Bidirectional speed reducer based on symmetrical row design

Abstract

The utility model relates to the technical field of speed reducers, and discloses a two-way speed reducer based on symmetrical row design, which comprises a speed reducer body, a motor and a middle shaft, the speed reducer body comprises a shell, a worm gear and a worm which are mutually meshed for transmission are rotatably mounted in the shell, and the shaft end of the worm is driven by the motor. The end faces of the two sides of the worm gear are each provided with a middle shaft extending in the axial direction, every two adjacent speed reducer bodies are designed in a row, and torque is transmitted between every two adjacent worms through a transmission assembly. Two-way output is achieved by arranging the middle shafts on the two sides of the worm gear, the adjacent speed reducer bodies are arranged in a row mode, torque is transmitted through the transmission assembly, and therefore the device can adapt to different transmission requirements of a single shaft, double shafts and the like by adjusting the row number and the output direction without changing the model number, the driving working conditions of different angles of a photovoltaic panel can be flexibly coped with, and the driving efficiency is improved. Batch stock can be achieved, stock types are reduced, time and production cost are reduced, and the problem that a traditional double-row speed reducer is poor in universality is solved.

Description

Technical Field

[0001] This utility model relates to the field of speed reducer technology, specifically a bidirectional speed reducer based on a symmetrical row design. Background Technology

[0002] In the field of new energy photovoltaic power generation, speed reducers for photovoltaic power generation are being widely used. As the core transmission component of the entire photovoltaic power generation system, the speed reducer plays a very important role.

[0003] Especially in scenarios requiring multi-axis drives, such as new energy photovoltaic power generation and automated production lines, traditional double-row reducers, due to structural design limitations, struggle to meet the demands for flexible adaptation and efficient operation and maintenance. Specific problems include:

[0004] 1. Extremely poor versatility, requiring multiple models to be stocked, resulting in high inventory costs.

[0005] Traditional double-row reducers are designed for unidirectional output. Different models are required for different operating conditions (such as single-axis drive and dual-axis tracking of photovoltaic panels). To cover five types of transmission needs, a photovoltaic power station operator needs to stock eight types of reducers, resulting in inventory capital accumulation of over 500,000 yuan. More seriously, the model mismatch rate is as high as 15%. In one project, 30 reducers were left idle due to incorrect model delivery, resulting in a loss of 120,000 yuan. Furthermore, the reordering of goods delayed the construction period by 20 days, affecting the photovoltaic panel installation progress.

[0006] 2. The stringent precision requirements for row installation result in low construction efficiency.

[0007] Traditional speed reducers require strict alignment of the worm shaft during installation, with deviations controlled within 0.1mm. In the installation of a 100MW photovoltaic project, the time spent on shaft alignment increased the installation time for a single unit to 2 hours, doubling the planned time and increasing labor costs by 300,000 yuan. If forced installation is attempted, it can lead to transmission jamming. In one case, a 0.3mm shaft deviation accelerated the worm wear rate by 3 times, requiring replacement every 6 months and resulting in maintenance costs exceeding 80,000 yuan.

[0008] 3. Difficulty in oil maintenance, frequent breakdowns in remote areas.

[0009] Traditional speed reducers require shutdown for oil changes. Photovoltaic power stations are mostly located in remote areas, and a single maintenance trip takes two days. At one power station, the failure to change the oil in time led to the sintering of gears in three speed reducers, reducing the average lifespan of the speed reducers.

[0010] As photovoltaic power plants develop towards large-scale operations, the shortcomings of traditional speed reducers in terms of versatility, installation efficiency, and maintenance costs have become key factors restricting project profitability, necessitating the breakthrough of bidirectional speed reducers with symmetrical row designs like this device. Utility Model Content

[0011] To address the technical problems existing in the background art, this utility model proposes a bidirectional speed reducer based on a symmetrical row design.

[0012] This utility model proposes a bidirectional reducer based on a symmetrical row design, including a reducer body, a motor, and a central shaft. The reducer body includes a housing, inside which a worm wheel and a worm are rotatably mounted for mutual meshing and transmission. The shaft end of the worm is driven by the motor. A central shaft extending axially is mounted on both end faces of the worm wheel. Two adjacent reducer bodies are designed in a row, and torque is transmitted between two adjacent worms through a transmission component.

[0013] Addressing the issues of poor versatility and the need to stock multiple models in traditional double-row reducers, this design achieves multi-functional adaptability through "bidirectional output + row transmission." The central shafts on both sides of the worm gear can output torque in two directions simultaneously without the need for an additional reversing mechanism, making it suitable for scenarios such as dual-shaft drives for photovoltaic panels. Adjacent reducer bodies are linked together through transmission components, allowing for flexible increases or decreases in quantity according to load requirements while maintaining a consistent transmission ratio. This enables owners to stock in bulk, reducing inventory costs. The housing adopts a symmetrical structure, allowing for rotation of the installation direction without affecting the assembly of other components, thus overcoming the limitations of traditional reducers with unidirectional output.

[0014] As a further optimized solution of this utility model, the transmission assembly includes a connecting shaft and a universal joint. One end of the connecting shaft is connected to the free end of the worm gear, the other end of the connecting shaft is connected to one end of the universal joint, and the other end of the universal joint is connected to the free end of the adjacent worm gear.

[0015] Universal joints can compensate for installation deviations of adjacent worm gears, ensuring efficient torque transmission. The flexible transmission of the connecting shaft in conjunction with the universal joint avoids jamming caused by rigid alignment errors during assembly, thereby shortening the installation period. It is especially suitable for scenarios such as photovoltaic brackets with limited space.

[0016] As a further optimization of this utility model, an external oil filtration mechanism is provided on the outside of the housing, including a filter cylinder. The lower end of the filter cylinder is connected to the oil discharge port at the lower end of the housing through an oil discharge pipe. A micro oil pump is installed on the upper end of the filter cylinder through a bracket. The oil discharge end of the micro oil pump is connected to the oil inlet at the upper end of the housing through an oil return pipe. The oil suction end of the micro oil pump extends downward into the filter cylinder and extracts the filtered oil in the filter cylinder.

[0017] The external oil filter mechanism forms a circulating filtration system that can purify the oil without stopping the machine. The micro oil pump pumps the filtered oil back to the housing, solving the problem of oil shortage for photovoltaic equipment in remote areas. Both the oil unloading pipe and the oil return pipe are made of oil-resistant rubber hoses to ensure that the oil circulation is leak-free.

[0018] As a further optimization of this utility model, an oil suction pipe is installed inside the filter cartridge. The upper end of the oil suction pipe is connected to the oil suction end of the micro oil pump through a hose, and the lower end of the oil suction pipe extends into the filter assembly at the bottom of the filter cartridge. The oil suction pipe extends deep into the bottom of the filter assembly to ensure that the extracted oil is fully filtered.

[0019] As a further optimized solution of this utility model, the filter assembly includes a filter element fitted around the lower end of the oil suction pipe. A partition and a bottom plate are respectively installed at the upper and lower ends of the filter element. The partition is annular and its inner and outer walls are slidably sealed to the outer surface of the oil suction pipe and the inner surface of the filter cylinder, respectively. The bottom plate is detachably connected to the lower opening of the filter cylinder and the connection is sealed.

[0020] The baffle is a ring made of nitrile rubber, which can prevent unfiltered oil from entering the oil extraction pipe directly, ensuring filtration efficiency. The detachable connection between the base plate and the filter cartridge allows the filter element to be removed downwards, shortening the replacement time and adapting to the needs of rapid maintenance in the field.

[0021] As a further optimization of this utility model, the lower end side wall of the filter cylinder is provided with a through hole that communicates with the lower end of the oil unloading pipe, and the through hole is located on the side close to the lower end of the filter element.

[0022] The through-hole position ensures that the oil enters from the bottom of the filter element and is forced to flow through the entire filter layer, maximizing the filtration path and improving the impurity interception effect. The through-hole diameter is 10mm, which matches the oil drain pipe to ensure sufficient oil flow.

[0023] As a further optimization of this utility model, the filter element is a combined filter element, including a filter membrane and a filter screen arranged from the inside to the outside. The filter membrane includes an inner ceramic membrane and an outer polymer composite membrane, which can intercept wear metal particles >0.02μm and adsorb more than 50% of oxide colloids; the filter screen is used for coarse filtration of large particulate impurities in the engine oil.

[0024] The combined filter element achieves multi-stage filtration: the filter screen (10μm pore size) intercepts large particles such as metal shavings, the ceramic membrane (0.02μm) traps tiny wear particles, and the polymer composite membrane adsorbs oxide colloids (efficiency 50%), reducing the oil contamination level from NAS8 to NAS6, extending the gearbox life by 1.5 times. The filter element can be repeatedly cleaned 3-5 times, reducing consumable costs.

[0025] As a further optimized solution of this utility model, the inner wall of the lower end opening of the filter cylinder has internal threads, the upper end face of the base plate is equipped with a threaded post and is threadedly connected to the lower end opening of the filter cylinder, and the base plate and the lower end face of the filter cylinder are sealed by a sealing ring.

[0026] The threaded connection ensures reliable sealing between the base plate and the filter cartridge. The sealing ring is made of fluororubber, which is resistant to oil corrosion and can adapt to working conditions from -20℃ to 120℃. The rotary disassembly and assembly design does not require special tools and is suitable for outdoor scenarios without equipment. Moreover, the filter element is a cylindrical shape with an open top, which can be installed and removed along the axial direction for easy disassembly and assembly, improving maintenance convenience.

[0027] As a further optimized solution of this utility model, an oil inlet hopper is installed at the upper end of the oil inlet, and the side of the oil inlet hopper is connected to the oil outlet of the return oil pipe. The upper end of the oil inlet hopper has an outwardly opening feeding port for manual addition of oil additives, including anti-wear agents, antioxidants, rust inhibitors, demulsifiers, etc.

[0028] The oil inlet hopper facilitates the addition of anti-wear agents (such as molybdenum disulfide) and antioxidants (such as phenolic compounds), improving the performance of regenerated oil (oil film strength increased by 20%). The capped design of the feed port prevents impurities from entering, making it suitable for the maintenance needs of photovoltaic equipment operating outdoors for extended periods. The oil and additives in the return oil pipe are pre-mixed in the oil inlet hopper to ensure uniform dispersion.

[0029] The bidirectional speed reducer based on a symmetrical array design proposed in this utility model has the following beneficial effects:

[0030] (i) By setting central shafts on both sides of the worm gear to achieve bidirectional output, and arranging adjacent reducer bodies in a row and transmitting torque through transmission components, the equipment can be adapted to different transmission requirements such as single shaft and double shaft by adjusting the number of rows and output direction without changing the model. For example, in photovoltaic power generation systems, it can flexibly cope with different driving conditions of photovoltaic panels at different angles. Owners and manufacturers can stock up in batches to reduce the types of inventory, thereby reducing time and production costs, and solving the problem of poor versatility of traditional double row reducers.

[0031] (ii) The transmission assembly consisting of the connecting shaft and the universal joint can compensate for the installation deviation between adjacent worm gears, ensuring stable torque transmission. When installed in a row, there is no need to strictly align the reducer body, which helps to shorten the installation period. It is especially suitable for scenarios such as photovoltaic brackets with limited space, avoiding transmission jamming caused by insufficient installation accuracy.

[0032] (III) By installing an external oil filter mechanism on the outside of the reducer body, the filter cartridge and the micro oil pump form a circulating filtration system. The ceramic membrane and polymer composite membrane of the combined filter element can intercept metal particles > μm and adsorb more than % of oxide colloids. Combined with the filter screen to coarsely filter large particulate impurities, it can quickly filter the oil during maintenance, so that the oil can be regenerated and reused. It is especially suitable for use in remote mountainous areas where photovoltaic equipment is installed, where there is a sudden shortage of oil and no backup oil.

[0033] (iv) The filter element is connected to the filter cylinder by a threaded connection through the base plate, which is convenient and quick to disassemble and install, so as to quickly replace the filter element. Anti-wear agents, antioxidants and other additives can be manually added to the oil inlet to further improve the performance of the regenerated oil.

[0034] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0035] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0036] Figure 2 This is a front sectional view of the present invention.

[0037] Figure 3 This is a schematic diagram of the structure of the reducer body of this utility model, in which transmission components are installed at both ends;

[0038] Figure 4 A schematic diagram of the structure of one embodiment of this utility model.

[0039] Figure descriptions: 1. Reducer body; 101. Housing; 102. Worm gear; 103. Worm; 2. Motor; 3. Central shaft; 4. Connecting shaft; 5. Universal joint; 6. Filter cartridge; 7. Oil discharge pipe; 8. Oil discharge port; 9. Oil return pipe; 10. Oil inlet; 11. Miniature oil pump; 12. Oil suction pipe; 13. Filter element; 14. Partition plate; 15. Base plate; 16. Support; 17. Oil inlet hopper. Detailed Implementation

[0040] The embodiments of this utility model are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0041] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0042] Please see Figure 1Figure 4 illustrates a specific implementation of a bidirectional speed reducer based on a symmetrical row design:

[0043] like Figures 1-3 As shown, the bidirectional reducer is designed with "symmetrical output + row transmission" as its core design concept. It achieves multi-scenario adaptation through modular layout. The housing 101 of the reducer body 1 is integrally cast from HT300 gray cast iron. The worm 103 is supported laterally by two tapered roller bearings inside. The worm wheel 102 is installed above the worm by a sliding bearing. The meshing center distance between the two is 50-100mm. It is adapted according to the transmission ratio to form a 90° staggered transmission.

[0044] Motor 2 is a YE2 series three-phase asynchronous motor with a power of 1.5kW and a speed of 1450r / min. It is connected to the input end of worm gear 103 through a flexible coupling with an axial compensation of ±2mm to ensure smooth power transmission. The two end faces of worm gear 102 are symmetrically connected to the central shaft 3 through A-type flat keys. The central shaft 3 is made of 45 steel with heat treatment and a hardness of HB220-250. The central shaft passes through the end caps on both sides of the housing. The end caps are equipped with skeleton oil seals to form a bidirectional output channel, which can transmit torque to the left and right sides at the same time. The maximum output torque is 300N・m. It can meet the bidirectional transmission requirements of photovoltaic panel dual-shaft drive and other applications without the need for an additional reversing mechanism.

[0045] The adjacent reducer bodies 1 adopt a row design, and the torque is transmitted synchronously through the transmission components. The number of rows can be expanded according to the load requirements. Each unit occupies an area of ​​0.12㎡. The overall layout is compact after rowing, which is suitable for space-constrained scenarios such as photovoltaic brackets.

[0046] This invention provides an embodiment, such as Figure 4 As shown, an external oil filtration and circulation system is installed on the outside of the reducer body 1, as detailed below:

[0047] The filter cartridge 6 is a welded cylinder made of 304 stainless steel. A Φ16mm through hole is opened on the lower side wall. It is connected to the oil discharge port 8 (with a manual valve installed inside) at the bottom of the housing 101 through the oil discharge pipe 7 (oil-resistant rubber tube, inner diameter 16mm, pressure resistance 1MPa). The upper end of the filter cartridge is fixed with a micro oil pump 11 (model DB-12, DC 12V, flow rate 2L / min, head 5m) through the bracket 16. The oil pump's oil suction end is connected to the oil suction pipe 12 through a Φ8mm PU hose, and the oil discharge end is connected to the oil inlet 10 at the upper end of the housing through the oil return pipe 9 (same as the oil discharge pipe specification).

[0048] Filter element 13 has a cylindrical composite structure. The outer layer is a 10μm stainless steel filter screen (316L material, 1500 mesh, 90% weaving density), which is fixed to the porous support cylinder by spot welding. The middle layer is a polyethersulfone (PES) polymer composite membrane (0.1mm thickness, 100,000 Da molecular weight cutoff), which is bonded to the outer filter screen by epoxy resin. The inner layer is an α-Al2O3 ceramic membrane (0.02μm pore size, 45% porosity), which is sintered on a Φ10mm stainless steel porous tube.

[0049] The upper baffle 14 of the filter element 13 is a nitrile rubber annular plate. Its inner and outer walls are respectively press-fitted with the inner wall of the oil suction pipe 12 and the filter cylinder 6 to form a dynamic seal. The bottom plate 15 at the lower end is machined with a threaded post in the center, which mates with the internal thread at the lower end of the filter cylinder. A fluororubber O-ring is installed at the connection to ensure a reliable seal. The through hole of the filter cylinder is set on the side near the bottom of the filter element, which forces the oil to enter from the bottom of the filter element. After being filtered layer by layer in the radial direction, it enters the central oil suction pipe. The filtration path length is 150mm, and the impurity rejection rate is ≥98%.

[0050] A hexagonal wrench is welded to the lower end face of the base plate 15, allowing for easy disassembly and assembly by hand or by rotating with a wrench. When replacing the filter element, there is no need to drain the oil (the oil level in the filter cartridge is ≤200mL), and the operation time is ≤5 minutes. The filter element can be cleaned repeatedly with kerosene ultrasonic cleaning up to 3 times, extending its service life to 1500 hours.

[0051] The oil inlet 10 is welded to the upper end of the oil inlet hopper 17, and the side is heat-fused to the return oil pipe 9 through a Φ16mm interface. The upper feeding port is equipped with a flip cover (with a silicone sealing ring) for manual addition of oil additives: anti-wear agent molybdenum disulfide, 3% addition amount; antioxidant 2,6-di-tert-butyl-p-cresol, 0.5% addition amount; and rust inhibitor barium petroleum sulfonate, 1% addition amount. The additives and return oil are pre-mixed in the hopper for ≥3 seconds to ensure uniform dispersion.

[0052] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A bidirectional speed reducer based on a symmetrical array design, comprising a speed reducer body (1), a motor (2), and a central shaft (3), wherein the speed reducer body (1) includes a housing (101), and a worm gear (102) and a worm (103) that mesh and transmit power to each other are rotatably mounted inside the housing (101), and the shaft end of the worm (103) is driven by the motor (2), characterized in that, Both ends of the worm gear (102) are equipped with axially extending central shafts (3), two adjacent reducer bodies (1) are designed in a row, and the torque is transmitted between two adjacent worms (103) through a transmission assembly.

2. The bidirectional speed reducer based on a symmetrical array design according to claim 1, characterized in that, The transmission assembly includes a connecting shaft (4) and a universal joint (5). One end of the connecting shaft (4) is connected to the free end of the worm (103), and the other end of the connecting shaft (4) is connected to one end of the universal joint (5). The other end of the universal joint (5) is connected to the free end of the adjacent worm (103).

3. A bidirectional speed reducer based on a symmetrical array design according to claim 1, characterized in that, An external oil filtration mechanism is provided on the outside of the housing (101), including a filter cylinder (6). The lower end of the filter cylinder (6) is connected to the oil discharge port (8) at the lower end of the housing (101) through an oil discharge pipe (7). A micro oil pump (11) is installed on the upper end of the filter cylinder (6) through a bracket (16). The oil discharge end of the micro oil pump (11) is connected to the oil inlet (10) at the upper end of the housing (101) through an oil return pipe (9). The oil suction end of the micro oil pump (11) extends downward into the filter cylinder (6) and extracts the filtered oil in the filter cylinder (6).

4. A bidirectional speed reducer based on a symmetrical row design according to claim 3, characterized in that, The filter cartridge (6) is equipped with an oil extraction pipe (12). The upper end of the oil extraction pipe (12) is connected to the oil extraction end of the micro oil pump (11) through a hose. The lower end of the oil extraction pipe (12) extends into the filter assembly at the bottom of the inner cavity of the filter cartridge (6).

5. A bidirectional speed reducer based on a symmetrical row design according to claim 4, characterized in that, The filter assembly includes a filter element (13) fitted around the lower end of the oil extraction pipe (12). The upper and lower ends of the filter element (13) are respectively equipped with a partition plate (14) and a bottom plate (15). The partition plate (14) is annular and its inner and outer walls are respectively slidably sealed to the outer surface of the oil extraction pipe (12) and the inner surface of the filter cylinder (6). The bottom plate (15) is detachably connected to the lower opening of the filter cylinder (6) and the connection is sealed.

6. A bidirectional speed reducer based on a symmetrical row design according to claim 5, characterized in that, The lower side wall of the filter cartridge (6) is provided with a through hole that communicates with the lower end of the oil unloading pipe (7), and the through hole is located on the side near the lower end of the filter element (13).

7. A bidirectional speed reducer based on a symmetrical row design according to claim 5, characterized in that, The filter element (13) is a combined filter element, including a filter membrane and a filter screen arranged from the inside to the outside. The filter membrane includes an inner ceramic membrane and an outer polymer composite membrane. The filter screen is used to coarsely filter large particulate impurities in the engine oil.

8. A bidirectional speed reducer based on a symmetrical row design according to claim 5, characterized in that, The lower end opening of the filter cylinder (6) has an internal thread on its inner wall. The upper end face of the base plate (15) is fitted with a threaded post and is threadedly connected to the lower end opening of the filter cylinder (6). The base plate (15) and the lower end face of the filter cylinder (6) are sealed by a sealing ring.

9. A bidirectional speed reducer based on a symmetrical row design according to claim 3, characterized in that, An oil inlet hopper (17) is installed at the upper end of the oil inlet (10). The side of the oil inlet hopper (17) is connected to the oil outlet of the return oil pipe (9). The upper end of the oil inlet hopper (17) has an outwardly opening feeding port for manual addition of oil additives.

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