A large cauldron toothed disc

Abstract

This utility model relates to the field of textile machinery technology, specifically to a large ding toothed disc, including a toothed disc body and a tooth layer integrally formed on the outer wall of the toothed disc body. The lower surface of the toothed disc body is integrally formed with a lower positioning boss, and the toothed disc body is also provided with a number of fixing bolt holes.

Description

Technical Field

[0001] This utility model relates to the field of textile machinery technology, specifically to a large tripod gear disc. Background Technology

[0002] The large gear disc is a core component of a circular knitting machine, often called the large gear. It acts as a giant gear on the upper level of the machine, responsible for power transmission and driving the upper needle plate. Visually, the large gear disc is a large disc or ring-shaped gear with teeth on its outer ring, connected to the upper needle plate below via components such as the needle tube mandrel. As the power hub of the upper level of the machine, the main function of the large gear disc is to transmit power and drive the upper needle plate. The motor of the circular knitting machine drives a small gear through a drive shaft, which meshes with the large gear disc, thus driving the entire upper needle plate to rotate. Simultaneously, by adjusting the height of the large gear disc, the gap between the upper needle plate and the lower needle cylinder can be changed, thereby controlling the fabric density and weight.

[0003] Although the existing technologies mentioned above can solve the corresponding technical problems, they still have certain drawbacks: In the existing installation process of the large cauldron gear plate, the operator needs to constantly adjust its position to ensure that the gear plate is located in the exact center inside the large cauldron of the large circular machine, and that the edge is precisely meshed with the small gear. Since the relative position of the large cauldron gear plate and the large cauldron needs to be continuously aligned during installation, even a slight deviation will lead to inaccurate positioning. In addition, the large cauldron gear plate has a large self-weight, and it is very difficult to fix it manually for a long time. Therefore, the entire installation process requires a high level of operator experience, and the steps are complex and difficult. Utility Model Content

[0004] The purpose of this utility model is to address the shortcomings and deficiencies of the existing technology by providing a large cauldron toothed disc that is easy to position and more convenient to fix.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a large cauldron toothed disc, comprising a toothed disc body and a tooth layer integrally formed on the outer wall of the toothed disc body, wherein a lower positioning boss is integrally formed on the lower surface of the toothed disc body, and a plurality of fixing bolt holes are provided on the toothed disc body, wherein a plurality of magnetic blocks are evenly embedded on the upper surface of the toothed disc body, and an upper positioning boss is integrally formed on the upper surface of the toothed disc body, and a hollow cavity is integrally formed inside the toothed disc body.

[0006] A further improvement is that the hollow cavity is filled with a hard resin block.

[0007] After adopting the above technical solution, the beneficial effects of this utility model are as follows: When this utility model is used and installed into the large cauldron, the gear disc body can be positioned on the outer wall of the sleeve of the large circular machine by means of the lower positioning boss. During installation and positioning, it is only necessary to fit the lower positioning boss into the outer wall of the sleeve to complete the positioning. Then, rotate the gear disc body to adjust the position of the fixing bolt hole, align the fixing bolt hole with the fixing bolt hole of the large cauldron, and then lock the bolt for fixation. This makes positioning faster and more convenient, installation more convenient, and reduces installation time and difficulty. At the same time, after assembly, the lower positioning boss can also increase the contact area between the gear disc body and the outer wall of the sleeve, making the two less likely to dislodge and more stable in use. Attached Figure Description

[0008] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0009] Figure 1 This is a top view of the structure of the large cauldron toothed disc of this utility model;

[0010] Figure 2 This is a structural schematic diagram of one side cross-section of the large cauldron gear disc of this utility model. Detailed Implementation

[0011] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0012] See Figure 1-2 As shown, the technical solution adopted in this specific embodiment is: a large cauldron gear plate, including a gear plate body 1 and a tooth layer 2 integrally formed on the outer wall of the gear plate body 1. The lower surface of the gear plate body 1 is integrally formed with a lower positioning boss 3. The gear plate body 1 is also provided with a number of fixing bolt holes 4. When in use, when it is installed in the large cauldron, the gear plate body 1 can be positioned on the outer wall of the sleeve of the large circular machine by means of the lower positioning boss 3. When installing and positioning, it is only necessary to fit the lower positioning boss 3 into the outer wall of the sleeve to complete the positioning. Then, rotate the gear plate body 1 to adjust the position of the fixing bolt holes 4, align the fixing bolt holes 4 with the fixing bolt holes of the large cauldron, and then lock the bolts for fixation. This makes positioning faster and more convenient, installation more convenient, and reduces installation time and installation difficulty. At the same time, after assembly, the lower positioning boss 3 can also increase the contact area between the gear plate body 1 and the outer wall of the sleeve, making the two less likely to dislodge and more stable in use.

[0013] As a preferred embodiment, the gear disc body 1 is integrally formed from ductile iron through a casting process. Its outer diameter is 800mm–1200mm, inner diameter is 600mm–1000mm, and thickness is 30mm–50mm. The tooth layer 2 has a module of 6–10 and 120–180 teeth. The tooth profile is formed by precision hobbing, and the tooth surface hardness reaches HB 200–240 to ensure transmission accuracy and wear resistance. The lower positioning boss 3 is an annular protrusion structure. Its outer diameter forms a transition fit with the inner diameter of the outer wall of the circular knitting machine sleeve, with the fit clearance controlled between 0.05mm and 0.15mm. The boss height is 10mm–20mm, and the end face of the boss has a chamfer for easy guiding installation. The fixing bolt holes 4 are evenly distributed around the toothed disc body 1, with a quantity of 3 to 12. This embodiment has 3 holes. The diameter of the hole position matches the bolts of M12 to M20 specifications. The diameter of the center circle of the hole position is determined according to the position of the corresponding screw hole on the cauldron. A countersunk groove can be set in the hole so that the bolt head can be sunk in.

[0014] Several magnetic blocks 12 are evenly embedded on the upper surface of the toothed disc body 1. This is beneficial for the toothed disc body 1 to be attracted upward to the cauldron by the attraction of the magnetic blocks 12 when it is installed on the cauldron, thereby reducing the force required for lifting and making the installation easier.

[0015] Specifically, the magnetic blocks 12 are neodymium iron boron permanent magnets with nickel plating for rust prevention. Each magnetic block 12 has a diameter of 20mm to 30mm and a thickness of 5mm to 10mm. The magnetic blocks 12 are embedded in pre-machined circular countersunk holes on the upper surface of the gear disc body 1 and are fixed with anaerobic adhesive or snap rings. There are 4 to 8 magnetic blocks 12; this embodiment has 6, evenly distributed in a ring along the upper surface of the gear disc body 1. The upper surface of the magnetic blocks 12 is flush with or slightly lower than the upper surface of the gear disc body 1 by 0.1mm to 0.3mm to avoid affecting the planar fit of other components. The magnetic force of each magnetic block 12 is designed to withstand a pulling force of 10kg to 20kg. The overall magnetic force is sufficient to temporarily fix the gear disc body 1 to the lower end face of the cauldron during installation, freeing the operator's hands to tighten the bolts.

[0016] It should be clearly stated that the magnetic block 12 is only used for auxiliary positioning and temporary adsorption during the installation process. Once all bolts are locked into the fixing bolt holes 4 and tightened to the specified torque, the magnetic block 12 no longer bears any working load. Before long-term operation of the equipment, the magnetic block 12 can also be removed from the countersunk hole as needed, and its removal will not affect the normal use of the gear disc body 1. Therefore, the magnetic block 12 does not participate in the stress during equipment operation and there is no risk of it falling off due to long-term vibration.

[0017] The upper surface of the toothed disc body 1 is also integrally formed with an upper positioning boss 5, which is conducive to being snapped into the installation position of the large cauldron by the upper positioning boss 5, thereby further facilitating the positioning during installation. At the same time, it limits the toothed disc during operation, making it more stable.

[0018] Furthermore, the upper positioning boss 5 is an annular boss, and its outer diameter forms a clearance fit with the inner diameter of the positioning groove corresponding to the lower end face of the cauldron. The clearance is controlled between 0.10mm and 0.20mm. The height of the upper positioning boss 5 is 8mm to 15mm, and its end face is also chamfered. The upper positioning boss 5 and the lower positioning boss 3 are coaxially arranged, and their coaxiality tolerance does not exceed φ0.05mm, thereby ensuring that the upper and lower positioning references of the gear disc body 1 are consistent after installation and avoiding skewing. The above coaxiality is ensured by the following process: after the gear disc body 1 is cast, the outer circle of the upper positioning boss 5 is used as the reference, and the outer circle and end face of the lower positioning boss 3 are machined in one clamping, thereby ensuring that the upper and lower positioning bosses are machined based on the same axis of rotation without additional adjustment.

[0019] The toothed disc body 1 has an integrally formed hollow cavity 11, which helps to significantly reduce the weight of the toothed disc body 1 through the hollow cavity 11, thus making it easier to lift during installation.

[0020] Specifically, the hollow cavity 11 is an annular cavity located inside the toothed disc body 1, between the upper and lower surfaces of the toothed disc body 1. The hollow cavity 11 has a 7-shaped cross-section, with a radial width of 30mm to 80mm and an axial height of 15mm to 30mm. The hollow cavity 11 is formed using a core or sand core during the casting process. After casting, the core residue is removed by machining, and the inner wall of the cavity is treated with rust prevention. The hollow cavity 11 can reduce the overall weight of the toothed disc body 1 by 15% to 25%, thereby reducing the labor intensity during handling and installation.

[0021] The hollow cavity 11 is filled with hard resin blocks. Their main function is to absorb vibrations and noise generated during gear transmission without significantly increasing weight, and to provide auxiliary support for the thin-walled areas of the hollow cavity 11, preventing localized deformation of the thin walls under accidental impacts. It should be noted that the main load of this gear disc is still borne by the ductile iron gear disc body 1; the hard resin blocks do not bear the main transmission load and therefore do not need to have a strength higher than that of cast iron. This allows for improved local impact resistance and damping characteristics of the gear disc body 1 through the hard resin blocks, without causing a significant increase in weight.

[0022] Furthermore, the rigid resin block is an epoxy resin-based composite material with 5%–15% chopped glass fiber or quartz powder added internally to improve its compressive strength and dimensional stability. During filling, the inner wall of the hollow cavity 11 is first cleaned and coated with a coupling agent. Then, the liquid epoxy resin mixture is injected into the cavity and cured for 24 hours at room temperature or under heating conditions, forming a rigid resin block that tightly adheres to the inner wall of the cavity. The cured rigid resin block has a compressive strength of no less than 80 MPa and a density of 1.2 g / cm³–1.5 g / cm³, far lower than the density of cast iron (approximately 7.2 g / cm³), thus improving overall rigidity without significantly increasing weight. In addition, the rigid resin block can effectively absorb vibrations and noise generated during gear transmission, improving operational smoothness.

[0023] To further verify the reliability of the structure, comparative tests were conducted. The same radial impact load of 500 N·m was applied to both the unfilled and resin-filled toothed disc bodies. The results showed that the local deformation of the hollow cavity area of ​​the resin-filled toothed disc body decreased from 0.12 mm to 0.03 mm, and the vibration decay time shortened from 0.8 seconds to 0.2 seconds. This demonstrates that the rigid resin block can indeed provide effective auxiliary support and vibration absorption without cracking due to differences in thermal expansion coefficients. After 2000 hours of operation under temperature cycling conditions from -10℃ to 60℃, no visible cracks or debonding were observed at the resin-cast iron interface. This is because the linear expansion coefficient of epoxy resin is approximately 50 × 10⁻⁻⁻⁻⁶. 6 / K, the coefficient of linear expansion of cast iron is approximately 10 × 10⁻ 6 / K, although there are differences between the two, the filler layer is thinner and the resin itself has plastic deformation ability, which can release thermal stress through micro creep. Its long-term reliability has been verified by durability test.

[0024] As a complete installation operation embodiment, the operator first cleans the outer wall of the sleeve of the large circular knives. Then, the large cauldron gear plate is moved to the bottom of the cauldron using hoisting equipment or manually, aligning the lower positioning boss 3 with the outer wall of the sleeve and slowly fitting it in. Initial positioning is achieved through a transition fit. Subsequently, the upper positioning boss 5 automatically engages with the positioning groove on the lower end face of the cauldron, completing double positioning. At this point, the magnetic force generated by the magnetic block 12 attracts the large cauldron gear plate upwards to the lower end face of the cauldron, allowing the operator to release their hands without continuous lifting. Next, the operator rotates the large cauldron gear plate to align the fixing bolt holes 4 with the fixing bolt holes on the cauldron, inserting and pre-tightening the bolts in sequence. Finally, a torque wrench is used to tighten all bolts diagonally to the specified torque, typically 120 N·m to 180 N·m, completing the installation. Throughout the process, thanks to the assistance of the positioning boss and the magnetic block, installation can be easily completed by a single person without repeated adjustments to the alignment, greatly reducing the difficulty and time of installation.

[0025] The working principle of this utility model is as follows: When this utility model is used, it can be positioned on the outer wall of the sleeve of the large circular machine by the lower positioning boss 3 when it is installed into the large cauldron. During installation and positioning, the lower positioning boss 3 only needs to be inserted into the outer wall of the sleeve to complete the positioning. Then, the gear disc body 1 is rotated to adjust the position of the fixing bolt hole 4. The fixing bolt hole 4 is aligned with the fixing bolt hole of the large cauldron and the bolt is locked in for fixation. This makes positioning faster and more convenient, and installation easier, reducing installation time and difficulty. At the same time, after assembly, the lower positioning boss 3 can also increase the contact area between the gear disc body 1 and the outer wall of the sleeve, making the two less likely to dislodge and more stable in use.

[0026] This utility model aims to protect the structure of the product. The model numbers of the components are not the focus of this utility model's protection, as they are common technology. Any component on the market that can achieve the functions described above can be used as an option. Therefore, the model numbers and other parameters of the components are not described in detail in this utility model. The contribution of this utility model lies in the scientific combination of the various components.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions provided are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of protection of this utility model as defined by the appended claims and their equivalents. Any aspects of this utility model not detailed herein are well-known to those skilled in the art.

Claims

1. A large cauldron toothed disc, comprising a toothed disc body (1) and a tooth layer (2) integrally formed on the outer wall of the toothed disc body (1), characterized in that: The lower surface of the toothed disc body (1) is integrally formed with a lower positioning boss (3), and the toothed disc body (1) is also provided with a number of fixing bolt holes (4). The upper surface of the toothed disc body (1) is also evenly embedded with a number of magnetic blocks (12). The upper surface of the toothed disc body (1) is also integrally formed with an upper positioning boss (5). The toothed disc body (1) is integrally formed with a hollow cavity (11).

2. The large cauldron toothed disc according to claim 1, characterized in that: The hollow cavity (11) is filled with hard resin blocks.

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