Abstract
The optimization of load sharing between planets is one of the most important goals in planetary gearbox design. Unevenly distributed load will cause locally higher flank pressures and therefore, less durability of gears and bearings. Furthermore, unevenly distributed or fluctuating loads can cause excitations in the gear mesh and structural vibrations. The load sharing in planetary gear stages depends on the individual stiffness conditions in each mesh position. The stiffness is not only influenced by the gear geometry but also by the surrounding structural elements like shafts, housings and torque arms. In wind industry these components are often designed very stiff in order to reduce their effect on the operational behavior.Within this paper, a method is presented, which allows combining the structural optimization process with a tooth contact analysis for planetary gearboxes. By means of this combined approach, it is possible to optimize the housing structure of the ring gear in terms of mass reduction while keeping the operational behavior in focus. With a weighted design objective function, it is possible to decide whether the main objective should be load distribution, excitation behavior, low mass or a balanced design.
Highlights
Introduction and motivationIn 2012, about 32% of the companies in the German mechanical and automotive engineering sector used lightweight construction technologies [1]
The term lightweight construction includes the use of lightweight construction materials such as high-strength steels or fiber composites, and structural
This report deals with the shape optimization of the housing structure of planetary gearboxes under consideration of the interactions between the tooth mesh and its surroundings
Summary
In 2012, about 32% of the companies in the German mechanical and automotive engineering sector used lightweight construction technologies [1]. Due to the high level of automation in production, the material accounts for approx. Due to the reduction of assigned material and a better material utilization, potential for cost reduction and profit maximization often results. This cost structure is not directly transferable into wind turbine industry, but shows that with a high percentage of automated processes, material costs become more important. Since a large part of the external structural components are casted from ductile cast iron, the material costs are lower compared to the casehardened steel of the gears. A structural optimization and the associated reduction of the mass of the external components leads to lower material demand and to lower transportation costs. An optimization of the gear environment, especially of planetary gear stages, has hardly been part of scientific investigations so far and could provide further potentials for increasing the power density
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