基于运行工况的三峡升船机齿轮齿条载荷与润滑状态分析

Analysis of Load and Lubrication State of Racks and Pinions of Three Gorges Ship Lift Based on Actual Service Conditions

三峡升船机齿轮齿条属低速重载开式硬齿面齿轮传动,一旦润滑不良极易产生齿面胶合等损伤,影响升船机运行的安全性和可靠性。根据三峡升船机的实际运行数据,采用油膜厚度准则系统分析了各种典型工况下齿轮齿条的润滑情况,推导了匀速工况时船厢误载水深与膜厚比之间的关系,计算了典型误载水深下润滑状态最危险啮合点的膜厚比;确定了船厢变速时齿轮齿条最差的润滑状态,分析了变速运行典型工况下的润滑状态与船厢水深的相关关系,进一步确定了较易产生胶合损伤的位置。结果表明,升船机匀速运行时,厢内水位处于最佳水位时,齿轮齿条的润滑状态最好;偏离最佳水位时,膜厚比随误载水深呈λ∝±Δh^(-0.13)的幂函数形式下降;齿轮齿条处于最危险啮合点时,齿轮齿根与齿条齿顶相接触且在大误载水深下齿面间的润滑状态更为恶劣;升船机变速运动时,润滑状态较差的工况为船厢水深为3.6 m时的上行加速和下行减速;因齿条上齿面接触频率高、润滑状态较差,发生胶合损伤的风险更高。

The rack and pinion of the three gorges ship lift is a low speed and heavy load open gear transmission with hard tooth surface.Once the lubrication is poor,it is easy to cause damage such as tooth surface scuffing,which will affect the operation safety and reliability of the ship lift.This study is based on the actual operation data of the three gorges ship lift,and the lubrication of racks and pinions under various typical service conditions is systematically analyzed using the oil film thickness criterion.The relationship between the false water depth and the film thickness ratio in the ship compartment is deduced and the film thickness ratio of the lubrication state of the most dangerous meshing point under typical false water depth is calculated when the ship compartment is under constant speed.The worst lubrication condition of the rack and pinion is determined when the ship compartment is ascending and descending with variable speeds,and the relationship between the water depth in the ship compartment and the lubrication condition under variable speed typical operating conditions is analyzed.The position where the scuffing damage is more likely to occur is further determined.The results show that,when the ship lift is running at a constant speed,the lubrication state of the rack and pinion is the best under the optimum water depth in the ship compartment,and the film thickness ratio of the deviation from the optimal water level decreases with the power function λ∝±Δh^(-0.13)of the false water depth.When the rack and pinion is at the most dangerous meshing point,the root of the pinion and the top of the rack are in contact,and the lubrication condition between tooth surfaces is worse under large false water depth.When the ship lift moves at variable speeds,the working condition with poor lubrication condition is the upward acceleration and downward deceleration when the water depth of the ship chamber is 3.6 m.Due to the high contact frequency of the upper tooth surface on the rack and poor lubrication state,the risk of scuffing damage is higher.