Simulation and test study on the dynamic performance of a double-branch toroidal worm helical gear reducer

WEI Bingyang; WU Jinhao; CHEN Chengyuan

doi:10.16578/j.issn.1004.2539.2026.06.001

Abstract：[Objective]Aiming at the demand for high reduction ratio,high rigidity and high power density in precision transmission,a double-branch zero-backlash toroidal worm helical gear mechanism was proposed.Tooth surface topology modification was adopted to improve the comprehensive curvature and load-bearing capacity of transmission pairs,and solve the problems of large backlash and insufficient dynamic stability in traditional worm helical gear transmission.[Methods]Firstly,a precise three-dimensional model of the reducer was established,and the finite element method was used to compare the equivalent stress and displacement distribution of the tooth surface before and after modification to determine the optimal topology modification parameters.Secondly,multi-body dynamic simulation was carried out using Adams software to analyze the dynamic response characteristics of the system under different rotational speeds and load conditions.Finally,a closed power flow reducer test bench was built,and vibration signals were collected through acceleration sensors to verify the dynamic performance of the double-branch mechanism.[Results]The results show that the bidirectional topology modification of tooth profile and helix can reduce the equivalent contact stress of the tooth surface by 18.2%,the strain by 24.5%,and the tooth root bending stress by 26.2%.The double-branch mechanism can significantly suppress the vibration response of the system,and the overall vibration acceleration amplitude is reduced by 25.09%compared with the single-branch mechanism.The test data have high consistency with the simulation results,which can provide a reference for the design of high-performance precision transmission devices.