Gear shaper suitable for ultra-large tooth width machining

Abstract

A gear shaper suitable for ultra-large tooth width machining comprises a lathe bed, a stand column, a cutter shaft and a workbench, a servo motor is adopted to drive a ball screw to serve as a main movement system, and a cutter rest sliding plate is driven to achieve accurate up-down reciprocating motion; the cutter shaft is rigidly connected with the sliding plate through an end face bearing and supported by hydrostatic bearings at the two ends, and the supporting distance L is larger than or equal to the tooth width * 2.5. The tool rest transmission system is integrated on the sliding plate and drives the tool shaft to rotate through a worm and gear pair. The radial feeding system drives a sliding seat to move through a servo motor and a ball screw; a workbench independent cutter relieving mechanism is innovatively adopted, and a servo motor drives a ball screw to achieve precise cutter relieving motion. According to the design, a traditional hydraulic system is abandoned, through a modularized multi-axis linkage structure, the mechanical layout is remarkably simplified, the machining precision and efficiency are improved, and the technical blank of large-modulus and ultra-long-tooth-width gear machining equipment is filled up.

Description

Technical Field

[0001] The present invention relates to a gear shaping machine, in particular to a gear shaping machine suitable for processing super-large tooth widths. Background Art

[0002] Gear shaping machines are a common gear processing machine tool used extensively in industries such as automotive, machinery, and petrochemicals. They are primarily used to produce cylindrical spur gears, internal and external gears, and helical gears. Currently, with the rise of green energy industries such as mining machinery and wind power, market demand for deep-hole internal gears and long-shaft gears has increased significantly. These gears generally feature extra-large tooth widths, exceeding the processing capabilities of conventional gear shaping machines.

[0003] There are two main types of drive mechanisms for gear shaping machines: 1. Crank-connecting rod slider drive: To meet the stroke required for machining extra-large tooth widths, the crank eccentricity must be increased accordingly. This not only results in a bulky machine structure, complex mechanical transmission, and high energy consumption, but also significantly increases machining difficulty and production cycle, making it difficult to meet user needs.

[0004] 2. Hydraulic cylinder drive: Although this solution can adapt to large tooth width processing, its hydraulic system is complex and costly, and the stroke position control accuracy of the hydraulic cylinder is insufficient, resulting in low efficiency. Summary of the Invention

[0005] The present invention aims to solve the above-mentioned problems and provides a gear shaping machine which has small size, simple structure and high control precision and is suitable for processing ultra-large tooth widths.

[0006] The technical solutions to the problems to be solved by the present invention are as follows: A gear shaping machine suitable for processing extra-large tooth widths comprises a bed, a column, a tool shaft and a worktable, and is characterized in that: a main motion system, a servo motor is connected to a ball screw, driving the tool holder slide to reciprocate up and down along a guide rail; a tool shaft connection structure and a support structure, the tool shaft is rigidly connected to the tool holder slide through at least a pair of end bearings, and both ends of the tool shaft are radially supported on the tool holder slide through hydrostatic bearings, and the support spacing L satisfies L≥maximum processing tooth width*2.5; a tool holder transmission system, a tool holder servo motor is installed on the tool holder slide, driving the tool shaft to rotate through a worm gear pair; a radial feed system, a radial servo motor drives the slide to move along the guide rail through a radial ball screw pair, and the slide carries the column; a tool letting mechanism, the worktable is installed on the guide rail pair, and the tool letting servo motor is connected to the tool letting ball screw pair to drive the worktable to let the tool move during gear shaping.

[0007] Preferably, the support spacing L of the hydrostatic bearing is fixed and satisfies L≥maximum processing tooth width*2.5; the cutter shaft moves axially relative to the worm gear pair to adapt to different processing tooth widths and enhance the rigidity when processing small tooth widths.

[0008] Preferably, the rotational movement of the workbench is driven by a rotary servo motor through a rotating worm gear pair, and the rotary servo motor is synchronously meshed with the tool holder rotary motor for rotation, and the tool-releasing servo motor is linked with the rotary motor of the main motion system for control, ensuring that the gear shaping machine tool is separated from the workpiece during the return stroke and the tool-releasing is achieved during the return stroke.

[0009] Preferably, the tool-releasing mechanism is configured to dynamically adjust the triggering timing of the tool-releasing action according to the idle tool length of the workpiece, and supports the worktable trajectory compensation function when processing drum-shaped teeth or small-taper teeth.

[0010] The beneficial effects of the present invention are as follows: The present invention directly uses a servo motor combined with a ball screw to drive the main motion and the tool release movement. This provides precise and reliable position control, avoiding hydraulic system errors. The worktable's independent tool release shaft replaces the traditional tool release system, making the tool release movement more precise and improving processing efficiency. The tool release movement is independently performed by the worktable, reducing wear on core components and extending equipment life. In addition, the tool holder transmission system is integrated into the main motion slide, allowing the tool shaft to achieve both reciprocating cutting and rotational motion, significantly simplifying the mechanical structure. Through modular design (column, slide, and worktable multi-axis linkage), the present invention achieves high-stability processing of ultra-long tooth widths (such as deep-hole internal gears and wind power long shaft gears), filling a market gap. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly describes the drawings required for the specific embodiments or the description of the prior art. Similar elements or parts are generally identified by similar reference numerals throughout the drawings. Elements or parts in the drawings are not necessarily drawn to scale.

[0012] Figure 1 1. It is a structural schematic diagram of the gear shaping machine of the present invention; Figure 2 yes Figure 1 A schematic structural diagram of the gear shaping machine from another angle. DETAILED DESCRIPTION

[0013] The following embodiments of the technical solution of the present invention will be described in detail with reference to the accompanying drawings. The following embodiments are intended only to more clearly illustrate the technical solution of the present invention, i.e., they provide a large number of specific details to provide a more thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention can be practiced without one or more of these details. In these examples, some technical features well known in the art are not described to avoid confusion with the present invention.

[0014] It should be understood that the present invention can be implemented in different forms and should not be construed as limited to the embodiments set forth herein. Therefore, they are only intended as examples and should not be used to limit the scope of protection of the present invention.

[0015] In addition, it should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should have the common meanings understood by those skilled in the art to which the present invention belongs.

[0016] See Figure 1 、 Figure 2 , a gear shaping machine suitable for processing extra-large tooth widths, includes a bed 14, a column 18, a tool spindle 8 and a worktable 10. The gear shaping machine is composed of the following mechanisms: a main motion system, a servo motor 1 connected to a ball screw 2, driving a tool holder slide 3 to reciprocate up and down along a guide rail 19; a tool spindle connection structure, in which the tool spindle 8 is rigidly connected to the tool holder slide 3 through an end bearing 5 to ensure radial rigidity during cutting; the tool spindle 8 is also radially supported from both ends by another hydrostatic bearing 4 to further ensure radial rigidity of the tool spindle 8 during cutting.

[0017] Tool holder transmission system, a tool holder servo motor 6 is installed on the tool holder slide 3, and drives the tool shaft 8 to rotate through the worm gear pair 7; radial feed system, a radial servo motor 15 drives the slide 17 to move along the guide rail 20 through a radial ball screw 16, so as to realize the radial feed movement of the tool shaft 8 along the worktable 10; the slide 17 carries the column 18; worktable transmission system, the worktable 10 is also driven by a rotary servo motor 11 connected to a rotary worm gear pair 9 to drive the worktable 10 to rotate; tool letting mechanism, the worktable 10 is installed on the guide rail pair 21, and the tool letting servo motor 12 is connected to the tool letting ball screw 13 to drive the worktable 10 to let the tool during gear cutting; the guide rail 20 and the guide rail pair 21 are both installed on the bed 14; tool shaft support structure, both ends of the tool shaft 8 are radially supported on the tool holder slide 3 through hydrostatic bearings 5, and the support spacing L satisfies L≥maximum processing tooth width*2.5.

[0018] During implementation, the gear shaping machine tool holder transmission system is mounted on the tool holder slide 3 of the gear shaping machine's main motion system and moves with the main motion. This simplifies the structure of the tool shaft 8 in the tool holder body, the core component of the gear shaping machine, and enables both up and down reciprocating motion and rotational motion. In addition, the active motion system is controlled by a servo motor, providing precise and reliable position control. The tool release motion during gear shaping is achieved through linkage with the workbench 10. The addition of a separate tool release motion axis to the workbench 10 makes tool release more accurate and reliable, extending the service life of the tool release axis. It is also important to note that the workbench's tool release motion is a short-stroke reciprocating motion and must withstand large radial cutting forces during cutting. Therefore, it is best to use a screw with a short pitch and high load-bearing capacity, such as a planetary roller screw.

[0019] Due to the ultra-long tooth width cutting, the support rigidity of the cutter shaft is required to be good. During implementation, it is also necessary to focus on the support distance of the hydrostatic bearings at both ends to increase the support rigidity of the cutter shaft as much as possible.

[0020] Furthermore, as an improvement to the present invention, the support spacing L of the hydrostatic bearing 4 is fixed and satisfies L≥maximum processing tooth width*2.5; the cutter shaft moves axially relative to the worm gear pair to adapt to different processing tooth widths and enhance the rigidity when processing small tooth widths.

[0021] Furthermore, as an improvement to the present invention, the rotational motion of the workbench 10 is driven by a rotary servo motor 11 through a rotary worm gear pair 9, and the rotary servo motor and the tool holder rotary motor rotate in synchronous meshing, and the tool-releasing servo motor is linked with the rotary motor of the main motion system to ensure that the gear shaping machine tool is separated from the workpiece by a certain distance when returning, so as to realize tool-releasing during the return stroke, and can realize the processing of cylindrical gears with any helical angle.

[0022] Furthermore, as an improvement to the present invention, the tool-releasing mechanism is configured to dynamically adjust the triggering timing of the tool-releasing action according to the idle tool length of the workpiece, that is, to adjust the delay or advance of the tool-releasing action according to the idle tool length of the workpiece, and support the worktable trajectory compensation function when processing drum-shaped teeth or small-taper teeth.

[0023] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some or all of the technical features therein. These modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present invention, and they should all be included in the scope of the claims and description of the present invention.

Claims

1. A gear shaping machine suitable for processing extra-large tooth widths, comprising a bed, a column, a cutter shaft, and a worktable, characterized in that: The main motion system consists of a servo motor connected to a ball screw, which drives the tool holder slide to move up and down along the guide rail; The tool shaft connection structure and support structure, the tool shaft is rigidly connected to the tool holder slide through at least one pair of end bearings, and both ends of the tool shaft are radially supported on the tool holder slide through hydrostatic bearings, and the support spacing L meets L ≥ maximum processing tooth width * 2.5; Tool holder transmission system, a tool holder servo motor is installed on the tool holder slide, driving the tool shaft to rotate through a worm gear pair; Radial feed system, a radial servo motor drives a slide to move along the guide rail through a radial ball screw pair, and the slide carries the column; The tool-allowing mechanism and the worktable are installed on the guide rail pair, and the tool-allowing servo motor connected to the tool-allowing ball screw pair drives the worktable to allow the tool to move during gear shaping cutting.

2. The gear shaping machine suitable for processing super-large tooth width according to claim 1, characterized in that: The support spacing L of the hydrostatic bearing is fixed and satisfies L≥maximum processing tooth width*2.5; the cutter shaft moves axially relative to the worm gear pair to adapt to different processing tooth widths and enhance the rigidity when processing small tooth widths.

3. The gear shaping machine suitable for processing super-large tooth width according to claim 1, characterized in that: The rotary motion of the workbench is driven by a rotary servo motor through a rotary worm gear pair, and the rotary servo motor is engaged and rotated synchronously with the tool holder rotary motor. The tool-releasing servo motor is linked with the rotary motor of the main motion system to ensure that the gear shaping machine tool is separated from the workpiece during the return stroke and the tool-releasing is achieved during the return stroke.

4. The gear shaping machine suitable for processing super-large tooth width according to claim 3, characterized in that: The tool-releasing mechanism is configured to dynamically adjust the triggering timing of the tool-releasing action according to the idle tool length of the workpiece, and supports the worktable trajectory compensation function when processing drum-shaped teeth or small-taper teeth.

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