Once the installation and disassembly sequence of the components on the shaft is established, the overall shape of the shaft can typically be determined. The general order of assembly is as follows: first, the central rotor component is installed, then placed into the housing. After that, the bearing end cap is mounted, followed by the bearing and outer bearing housing. Finally, the pulley and flywheel are attached to both ends.
The diameter of each segment of the shaft depends on the load it will carry. However, during the initial design phase, the exact location of the support forces and the distribution of bending moments may not yet be known. As a result, it’s not possible to determine the main shaft diameter based solely on the specific load and the resulting stress. Instead, the torque acting on the shaft is usually known early in the design process, so the initial diameter estimation is based on this torque value. It’s important to note that the minimum diameter calculated at this stage should be adjusted according to the structural requirements. Once the assembly plan and positioning needs are clear, the diameters of each individual shaft section can be determined step by step. Additionally, the shaft sections that accommodate bearings or standard components must use standard diameters, along with appropriate fit tolerances, especially for ball mill applications.
Determining the length of each shaft segment involves balancing compactness with the necessary space for assembly and adjustments. This includes considering the axial dimensions of mating parts such as the rotor, pulley, flywheel, and bearings, as well as ensuring proper clearance between adjacent components. Since the general dimensions of the rotor, flywheel, and pulley have already been designed, the overall length of the shaft can be estimated accordingly. Careful planning at this stage ensures that the final design is both functional and practical for real-world application.
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