有轨电车齿轮箱卡死故障分析及处理

Fault Analysis and Handling of Gearbox Stuck in Trams

齿轮箱是有轨电车转向架的关键零部件之一,其性能关乎车辆运营安全。文章针对有轨电车齿轮箱卡死故障,按照故障检查、原因分析、方案设计、仿真分析、试验验证过程,开展了齿轮箱拆解检查、润滑油成分检测、齿轮箱结构分析等研究工作,确定了齿轮箱卡死故障的原因为轴承外挡圈微动磨损发展至异常磨损,提出了提高齿轮箱轴承外挡圈耐磨性,增加小端盖压紧量的解决方案;通过有限元仿真分析确定了最小压紧量,并确认最大压紧量下各零部件满足强度要求,经过实物试验验证,原方案的轴承外挡圈发生转动和蓝油磨损,改进后的方案轴承外挡圈未发生转动和磨损,证明了齿轮箱卡死故障解决方案的可行性,并在现车上进行了装车验证,有效解决了齿轮箱卡死故障。文章中的分析方法和改进方案可为有轨电车齿轮箱从业人员提供参考。

The gearbox is one of the key components of the tram bogie,and its performance is related to the operation safety of the vehicle.For the tram gearbox stuck fault,this article carried out research work such as disassembly inspection of the gearbox,testing of lubricating oil composition,and structural analysis of the gearbox according to the process of fault inspection,cause analysis,scheme design,simulation analysis,and experimental verification;it is determined that the cause of the gearbox stuck fault is the abnormal wear developed by the micro-motion wear of the bearing outside collar,and the solution to improve the wear resistance of the gearbox bearing outer ring and increase the small end cap compression amount is proposed;the minimum pressing force is determined by finite element simulation analysis,and it is confirmed that the components meet the strength requirements under the maximum compression amount.Physical test verified that the bearing outer ring of the original solution was found to rotate with blue oil wear,while the bearing outer ring of the improved solution did not rotate and wear,which proved the feasibility of the solution to the gearbox stuck fault.Moreover,the solution effectively solved the gearbox stuck failure as verified by loading on the current vehicle.The analysis method and improvement program in this paper can provide reference for tram gearbox practitioners.