Gear Motor Handbook

Materials.- 1.4.3 Bronzes.- 2 Geometry and Gears.- 2.1 General Features.- 2.2 Involute to a Circle.- 2.3 Elementary Geometric Wheel. Meshing Theory.- 2.4 Standard Basic Rack Tooth Profile.- 2.5 Geometrical Wheel - Basic Rack Profile.- 2.6 Tooth Thickness.- 2.7 Influence of the Rack Shift Factor. Undercut and Meshing Interference.- 2.8 Reference Centre Distance. Modified Centre Distance.- 2.9 Contact Ratio.- 2.10 Calculation of an Angle Starting from its Involute.- 3 Mechanical Gears.- 3.1 General Spur Features.- 3.2 Cylindrical Wheels.- 3.2.1 Definition.- 3.2.2 Geometry.- 3.2.3 Standardized Basic Profile and Modules.- 3.2.4 Facewidth.- 3.2.5 Undercut.- 3.2.6 Tooth Thickness.- 3.2.7 Internal Toothing.- 3.3 Parallel Spur Gears.- 3.4 Helical Gears. Involute Helicoid.- 3.4.1 Helical Wheel.- 3.4.2 Helical Parallel Gear Pairs.- 3.4.3 Sliding.- 3.4.4 Forces.- 3.4.5 Gear Ratio - Speed Ratio.- 3.4.6 Normal Pressure.- 3.4.7 Rack Shift Factor.- 3.4.8 Gears that Reduce Speed/Gears that Increase Speed.- 3.4.9 Tooth Modifications.- 3.4.10 Mechanical Losses in Gears.- 3.5 Bevel Gear Pair.- 3.5.1 Definition.- 3.5.2 Equivalent Gears. Trestgold's Hypothesis.- 3.5.3 Constant Tooth Depth Bevel Gear.- 3.5.4 Constant Tooth Depth Gear.- 3.5.5 Forces on Bevel Gear Pairs.- 3.5.6 Dimensions of the Blanks Forming the Gears.- 3.6 Worms and Worm Wheels.- 3.6.1 Definition.- 3.6.2 Main Dimension.- 3.6.3 Efficiency of Worms and Worm Wheels. Reversing.- 3.6.4 Tooth Profile.- 3.6.5 Forces.- 3.7 Single Planetary Gear Train.- 3.7.1 Description.- 3.7.2 Kinematic Relation.- 3.7.3 Forces.- 3.7.4 Advantages Derived from the Use of Planetary Train Gears.- 4 Gear Measuring.- 4.1 Measurement of the Tooth Thickness.- 4.1.1 Base Tangent Measurement.- 4.1.2 Normal Chordal Tooth Thickness Measurement.- 4.1.3 Measuring by Balls and Pins.- 4.2 Pitch Measurement.- 4.3 Profile Measurements.- 4.4 Measurement of the Helix Deviation.- 4.5 Composite Tangential Deviation.- 4.6 Composite Radial Deviation (Measurement on the two Flanks).- 4.7 Eccentricity.- 4.8 Precision in Gear Blank.- 4.9 Centre Distance Deviation and Axis Parallelism.- 4.10 Information on Standards.- 4.11 Backlash.- 4.12 Contact Pattern Measurement.- 5 Gear Calculation.- 5.1 Aspects of Teeth After Operation.- 5.2 Parallel Gear and Bevel Gear Pair Load Capacity.- 5.2.1 Prevention of Pitting (Contact Stress).- 5.2.2 Stress Applied to the Tooth Root.- 5.3 Standard ISO 6336 (or DIN 3990).- 5.3.1 Introduction.- 5.3.2 Influence Factors.- 5.3.3 Contact Stress Calculation.- 5.3.4 Calculation of the Tooth Bending Strength.- 5.3.5 Allowable Stress Number.- 5.4 Standard ISO 10300 (Bevel Gear Pairs).- 5.4.1 Introduction.- 5.4.2 Influence Factors.- 5.4.3 Contact Area.- 5.4.4 Contact Stress Calculation.- 5.4.5 Calculation of Tooth Bending Strength.- 5.4.6 Materials.- 5.5 Calculation with a Load Spectrum.- 5.5.1 Complex Calculation.- 5.5.2 Approximate Calculation.- 5.6 Worm and Worm Wheel Calculation.- 5.6.1 General Features.- 5.6.2 Load Capacity for Contact Stress.- 5.6.3 Wear Prevention.- 5.6.4 Tooth Strength.- 5.6.5 Standard Information.- 5.6.6 Reversing and Efficiency.- 6 Shafts.- 6.1 Definition and Function.- 6.2 Shafts and Forces in Gears.- 6.3 Study of the Theoretical Stresses.- 6.3.1 Bending.- 6.3.2 Torsion.- 6.3.3 Normal Stress.- 6.3.4 External Compression.- 6.4 Real Stresses (Stress Concentration Factor - Form Factor).- 6.5 Static Allowable Stress.- 6.5.1 Static Breaking Stress due to Traction.- 6.5.2 Elastic Limit.- 6.5.3 Allowable Static Stress.- 6.6 Allowable Stress for an Unlimited Duration.- 6.6.1 Endurance (Endurance Factor Yc).- 6.6.2 Factor Modifying Endurance.- 6.6.3 Allowable Stress for Unlimited Life Duration.- 6.7 Allowable Stress.- 6.8 Stress Concentration Factor.- 6.8.1 Definition.- 6.8.2 Notch Sensibility Factor.- 6.8.3 Notch Gradient.- 6.8.4 Notch Factor.- 6.8.5 Values of the Allowable Stress Concentration Coefficient and Notch Gradient.- 6.8.6 Static Stress Concentration Factor.- 6.9 Form Factor.- 6.10 Real Stress.- 6.11 Safety Factors.- 6.11.1 Simple Stress.- 6.11.2 Stress Reduced to Reference Stress.- 6.11.3 Composition of Stresses Following the same Direction.- 6.11.4 Stresses Having any Direction.- 6.11.5 Stresses Generated by a Spectrum of Loads.- 6.12 Stress Concentration Importance.- 6.13 Shaft Designing.- 6.14 Distortion of the Shaft.- 7 Fits Between the Shaft and the Hub and Fits Between the Shaft and the Shaft.- 7.1 ISO System Concerning Tolerances.- 7.2 Measurement of Roughness.- 7.3 Fixing by means of Prismatic Key.- 7.4 Interference Mounting.- 7.5 Fretting Corrosion.- 7.6 Splines.- 7.7 Couplings - Generalities.- 7.8 Rigid Couplings.- 7.9 Elastic Couplings.- 7.10 Gear Toothing Couplings.- 7.11 Clutch Couplings.- 7.12 Couplings by Means of Shrink Disks.- 8 Bearings.- 8.1 Generalities.- 8.2 Classification of Bearings on the Basis of the Rolling Elements.- 8.3 Classification of Bearings on the Basis of their Positioning.- 8.4 Calculation of Bearings.- 8.5 Variable Loads.- 8.6 Static Capacity.- 8.7 Dimensions of Bearings.- 8.8 Radial Deep Groove Ball Bearings.- 8.9 Double Row Self-Aligning Ball Bearings.- 8.10 Cylindrical Roller Bearings.- 8.11 Double Row Self-Aligning Roller Bearings.- 8.12 Angular Contact Ball Bearings.- 8.13 Taper Roller Bearings.- 8.14 Selection of Bearings.- 8.15 Bearing Fixings.- 8.16 Dismounting of Bearings.- 8.17 Maximum Speed and Number of Cycles.- 8.18 Oil Seals.- 9 Lubricants and Lubrication.- 9.1 Function of Lubrication.- 9.2 Lubricants.- 9.3 Mineral Lubricants.- 9.4 Greases.- 9.5 Synthetic Lubricants.- 9.6 Viscosity.- 9.6.1 Definition.- 9.6.2 Variation of Viscosity by Temperature.- 9.6.3 Viscosity Variation due to Pressure.- 9.6.4 Measurement of Viscosity.- 9.6.5 Standardized Designation of Viscosity (ISO).- 9.7 Other Properties of Lubricants.- 9.8 Causes of Deterioration.- 9.9 Selection of Lubricants.- 9.10 Working at Low Temperatures.- 9.11 Working at High Temperatures.- 9.12 Modalities of Lubrication of Gearing.- 9.13 Elasto-Hydro-Dynamic State (EHD).- 9.14 Scoring.- 10 Housings.- 10.1 Definitions and Function.- 10.2 Materials.- 10.3 Primary Function: Support the Bearings.- 10.4 Calculation with Finite Elements.- 10.5 Second Function: Seal.- 10.6 Third Function: External Fixing.- 10.7 Accessories.- 10.8 Working and Precision of Housings.- 10.9 Mounting Screwed Elements (Bolts and Nuts).- 10.10 Economic Conditions Influencing the Selection of Housings.- 11 Standard Gear Units.- 11.1 Definition and Fields of Application.- 11.2 Design Principle.- 11.3 Types of Gearboxes.- 11.4 Selection of a Gear Unit.- 11.5 Service Factor.- 11.6 Equivalent Power.- 11.7 Example of Calculation.- 11.8 Factors that Influence the Operation Factor.- 11.9 Particular Precautions.- 11.10 Gear Motors.- 12 Vibrations and Noises.- 12.1 Natural Vibration.- 12.2 Forced Vibration.- 12.3 Vibration Modalities.- 12.4 Flexion Vibration.- 12.5 Torsion Vibration.- 12.6 Sinusoidal Vibration Function.- 12.7 Periodic Vibration Function (Fourier).- 12.8 Modal Anlysis.- 12.9 Measurement of Vibrations.- 12.10 Causes of Vibrations in Gearboxes. Frequency of Meshing.- 12.11 Effects of Vibrations.- 12.12 Noise.- 12.13 Measurement of the Noise.- 12.14 Well-Considered Scales (dBA).- 12.15 Measurement of the Noise Produced by Gear Units.- 13 Thermal Power of the Gearing.- 13.1 Definition.- 13.2 Losses in Gearboxes.- 13.3 Losses During the Meshing.- 13.4 Losses due to Dipping.- 13.5 Losses in Bearings.- 13.6 Losses in Sealings.- 13.7 Total Losses.- 13.8 Dissipation of Heat.- 13.9 Efficiency of Gearboxes.- 13.10 Measurement of the Efficiency of Gearboxes.- 13.10.1 Open Circuit Measurement.- 13.10.2 Back to Back Measurement.- 13.11 Comparison Between the Different Types of Gear Units.- 14 The Manufacturing of Gearboxes.- 14.1 Introduction.- 14.2 The Raw Material.- 14.3 The Processing of Carters.- 14.4 The Processing of Shafts.- 14.5 The Working of Gear Blanks.- 14.6 Cutting Cylindrical Spur and Helical Gears.- 14.6.1 Particulars.- 14.6.2 Processing by Milling with Form Tools.- 14.6.3 Processing by Generation. Principle.- 14.6.4 Cutting by Rack-Tool.- 14.6.5 Cutting by Pinion-Tool.- 14.6.6 Processing by Lead-Miller (Hob).- 14.6.7 Processing by a Tool of Carbide or Fired Clay.- 14.7 The Processing of Bevel Gears.- 14.8 The Processing of Worm and Worm Wheels.- 14.9 The Finishing of Cylindrical Gears.- 14.9.1 Grinding.- 14.9.2 Shaving.- 14.9.3 Honing.- 14.9.4 Skiving.- 14.10 Finishing of Bevel Gears.- 14.11 Grinding of Worms.- 14.12 Assembly.- 15 Applications.- 15.1 The Application of Gears.- 15.2 Hoisting Instruments.- 15.2.1 Bridge Cranes.- 15.2.2 Cranes.- 15.3 Conveyors.- 15.3.1 Belt Conveyors.- 15.3.2 Chain Conveyors.- 15.3.3 Roller Conveyors.- 15.3.4 Screw Conveyors.- 15.4 Waste and Treatment of Used Water.- 15.4.1 Waste Treatment.- 15.4.2 The Treatment of Used Waters.- 15.5 Special Vehicles and Farm Machines.- 15.6 Equipments Used for Intermittent Operation.- 15.7 Precision Positioners.- Appendix. Hydraulic Motors and Variators.- A.l Hydraulic Motors.- A.2 Speed Variators.- A.2.1 Belt Variators.- A.2.2 Planetary Variators.- The ISO Standards Relating to Gears (TC 60).- IV: Editor: Dierk Schroder.- 1 Electric Machines-Standards and Definitions.- 1.1 Introduction and Standards.- 1.2 Duty and Rating.- 1.3 Machines with Different Duty Types.- 1.4 Operating Conditions: Altitude, Ambient Temperatures and Coolant Temperatures.- 1.5 Electrical Conditions.- 1.6 System: Production Machine-Driving Machine.- 1.6.1 Stationary Behaviour of the Production Machine.- 1.6.2 Stationary Behaviour of the Driving Machine: tM = f(n,?).- 1.6.3 Static Stability at the Operating Point.- 1.6.4 Rating of the Electrical Drive System.- 2 Electric Machines.- 2.1 Direct-Current Machine.- 2.2 Rotating-Field Machines.- 2.2.1 Fundamental Principle of the Rotating-Field Machines.- 2.2.2 Synchronous Machines.- 3 Direct-Current Machine.- 3.1 Signal-Flow Graph of Separately Excitated DC-Machine Armature Circuit.- 3.1.1 Normalization.- 3.1.2 Field Circuit Excitation Circuit.- 3.2 Transfer-Functions Transient Responses.- 3.2.1 Variable Command Behaviour and Variable Command Transfer Function.- 3.2.2 Load Behaviour and Disturbance Transfer-Function.- 3.2.3 Influence of ? on n (Field Weakening).- 3.3 Open-Loop Speed Control.- 3.3.1 Open-Loop Speed Control by Means of Armature Voltage.- 3.3.2 Open-Loop Control Through Field Weakening.- 3.3.3 Control Through Armature and Field-Voltage.- 3.3.4 Control with a Series-Resistor on the Armature Circuit.- 4 Converters and DC-Machine Control.- 4.1 DC-DC-Converter.- 4.1.1 DC-DC-Converter Principle.- 4.1.2 Control Strategies for DC-DC-Converters.- 4.1.3 DC-DC-Converters for one or Multiple Quadrant Operation of DC-DC-Motors.- 4.2 Line Commutated Converters.- 4.2.1 Three Phase "Y" Half Wave Converter.- 4.2.2 Single-Phase Converters.- 4.2.3 Three-Phase Bridge-Converter.- 4.2.4 Operating Limits Converter and Machine.- 4.2.5 Torque Reversal of DC-Machines Supplied by Converters.- 4.3 Control of DC-Drives (Current-Control, Speed Control).- 4.3.1 Control of the Armature Current.- 4.3.2 Speed Control.- 5 Three-Phase AC-Machines Signal Flow Graphs.- 5.1 Space-Vector Theory -Phasors.- 5.2 General Rotating Field Machine.- 5.3 Induction Machine in the Steady State Supplied from the Mains.- 5.3.1 Mains and Converter Power Supply.- 5.4 Single-Phase Equivalent Circuit in Steady-State Operation.- 5.4.1 Equivalent Electrical Circuit for the IM.- 5.5 Induction Machine Supplied by Inverter.- 5.5.1 Control Strategies Based on Constant Stator Flux.- 5.5.2 Control Strategies Based on Constant Rotor Flux.- 6 Synchronous Machine.- 6.1 Synchronous Machine with Salient Pole Rotor.- 6.6.1 Machine with Salient Pole Rotor with Impressed Stator Voltage-Signal Flow Graph.- 6.2 Synchronous Machine with Non-Salient Pole Rotor.- 6.3 Non-Salient Pole Rotor Synchronous Machine Control.- 7 Inverter Drives.- 7.1 Cycloconverter.- 7.2 Wound Rotor Induction Machine with Slip-Power Recovery (Subsynchronous Cascade; Scherbius Drive).- 7.3 Double Fed Induction Machine.- 7.4 The Load-Commutated Inverter Drive.- 7.5 Forced Commutation Current Source Inverter with Thyristors.- 7.6 Voltage Source Inverter with Intermediate Direct Voltage (VSI).- 7.6.1 VSI with Variable DC-Voltage.- 7.6.2 VSI with Constant Intermediate Direct Voltage.- 8 Basic Considerations for the Control of Rotating Field Machines.- 8.1 Decoupling.- 8.2 Field Orientation.- 9 Permanent Magnet Machines.- 9.1 Permanent Magnet Synchronous Machine.- 9.2 Brushless DC-Machine.- V: Editor: Haijme Yamashina.- 1 Outline of Total Quality Management.- 1.1 Definition of Quality.- 1.2 Brief History of Total Quality Management in Japan.- 1.2.1 Introduction of SQC (Statistical Quality Control).- 1.2.2 Necessity of Quality Assurance.- 1.2.3 Toward Total Quality Management.- 1.3 Importance of Production Techniques to Build-in Quality in New Innovative Product Development.- 1.3.1 Product and Process Technology.- 1.3.2 A Closer Look at the Production Process.- 1.3.3 Matching Manufacturing to Market Changes.- 1.3.4 Costs of Diversification.- 1.3.5 Mobile Competitive Edge.- 2 The QC Viewpoint.- 2.1 Customer Orientation.- 2.2 Customer's Quality Requirements.- 2.2.1 Quality Requirements and Substitutional Characteristics.- 2.2.2 How to Express Quality.- 2.3 Management through Quality to Satisfy Customers.- 2.3.1 Problems in Conventional Management.- 2.3.2 Management by Rotating the Plan-Do-Check-Act Cycle.- 3 Quality Assurance.- 3.1 Basic Quality Assurance Policy.- 3.2 Quality Assurance Organization.- 3.3 Quality Assurance Process.- 3.4 Quality Assurance System Diagram.- 4 Main Quality Control Activities.- 4.1 Quality Control at the Product Design Stage.- 4.1.1 Quality Engineering.- 4.1.2 FMEA and FTA.- 4.2 Quality Control at the Preparation Stage for Production.- 4.2.1 Quality Engineering.- 4.2.2 Process FMEA.- 4.2.3 Process Capability Assessment.- 4.2.4 Fool-Proof System.- 4.2.5 Quality Control of Purchased Goods.- 4.3 Quality Control at the Daily Production Stage.- 4.3.1 Statistical Process Control (SPC) by Using the Control Chart.- 4.3.2 Every Aspect of Inspection.- 4.3.3 QA Network.- 4.3.4 Establishment of the Standard Operation.- 4.3.5 Role of the Foreman.- 4.3.6 Quality Maintenance.- 4.3.7 QC Circle Activities.- 4.3.8 Quality Control of Purchased Goods.- 4.4 Necessity of Education and Training and Training on the QC-Tools.- Author- and Subject Index.