90度交錯軸螺旋齒輪廣泛應用於電路板與顯示器面板製程之傳送滾輪之傳動系統，然而大多設備廠商皆使用45度螺旋角之傳統漸開線圓柱型螺旋齒輪組作為90度交錯軸之螺旋齒輪，產生的問題為接觸齒印過小、高接觸應力、高磨耗與低使用壽命，齒輪磨耗及破壞並會導致電路版製程良率及產能降低。本研究首先將基於齒輪嚙合原理與刀具幾何，基於90度交錯軸之共軛齒形理論，推導具共軛齒型之90度交錯軸螺旋齒輪理想齒面幾何。接著以塑膠齒輪之材料性質、熱膨脹係數及剛性等，並考慮組裝誤差、齒面接觸應力、滑動速度與齒根強度等條件，以最佳化演算法搭配自行發展之齒面接觸分析程式、齒印程式與有限元素分析，探討具最大接觸齒印且不具干涉的塑膠90度交錯軸螺旋齒輪，提供廠商作為射出成形模具之參考依據。並將打樣原型進行齒印實驗，驗證模擬結果的正確性。本研究預期將設計出對組裝誤差不敏感且具較低磨耗之90度交錯軸塑膠螺旋齒輪，將可大幅提升電路板製程輸送滾輪設備之穩定性與壽命。 ;Crossed-axis helical gear with 90-degree crossing angle are widely used in the transmission module for printed circuit board (PCB) and display panel manufacturing facilities. However, involute cylindrical helical gears 45-degree helix angle are used in most of the transmission applications. The resulting drawbacks includes small contact area, high contact stress, high tooth wear and low service life of these helical gears.In this research project, first, the conjugate tooth profile for crossed-axis helical gear with 90-degree crossing angle will be developed based on the theory of gearing and tool geometry. The material properties of industry plastics, thermal expansion and stiffness will be considered along with the assembly conditions, contact stress, sliding velocity and toot bending stress. Computer programs capable of tooth contact analysis, contact pattern calculation as well as finite element analysis will be conducted for the helical gear design. An optimization approach will then be applied to achieve an optimum tooth profile for the plastic helical gear with 90-degree crossing angle, exhibiting large contact ellipses and no interference. Finally, a prototype of the optimum crossed-axis helical gear with 90-degree crossing angle will be made and tested for the contact patterns to verify the simulation results.This research will result in an optimum design for crossed-axis helical gear with 90-degree crossing angle, and the outcome will be beneficial for the PCB manufacturing industry.
