China manufacturer Udl0.55 Speed Variator, Speed Variable Gearbox gearbox design

Product Description

Specifications

The design of UDL series planet cone-disk step-less speed variator compromises the advanced technology both at home and abroad. 

The products include the following main characteristics:

1) High speed regulating precision,up to 0.5-1 rotation

2) Large speed changing range:the speed ratio ranges from 1:4 to 1:7 freely

3) High in strength and long in service life

4) Convenient to regulate the speed

5) Continuous in running, front to back in running direction,smooth in driving,stable in performance and low in noise

6) Full in sealing and suitable for any environment

7) Compact in structure and small in volume

8) Made of high-quality aluminium alloy diecast into forming,good surface,light in weight and it never gets rusty

9) Good in adaptation: UDL series planet cone-disk stepless speed variators can be combined with all kinds of speed reducers as to achieve low stepless speed changing

UDL series planet cone disk stepless speed variators are widely used for foodstuffs,ceramics,packing,chemicals,pharmacy,plastics,paper making, mchine-tools, transportation,and all kinds of automatic production lines,pipelines and assembly lines which need speed-regulation.it is a good companion for your production.

 

Basic model: UDL 0.55 B5

UD

Code of planetary cone-disk stepless variator

L

Aluminium alloy casing,and no mark means castiron casing

0.55

Relevant motor power

B5

Installation position code

                   

 Combination of gear speed reducer and basic model

UDL

Code of planetary cone-disk stepless variator with aluminium alloy casing

0.55

Relevant motor power

2

Second gear speed reducer,no mark means first gear speed reducer

C

Code of gear speed reducer

5

Speed ratio of gear speed reducer

B5

Installation position code

 

Speed variator Structure & principle

Speed variator is mainly composed of the below mentioned componenta:sun wheel(11)pressed
 by disc spring is connected with inputshaft,fixing plate(7)if fixed in the shell of speed variator,
the inner edge of many proportional planetary conedishes(8) is clamped by sun wheel,the outer edge of planetary cone-dishes is wedged into the clearance between
 fixing plate and speed regulating cam(2),slide block(13)supported every conedish axes is mounted in the radial proportional groove of planetary rack(12)which connected with output 
shaft(1).with the movement of input shaft,the axes of whole planetary cone dishes group 
makes revolution movement while every planetary cone dish surrounds itself whirligig,
it is just that the planetary rack distilled this revolution movement and passed into output shaft
output speed.

     The speed is adjusted by speed regulation hand wheel(6).while moving hand wheel.the 
screw closed to hand wheel dries speed regulating cam to make circumferential displacement
 by extracting pin(4) Under the action of cam gears of fixing cam(3) and speed regulating cam,
this circumferential displacement can transfer to axial displacement of speed regulating cam by 
steel ball(14).it also can make the clear ace between fixing cam and speed regulating cam
 larger or smaller,the result is that the axes of planetary cone dishes group make radial 
displacement outwards or inwards along the radial proportional groove of planetary rack,
so it can up to speed regulation with transmission ratio`s varation.

 

     Torque is transferred by the attrition of sun wheel and planetary cone dish,planetary cone 
dish and fixing plate.the given oil of speed variator can make friction belt produce good traction

Outline surface for basic model-B5
Planrtary stepless speed variator Structure and mounting position
Planrtary stepless speed variator Installation diagram for output flange
Planrtary stepless speed variator Installation diagram for torque arm
Planrtary stepless speed variator Installation diagram for output shafts AZ,GZ

Planrtary stepless speed variator Endless transmission view & name of part

Application: Motor, Motorcycle, Machinery
Hardness: Soft Tooth Surface
Installation: Vertical Type
Layout: Coaxial
Gear Shape: Conical – Cylindrical Gear
Step: Three-Step
Customization:
Available

|

Customized Request

variator gearbox

How do variator gearboxes ensure efficient power transmission and speed regulation?

Variator gearboxes are designed to ensure efficient power transmission and speed regulation through a combination of mechanical principles and control mechanisms. Here’s how they achieve these objectives:

Efficient Power Transmission:

Variator gearboxes employ various mechanisms to ensure efficient power transmission from the input to the output shaft. These mechanisms minimize energy losses and maximize the transfer of mechanical power. Here are a few key factors that contribute to efficient power transmission:

  1. Optimized Gear Design: Variator gearboxes are engineered with carefully designed gear profiles, tooth shapes, and gear ratios. These design elements help to reduce friction, minimize backlash, and improve the meshing efficiency between the gears. By optimizing the gear design, variator gearboxes can achieve higher power transmission efficiency.
  2. High-Quality Bearings: Variator gearboxes utilize high-quality bearings that reduce friction and allow smooth rotation of the gears and shafts. Well-lubricated bearings minimize energy losses due to friction, thereby improving overall power transmission efficiency.
  3. Lubrication Systems: Proper lubrication is essential for efficient power transmission in variator gearboxes. Lubricants reduce friction and wear between moving components, ensuring smooth operation and minimizing energy losses. Variator gearboxes often incorporate dedicated lubrication systems that deliver lubricants to critical areas, optimizing power transmission efficiency and extending the lifespan of the gearbox.
  4. Material Selection: The choice of materials in variator gearboxes plays a significant role in power transmission efficiency. High-strength and low-friction materials are often used for gears, shafts, and other critical components to minimize energy losses through friction and maximize power transfer.
  5. Minimization of Internal Losses: Variator gearboxes are designed to minimize internal losses caused by factors such as windage, churning, and fluid flow resistance. Streamlined housing designs, efficient cooling systems, and optimized fluid dynamics within the gearbox contribute to reducing these losses, resulting in improved power transmission efficiency.

Speed Regulation:

Variator gearboxes excel in speed regulation by providing precise and adjustable speed control according to the requirements of the application. The following features enable accurate speed regulation:

  1. Continuous Adjustment: Variator gearboxes offer continuous and stepless adjustment of the gear ratio or speed control mechanism. This allows for fine-tuning the output speed to match the specific speed requirements of the application. Continuous adjustment ensures that the desired speed can be precisely achieved, enabling effective speed regulation.
  2. Responsive Control Mechanisms: Variator gearboxes incorporate control mechanisms that respond quickly to speed adjustment inputs. These mechanisms can be mechanical, hydraulic, electronic, or a combination of these. Responsive control systems enable rapid and accurate regulation of the output speed, ensuring precise speed control in real-time.
  3. Wide Speed Range: Variator gearboxes can offer a wide range of achievable speeds, allowing for flexibility in speed regulation. By adjusting the gear ratio or other speed control mechanisms, variator gearboxes can cover a broad range of speed requirements, making them versatile in applications where speed variation is essential.
  4. Stable Speed Maintenance: Variator gearboxes are designed to maintain the selected speed setting with high stability. Once the desired speed is achieved, the gearbox is engineered to minimize speed variations due to external load changes or disturbances. This stability ensures that the output speed remains consistent, contributing to reliable speed regulation.
  5. Feedback and Control Systems: Some variator gearboxes incorporate feedback and control systems that monitor the output speed and adjust the gear ratio or control parameters accordingly. These systems provide closed-loop control, constantly comparing the actual speed with the desired speed, and making adjustments to maintain accurate speed regulation even in the presence of external factors affecting the load or operating conditions.

By incorporating efficient power transmission mechanisms and precise speed regulation features, variator gearboxes can optimize energy transfer and maintain the desired speed levels in a wide range of applications. This enables them to deliver efficient power transmission while offering reliable and adjustable speed regulation.

variator gearbox

How do manufacturers ensure the durability of variator gearboxes in industrial environments?

Manufacturers employ various strategies and techniques to ensure the durability of variator gearboxes in industrial environments. These measures are implemented during the design, construction, and testing stages to enhance the gearbox’s ability to withstand the harsh conditions and rigorous demands of industrial applications. Here’s how manufacturers ensure the durability of variator gearboxes:

Rugged Construction:

Manufacturers use robust and durable materials for constructing variator gearboxes. High-quality metals, such as steel or cast iron, are commonly used for gearbox housings and essential components. These materials possess excellent strength, wear resistance, and thermal stability, enabling the gearbox to withstand heavy loads, vibrations, and temperature variations typically encountered in industrial environments.

Enhanced Gear Design:

The gear design of variator gearboxes is optimized for durability. Manufacturers carefully select gear materials, tooth profiles, and surface treatments to minimize wear, improve load distribution, and enhance the gearbox’s ability to handle torque and shock loads. Advanced manufacturing techniques, such as precision machining and heat treatment processes, are employed to ensure the gears have the required hardness, toughness, and dimensional accuracy for long-lasting performance.

Sealing and Protection:

Variator gearboxes are equipped with effective sealing systems to prevent the ingress of contaminants, such as dust, dirt, and moisture, into the gearbox. Seals, gaskets, and O-rings are used to create a barrier that protects internal components from environmental elements. Additionally, manufacturers often incorporate protective measures, such as breather vents or pressure relief valves, to maintain an appropriate internal pressure and prevent the buildup of excessive heat or pressure that could compromise the gearbox’s durability.

Effective Lubrication:

Proper lubrication is critical for the durability of variator gearboxes. Manufacturers ensure that the gearbox is designed with efficient lubrication systems that provide adequate lubricant flow to all critical components. This lubrication helps reduce friction, dissipate heat, and prevent excessive wear and corrosion. Manufacturers may also specify the use of specific lubricants that are suitable for the operating conditions and requirements of the variator gearbox, further enhancing its durability.

Thorough Testing and Quality Control:

Manufacturers subject variator gearboxes to rigorous testing procedures to validate their durability in industrial environments. These tests may include load testing, endurance testing, temperature cycling, and performance verification. Through comprehensive testing, manufacturers can identify potential weaknesses or design flaws and make necessary improvements to ensure the gearbox’s durability. Additionally, stringent quality control measures are implemented throughout the manufacturing process to maintain consistency and reliability in the production of variator gearboxes.

Compliance with Standards and Regulations:

Manufacturers adhere to industry standards and regulations to ensure the durability and safety of variator gearboxes. Compliance with standards, such as ISO (International Organization for Standardization) and specific industry guidelines, helps manufacturers design and manufacture gearboxes that meet or exceed the required performance and durability criteria. This ensures that the variator gearboxes are suitable for use in industrial environments and can withstand the demanding operating conditions they may encounter.

By employing rugged construction, enhanced gear design, sealing and protection measures, effective lubrication systems, thorough testing and quality control, and compliance with standards and regulations, manufacturers ensure the durability of variator gearboxes in industrial environments. These measures contribute to the reliability, longevity, and performance of variator gearboxes, making them well-suited for demanding industrial applications.

variator gearbox

What benefits do variator gearboxes offer in various industrial applications?

Variator gearboxes offer several benefits in various industrial applications, making them valuable components in numerous systems. Here are some of the key advantages they provide:

  1. Continuously Adjustable Speed: One of the primary benefits of variator gearboxes is their ability to provide continuously adjustable speed control. Unlike traditional gearboxes with fixed gear ratios, variators offer stepless speed variation within a certain range. This feature allows for precise control of rotational speeds in industrial machinery, optimizing performance and efficiency in different processes.</li
  2. Optimized Power Efficiency: Variator gearboxes help optimize power efficiency in industrial applications. By allowing for continuous speed adjustment, they enable the machinery to operate at the most efficient speed for a given task. This ensures that the system consumes only the necessary amount of power, minimizing energy waste and reducing operating costs.
  3. Flexible Torque Transmission: Variator gearboxes can handle a wide range of torque requirements, making them suitable for various industrial applications. They can transmit high torque while maintaining their efficiency, allowing industrial machinery to generate the necessary power for demanding tasks. This flexibility in torque transmission contributes to the versatility and adaptability of variator gearboxes in industrial settings.
  4. Smooth and Precise Control: Variator gearboxes provide smooth and precise control over rotational speeds. The stepless speed adjustment allows for seamless transitions between different speeds without sudden jumps or changes. This smooth control enhances the precision and accuracy of industrial processes, ensuring consistent performance and high-quality output.
  5. Improved System Performance: By enabling precise speed control, variator gearboxes enhance the overall performance of industrial systems. They allow machinery to operate at the optimal speed for specific tasks, leading to improved productivity, reduced cycle times, and enhanced product quality. The ability to fine-tune the speed also facilitates better synchronization between different components or processes, further optimizing system performance.
  6. Reduced Mechanical Stress: Variator gearboxes can help reduce mechanical stress on industrial machinery. By allowing for gradual speed adjustments, they minimize sudden changes in load or torque, which can put excessive stress on components. This reduction in mechanical stress contributes to extended equipment lifespan, reduced maintenance requirements, and improved reliability in industrial applications.
  7. Adaptability to Changing Conditions: Variator gearboxes offer adaptability to changing operating conditions. They allow for real-time adjustments in speed, which is particularly beneficial in applications where the load or process requirements vary. This adaptability enables industrial machinery to respond quickly to changing demands, ensuring optimal performance and efficiency in dynamic environments.

In summary, variator gearboxes provide benefits such as continuously adjustable speed control, optimized power efficiency, flexible torque transmission, smooth and precise control, improved system performance, reduced mechanical stress, and adaptability to changing conditions. These advantages make variator gearboxes valuable in various industrial applications, including manufacturing, material handling, packaging, robotics, and many others, where precise speed control and efficient power transmission are essential.

China manufacturer Udl0.55 Speed Variator, Speed Variable Gearbox   gearbox design		China manufacturer Udl0.55 Speed Variator, Speed Variable Gearbox   gearbox design
editor by CX 2023-10-09