0534-液力傳動變速箱設計與仿真
0534-液力傳動變速箱設計與仿真,傳動,變速箱,設計,仿真
液力傳動變速箱設計與仿真
摘要
本課題是設計一個液力傳動變速箱，液力傳動變速箱是汽車中的驅動設備，廣泛的應用于叉車、牽引車、挖掘車等工業(yè)車輛中。根據本次設計的的要求，本論文是一個驅動60噸的液力傳動變速箱設計過程。液力傳動變速箱主要由變速箱、液力變矩器、油泵總成與主調壓閥和溢流閥組件、操縱閥組件、離合器和液壓控制等部分組成。由液力變矩器提供轉矩和具有前進二檔、后退二檔共四個檔位的動力換檔變速箱，液力傳動變速箱采用單級二相三工作輪綜合式液力變矩器。液力變矩器使該液力傳動變速箱具有液力傳動輸出的自動適應性，能隨著外負載的變化而相應改變其輸出扭矩和轉速，而且要求能夠吸收和消除來自發(fā)動機和外負載對傳動系統(tǒng)的沖擊振動。所采用的換檔方式要求操縱簡單、方便，起動平穩(wěn)，較大地減輕操作者勞動強度。
本課題通過液力傳動變速箱主要參數的設計，用三維設計軟件Pro/E來實現(xiàn)液力傳動變速箱的零部件造型和整機造型。在液力傳動變速箱設計過程中，在投入生產之前利用計算機進行裝配仿真，及時糾正設計中的不足。
關鍵字：液力傳動變速箱；液力變矩器；離合器；操縱閥
The Liquid Dint Spread To Move To Become Soon a Box a Design With Imitate True
ABSTRACT
This topic is a design a liquid dint spread to move to become soon a box, the liquid dint spread to move to become soon a box is in the car of drive an equipments, extensive of application at the fork car, lead a car and scoop out a car etc. industry vehicle in.According to this time design of of request, this thesis is soon a the liquid dint which drive 60 tons to spread to move to become box design process.The liquid dint spread to move to become soon a box main from become soon the box, liquid dint change Ju machine, oil pump total become with lord adjust to press valve and overflow to flow valve module and manipulate valve module, clutch and liquid to press control etc. part constitute.From the liquid dint change the Ju machine provide to turn Ju and have to go forward two files, retreat two files' motive of four total file shift gear to become soon a box, the liquid dint spread to move to become soon a box an adoption list class two mutually three work round comprehensive type liquid the dint change Ju machine.The liquid dint change the Ju machine make that liquid dint spread to move to become soon the box have liquid dint to spread to move output's auto adaptability, ability along with outside load of variety but correspond change it output twist Ju and turn soon, and request can absorb and cancellation come from launching machine and outside load to spread to move system of pound at vibration.Adoption of shift gear a way request to manipulate simple, convenience, start steady, compare the earth ease operation labor strength.
This topic through a liquid dint spread to move to become a box the design of the main parameter soon, use 3D design the software Pro/E come to realization liquid the dint spread to move to become soon zero parts shape and the whole machine shape of box.In the liquid dint spread move become soon the box the design the process, at devotion produce before make use of the calculator carry on assemble to imitate true, rectify a design in time in of shortage.
Keywords: The Liquid Dint Spread To Move To Become Soon A Box;Become Soon Box;The Liquid Dint Change Ju Machine;Clutch;Manipulate valve
II
目 錄
1 緒論 1
1.1 研究的目的和意義 1
1.2 本課題的主要研究內容 1
1.3 國內外研究現(xiàn)狀 2
1.3.1 發(fā)展概述 2
1.3.2 液力傳動變速箱的技術發(fā)展趨勢 2
2 總體方案的設計 3
2.1 液力傳動變速箱概述 3
2.2 主要技術參數 3
2.3 工作原理 3
2.4 結構介紹 4
2.4.1 變速箱 4
2.4.2 液力變矩器 4
2.4.3 油泵總成 4
2.4.4 主調壓閥、溢流閥部件 5
2.4.5 操縱閥部件 5
2.4.6 離合器 5
2.5 變速箱的三維建模及運動仿真 5
2.6 變速箱使用注意事項 5
2.7 本章小結 6
3 變速箱設計 7
3.1 變速箱傳動方案設計 7
3.2 前進檔設計 8
3.2.1 前進擋概述 8
3.2.2 前進擋檔數的確定 8
3.2.3 前進擋齒輪設計 8
3.2.4 齒輪強度計算方法概述 9
3.2.5 前進擋軸的設計 9
3.3 倒檔設計 10
3.3.1 倒檔概述 10
3.3.2 倒檔零件設計 11
3.4 剎車檔設計 11
3.5 變速箱總體結構 12
3.6 本章小結 12
4 液力變矩器設計 13
4.1 液力變矩器概述 13
4.2 液力變矩器的結構與工作原理 13
4.3 液力變矩器的設計計算 14
4.3.1 液力變矩器的轉矩功率計算 14
4.3.2 液力變矩器循環(huán)圓設計 14
4.3.3 液力變矩器葉片設計 15
4.3.4 液力變矩器各種性能及其評價 15
4.4 液力變矩器的冷卻裝置設計 16
4.5 本章小結 16
5 液壓傳動部分設計 17
5.1 液力傳動變速箱油路原理 17
5.2 油泵總成設計 17
5.3 主調壓閥、溢流閥部件 18
5.4 本章小結 19
6 離合器（專題部分） 20
6.1 引言 20
6.2 離合器的功能與要求 21
6.3 離合器的結構方案的確定 21
6.3.1 摩擦離合器的基本組成和工作原理 21
6.3.2 離合器的結構方案分析 22
6.4濕式多片式液力離合器的結構與工作原理 26
6.4.1 結構介紹 26
6.4.2 工作原理 27
6.5 前進離合器的設計與計算 29
6.5.1 離合器的基本參數和主要尺寸的選擇 29
6.5.2 從動盤的設計 31
6.5.3 壓盤設計 32
6.5.4 壓緊彈簧的設計計算 33
6.5.5 扭轉減振器的設計 34
6.6倒檔離合器的設計與計算 35
6.6.1 倒檔離合器基本參數的選擇 35
6.6.2 從動盤的設計 36
6.6.3 壓盤設計 37
6.6.4 壓緊彈簧的設計計算 38
6.6.5 扭轉減振器的設計 38
6.7 本章小結 39
7 操縱閥組件（專題部分） 40
7.1 離合器操縱機構介紹 40
7.2 操縱閥原理簡介 41
7.3 操縱閥結構設計 41
7.4 本章小結 44
8 變速箱的三維動態(tài)仿真 45
8.1 PRO/E軟件介紹 45
8.2 變速箱三維模型的建立 45
8.3 變速箱的動態(tài)仿真 46
8.3.1 機構模塊簡介 46
8.3.2 總體界面及使用環(huán)境 46
8.3.3 機械設計模塊的分析流程 46
8.3.4 機械設計運動分析詳解 47
8.3.5 運行分析 47
8.3.6 齒輪從動連接 47
8.3.7回放 47
8.4 三維模型轉換為工程圖 48
8.4.1 圖樣轉換的實現(xiàn) 48
8.4.2 變速箱各部分工程圖 48
8.5 本章小結 50
9 總結 51
謝 辭 52
參考文獻 53
附 錄 54
附錄A： 54
附錄B： 59
附 錄
附錄A：
The United States The Allison Liquid Dint Spread To Move To Become Soon A Box An Examination Experiment The Set Develop With Application
Abstract: Article analysis Allison in the United States become soon box structure, work principle and function characteristics, developped liquid dint to spread to move to become soon box examination experiment set, introduction become soon box big fix to solve in the process of key problem.
Keywords: The Allison become soon box; The examination experiment Taiwan; Develop; Application
1. Introduction
Along with society economy of fly soon development, the liquid dint spread to move to become soon a box gradual replaced a machine type to spread move of common become soon box.According to investigate, the United States Alli2 son etc. the liquid dint spread to move to become soon box market dosage very big, but its price be expensive, structure complications, fix a technique content Gao, break down judgment difficulty big, and still demand examination experiment the pedestal arouse operation, examination the liquid dint spread to move to become soon a box of hydraulic-pneumatic, turn soon, temperature etc., acceptance various technique parameter, judgment expel break down.But want to purchase a set an examination an equipments demand investment more than 10000 dollars 200.For the sake of economy availably exaltation the liquid dint spread to move to become soon a box to fix speed and quality and expand big northwest of fix a market, long celebrate petroleum to investigate to explore a bureau three service center machine of the oil extraction techniques to maintain station by oneself design manufacturing the ZF, Allison liquid dint spread to move to become soon a box examination experiment set etc. the work pack an equipments, and devotion the liquid dint spread to move to become soon a box fix usage medium;Development Germany ZF, the United States the Allison liquid dint spread to move to become soon a box to fix a craft technique, success fixed ZF, Allison to become box soon take burden examination experiment empress install to fix well on board devotion fix well usage.
The United States the Allison liquid dint spread to move to become soon a box examination experiment develop of pedestal, make the liquid dint after fix spread to move to become soon the box can pass examination experiment the pedestal take burden examination experiment, acceptance technique parameter, judgment expel break down, analysis application effect etc..Request develop of the liquid dint spread to move to become soon a box examination experiment set in time accurately reflection quilt examination the liquid dint spread to move to become soon a box of each item technique parameter, include examination acceptance various block one hydraulic-pneumatic, lubricate hydraulic-pneumatic, turn soon, torque, temperature etc. technique parameter, judgment expel difference ring, reveal a clutch, make to move a machine, clutch dozen slippery, return to a can not compare with etc. break down.For making the liquid dint spread to move to become soon box examination experiment set design reasonable, insure big fix examination to experiment behind of the liquid dint spread to move to become soon a box work steady, function stability, safety credibility, we first research the liquid dint spread to move to become soon the structure, function of the box and work principle.
2 Become soon box structure and work principle
Allison in the United States become soon the box be main from change to twist a machine and shut lock clutch, planet wheel gear and clutch, liquid dint gearbox to constitute.
(1).Change to twist a machine: From the pump round, turbine, lead a round to constitute a circulation circle system, liquid in proper order pass circulation to flow.Pump round from launch machine to drive, is a motive importation component.The turbine is through liquid dint spread to move by the pump round, is a power output component.The function which lead a round lead to flow and enlarge to twist Ju.The gearbox provide an oil pump continuously to change the Ju machine provide oil and make to change Ju machine work, increment launch machine of output twist Ju.The oil which pass to change a Ju machine to eject take calories of change the Ju machine.
Liquid from pump by turn go into turbine change direction.Leading a round will from the turbine run off of oil through oil way change direction empress again inflow pump round, so lead a round to be subjected to an adverse effect twist Ju.Turbine and pump round twist Ju ratio for change Ju ratio, with turn of turbine and pump round soon ratio lower but enlarge, with output turn soon of exaltation, change Ju ratio lower.Passing to change a Ju machine, outputting to turn soon can have no class variety, drive to twist Ju auto the orientation need of load twist Ju.When the turbine turn to soon attain a pump to rotate soon of the turbine twist Ju to equal pump round to twist Ju and change at this time Ju machine equal to 1 accidentally match a machine.
When the car soon go up, change Ju ratio close 1, and lead dint to no longer enlarge, shut lock clutch auto shut lock.
(2).Shut lock clutch(CT type and CBT type excepted):be the turbine go up certain turn soon, liquid pressure auto pair of pump round and turbine lock live.Become soon while shut the function of lock clutch box importation stalk of turn soon with launch machine homology.
(3)Planet wheel gear and clutch:The four sets of planet row's wheel gear's creation is five headway file and 1 to pour file.The planet wheel gear manipulate through six clutch that the liquid press a coalescence.All wheel gear for often the Nie match type.
(4)Liquid dint gearbox:CBT and CLBT754 type become soon the box have liquid dint gearbox.Liquid dint gearbox top have a take leaf's slice of turn son and two take leaf's slice of settle son to constitute.
(5) Block and coalescence clutch:
Empty block:one file clutch, 2 file clutches.
Go forward file:one file and one file clutch, 2 files and 2 file clutches, 3 files and 3 file clutches, 4 files and 4 file clutches, 5 files and 5 file clutches.
Pour file:5 file with one file clutch, 5 files with 2 file clutches.
3.The liquid dint spread to move to become soon a box a function characteristics
In the equal work under the condition, with common become soon the box compare, usage the liquid dint spread to move to become soon a box can stanza oil 5% ～ be 22%.And operation simple, usage convenience, function credibility.Launch machine and spread service life of move the system and launch the motive, economy of the machine and the safety function effect of the vehicle equipments to show Zhao very to the exaltation.The Allison liquid dint in the United States spread to move to become soon a box a which is 1 kind to be located on motive machine and work machine of take liquid as a work to lie the fluid of quality to spread to move a machine, and according to load power of variety to realization become soon.In the meantime, according to material of demand can allocation cent move a box brief name Christian Trinity box.Control part at will sex be strong, can constitution the machine control, electricity control, spirit control, the liquid control system and equip.Can according to need constitution to realization auto become soon.Its adaptability is strong and also to have to lead to carry protection function etc..BE exactly because of this kind of many precious characteristics which spread to move part to have in spread moving function, make it get day by day extensive of application.And regardless it application of a realm still its product sale, all increase with each passing day of trend, its development foreground very vast.
4.The liquid dint spread to move to become soon a box examination to experiment a set to develop
For the exaltation liquid dint spread to move to become a fix of box speed soon, insure to fix quality, we developped liquid dint to spread to move to become soon box examination experiment set etc. the work equip have.
4.1 whole conceive outline a design
Owing to drive examination the liquid dint spread to move to become soon a box a control part at will sex be strong, as a result can constitution become electricity to control, the liquid control, spirit control or machine control.It's equipments' turn to is main examination pressure, we acquired necessary material locally design total size is long 3. 65 m, breadth 0. 7 m, Gao 1. The liquid dint with 9 m spread to move to become soon a box examination to experiment Taiwan.Be suitable for to install examination Allison or ZF etc. various size, model number dissimilarity of the liquid dint spread to move to become soon a box.
4.2 control systems and work principle
In the liquid dint spread to move to become a box an examination soon experiment pedestal control plank operation on the stage constitution six big control system:power supply control system, SVF(change the Pin adjust soon) control the system, liquid press control system, ZF control system, Allison control system, load regulate system, gather electricity to control, the liquid control, spirit control, the machine control for the integral whole, examination the function be well-found, shape beauty, operation simple, try movement safety credibility.
① Power supply control system:the control change the Pin adjust soon a machine, electrical engineering, liquid to press and the ZF, Allison etc. be each control the power supply need by system.
② SVF(change the Pin adjust soon) control system:main from SVF- 400 change the Pin adjust soon a machine to constitute, control 55 kW,
The electrical engineering of 2950 r/ min turn soon, make the electrical engineering turn to can arbitrarily regulate soon in the provision turn soon the scope, the realization become soon box dissimilarity block a become of soon.Turned soon watch to is clear at a glance at any time a reflection the dissimilarity of the electrical engineering to turn soon.
③ Liquid press control system: is become soon box auto encourage, change oil system, can also seal completely inside examination clutch whether piece reveal or not.It is pressed four valve, 4 KW electric motor, fuel tank, liquid of pump, 3 by the liquid to press pipeline's etc. to constitute.Hydraulic-pneumatic plank
Top of oil pressure gauge clearly reflection block one hydraulic-pneumatic hydraulic-pneumatic with system.
④ ZF control system:main become for the control ZF box soon block of conversion, design a set of procedure.
⑤ Allison: The HT750 Allison in DR the United States become soon the box have 7 to block, namely D5, D4, D3, D2, D1, N, R.According to generator load the variety of the power realization become soon become of box soon.
⑥ Load control system:main examination become soon box of output power, from power form, load control the cabinet, generator...etc. constitute.
⑦ Spirit road and oil road control:spirit the road is soon main control to become the box shift gear organization, oil road control become soon box of performance organization, be also rub slice with make to move a combine of machine or separate.
5 Conclusion:The Allison become soon the box be big to fix to solve in the process of key problem
The well next three company HT750 DR the United States the Allison become soon the box pass disintegration check detection existence the following problem:
(1)Note the oil pump drive a wheel gear dozen to drop, the metals end drop into become soon box oil bottom hull;1- 5 file clutches rub a slice to wear away;Shut the lock clutch rub a slice to wear away.We will can't repair of note oil pump, push bearings, lead bridge wheel gear and bearings, drive wheel gear and all rub slice, seal completely a piece and filter Xin to carry on replace, assemble each cent total become again construction become become soon box.Put clean become soon box oil, tie up good the outside Lou oil way, use fix fix steady.Will become soon box total become install to arrive an examination experiment on the stage, press test the norm carry on adjusting to try and come to an index sign request.Make to move a machine work normal, just like ring, reveal, success devotion fix well usage.
(2) The well next two company fix Allison in DR the United States of the well machine HT750 to become soon box temperature to lead Gao, pressure lead low.At the disintegration install to fix well after fix on board, change the Ju machine leak oil till° to launch the machine flywheel hull body, make to launch the machine flywheel hull oil to go up, the pressure go up and result in flywheel hull the oil seal leak oil.Because leak oil to several times dismantle to unload a check just
Detection this set become soon change of box the Ju machine outer shell crack.Get on the car after re- welding
The bed process good, break down can expel.
(3) Fix the company CLT754 especially the United States the Allison become soon box disintegration check hour detection problem being more: Note an oil pump wheel gear loose bearings in the Kuang damage;Two file pistons sell pillar to break Sun 1;Medium the seniority star wheel gear loose mineral;Turn soon a form stalk head to wear away;Shut lock backboard and(rhombus) key wear away;The principal axis(take a wheel gear flower key) stalk head wear away;Take dint bearings, shut a lock to rub a slice and each go forward file steel slice, rub slice, seal completely a piece damage.We replace medium seniority star total become etc. total become piece or accessories 91, processed repair to note an oil pump total become, principal axis, flywheel total become, shut lock backboard, one file piston etc., expel break down, solved existence of problem.Construction adjust to try to complete, send produce to front install to fix well on board devotion fix well usage.
(4) Well's descending the two greatest brigades CLT754 the United States Allison to become soon a box speed is soonlow, temperature Gao, shut lock clutch dozen slippery, rub slice and steel slice wear away.Pass to dismantle each file of check detection friction slice and steel slice, seal completely a piece and push dint bearings damage.We replaced to seal completely a piece big fix pack, each file rub slice and steel slice, push bearings' etc. is 68, construction adjust to try to complete, install to fix well on board devotion fix well usage.
附錄B：
美國Allison 液力傳動變速箱檢測試驗臺研制與應用
摘要: 文章分析了美國Allison 變速箱結構、工作原理及性能特點,研制了液力傳動變速箱檢測試驗臺,介紹了變速箱大修過程中解決的主要問題。
關鍵詞: Allison 變速箱; 檢測試驗臺; 研制; 應用
1 引言
隨著社會經濟的飛速發(fā)展 ,液力傳動變速箱逐漸取代了機械式傳動的普通變速箱。據調查，美國Allison 等液力傳動變速箱市場用量很大 ,但其價格昂貴、結構復雜、修理技術含量高、故障判斷難度大 ,而且還需要檢測試驗臺帶動運轉 ,檢測液力傳動變速箱的油壓、轉速、溫度等 ,錄取各種技術參數 ,判斷排除故障。而要購買一臺檢測設備需要投資200 多萬元。為了經濟有效地提高液力傳動變速箱修理速度和質量 ,開拓大西北的修理市場 ,長慶石油勘探局第三采油技術服務處機械維修站自行設計制造了ZF 、Allison 液力傳動變速箱檢測試驗臺等工裝設備 ,并投入了液力傳動變速箱修理使用中;開發(fā)了德國ZF 、美國Allison 液力傳動變速箱修理工藝技術 ,成功修理了ZF 、Allison 變速箱 ,帶負荷檢測試驗后安裝到修井機上投入了修井使用。
美國Allison 液力傳動變速箱檢測試驗臺的研制 , 使修理后的液力傳動變速箱能夠通過檢測試驗臺帶負荷檢測試驗 ,錄取技術參數、判斷排除故障,分析應用效果等。要求研制的液力傳動變速箱檢測試驗臺及時準確地反映被檢測液力傳動變速箱的各項技術參數 , 包括檢測錄取各種擋位油壓、潤滑油壓、轉速、扭力、溫度等技術參數 ,判斷排除異響、泄露離合器、制動器、離合器打滑、回位不及時等故障。為了使液力傳動變速箱檢測試驗臺設計合理 ,確保大修檢測試驗后的液力傳動變速箱工作平穩(wěn)、性能穩(wěn)定、安全可靠 ,我們首先研究了液力傳動變速箱的結構、性能及工作原理。
2 變速箱結構及工作原理
美國Allison 變速箱主要由變矩器、閉鎖離合器、行星齒輪和離合器、液力變速器組成。
（1）變矩器: 由泵輪、渦輪、導輪組成一個循環(huán)圓系統(tǒng) ,液體順序通過循環(huán)流動。泵輪由發(fā)動機驅動 ,是動力輸入元件。渦輪由泵輪經過液力傳動 ,是動力輸出元件。導輪的作用是導流 ,增大扭矩。變速器的供油泵不斷向變矩器供油,使變矩器工作 ,增加發(fā)動機的輸出扭矩。通過變矩器排出的油帶走變矩器的熱量。
液體由泵輪流入渦輪改變方向。導輪將從渦輪流出的油經油道改變方向后再流入泵輪 ,因此導輪受一反作用扭矩。渦輪與泵輪扭矩比為變矩比,隨渦輪與泵輪的轉速比降低而增大 ,隨輸出轉速的提高,變矩比降低。通過變矩器 ,輸出轉速可無級變化 ,驅動扭矩自動適應所需的負載扭矩。當渦輪轉速達到泵輪轉速的渦輪扭矩等于泵輪扭矩 ,此時變矩器相當于一個偶合器。
當車速升高,變矩比接近 1 ,且牽引力不再增大時,閉鎖離合器就自動閉鎖。
（2）閉鎖離合器（CT型和CBT型除外）:當渦輪升高到一定轉速時,液壓力自動把泵輪和渦輪鎖住。在閉鎖離合器的作用下 ,變速箱輸入軸的轉速和發(fā)動機相同。
（3）行星齒輪和離合器：四組行星排齒輪產生五個前進檔和一個倒檔。行星齒輪通過六個液壓接合的離合器操縱。全部齒輪為常嚙合式。
（4）液力變速器:CBT和CLBT754 型的變速箱裝有液力變速器。液力變速器上有一個帶葉片的轉子和兩個帶葉片的定子組成。
(5) 擋位和接合離合器:
空擋:1檔離合器、2檔離合器。
前進檔:1檔和 1檔離合器、2 檔和 2檔離合器、3檔和 3 檔離合器、4 檔和4檔離合器、5檔和5檔離合器。
倒檔:5 檔和 1 檔離合器、5 檔和2 檔離合器。
3.液力傳動變速箱性能特點
在同等工況下 ,與普通變速箱相比,使用液力傳動變速箱可節(jié)油5 %～22 % 。而且操作簡單 ,使用方便 , 性能可靠。對提高發(fā)動機以及傳動系統(tǒng)的使用壽命、發(fā)動機的動力性、經濟性和車輛設備的安全性能效果十分顯著。美國Allison 液力傳動變速箱是一種位于動力機與工作機之間的以液體為工作介質的流體傳動機械 ,并根據負載功率的變化來實現(xiàn)變速。同時,根據裝備的需要可配置分動箱 簡稱三位一體箱子。控制部分隨意性強,可設置機控、電控、氣控、液控系統(tǒng)及裝置?？砂葱枨笤O置來實現(xiàn) 自動變速。它本身適應性強,還具備了過載保護性能等。正是由于這種傳動部分在傳動性能上具有的諸多寶貴特點,使之得到了日益廣泛的應用。而且無論其應用的領域還是其產品銷售方面 ,都有與日俱增的趨勢 ,其發(fā)展前景頗為廣闊。
4.液力傳動變速箱檢測試驗臺研制
為提高液力傳動變速箱的修理速度,確保修理質量,我們研制了液力傳動變速箱檢測試驗臺等工裝設備。
4. 1 整體構思設計
鑒于被檢測液力傳動變速箱控制部分隨意性強,因而可設置成電控、液控、氣控或機械控制。該設備主要檢測壓力,我們就地取材設計了總體尺寸為長3. 65m、寬0. 7 m、高1. 9 m 的液力傳動變速箱檢測試驗臺。適于安裝檢測Allison 或ZF 等各種大小、型號不同的液力傳動變速箱。
4. 2 控制系統(tǒng)及工作原理
在液力傳動變速箱檢測試驗臺控制板操作臺上設置了六大控制系統(tǒng):電源控制系統(tǒng)、SVF (變頻調速) 控制系統(tǒng)、液壓控制系統(tǒng)、ZF 控制系統(tǒng)、Allison 控制系統(tǒng)、負載調節(jié)系統(tǒng),集電控、液控、氣控、機控為一體,檢測功能齊全、外形美觀、操作簡便,試運行安全可靠。
①電源控制系統(tǒng):控制變頻調速器、電機、液壓、ZF、Allison 等各控制系統(tǒng)所需的電源。
②SVF(變頻調速)控制系統(tǒng):主要由SVF - 400變頻調速器組成,控制55 kW、2950 r/ min的電機轉速,使電機在規(guī)定轉速范圍內轉速可以任意調節(jié),實現(xiàn)變速箱不同擋位的變速。轉速表一目了然隨時反映了電機的不同轉速。
③液壓控制系統(tǒng):是變速箱自動加油、換油系統(tǒng),也可檢測離合器內密封件是否泄露。由液壓泵、三位四通閥、4KW電動機、油箱、液壓管線等組成。油壓板上的油壓表清晰地反映了擋位油壓和系統(tǒng)油壓。
④ZF 控制系統(tǒng):主要為控制ZF變速箱擋位的轉換,設計了一套程序。
⑤Allison 控制系統(tǒng): HT750DR 美國Allison 變速箱有七個擋位,即D5 、D4 、D3 、D2 、D1 、N、R。根據發(fā)電機負載功率的變化實現(xiàn)變速箱的變速。
⑥負載控制系統(tǒng):主要檢測變速箱的輸出功率,由功率表、負載控制柜、發(fā)電機等組成。
⑦氣路和油路控制:氣路主要控制變速箱換檔機構,油路控制變速箱的執(zhí)行機構,也就是摩擦片和制動器的結合或分離。
5 結束語：Allison 變速箱大修過程中解決的主要問題
井下三公司HT750DR 美國Allison 變速箱通過解體檢查發(fā)現(xiàn)存在以下問題:
(1)注油泵驅動齒輪打掉,金屬末掉進變速箱油底殼;1 - 5 檔離合器摩擦片磨損;閉鎖離合器摩擦片磨損。我們將無法修復的注油泵、止推軸承、過橋齒輪及軸承、驅動齒輪及全部摩擦片、密封件、濾芯進行更換,裝配各分總成再組裝成變速箱。放干凈變速箱油,包扎好外露油道,用固定架固定穩(wěn)妥。將變速箱總成安裝到檢測試驗臺上,按測試規(guī)范進行調試,達到了指標要求。制動器工作正常,無異響、無泄露,成功投入了修井使用。
(2) 井下二公司修井機HT750DR 美國Allison 變速箱溫度過高,壓力過低。在解體修理后安裝到修井機上時,變矩器漏油漏到發(fā)動機飛輪殼體,使發(fā)動機飛輪殼油位升高,壓力升高,造成飛輪殼油封漏油。因為漏油幾次拆卸檢查才
發(fā)現(xiàn)這臺變速箱的變矩器外殼裂了。重新焊接后上車
床加工好,故障得以排除。
(3) 特修公司CLT754 美國Allison 變速箱解體檢查時發(fā)現(xiàn)問題較多: 注油泵齒輪松曠內軸承損壞;二檔活塞銷柱斷損1 只;中排行星齒輪松礦;轉速表軸頭磨損;閉鎖后板及(菱形) 鍵磨損;主軸(帶齒輪花鍵) 軸頭磨損;取力軸承、閉鎖摩擦片及各前進檔鋼片、摩擦片、密封件損壞。我們更換中排行星架總成等總成件或配件91 件,加工修復了注油泵總成、主軸、飛輪總成、閉鎖后板、一檔活塞座等,排除故障,解決了存在的問題。組裝調試完畢,送生產前線安裝到修井機上投入了修井使用。
(4) 井下二大隊CLT754美國Allison 變速箱速度低,溫度高,閉鎖離合器打滑，摩擦片和鋼片磨損。通過拆檢發(fā)現(xiàn)各檔摩擦片和鋼片、密封件、推力軸承損壞。我們更換了密封件大修包,各檔摩擦片和鋼片、止推軸承等68 件,組裝調試完畢,安裝到修井機上投入了修井使用。
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