Environmental protection design of the hottest cou

2022-08-16
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The environmental protection design of the coupling

the mass moment of inertia of the clutch used to transmit high power is relatively low, which has a positive impact on the driving power and energy consumption required by the system, although this effect is very limited. High power density means less raw materials are used in production, and it is precisely here that there is a great saving potential

on the premise of reducing CO2 emissions, machine tools and equipment should reduce energy consumption as much as possible. This is the requirement put forward in the latest EUP EU Directive (Framework Directive on ecological design of energy using products). The established goal of all machine tool R & D activities is to reduce the weight of existing automobile bodies, and semi spare parts should be designed and manufactured according to regulations

the coupling is a purely mechanical component, so it is not included in the scope of EU directives. Nevertheless, it also has a certain economic benefit in the forming process and the quality stability of the parts in the use process. Couplings with compact structure and high power density, such as the gapless all steel coupling roba-ds developed and produced by Mayr drive technology company, have very low mass moment of inertia, which directly reduces the required drive power. Therefore, the design of the coupling has created a Xintiandi of energy saving. In its R & D and production process, it has successfully achieved higher power density than other all steel couplings. That is to say, the volume of this coupling is smaller and the torque that can be transmitted is larger. Small size means less raw materials are needed to produce the coupling

Figure 1 on the transmission test bench of EGM (Hannover assembly technology research and development company), the roba-ds coupling uses a long sleeve to connect the EAS safety protection clutch

the saving potential of metal materials is very considerable. Depending on the size and structural form of the coupling, 40% - 70% of metal materials can be saved. If the coupling is replaced with a variety of patented roba-ds coupling in all practical applications, the whole Germany can save about 600t of steel every year

Figure 2 the structural design of roba-ds coupling has the characteristics of small volume and large transmission torque, so it can save steel and reduce CO2 emissions.

Tyson group released such a figure in their "2004-2005 sustainable development report": its Duisburg steel plant consumes 18.5gj of energy per 1t of steel production. According to Tyson group, the steel plant is a world-wide steel production plant with excellent economy. If 600t steel is saved every year, even Duisburg steel plant, which is extremely economical, will save 11100gj of energy. The annual energy consumption per 1m2 of living area in a family residence with ventilation monitoring and regulation device is 30kwh. The energy required for the annual heating of this kind of residence with an area of 100 m2 is 10.8gj. Based on this calculation, the energy required to produce 600t steel can be used by 1028 households for one year. In terms of the meaning of the EUP EU Directive (Framework Directive on ecological design of energy using products), the more important significance of the 11100gj energy saved by using the roba-ds chip coupling is to reduce CO2 emissions. For example, 1L civil fuel oil can produce 10kwh or 36mj of energy. The energy required to produce 600t steel is equivalent to 308333l of civil fuel oil. However, the CO2 released during the combustion of 1l civil fuel oil is 3kg, and a total of 925t CO2 will be discharged according to this calculation

couplings bring energy conservation

according to the provisions of the EUP Directive, couplings are not within the 'ecological design framework of energy consuming products'. However, through the practical application of roba-ds disc coupling, we can see the important role played by mechanical parts in the whole production and CO2 emission reduction process. The roba-ds coupling developed and designed by Mary drive technology company has strong torsional rigidity, but also has good bending adaptability and axial, angular and radial compensation performance. At present, the roba-ds series coupling can transmit a rated power of 24000nm. It is a highly reliable and durable coupling, which can be used in a very harsh working environment. Its working temperature range and power density can at least reach the level of other types of shaft couplings; If the size, installation and use are proper, its service life is almost infinite. The plate coupling also has the advantages of wear resistance, maintenance free and good torsional rigidity. Many couplings (about 50%~80%) rely on friction to transmit torque, and the rest rely on matching bolts to transmit torque. When the load exceeds the torque of friction transmission, there will be a small relative displacement between the plate couplings, which brings a lot of defects and deficiencies. With the change of load size and direction, the relative displacement between various parts will occur, resulting in the unstable balance of the coupling and the stable and reliable performance

The relative movement between the plates of the

plate coupling will lead to the decrease of the pre tightening force of the mating bolt, the increase of the bending load borne by the bolt, and finally the bolt fracture. In order to avoid this evil effect, the manufacturer of the plate coupling usually restricts the transmission of alternating torque or takes other measures. Although there are clear provisions on the bearing capacity in the product catalogue, users will generally choose a larger coupling to avoid the fracture of the mating bolt

Figure 3 environmentally conscious design

combination of high power density and absolutely no gap

the application of roba-ds coupling is completely different from the above coupling. In order to combine the high power density with the use temperature of the absolute universal special engineering plastics at about 180 ℃, the roba-ds coupling adopts a special sand blasting process at its fastening part. In addition, it also takes other safeguard measures, that is, the special shape of the shaft sleeve is used in the coupling hub and intermediate connecting pieces, so that the pre tightening force of the matching bolt can be transmitted to the coupling hub without gap connection, so as to ensure the transmission of high power density at the power input end and output end of the coupling. In contrast, the size specification of the mating bolt used is small, so the free bending length of the mating bolt is short, so there is no need to limit the displacement performance of the bolt, so the rated torque specified in the product catalog can be transmitted without any restrictions

EU requirements for energy efficiency

the EU has taken a series of measures to reduce the harm to the environment in the production, use and emission of products. In the field of drive technology, the R & D and design of drive technology products must comply with the relevant requirements and regulations of WEEE "electrical and electronic product Waste Directive" and RoHS "directive on restricting the use of certain hazardous substances in electronic and electrical equipment". In addition, the EUP Framework Directive on ecological design of energy using products, which is an EU directive aimed at reducing CO2 emissions, should be added. To achieve the requirements of this directive, we must take measures that can effectively improve energy efficiency. However, the effect of the improvement of only one mechanical component is extremely weak. For example, the improvement of engine performance is far from enough. The whole drive system must be optimized, including the optimization and improvement of coupling, brake, transmission and other transmission parts. Through these optimization and improvement measures, people and the environment will benefit from less CO2 emissions and less power consumption. (end)

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