12.

FRICTION TRANSMISSIONS. VARIABLE TRANSMISSIONS (VARIATOARE)

BASICS

12.1.

The variable transmissions are usually transmitting the load by friction as a result of pressing the elements in contact. They are achieving a variable speed at the driven element. Their main advantages are: they are running with low level of noise and vibrations; assure overloads protection; the variable speed at the driven element is adjusted to the needs of the driven machine; the constructive solution is sometimes very simple. Some of the disadvantages of these transmissions are: the transmission ratio is not constant, being dependant on the load, as a result of the specific sliding between elements; the mechanical efficiency may be low in the case of some solutions, due to sliding; the slipery may be drasticaly influencing the durability; there is a need for high pressing forces loading the shafts and bearings and usually increasing the overall dimension of the transmission. 12.2. FAILURES

The main failures are involving the active surface of the elements: fatigue pitting (oboseala de contact) and/or seizing (griparea) in the case of lubricated surfaces; abrasive wear (uzura abraziv) and/or seizing in the case of non lubricated surfaces. 12.3. MATERIALS

The materials used for the active elments of the friction variable transmissions must be characterised with high pitting and wear strength and large friction coefficients. The main used couples of materials are: hardened steel/ hardened steel for high loaded transmissions with or without lubrication; casting iron/ hardened steel for medium loaded transmissions with or without lubrication, having an increased seizing strength; casting iron / casting iron for medium loaded transmissions with lubrication; non metallic materials/casting iron or hardened steel for low loaded transmissions without lubrication, for high friction coefficients. 12.4. CALCULUS ELEMENTS

The main calculus is the contact stress calculus, avoiding the pitting failure for the lubricated transmissions. The maximum stress is establish, based on Hertzs calculus relation, considering the two surfaces in contact as two cylinders with radiuses 1 and 2, under the action of a normal force Fn H = ZE Fn 1 HP , b (12.1)

where: ZE is the elastic coefficient of the two materials in contact; Fn normal force; b contact length; 1/ - reduced arch (curbura redus) 1 1 1 = , (12.2) 1 2

where the + sign is for the exterior contact and the sign is for the interior contact; HP the admissible contact strength 12.5. VARIABLE TRANSMISSIONS 12.5.1 Main Characteristics The main characteristics of the variable transmissions are: input power P1; input rotational speed n1; output rotational speed n2x range between n2min and n2max control range (gama de reglare) G: mechanical efficiency . The control range is defined as a ratio n G = 2 max . (12.3) n2 min The transmission ratio is n ix = 1 , n2 x with values between imin and imax, where: n n i min = 1 ; i max = 1 . n2 max n2 min From relations (12.3) and (12.5) i G = max . imin 12.5.2 Frontal Mono Variable Transmission (Variatorul frontal mono) (fig. 12.1) Transmission ratios R R R i x = 2 x ; i min = 2 min ; i max = 2 max R1 R1 R1 Control range R G = 2 max . R2 min Necessary pressing force cM t1 Fn = R1 where c is a safety coefficient for slippery. Reduced arch 1 1 1 1 = + = 1 2 R1 where 1 = R1 and 2 . Fig.12.1 (12.4)

(12.5)

(12.6)

12.5.3 Conical Mono Variable Transmission (Variatorul conic mono) (fig. 12.2) Transmission ratios R R R i x = 2 x ; i min = 2 min ; i max = 2 max R1 R1 R1 Control range -2-

G=

R2 max . R2 min

Necessary pressing force cM t1 Fn = R1 where c is a safety coefficient for slippery. Reduced arch 1 1 1 1 cos = + = + 1 2 R1 R2 min where 1 = R1 and 2 min = R2 min cos .

12.5.4 Frontal Duo Variable Transmission With Cylindrical Roller (Variatorul frontal cu rol intermediar cilindric (duo)) (fig. 12.3) Transmission ratios R R R i x = 2 x ; i min = 2 min ; i max = 2 max , R1x R1 max R1 min Control range R R G = 1 max 2 max . R1 min R2 min Necessary pressing force cM t1 Fn = R1 min Reduced arch 1 1 1 1 1 1 = + = + = , 1 3 2 3 R3 where 1 , 2 , 3 = R3 .

Fig.12.2

Fig.12.3

-3-

12.5.5 Frontal Duo Variable Transmission With Tapered Roller (Variatorul frontal cu rol intermediar conic (duo)) (fig. 12.4, a and b with bifurcated power flow)

Fig.12.4 Transmission ratios R R R i x = 2 x ; i min = 2 min ; i max = 2 max , R1x R1 max R1 min Control range R R G = 1 max 2 max . R1 min R2 min Necessary pressing force cM t1 Fn = R1 min Reduced arch 1 1 1 1 1 cos = + = + = , 1 3 2 3 R3 where 1 , 2 , 3 = R3 cos .

12.5.6 Frontal Duo Variable Transmission With Balls (Variatorul frontal cu bile (duo)) (fig. 12.5) Transmission ratios R R R i x = 2 x ; i min = 2 min ; i max = 2 max , R1x R1 max R1 min Control range R R G = 1 max 2 max . R1 min R2 min Necessary pressing force cM t1 Fn = R1 min Reduced arch -4Fig.12.5

1 1 1 1 1 1 = + = + = , 1 3 2 3 R3 where 1 , 2 , 3 = R3 . 12.5.7 Frontal Toroidal Variable Transmission (Variatorul toroidal (duo)) (fig. 12.7) Transmission ratios R R i x = 2 x ; i min = 2 min ; R1x R1 max R2 max , R1 min Control range R R G = 1 max 2 max . R1 min R2 min Necessary pressing force cM t1 Fn = R1 min 12.5.8. Variable Transmissions With Cones (Variatoare cu conuri deplasabile) (fig. 12.7, 12.8) i max = The variable transmissions with movable cones are using as intermediary element a rigid ring, a chain or a belt. There are duo solutions (like the one from fig. 12.7) with mobility on both pairs of cones, with the following characteristics: Transmission ratios R R i x = 2 x ; i min = 2 min ; R1x R1 max i max = R2 max , R1 min

Fig.12.6

Control range R R G = 1 max 2 max . R1 min R2 min Necessary pressing force cM t1 Fn = R1 min Other solutions are mono (like the ones from fig. 12.8) with mobility on one pair of cones and on the center distance, with the following characteristics: Transmission ratios -5Fig.12.8

Fig.12.7

ix =

R2 x R2 max R2 min ; i min = ; i max = R1 R1 R1

Control range R G = 2 max . R2 min Necessary pressing force cM t1 Fn = 2R1 Variatoarele cu conuri deplasabile i inel rigid funcioneaz n baie de ulei, conurile i Mobile inelele fiind executate din oel. assemblings Constructive solutions for the controled pairs of cones are presented in fig. 12.9 Constructive solutions for the elastically supported pairs of cones are presented in fig. 12.10

Fig.12.9

-6Fig.12.10