%0 Journal Article
%T PROTOS 2C卷烟机牙嵌分段式涂胶辊轴的设计应用
Design and Application of Tooth-Embedded Segmented Glue Roller Shaft for PROTOS 2C Cigarette Maker
%A 许文豪
%A 周子存
%A 付寿华
%A 史云庆
%A 李新林
%J Instrumentation and Equipments
%P 136-145
%@ 2332-7006
%D 2025
%I Hans Publishing
%R 10.12677/iae.2025.132020
%X 针对PROTOS 2C卷烟机接装纸上胶组件频繁出现的涂胶辊传动连接销断裂及轴端螺纹段断裂问题，本研究通过结构优化与工艺改进提出系统性解决方案。首先，将传统销钉传动方式改进为6齿矩形牙嵌式连接，通过优化牙型参数(外径61 mm、内径46 mm、齿高6 mm)与均匀对称布局，在保留原螺母调整功能的同时显著提升传动强度与可靠性，经挤奶压应力校核(计算值1.21 MPa < 许用值20 MPa)满足使用需求。其次，创新设计可分离式涂胶辊轴端螺纹段结构，采用细牙螺纹配合紧定螺钉防松，实现局部易损件快速更换，避免整轴报废。同时，结合陶瓷热喷涂工艺对配合轴段进行表面强化(显微硬度90 HRC)，在提升耐磨性的同时减少淬火脆性影响。实施后，10台设备年故障维修时间减少1620分钟，新增产量折合经济效益176.37万元，节约维修成本1.0万元，故障率降为零。项目创新性体现于牙嵌传动的偶数齿适配性设计、轴端模块化结构及表面喷涂工艺优化，对同类卷接设备(如ZJ17、PROTOS M8等)具有显著推广价值，为高速精密机械的可靠性提升与维护成本控制提供了有效范例。
To address frequent failures of the glue roller transmission pin fracture and threaded shaft-end fracture in the tipping paper gluing unit of PROTOS 2C cigarette makers, this study proposes systematic solutions through structural optimization and process improvements. First, the traditional pin transmission is redesigned into a 6-tooth rectangular tooth-embedded connection. By optimizing tooth parameters (outer diameter 61 mm, inner diameter 46 mm, tooth height 6 mm) and symmetrical layout, the transmission strength and reliability are significantly enhanced while retaining the original nut adjustment function. Compressive stress verification confirms compliance with requirements (calculated value: 1.21 MPa < allowable value: 20 MPa). Second, an innovative separable threaded shaft-end structure is developed, utilizing fine-pitch threads and locking screws to enable rapid replacement of localized wear-prone components, avoiding full shaft scrapping. Additionally, ceramic thermal spraying is applied to strengthen the shaft’s surface (microhardness: 90 HRC), improving wear resistance while reducing brittleness caused by quenching. Post-implementation, annual fault repair time for 10 machines is reduced by 1620 minutes, generating additional output equivalent to ¥1.7637 million in economic benefits and saving ¥10,000 in maintenance costs, with failure rates dropping to zero. Innovations include even-tooth adaptation for tooth-embedded transmission, modular shaft-end design, and surface coating optimization. This approach holds significant value for similar cigarette makers (e.g. ZJ17, PROTOS M8) and provides an effective model for enhancing reliability and controlling maintenance costs in high-speed precision machinery.
%K PROTOS 2C卷烟机胶辊轴，
%K 轴端螺纹段断裂，
%K 牙嵌式连接，
%K 结构优化
PROTOS 2C Cigarette Machine Glue Roller Shaft
%K Fracture of the Threaded Section at the Shaft End
%K Hook-Type Connection
%K Structure Optimization
%U http://www.hanspub.org/journal/PaperInformation.aspx?PaperID=116486