mm, 0.17 mm, 0.2 mm, etc. Here, the thickness of the adhesive layer 60 is controlled within 0.1 mm-0.2 mm, which can provide sufficient bonding strength to ensure the tight bonding between the ring gear 40 and the web 13, and prevent relative sliding or loosening under high torque transmission and vibration conditions. At the same time, the impact on the overall size and weight of the composite gear 100 is minimized.

[0116] Specifically, before assembling the ring gear 40 of the continuous fiber 3D printed composite-metal material hybrid composite gear 100, the bottom end plane of the ring gear 40 of the composite gear 100 can be coated with adhesive to form an adhesive layer 60. Its function is to assist in gluing and connecting the ring gear 40 of the composite gear 100 and the first sub-plate 1301 that has been printed.

[0117] The gear processing method according to the second embodiment of the present invention can be used to process the composite gear 100 according to the first embodiment of the present invention. Fig.17 , including the following steps:

[0118] S1: Use the hub 15 as a printing reference for positioning;

[0119] S3: Using a 3D printer, the carbon fiber is continuously printed to form a first sub-plate 1301, wherein the first sub-plate 1301 takes the hub 15 as the center, and the first sub-plate 1301 takes the outer circumference of the hub 15 as the inner side constraint;

[0120] S5: placing the ring gear 40 on the first sub-plate 1301, the ring gear 40 surrounds the radial outer side of the hub 15, wherein the ring gear 40 is provided with a flange 44 extending radially inward;

[0121] S7: Using a 3D printer, the carbon fiber is continuously printed to form a second sub-plate 1302, the second sub-plate 1302 is located on the first sub-plate 1301, the second sub-plate 1302 takes the hub 15 as the center, the second sub-plate 1302 takes the outer circumference of the hub 15 as the inner constraint, and the second sub-plate 1302 takes the inner circumference of the flange 44 as the outer constraint;

[0122] S9: Continue to use the 3D printer to continuously print the carbon fiber to form the third sub-plate 1303. The third sub-plate 1303 is located on the flange 44 and the second sub-plate 1302. The third sub-plate 1303 takes the hub 15 as the center. The third sub-plate 1303 uses the outer circumference of the hub 15 as the inner constraint. The third sub-plate 1303 uses the inner circumference of the gear ring 40 as the outer constraint.

[0123] In this way, 3D printing can not only form a web 13 that reduces weight and ensures torque strength and bending moment strength, but also utilize the curing process of the web 13 after 3D printing to combine the hub 15 and the ring gear 40 into a whole.

[0124] This composite gear 100, which can be formed by continuous fiber 3D printing of a mixture of composite materials and metal materials, achieves the high performance, lightweight and low-cost attributes of the components. It can achieve a weight reduction of more than 50% at the component level while maintaining comparable performance and cost, solving the problem of performance improvement and lightweight design of gear parts in traditional helicopter transmission systems.

[0125] In some embodiments, in step S7, the thickness of the second sub-board 1302 is equal to the thickness of the flange 44. In this way, the surfaces of the second sub-board 1302 and the flange 44 can be flush. In this way, when printing the third sub-board 1303, the flush plane of the two can be used as the printing plane, thereby reducing the difficulty of printing and improving the bonding strength of the materials.

[0126] In some embodiments, in step S7, in step S3, the outer circumferential surface of the first sub-plate 1301 is the same as the outer circumferential surface of the gear ring 40, and in step S5, the outer circumferential surface of the first sub-plate 1301 is flush with the outer circumferential surface of the gear ring 40. In this way, when the outer circumferential surface of the gear ring 40 is subjected to force, the first sub-plate 1301 and the gear ring 40 bear the force together, reducing the risk of separation and breakage of the two.

[0127] In some embodiments, step S4 is further included between step S3 and step S5: an adhesive layer 60 is coated on at least one of the ring gear 40 and the first sub-board 1301, so that after the ring gear 40 is placed on the first sub-board 1301 in step S5, the ring gear 40 is glued to the first sub-board 1301. The adhesive layer 60 is used to assist in connecting the ring gear 40 and the first sub-board 1301, which on the one hand improves the connection strength between the two, and on the other hand, after the adhesive layer 60 connects and fixes the two, it is easy to position the second sub-board 1302 when printing, thereby reducing the difficulty of printing and positioning.

[0128] The reduction transmission assembly 1000 according to the third aspect of the present invention comprises: a casing 200, an input gear 300 and an output gear 400. Fig.18 - Fig. 20 The casing 200 defines an assembly cavity 203, and the casing 200 is provided with an input shaft hole 201 and an output shaft hole 202. The input gear 300 is assembled at the input shaft hole 201. The output gear 400 is assembled at the output shaft hole 202, and the output gear 400 meshes with the input gear 300 in the assembly cavity 203. Fig.21 , wherein at least one of the input gear 300 and the output gear 400 is the composite gear 100 according to the first embodiment of the present invention.

[0129] In the above technical solution, the casing 200 defines an assembly cavity 203. The assembly cavity 203 is used to accommodate multiple components of the reduction transmission assembly 1000, such as the input gear 300, the output gear 400, etc. The assembly cavity 203 provides a safe space for the reduction transmission assembly 1000 to ensure that it can run smoothly during operation.

[0130] The casing 200 is provided with an input shaft hole 201 and an output shaft hole 202. The input shaft hole 201 is used to install the input gear 300, and the output shaft hole 202 is used to install the output gear 400. The arrangement of these holes needs to ensure that the shaft can be smoothly inserted and firmly fixed inside the casing 200 through supporting structures such as bearings.

[0131] The input gear 300 is assembled at the input shaft hole 201. Optionally, the input gear 300 is mounted on the input shaft through a keyway and supported in the input shaft hole 201 in the casing 200 through a bearing. Such a connection method can ensure that the input gear 300 does not wobble when rotating.

[0132] The output gear 400 meshes with the input gear 300 in the assembly cavity 203. This means that the two gears can transmit torque through the mutual meshing of the gear teeth when rotating. The rotation of the input gear 300 is transmitted to the output gear 400 through meshing, thereby achieving a deceleration or acceleration effect.

[0133] At least one of the input gear 300 and the output gear 400 is the composite gear 100 according to the first embodiment of the present invention.

[0134] When the input gear 300 is a composite gear 100, the composite gear 100 with a lightweight advantage can reduce the total weight of the reduction transmission assembly 1000, thereby reducing the inertia of the moving parts, so that the input gear 300 requires less energy when rotating, thereby improving the transmission efficiency. At the same time, this composite gear 100 has a metal hub 15 and a ring gear 40, which can provide higher hardness and wear resistance, ensuring the reliability of the composite gear 100 during high torque transmission. Therefore, by combining a lightweight design with a high-strength metal ring gear 40, the composite gear 100 can maintain stable operation when subjected to high torque, thereby improving the overall reliability of the reduction transmission assembly 1000.

[0135] When the output gear 400 is a composite gear 100, the weight of the reduction gear assembly 1000 is reduced due to the use of a lightweight composite gear 100, and the inertia of the output gear 400 is also reduced. This means that less power is required when starting and stopping, which can reduce energy loss to a certain extent and improve the response speed and efficiency of the system.

[0136] In order to further reduce the total weight of the reduction transmission assembly 1000 , reduce inertia, improve transmission efficiency, and ensure reliability under high torque transmission conditions, in some optional embodiments, both the input gear 300 and the output gear 400 are composite gears 100 .

[0137] like Fig. 22 - Fig.24 As shown, the aircraft 10000 according to the fourth aspect of the present invention comprises: a power system 2000, a reduction transmission assembly 1000 and a rotor system 3000. The reduction transmission assembly 1000 is the reduction transmission assembly 1000 according to the third aspect of the present invention, wherein the input gear 300 is connected to the power system 2000. The rotor system 3000 is connected to the output gear 400.

[0138] In the above technical solution, the input gear 300 is connected to the power system 2000 and is responsible for transmitting the power generated by the engine to the reduction transmission assembly 1000. Fig.23 , the power system 2000 is connected to the input gear 300 through the input shaft hole 201. When the input gear 300 is a composite gear 100, the lightweight characteristics of the composite gear 100 can be utilized to reduce the inertia of the input gear 300, so that the power transmission is faster and more efficient. At the same time, due to the lightweight design of the composite gear 100, it also helps to reduce energy loss during the start and stop process, and improve the response speed and efficiency of the power system 2000.

[0139] The rotor system 3000 is connected to the output gear 400 and is responsible for transmitting the decelerated power to the rotor blades. Fig.24 , the rotor system 3000 is connected to the output gear 400 through the output shaft hole 202. By setting the composite gear 100 with a higher degree of lightness as the output gear 400, the output gear 400 can be made more efficient in transmitting power, thereby reducing energy loss. At the same time, by reducing the weight and inertia of the output gear 400, the response speed of the rotor system 3000 can be improved, so that the rotor blades can reach the required rotation speed faster, thereby improving the maneuverability and efficiency of the aircraft 10000.

[0140] In summary, by using the composite gear 100 in the key transmission components of the aircraft 10000, the weight of the entire aircraft 10000 can be reduced. This is very beneficial to improving the fuel efficiency and endurance of the aircraft 10000. Moreover, the high strength of the composite gear 100 also ensures reliability under high torque transmission conditions. It reduces maintenance frequency and costs, and improves the overall reliability of the aircraft 10000. In addition, the high hardness and wear resistance of the metal gear ring 40 enables the composite gear 100 to maintain good performance under high torque conditions, thereby extending the service life of the reduction transmission assembly 1000 and the entire aircraft 10000.

[0141] It is worth noting that according to the embodiment of the present application, the type of the aircraft 10000 is not limited, and it can be a helicopter or a drone, etc.

[0142] Other components of the composite gear 100 according to the embodiment of the present invention, such as the reduction transmission assembly 1000 and the aircraft 10000, and operations thereof are known to those skilled in the art and will not be described in detail herein.

[0143] In the description of this specification, the description with reference to the terms "embodiment", "example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0144] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A gear processing method, characterized in that: Continuous fiber 3D printed composite-metal hybrid gears, including: A web, wherein the web is a continuous carbon fiber 3D printed part, the center of the web has a central hole, and the web has periodic hollow holes; A wheel hub, the wheel hub is fitted at the center hole, and the wheel hub is a metal part; A gear ring, the gear ring is connected to the web, the gear ring is coaxially arranged with the wheel hub, the gear ring is provided with meshing teeth distributed at intervals along the circumferential direction, and the gear ring is a metal part; The web comprises at least two layers of sub-plates stacked in the axial direction, each layer of the sub-plates is made by continuous printing of carbon fibers by a 3D printer, each layer of the sub-plates has periodic hollow holes, and all layers of the sub-plates are formed by printing layer by layer; The thickness of the web is at least 18 mm, and the torsional strength of the web is in the range of 100 MPa-150 MPa, and the bending strength is in the range of 170 MPa-220 MPa; The processing of the composite gear includes: S1: Using the wheel hub as a printing reference for positioning; S3: using a 3D printer to continuously print carbon fibers into a first sub-plate, wherein the first sub-plate takes the wheel hub as a center and the first sub-plate takes the outer circumference of the wheel hub as an inner constraint; S5: placing the gear ring on the first sub-plate, the gear ring surrounding the radial outer side of the hub, wherein the gear ring is provided with a flange extending radially inward; S7: Using a 3D printer, continuously printing the carbon fiber to form a second sub-plate, wherein the second sub-plate is located on the first sub-plate, the second sub-plate takes the wheel hub as the center, the second sub-plate takes the outer circumference of the wheel hub as the inner constraint, and the second sub-plate takes the inner circumference of the flange as the outer constraint; S9: Continue to use the 3D printer to continuously print the carbon fiber to form a third sub-plate, wherein the third sub-plate is located on the flange and the second sub-plate, the third sub-plate takes the wheel hub as the center, the third sub-plate takes the outer circumference of the wheel hub as the inner constraint, and the third sub-plate takes the inner circumference of the gear ring as the outer constraint.

2. The gear processing method according to claim 1, characterized in that: In step S7, the thickness of the second sub-plate is equal to the thickness of the flange.

3. The gear processing method according to claim 1, characterized in that: In step S7, in step S3, the outer circumferential shape of the first sub-plate is the same as the outer circumferential shape of the ring gear, and in step S5, the outer circumferential surface of the first sub-plate is flush with the outer circumferential surface of the ring gear.

4. The gear processing method according to claim 1, characterized in that: The method further includes step S4 between step S3 and step S5: applying an adhesive layer on at least one of the ring gear and the first sub-plate, so that after the ring gear is placed on the first sub-plate in step S5, the ring gear is glued to the first sub-plate.

5. The gear processing method according to claim 1, characterized in that: The inner circumferential surface of the flange is a non-cylindrical surface; In step S7, when printing the second sub-plate, the outer circumferential surface of the second sub-plate is brought into contact and connected with the inner circumferential surface of the flange.

6. The gear processing method according to any one of claims 1 to 5, characterized in that: The flange comprises a plurality of triangular areas arranged in sequence along the circumferential direction, the top angle of each triangular area is arranged toward the hub and is rounded, and the sides of two adjacent triangular areas are connected by an arc transition.

7. A reduction transmission assembly, characterized in that: include: A casing, wherein an assembly cavity is defined in the casing, and an input shaft hole and an output shaft hole are provided on the casing; An input gear, the input gear being assembled at the input shaft hole; An output gear, the output gear is assembled at the output shaft hole, and the output gear is meshed with the input gear in the assembly cavity; Wherein, at least one of the input gear and the output gear is processed by the gear processing method according to any one of claims 1-6.

8. An aircraft, characterized in that: include: Powertrain; A reduction transmission assembly, wherein the reduction transmission assembly is the reduction transmission assembly according to claim 7, wherein the input gear is connected to the power system; A rotor system is connected to the output gear.

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