动车组横向止挡防脱结构设计优化与可靠性验证

Design Optimization and Reliability Verification of the Anti-separation Structure of EMU Lateral Stop

通过对既有高速动车组二系横向止挡进行防脱结构设计、优化选型和可靠性验证,实现了其结构防脱功能,并显著提升其安全可靠性能。首先通过设计出不同的防脱结构型式,在结构设计、制造工艺、质量控制、实际运用和强度仿真等方面进行多维度的安全性对比分析,选出了最优防脱结构设计方案。然后试制出完全无粘接状态的最优防脱结构的样机,通过设计的剪切和疲劳防脱试验对新结构的防脱功能进行了充分的可靠性验证和效果评估。最后试制出合格的粘接状态的样机,并完成了防脱新结构的系列型式试验验证。结果表明,底座采用阶梯孔橡胶柱和摩擦板采用环形凹槽橡胶环的防脱结构在满足现有接口尺寸和性能要求的条件下,能够与原型产品进行对等替换,实现了结构防脱功能且大幅提升了安全可靠性。

The structural anti-separation function is realized and its safety and reliability performance are significantly improved by using antiseparation structural design,optimization selection and reliability verification of the secondary lateral stop of the existing high-speed EMU.First,the optimal anti-separation structural design scheme is selected by designing different anti-separation structure types and conducting a multi-dimensional safety comparative analysis regarding structural design,manufacturing process,quality control,practical application and strength simulation.Then,a prototype of the optimal anti-separation structure in a completely non-bonded state is produced,and the antiseparation function of the new structure is fully verified and evaluated through the designed shear and fatigue anti-separation tests.Finally,a prototype with qualified bonding status is produced,and a series of type test verifications of the new anti-separation structure are completed.The results show that the anti-separation structure using stepped hole rubber columns at the base and annular grooved rubber rings for the friction plate can be equivalently replaced with the existing product under the condition that the existing interface size and performance requirements are met,achieving the structural anti-separation function and greatly improved safety and reliability.