Development and Applications of Precision Heavy Duty Reducers for Double Rotating Shaft Mechanisms in Large Wind Tunnels

doi:10.3969/j.issn.1004-132X.2025.10.032

Abstract

Abstract:

In order to reduce the degree of blockage， strictly control the equipment size of a large-scale continuous transsonic wind tunnel double rotating shaft mechanisms， a small volume， high torque and high transmission accuracy reduction unit for heavy duty double rotating shaft mechanisms was developed. By comparing the common precision deceleration methods such as involute planet， cycloid-pin， harmonic and worm gears， the precision heavy duty transmission method of RV and NGW planetary reducer in series combination was put forward. Optimization design of the planetary reducer and strength analysis of key components were conducted based on ISO 6336， sequential quadratic programming algorithm， and finite element method. The return difference and transmission errors of the planetary transmission unit were calculated， and precision theoretical analysis of the reducers was performed. Among them， the processing and assembly of small backlash planetary transmission were the key technology， breaking through the precision machining of internal gear ring and planetary carrier， gear heat treatment deformation control and high-precision grinding， as well as the whole complex structure assembly adjustment technology. The dedicated test rig was developed to evaluate the transmission performances of the current precision heavy duty reducer， followed by validation in the wind tunnel， confirming that the manufactured reduction unit meets the requirements for applications in a large continuous transonic wind tunnel double rotating shaft mechanisms.

Key words: wind tunnel, double rotating shaft, precision, heavy duty, RV reducer, planetary transmission

摘要：

为减小堵塞度，严格控制某大型连续式跨声速风洞双转轴机构装备尺寸，研制出一种用于大负载双转轴机构的小体积、高扭矩、高传动精度的减速单元。通过对比分析渐开线行星、摆线针轮、谐波及蜗轮蜗杆传动等常用精密减速方式，提出了成熟摆线针轮RV传动与NGW行星传动串联组合的精密重载传动方式。基于ISO 6336、序列二次规划算法、有限元法对行星减速器进行优化设计及关键零部件强度分析，计算行星传动单元的回差与传动误差，对减速器进行了精度理论分析。其中，小齿隙行星传动加工及装配为其关键技术，突破了内齿圈及行星架精密加工、齿轮热处理变形控制与高精磨齿、整机复杂结构装配调整技术。研制专用试验台对该精密重载减速器进行传动性能测试，然后对其进行风洞验证，证明了所研制的减速单元满足某大型连续式跨声速风洞双转轴机构应用要求。

关键词: 风洞, 双转轴, 精密, 重载, RV减速器, 行星传动

CLC Number:

TH132

Yangyi XIAO, Yi ZHANG, Runyang SUN, Yongtao YIN, Shaojie PAN, Zhenhua ZHU. Development and Applications of Precision Heavy Duty Reducers for Double Rotating Shaft Mechanisms in Large Wind Tunnels[J]. China Mechanical Engineering, 2025, 36(10): 2423-2432.

肖洋轶, 张诣, 孙润阳, 尹永涛, 潘少杰, 朱振华. 大型风洞双转轴机构精密重载减速器研制及应用[J]. 中国机械工程, 2025, 36(10): 2423-2432.

Figures/Tables 19

Fig.1 Installation of double rotating shaft mechanism and its precision heavy duty reducer in large wind tunnels

Tab.1 Main technical specification of rear axle precision heavy duty reducer

额定输出转速	1.667 r/min	传动精度	≤3 arc min
额定输出扭矩	80 kN·m	无故障工作时间	≥12000 h
最大输出扭矩	≥105 kN·m	防护等级	IP65
外径	≤640 mm	润滑方式	脂润滑
长度	≤930 mm

Fig.2 Precision heavy duty reduction transmission scheme for rear axle

Tab.2 Basic parameters of a certain type RV reducer

额定输出扭矩

启停容许转矩

瞬时最大容许转矩

输出额定

转速

Tab.3 Transmission ratio distribution

项目	电机	RV	NGW
传动比		236.29	5.442
输出转速/（r·min^-1）	2143.649	9.072	1.667
输出扭矩/（N·m）	62.212	14700	80000

Tab.4 Main parameters of NGW planetary reducer

	太阳轮	行星轮	内齿圈
齿数	31	53（4个）	137
模数/mm	3.75
压力角/（°）	25
齿宽/mm	165	160	155
变位系数	0.0962	$-$ 0.0962	0.0962
中心距/mm	157.5
材料	18CrNiMo7-6（渗碳淬火）
精度等级（ISO 1328）	4	4	5
润滑方式	0号油脂润滑
重合度	1.504		1.649
疲劳安全系数	S_Fs=2.197 S_Hs=1.279	S_Fp=1.419 S_Hp=1.515	S_Fr=1.932 S_Hr=1.634

Tab.4 Main parameters of NGW planetary reducer

	太阳轮	行星轮	内齿圈
齿数	31	53（4个）	137
模数/mm	3.75
压力角/（°）	25
齿宽/mm	165	160	155
变位系数	0.0962	$-$ 0.0962	0.0962
中心距/mm	157.5
材料	18CrNiMo7-6（渗碳淬火）
精度等级（ISO 1328）	4	4	5
润滑方式	0号油脂润滑
重合度	1.504		1.649
疲劳安全系数	S_Fs=2.197 S_Hs=1.279	S_Fp=1.419 S_Hp=1.515	S_Fr=1.932 S_Hr=1.634

Fig.3 Design drawing of rear axle precision heavy duty reducer

Fig.4 Equivalent stress of planetary carrier

Fig.5 Deformation of planetary carrier

Fig.6 Equivalent stress of reducer shell

Fig.7 Deformation of reducer shell

Tab.5 Geometrical accuracy parameters of rear axle planetary reducer gears

项目	太阳轮	行星轮	内齿圈
单个齿距偏差±f_pt	4.6	5.0	8.0
齿距累积偏差F_p	14.0	18.0	33.0
齿廓偏差F_α	6.5	7.5	12.0
螺旋线偏差F_β	10.0	8.5	13.0
径向跳动F_r	11.0	14.0	27.0

Tab.6 Rear axle planetary reducer transmission errors

项目	太阳轮	行星轮	内齿圈
切向综合误差 $F i'$ /μm	24	29	51
齿间切向综合误差 $f i'$ /μm	10	11	18
齿轮孔与轴之间间隙 $e 1$ /μm		2
齿轮安装处轴径跳动 $e 2$ /μm	120	10
轴承径向间隙 $e 3$ /μm		10
单齿最大误差 $T m a x$ /μm	154	62	51
传动误差最大值 $φ m a x$ /arc min	0.915

Tab.6 Rear axle planetary reducer transmission errors

项目	太阳轮	行星轮	内齿圈
切向综合误差 $F i'$ /μm	24	29	51
齿间切向综合误差 $f i'$ /μm	10	11	18
齿轮孔与轴之间间隙 $e 1$ /μm		2
齿轮安装处轴径跳动 $e 2$ /μm	120	10
轴承径向间隙 $e 3$ /μm		10
单齿最大误差 $T m a x$ /μm	154	62	51
传动误差最大值 $φ m a x$ /arc min	0.915

Fig.8 The reducer test rig

Fig.9 Transmission efficiency curve of reducer in forward and reverse rotation

Fig.10 Reducer hysteresis curve

Fig.11 Transmission error curves of reducer under different loads

Fig.12 Reducer experiment in wind tunnel

Fig.13 Transmission error of double rotating shaft mechanism under wind tunnel test

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