CMC-16道岔打磨车走行齿轮箱关键设计技术研究
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摘要
钢轨打磨列车是高速、重载铁路及城市轨道交通线路整修的重要技术装备。CMC-16道岔打磨车可以对各类线路进行连续打磨作业,消除钢轨的磨耗及其它各种局部缺陷。在钢轨打磨车走行传动系统中,走行齿轮箱是其关键核心部件,它的好坏能直接影响到打磨车使用的安全性、舒适性和操控性,打磨车车作业和高速走行均由它驱动。
我国现装车使用的打磨车齿轮箱,因设计不合理,齿轮箱性能低、可靠性差,故障率高。齿轮箱在运行时存在温度过高,换挡效率低、锁紧不可靠、换挡锁紧机构易损坏,润滑不充分及密封不可靠等问题,从而影响整车的使用效率。钢轨打磨车齿轮箱设计制造的关键技术一直是困扰我国钢轨打磨技术快速发展的重要因素。
本文以CMC-16道岔打磨车走行齿轮箱为主要研究对象。首先,对打磨车的总体技术参数、运用条件和齿轮箱的设计要求进行了综合研究分析,通过理论计算分析,对齿轮箱系统参数进行了设计,为进一步研究提供基础。
其次,结合我国钢轨打磨车齿轮箱的使用现状,针对CMC-16道岔打磨车走行齿轮箱的关键设计技术,从理论分析、计算和试验验证方面入手,分别对齿轮箱箱体、换挡锁紧机构、润滑系统、密封系统等关键设计技术进行了较为深入细致的研究分析和设计开发。优化了齿轮箱的综合性能,克服了现使用的打磨车齿轮箱所存在的弊病,提高了齿轮箱的可靠性。
最后,对本文设计开发的齿轮箱的润滑和密封性能,齿轮箱热负荷性能,齿轮箱强度和振动,换挡锁紧机构操纵性能等主要性能指标和设计计算正确性进行了试验验证。
通过本文的研究,克服了现使用的打磨车齿轮箱所存在的弊病,为今后相关领域进一步的研究工作打下了良好的基础。本文将设计、计算、建模、分析和试验验证一体的研究,对齿轮箱的设计水平和设计效率的提高具有重要意义。
Rail grinding vehicle is the importance technical equipment of high-speed,heavy railway and urban rail transit lines to repair. CMC-16 switch grinding vehicle can be a continuous grinding operation for various lines. Elimination the rail wear and various other local defects of rail. In transmission system of the rail grinding vehicle,the running gear box is its key core components of traveling system for the vehicle. Its performance can directly affect the safety,comfort and handling of the grinding vehicles. It is the driver of operation and high-speed running of the vehicle.
Nowadays,running gear box is loading rail grinding vehicle due to unreasonable design,there are many problems,the running gear box low performance,poor reliability,high failure rate. There are run-time temperature is too high,low efficiency in chang gear,locking is not reliable,shift locking mechanism easily is damaged,inadequate lubrication and seal is not reliable etc. Thus affected the use efficiency of the vehicle,it is difficult to meet customer needs. The key technology of rail grinding vehicle gear box design and manufacture,it is an important factor which has been troubled by the rapid development of rail grinding technology in our country. This article,running gear box used in CMC-16 switch grinding vehicle is the main object of study.
At first,here carried out a comprehensive study and analysis grinding vehicle on the overall technical parameters,the use of conditions and the gearbox design requirements,through theoretical calculation and analysis. System parameters on the gear box has been designed,it provide a basis for further study.
Second,combination the use of status quo of gear box used in rail grinding vehicle in china,for the key design techniques of running gear box for CMC-16 switch grinding vehicle. From the theoretical analysis,calculation and testing argumentation aspects. Respectively,research,analysis and design on the key design technology of its,such as box,shift locking mechanism,lubrication system, sealing system etc. Optimize the integrated performance and improve the reliability of the gear box. Overcome the shortcomings is exist to the gear box of grinding vehicle.
At last,the main design performance indicators of the design and development gear box were tested demonstration,such as,lubrication and seals systems proper- ties,heat load performance and libration of the gear box,box strength,maneuver- ability of the shift locking mechanism and design and calculation accuracy etc. Through this study,is used to overcome the exist many shortcomings of gearbox used in grinding vehicle and for future research in related fields to lay a good found- ation in the future.
This article merges the design,calculation,modeling,analysis and experimental verification into one study,which possesses an important meaning to raise the design standard and efficiencu of the gear box.
我国现装车使用的打磨车齿轮箱,因设计不合理,齿轮箱性能低、可靠性差,故障率高。齿轮箱在运行时存在温度过高,换挡效率低、锁紧不可靠、换挡锁紧机构易损坏,润滑不充分及密封不可靠等问题,从而影响整车的使用效率。钢轨打磨车齿轮箱设计制造的关键技术一直是困扰我国钢轨打磨技术快速发展的重要因素。
本文以CMC-16道岔打磨车走行齿轮箱为主要研究对象。首先,对打磨车的总体技术参数、运用条件和齿轮箱的设计要求进行了综合研究分析,通过理论计算分析,对齿轮箱系统参数进行了设计,为进一步研究提供基础。
其次,结合我国钢轨打磨车齿轮箱的使用现状,针对CMC-16道岔打磨车走行齿轮箱的关键设计技术,从理论分析、计算和试验验证方面入手,分别对齿轮箱箱体、换挡锁紧机构、润滑系统、密封系统等关键设计技术进行了较为深入细致的研究分析和设计开发。优化了齿轮箱的综合性能,克服了现使用的打磨车齿轮箱所存在的弊病,提高了齿轮箱的可靠性。
最后,对本文设计开发的齿轮箱的润滑和密封性能,齿轮箱热负荷性能,齿轮箱强度和振动,换挡锁紧机构操纵性能等主要性能指标和设计计算正确性进行了试验验证。
通过本文的研究,克服了现使用的打磨车齿轮箱所存在的弊病,为今后相关领域进一步的研究工作打下了良好的基础。本文将设计、计算、建模、分析和试验验证一体的研究,对齿轮箱的设计水平和设计效率的提高具有重要意义。
Rail grinding vehicle is the importance technical equipment of high-speed,heavy railway and urban rail transit lines to repair. CMC-16 switch grinding vehicle can be a continuous grinding operation for various lines. Elimination the rail wear and various other local defects of rail. In transmission system of the rail grinding vehicle,the running gear box is its key core components of traveling system for the vehicle. Its performance can directly affect the safety,comfort and handling of the grinding vehicles. It is the driver of operation and high-speed running of the vehicle.
Nowadays,running gear box is loading rail grinding vehicle due to unreasonable design,there are many problems,the running gear box low performance,poor reliability,high failure rate. There are run-time temperature is too high,low efficiency in chang gear,locking is not reliable,shift locking mechanism easily is damaged,inadequate lubrication and seal is not reliable etc. Thus affected the use efficiency of the vehicle,it is difficult to meet customer needs. The key technology of rail grinding vehicle gear box design and manufacture,it is an important factor which has been troubled by the rapid development of rail grinding technology in our country. This article,running gear box used in CMC-16 switch grinding vehicle is the main object of study.
At first,here carried out a comprehensive study and analysis grinding vehicle on the overall technical parameters,the use of conditions and the gearbox design requirements,through theoretical calculation and analysis. System parameters on the gear box has been designed,it provide a basis for further study.
Second,combination the use of status quo of gear box used in rail grinding vehicle in china,for the key design techniques of running gear box for CMC-16 switch grinding vehicle. From the theoretical analysis,calculation and testing argumentation aspects. Respectively,research,analysis and design on the key design technology of its,such as box,shift locking mechanism,lubrication system, sealing system etc. Optimize the integrated performance and improve the reliability of the gear box. Overcome the shortcomings is exist to the gear box of grinding vehicle.
At last,the main design performance indicators of the design and development gear box were tested demonstration,such as,lubrication and seals systems proper- ties,heat load performance and libration of the gear box,box strength,maneuver- ability of the shift locking mechanism and design and calculation accuracy etc. Through this study,is used to overcome the exist many shortcomings of gearbox used in grinding vehicle and for future research in related fields to lay a good found- ation in the future.
This article merges the design,calculation,modeling,analysis and experimental verification into one study,which possesses an important meaning to raise the design standard and efficiencu of the gear box.
引文
[1]张铭达,高速重载线路钢轨打磨方法优化研究[D],西南交通大学,2006
[2]金学松,杜星,郭俊,钢轨打磨技术研究进展[J],西南交通大学学报,第45卷第1期,2010.2,1-11
[3]贺振中,国外钢轨打磨技术的应用与思考[J],中国铁路,2000.10,38-40
[4]汪奕,钢轨打磨列车[M],北京:中国铁道出版社,2008.8,5-44页
[5]王文健,陈明韬,郭俊,高速铁路钢轨打磨技术及其应用[J],西南交通大学学报,第42卷第5期,2007.10,574-577
[6]晆小利,几种典型铁路大型养路机械车轴齿轮箱及换挡机构[J],设计与研究,2009.6,20-25
[7]刘晓利,DIN5480标准渐开线花键加工浅析[J],金属加工工艺,2009.9,30-31
[8]詹昭平,常宝印,明翠新,渐开线花键标准应用手册[M],北京:中国标准出版社,1997.5,19-24
[9]张兴旺,刘志奇,李永堂,渐开线花键的冷滚压精密成形工艺研究[J],电加工与模具,2009年增刊,52-54
[10]国家质量监督检验检疫总局.GB/T 17855-1999.花键承载能力计算方法.北京:中国标准出版社,2000
[11]周平,陈志芳,刘忠伟等,“先锋号”动力分散式高速电动车组驱动齿轮箱的开发[J],机车车辆工艺,2006.10,8-10
[12]曹晓龙,290马力轨道车机械换向分动箱设计[D],大连交通大学,2008
[13]周平,300km/h高速动力车车轴齿轮箱的研制[J],机车车辆工艺,2000.2,5-7
[14]陈秀宁,施高义,机械设计课程设计[M],杭州:浙江大学出版社,2001.10,60-66
[15]广州市科学技术经验交流馆,铸铁工艺[M],广州:广东省科学技术出版社,1978,69-101
[16]钟延志,曹占伦,刘东明,新编常用金属材料手册[M],北京:人民邮电出版社,2008.5,111-119
[17]叶荣茂,铸造工艺设计简明手册[M],北京:机械工业出版社,1997
[18]国家技术监督局.GB/T 3480-1997.渐开线圆柱齿轮承载能力计算方法.北京:中国标准出版社,1998
[19]国家质量监督检验检疫总局.GB/Z 6413.2-2003.渐开线圆柱齿轮胶合承载能力计算.北京:中国标准出版社,2004
[20] Jiang Q.Y., Function of Particle Size Distribution and Calculation Criterion of Reliability of Lubricating State in Rubbing Pairs. Chinese Jour. of Mech. Engr.1991,4(4):303-311
[21] Roylance B.J, Pocock G, Wear Study Through Particle Size Distribution. Wear,1983,90:113-147
[22]朱孝录,齿轮传动设计手册(第二版)[M],北京:化学工业出版社,2010.4,76
[23] SKF轴承综合型录[M],2003,52,606-607
[24]王文清,李魁盛,铸造工艺学[M],北京:机械工业出版社,2004,216-217
[25]刘宏梅,大功率矿用减速器箱体优化设计[D],辽宁工程技术大学,2006
[26]国家质量监督检验疫总局.GB/Z19414-2003/ISO/TR 13593:1999.工业用闭式齿轮传动装置.北京:中国标准出版社,2003
[27]黄智勇,高速列车传动齿轮箱的热平衡计算分析[D],上海交通大学,2007
[28]崔燕娟,QC485柴油机机体试验模态与有限元分析[D],江苏大学,2009
[29]彭军祥,齿轮减速箱可靠性有限元强度计算及分析[J],铁道建筑,2009.1,4-6
[30]张学亮,齿轮箱模态分析和结构优化方法研究[D],太原理工大学,2007
[31]李杰,王乐勤,1.5MW风力发电齿轮箱箱体的有限元分析[J],太阳能学报,2008.11,1438-1442
[32] Mrogado T L,Branco C M,Infante V.A failure study of housing of the gearbox of series2600 locomotives of the portuguese railway company. Engineering Failure Analysis,2007
[33]齐友军,杨高宏,基于ANSYS Workbench的齿轮箱体固有特性分析[J],煤矿机电,2009.1,40-42
[34]董进朝,大型风电齿轮箱关键设计技术研究[D],郑州机械研究所,2007
[35] H.Nahvi,M.JabbariCrack,Detection in beams using experiment modal data and finate element model.Intermational Journal of Mechanical Sciences,2005,(47):1477-1479
[2]金学松,杜星,郭俊,钢轨打磨技术研究进展[J],西南交通大学学报,第45卷第1期,2010.2,1-11
[3]贺振中,国外钢轨打磨技术的应用与思考[J],中国铁路,2000.10,38-40
[4]汪奕,钢轨打磨列车[M],北京:中国铁道出版社,2008.8,5-44页
[5]王文健,陈明韬,郭俊,高速铁路钢轨打磨技术及其应用[J],西南交通大学学报,第42卷第5期,2007.10,574-577
[6]晆小利,几种典型铁路大型养路机械车轴齿轮箱及换挡机构[J],设计与研究,2009.6,20-25
[7]刘晓利,DIN5480标准渐开线花键加工浅析[J],金属加工工艺,2009.9,30-31
[8]詹昭平,常宝印,明翠新,渐开线花键标准应用手册[M],北京:中国标准出版社,1997.5,19-24
[9]张兴旺,刘志奇,李永堂,渐开线花键的冷滚压精密成形工艺研究[J],电加工与模具,2009年增刊,52-54
[10]国家质量监督检验检疫总局.GB/T 17855-1999.花键承载能力计算方法.北京:中国标准出版社,2000
[11]周平,陈志芳,刘忠伟等,“先锋号”动力分散式高速电动车组驱动齿轮箱的开发[J],机车车辆工艺,2006.10,8-10
[12]曹晓龙,290马力轨道车机械换向分动箱设计[D],大连交通大学,2008
[13]周平,300km/h高速动力车车轴齿轮箱的研制[J],机车车辆工艺,2000.2,5-7
[14]陈秀宁,施高义,机械设计课程设计[M],杭州:浙江大学出版社,2001.10,60-66
[15]广州市科学技术经验交流馆,铸铁工艺[M],广州:广东省科学技术出版社,1978,69-101
[16]钟延志,曹占伦,刘东明,新编常用金属材料手册[M],北京:人民邮电出版社,2008.5,111-119
[17]叶荣茂,铸造工艺设计简明手册[M],北京:机械工业出版社,1997
[18]国家技术监督局.GB/T 3480-1997.渐开线圆柱齿轮承载能力计算方法.北京:中国标准出版社,1998
[19]国家质量监督检验检疫总局.GB/Z 6413.2-2003.渐开线圆柱齿轮胶合承载能力计算.北京:中国标准出版社,2004
[20] Jiang Q.Y., Function of Particle Size Distribution and Calculation Criterion of Reliability of Lubricating State in Rubbing Pairs. Chinese Jour. of Mech. Engr.1991,4(4):303-311
[21] Roylance B.J, Pocock G, Wear Study Through Particle Size Distribution. Wear,1983,90:113-147
[22]朱孝录,齿轮传动设计手册(第二版)[M],北京:化学工业出版社,2010.4,76
[23] SKF轴承综合型录[M],2003,52,606-607
[24]王文清,李魁盛,铸造工艺学[M],北京:机械工业出版社,2004,216-217
[25]刘宏梅,大功率矿用减速器箱体优化设计[D],辽宁工程技术大学,2006
[26]国家质量监督检验疫总局.GB/Z19414-2003/ISO/TR 13593:1999.工业用闭式齿轮传动装置.北京:中国标准出版社,2003
[27]黄智勇,高速列车传动齿轮箱的热平衡计算分析[D],上海交通大学,2007
[28]崔燕娟,QC485柴油机机体试验模态与有限元分析[D],江苏大学,2009
[29]彭军祥,齿轮减速箱可靠性有限元强度计算及分析[J],铁道建筑,2009.1,4-6
[30]张学亮,齿轮箱模态分析和结构优化方法研究[D],太原理工大学,2007
[31]李杰,王乐勤,1.5MW风力发电齿轮箱箱体的有限元分析[J],太阳能学报,2008.11,1438-1442
[32] Mrogado T L,Branco C M,Infante V.A failure study of housing of the gearbox of series2600 locomotives of the portuguese railway company. Engineering Failure Analysis,2007
[33]齐友军,杨高宏,基于ANSYS Workbench的齿轮箱体固有特性分析[J],煤矿机电,2009.1,40-42
[34]董进朝,大型风电齿轮箱关键设计技术研究[D],郑州机械研究所,2007
[35] H.Nahvi,M.JabbariCrack,Detection in beams using experiment modal data and finate element model.Intermational Journal of Mechanical Sciences,2005,(47):1477-1479
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