Speed reducer with overload protection function

Abstract

The invention discloses an overload protection speed reducer which comprises a speed reducer case, a transmission gear, an output shaft rod, a coupling male head, a female connection seat and an air distribution disc arranged on the inner sides of the speed reducer case and the transmission gear. The coupling male head and the female connection seat are fixed to the output shaft rod and the transmission teeth respectively and are in controllable connection with the meshing groove through the insertion disc, the piston magnetic ring and the ratchet ball bead. The air distribution disc adjusts the position of a piston magnetic ring through an air path, so that the joint depth of a ratchet ball bead and a meshing groove is changed, and dynamic adjustment of overload torque is achieved. When the torque exceeds a set value, the ratchet ball is automatically disengaged under the action of the hole retreating groove, and overload protection is achieved. A touch switch is arranged on the plug-in disc and can output an alarm signal when the plug-in disc is disconnected; the spring box, the joint control gear ring and the claw connecting lug act synergistically, elastic deflection and auxiliary clamping are achieved, complete disconnection is avoided, and maintenance is convenient. The structure has the advantages of being adjustable in overload torque, rapid in response, timely in alarm, convenient to maintain and the like, and the safety and reliability of the speed reducer are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of speed reducer technology, specifically to a speed reducer with overload protection. Background Technology

[0002] Currently, speed reducers, as key components in transmission devices, are widely used in machinery manufacturing, automated production, and power transmission systems. During operation, speed reducers need to withstand significant torque and impact loads. When the actual transmission torque exceeds the design limit, it can easily lead to gear breakage, shaft distortion, or motor damage. Therefore, overload protection mechanisms are generally required.

[0003] In existing technologies, common overload protection reducers mainly employ the following structures: Overload disengagement is achieved through friction plates, springs, or pins, such as using a friction clutch or safety pin to cut off transmission. These devices are relatively simple in structure, but the torque threshold is fixed and cannot be adjusted in real time during operation. Once set, they lack flexibility and cannot adapt to changes in operating conditions. Some reducers use magnetic couplings or magnetic balls for torque transmission and protection. Under overload, the magnetic force is insufficient to maintain engagement, and the coupling automatically disengages. While this method avoids mechanical wear, the magnetic strength is limited, and the protection torque is uncontrollable, resulting in insufficient protection accuracy. Some devices use displacement sensors or current detection to trigger alarms under overload conditions, but these typically only provide an alarm indication and cannot be linked with the overload protection mechanism for coordinated control, leading to a delayed protection response and failing to effectively prevent damage to the reducer.

[0004] However, existing technologies generally have the following shortcomings: Existing mechanical or magnetic overload protection devices typically have torque disengagement values ​​determined by preset spring pressure or magnetic force, making real-time adjustment during operation difficult. Changes in the working environment can cause the protection value to become too high or too low, leading to either malfunctions or failure to provide timely protection.

[0005] Most overload protection gearboxes can only passively cut off the transmission after an overload, and cannot output alarm signals in real time. Even if some devices have alarm functions, they often rely on additional sensors, which are separate from the protection mechanism and cannot act synchronously, increasing control complexity and response delay.

[0006] Traditional structures typically separate completely under overload conditions, easily leading to complete failure at both ends of the coupling. The reducer needs to be reassembled before it can be put back into operation, making maintenance inconvenient. At the same time, most existing devices lack secondary clamping or auxiliary limiting mechanisms, resulting in overly abrupt protection actions and a lack of buffering and controllability during overload processes, which is detrimental to the long-term stable operation of the equipment.

[0007] In summary, existing overload protection reducers have significant shortcomings in terms of dynamic adjustment of torque protection threshold, overload alarm feedback, and the stability and maintainability of coupling connections. They are no longer sufficient to meet the application requirements of modern equipment in terms of high reliability, intelligence, and ease of maintenance. Summary of the Invention

[0008] The present invention aims to solve one of the technical problems existing in the prior art or related technologies.

[0009] Therefore, the technical solution adopted in this invention is as follows: an overload protection reducer, including a reducer housing, transmission gears, an output shaft, a male coupling, a female coupling, and an air distribution plate arranged inside the male and female couplings. The male and female couplings are respectively fixed to the ends of the output shaft and the transmission gears, and their internal components form a controllable connection with the engagement groove through a connector, a piston magnetic ring, and a ball bearing. Under the pneumatic control of the air distribution plate, the overload torque is dynamically adjusted. When the transmission torque exceeds a set value, the ball bearing automatically disengages from the engagement groove, achieving rapid disengagement protection. The system also includes a touch switch, a spring box, a control gear ring, and connecting claw ears for alarm feedback and auxiliary clamping, ensuring a stable and controllable connection state during overload protection and recovery.

[0010] In this embodiment, the coupling male connector is further configured as follows: the male connector includes a bushing seat, a connecting claw lug, a spring barrel, and a plug plate fixed to one side of the bushing seat. A piston magnetic ring is slidably mounted on the end of the plug plate. The surface of the piston magnetic ring is provided with a plurality of ball bearings. The surface of the plug plate is provided with a plurality of uncoiling grooves. The surface of the female connector is provided with a meshing groove. The air distribution plate is used to drive the piston magnetic ring to move, thereby realizing the engagement and disengagement of the ball bearings and the meshing groove.

[0011] Specifically, this structure can maintain stable meshing transmission under normal working conditions and achieve automatic and rapid disengagement under overload conditions, avoiding damage to the transmission teeth and output shaft.

[0012] In this embodiment, it is further configured such that: the inner surface of the transmission gear and the output shaft are provided with air passages communicating with the air distribution plate, and the surfaces of the transmission gear and the output shaft are provided with pneumatic control components.

[0013] Specifically, this structure can control the position of the piston magnetic ring in real time by adjusting the air pressure, thereby dynamically changing the engagement depth between the ratchet ball and the meshing groove, realizing real-time adjustment of the overload torque threshold, and improving the reducer's ability to adapt to different working conditions.

[0014] In this embodiment, the meshing groove is further configured as follows: the piston magnetic ring is magnetic, and the spiked ball is a ferromagnetic sphere.

[0015] Specifically, by combining magnetic action with pneumatic control, the initial position of the ratchet ball can be stabilized and its engagement depth can be controlled. When the torque exceeds the set threshold, the ratchet ball can smoothly exit the engagement groove, thereby ensuring the sensitivity and reliability of overload protection.

[0016] In this embodiment, the air distribution plate is further configured such that: the surface of the air distribution plate is provided with a plurality of air distribution holes, and the inner sides of the female connector and the plug plate are respectively provided with air passages communicating with the meshing groove and the unloading groove.

[0017] Specifically, this air distribution structure can precisely control the movement of the ball bearing between engagement and disengagement, thereby ensuring that the overload disengagement action is fast and stable.

[0018] In this embodiment, the surface of the connector plate is provided with a touch switch for monitoring the relative slippage between the female connector and the connector plate.

[0019] Specifically, when an overload occurs and the device trips, the touch switch can be triggered immediately and output an alarm signal, thereby enabling real-time detection and alerts of the overload condition and improving the intelligence level of the equipment.

[0020] In this embodiment, the piston magnetic ring is further configured such that: the surface of the piston magnetic ring has several through holes with a diameter smaller than that of the ball bearing; the inner side of the plug-in plate is provided with an annular piston groove; the piston magnetic ring is annular and its inner and outer circumferences are sealed and abutted against the annular piston groove on the inner side of the plug-in plate.

[0021] Specifically, this sealing structure ensures that airflow does not leak during the movement of the piston magnetic ring, thereby improving the accuracy and reliability of pneumatic control.

[0022] In this embodiment, the surface of the control toothed ring is arranged in an oblique tangential direction, and the lever deflection of the connecting claw ear is achieved by the deflection movement of the control toothed ring and the ratchet.

[0023] Specifically, this structure can ensure that the connecting claws continuously clamp the female connector during overload, preventing the male and female connectors from completely disengaging and improving the controllability of overload protection.

[0024] In this embodiment, it is further configured such that: the mainspring box is provided with a mainspring and an output key shaft. The mainspring drives the output key shaft to deflect elastically, thereby driving the control gear ring to deflect, thereby achieving elastic clamping contact between the end of the connecting claw ear and the claw hook groove.

[0025] Specifically, this structure provides elastic buffering for overload protection, and when manual disassembly is required, the connecting claw lugs can quickly deflect under the action of the spring force, improving the maintenance convenience of the reducer.

[0026] The beneficial effects achieved by this invention are as follows: 1. In this invention, by setting up a mating structure including an air distribution plate, piston magnetic ring, ratchet ball, and meshing groove, the engagement depth of the ratchet ball can be dynamically adjusted under pneumatic control, thereby achieving real-time adjustment of the overload torque threshold. This structure not only ensures stable meshing during transmission but also allows for rapid disengagement under overload conditions, preventing damage to critical components such as the reducer housing, transmission gears, and output shaft due to overload, significantly improving the safety and reliability of the reducer.

[0027] 2. In this invention, the touch switch on the connector plate can trigger an alarm signal immediately when the male and female couplings slide relative to each other. Combined with the elastic deflection function of the spring box, the control gear ring, and the connecting claw lug, it realizes timely monitoring and feedback of overload conditions, enhancing the intelligence and controllability of the device.

[0028] 3. In this invention, the ratchet of the linkage gear ring is arranged obliquely and forms a lever engagement with the connecting claw lug, enabling it to maintain elastic clamping of the female connector during overload protection, preventing complete disengagement of the male coupling from the female connector. Simultaneously, by manually controlling the deflection of the connecting claw lug, quick assembly and disassembly of the coupling connection can be achieved, improving the maintenance convenience and operational flexibility of the reducer. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of one embodiment of the present invention; Figure 2 This is a schematic diagram of the connection structure of the male and female couplings according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the cross-sectional structure of the male and female couplings according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the connection state of the male and female couplings according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the plug-in disk and piston magnetic ring structure according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the connecting claw ear and the linked control toothed ring structure according to an embodiment of the present invention; Figure 7 This is a schematic diagram of the connecting claw lug, the linked control toothed ring, and the spring barrel structure according to an embodiment of the present invention; Figure 8 This is a schematic diagram of the air distribution plate structure according to an embodiment of the present invention.

[0030] Figure label: 100. Gearbox; 110. Transmission gear; 120. Output shaft; 200. Male coupling; 210. Shaft sleeve seat; 220. Connecting claw lug; 230. Spring barrel; 240. Interlocking gear ring; 250. Connecting plate; 260. Piston magnetic ring; 221. Slider; 241. Ratchet; 251. Unscrew groove; 252. Touch switch; 261. Ratchet ball; 300, Female connector; 301, Claw hook groove; 302, Engagement groove; 400, Air distribution plate; 401, Sealing plate. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0032] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0033] The following describes, with reference to the accompanying drawings, some embodiments of the present invention, providing an overload protection speed reducer.

[0034] Combination Figures 1-8 As shown, the present invention provides an overload protection speed reducer, including a speed reducer housing 100, a transmission gear 110, an output shaft 120, a male coupling 200, a female coupling 300, and an air distribution plate 400 arranged inside the male coupling 200 and the female coupling 300.

[0035] The male coupling 200 and female coupling 300 are respectively fixedly installed on the end of the output shaft 120 and the surface of the transmission gear 110, for realizing the coupling connection between the transmission gear 110 and the output shaft 120. A sealing disc 401 is fixedly installed on one side of both the male coupling 200 and the female coupling 300, for positioning the air distribution disc 400 inside the male coupling 200 and the female coupling 300.

[0036] The male coupling 200 includes a bushing seat 210, a connecting lug 220, a spring barrel 230, and a connector plate 250 fixed to one side of the bushing seat 210. A piston magnetic ring 260 is slidably mounted on the end of the connector plate 250. The surface of the piston magnetic ring 260 is provided with a plurality of ball bearings 261, and the surface of the connector plate 250 is provided with a plurality of retraction grooves 251 for the retraction of the ball bearings 261.

[0037] The female connector 300 has a meshing groove 302 on one side for engaging with the ball bearing 261. The air distribution plate 400 is arranged inside the male connector 200 and the female connector 300 to drive the piston magnetic ring 260 to move, thereby realizing the engagement and disengagement of the ball bearing 261 with the meshing groove 302.

[0038] The surface of the spring barrel 230 is provided with a key shaft rod that meshes with the surface of the interlocking gear ring 240, and the surface of the interlocking gear ring 240 is provided with a ratchet 241. The connecting claw lug 220 is rotatably mounted on the surface of the connector plate 250, and the surface of the female connector 300 is provided with a claw hook groove 301. One end of the interlocking gear ring 240 is provided with a ratchet 241 that contacts the inner side of the claw hook groove 301.

[0039] In this embodiment, both the transmission gear 110 and the output shaft 120 have air passages communicating with the interior of the air distribution plate 400, and the surfaces of the transmission gear 110 and the output shaft 120 are equipped with pneumatic control components. Specifically, during transmission overload, the radial position of the piston magnetic ring 260 can be controlled through the air passage, causing a change in the clamping depth of the ratchet ball 261, thereby dynamically adjusting the overload disengagement torque in real time.

[0040] In this embodiment, the engagement groove 302 is a hemispherical groove structure, the piston magnetic ring 260 is magnetic, and the ball bearing 261 is a ferromagnetic sphere. Specifically, the initial position of the piston magnetic ring 260 is controlled by air pressure, which adjusts the engagement depth between the ball bearing 261 and the engagement groove 302. When the engagement depth is large, the overload torque intensity is large; when the engagement depth is small, the overload torque intensity is small. When the transmission torque exceeds a set threshold, the female connector 300 and the male coupling 200 are relatively deflected, and the ball bearing 261 exits the engagement groove 302 under the action of the un-groove groove 251, causing the male coupling 200 to separate from the female connector 300, thereby cutting off the transmission link.

[0041] In this embodiment, the surface of the air distribution plate 400 is provided with a plurality of air distribution holes, and the inner sides of the female connector 300 and the insertion plate 250 are respectively provided with air passages communicating with the engagement groove 302 and the withdrawal groove 251. Specifically, the initial positions of the piston magnetic ring 260 and the ratchet ball 261 can be controlled by adjusting the air passages, thereby achieving precise control of the overload protection critical torque.

[0042] In this embodiment, the surface of the connector 250 is provided with a touch switch 252 that abuts against one end of the female connector 300, for monitoring the relative sliding between the female connector 300 and the connector 250. Specifically, once the male connector 200 and the female connector 300 undergo relative rotational displacement, the touch switch 252 can trigger an electrical signal and output an alarm signal, thereby realizing an alarm prompt under overload conditions.

[0043] In this embodiment, the surface of the piston magnetic ring 260 has several through holes with a diameter smaller than that of the ball bearing 261 for mounting the ball bearing 261. The inner side of the connector 250 has an annular piston groove, and the piston magnetic ring 260 has an annular structure, with both its inner and outer circumferences sealingly abutting against the annular piston groove on the inner side of the connector 250. This structure ensures a stable sealing effect for the piston magnetic ring 260 during radial movement, preventing airflow leakage.

[0044] In this embodiment, the surface ratchet 241 of the control ring 240 is arranged obliquely. Specifically, through the deflection movement of the control ring 240 and the ratchet 241, the lever deflection of the connecting claw ear 220 can be realized, thereby further ensuring that the connecting claw ear 220 can maintain elastic clamping on the female connector 300 under overload conditions, achieving a reliable limiting effect.

[0045] In this embodiment, the mainspring box 230 is equipped with a mainspring and an output key shaft inside. Specifically, the mainspring drives the output key shaft to deflect elastically, which in turn causes the control gear ring 240 to deflect, so that the end of the connecting claw lug 220 maintains elastic clamping contact with the claw hook groove 301, thereby ensuring the stability of the connection state and providing auxiliary deflection force when disconnection is required.

[0046] Working principle and usage process of this invention: The overload protection reducer of this invention mainly relies on the synergistic effect of the coupling male connector 200, female connector 300, air distribution plate 400, plug plate 250, piston magnetic ring 260, and ratchet ball 261 to achieve automatic control and disengagement protection of overload torque during transmission. Its basic principle is as follows: During normal transmission, the ratchet ball 261, under the radial pressing action of the piston magnetic ring 260, engages with the meshing groove 302 on the female connector 300, forming a stable torque transmission path, so that the transmission gear 110 and the output shaft 120 rotate synchronously, realizing reliable power transmission.

[0047] Torque adjustment and initial position control: The air distribution plate 400 is connected to the air passages in the transmission gear 110 and output shaft 120 through air distribution holes. Under the drive of the pneumatic control components, it can adjust the initial position of the piston magnetic ring 260, thereby changing the engagement depth of the ratchet ball 261 and the meshing groove 302. When the engagement depth is large, the overload torque value increases; when the engagement depth is small, the overload torque value decreases, thus achieving dynamic adjustment of the critical torque for transmission disengagement.

[0048] Overload protection state: When the torque between the transmission gear 110 and the output shaft 120 exceeds the set threshold, the ratchet ball 261 automatically exits the engagement groove 302 under the action of the unloading groove 251, and a relative deflection occurs between the female connector 300 and the male coupling 200, thereby separating the male coupling 200 and the female connector 300, cutting off the transmission link and preventing damage to the reducer and related equipment.

[0049] Additional control and feedback: A touch switch 252 is provided on the connector plate 250. Once relative slippage occurs, the touch switch 252 is activated and outputs an electrical signal to generate an alarm indication. The mainspring inside the spring box 230 cooperates with the output key shaft to cause the linkage gear ring 240 to elastically deflect, which drives the connecting claw lug 220 to deflect and maintain elastic clamping with the claw hook groove 301, thereby maintaining a stable connection state.

[0050] Lever and deflection action: The surface of the linkage gear ring 240 is provided with a ratchet 241, which is arranged obliquely. Under the action of abutment, it can drive the connecting claw ear 220 to maintain the clamping effect on the surface of the female connector 300, and limit the movement to prevent the complete separation of the male connector 200 and the female connector 300. Furthermore, when it is necessary to disconnect, the elastic deflection of the connecting claw ear 220 can be manually controlled to achieve the detachable connection of the male connector 200 and the female connector 300.

[0051] In the description of this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0052] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A speed reducer with overload protection, characterized in that, It includes a gearbox (100), transmission gears (110), output shaft (120), male coupling (200), female coupling (300), and an air distribution plate (400) arranged inside the male coupling (200) and female coupling (300). The male coupling (200) and female coupling (300) are respectively fixed to the end of the output shaft (120) and the surface of the transmission gear (110) to realize the coupling connection between the transmission gear (110) and the output shaft (120); A sealing disc (401) is fixedly installed on one side of both the male coupling (200) and the female coupling (300) for positioning the air distribution disc (400) inside the male coupling (200) and the female coupling (300); The male coupling (200) includes a bushing seat (210), a connecting lug (220), a spring barrel (230), and a plug plate (250) fixed to one side of the bushing seat (210). A piston magnetic ring (260) is slidably mounted on the end of the plug-in plate (250). The surface of the piston magnetic ring (260) is provided with a plurality of ratchet balls (261). The surface of the plug-in plate (250) is provided with a plurality of retraction grooves (251) for the retraction of the ratchet balls (261). The female connector (300) has a meshing groove (302) on one side for meshing with the ratchet ball (261). The air distribution plate (400) is arranged inside the male coupling (200) and the female coupling (300) to drive the piston magnetic ring (260) to move and realize the engagement and separation of the ratchet ball (261) and the meshing groove (302); The surface of the spring box (230) is provided with a key shaft rod that meshes with the surface of the control ring (240). The surface of the control ring (240) is provided with a ratchet (241). The connecting claw ear (220) is rotatably mounted on the surface of the plug plate (250). The surface of the female connector (300) is provided with a claw hook groove (301). One end of the control ring (240) is provided with a ratchet (241) that contacts the inner side of the claw hook groove (301).

2. The overload protection reducer according to claim 1, characterized in that, The transmission gear (110) and the output shaft (120) are both provided with air passages that communicate with the inside of the air distribution plate (400). The transmission gear (110) and the output shaft (120) are provided with pneumatic control components. When the transmission is overloaded, the piston magnetic ring (260) is controlled to move through the air passage, thereby realizing real-time dynamic adjustment of the overload release torque.

3. The overload protection reducer according to claim 1, characterized in that, The engagement groove (302) is hemispherical, the piston magnetic ring (260) is magnetic, and the spiked ball (261) is a ferromagnetic ball. The position of the piston magnetic ring (260) is adjusted by air pressure control to adjust the engagement depth of the spiked ball (261) and the engagement groove (302).

4. The overload protection reducer according to claim 1, characterized in that, The surface of the air distribution plate (400) is provided with several air distribution holes. The inner sides of the female connector (300) and the plug plate (250) are respectively provided with air passages that communicate with the meshing groove (302) and the unloading groove (251). The initial positions of the piston magnetic ring (260) and the ratchet ball (261) are adjusted through the air passages.

5. The overload protection reducer according to claim 1, characterized in that, The surface of the plug plate (250) is provided with a touch switch (252) that abuts against one end of the female connector (300) to monitor the relative sliding between the female connector (300) and the plug plate (250).

6. The overload protection reducer according to claim 1, characterized in that, The surface of the piston magnetic ring (260) has several through holes with a diameter smaller than that of the ball bearing (261) for the installation of the ball bearing (261); the inner side of the plug-in plate (250) is provided with an annular piston groove, and the piston magnetic ring (260) is annular with its inner and outer circumferences sealingly abutting against the annular piston groove on the inner side of the plug-in plate (250).

7. The overload protection reducer according to claim 1, characterized in that, The surface of the control ring (240) has a tangentially arranged ridge protrusion (241). Through the deflection motion of the control ring (240) and the ridge protrusion (241), the lever deflection of the connecting claw ear (220) is realized.

8. The speed reducer with overload protection according to claim 1, characterized in that, The mainspring box (230) is equipped with a mainspring and an output key shaft. The mainspring drives the output key shaft to deflect elastically, which in turn drives the control gear ring (240) to deflect, thereby achieving elastic clamping contact between the end of the connecting claw ear (220) and the surface of the claw hook groove (301).

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