本文選題：裝載機　切入點：變速箱　出處：《吉林大學》2011年碩士論文

【摘要】：本文結(jié)合某裝載機生產(chǎn)企業(yè)的專項技術(shù)研究項目,以目前國內(nèi)5t級裝載機通常使用的ZL50行星式變速箱作為研究對象,在對其常見的故障進行分析、相關(guān)參數(shù)校核的基礎(chǔ)上,提出和實施一些有效的改進措施,降低變速箱的故障頻率、提高其可靠性、延長其使用壽命,是變速箱技術(shù)改進在裝載機產(chǎn)品上的工程應用實例。本文進行了如下理論分析和實驗研究。 1)綜述了裝載機變速箱現(xiàn)狀及本課題研究的目的和內(nèi)容 廣泛了解和借鑒國內(nèi)5t級裝載機產(chǎn)品現(xiàn)有的變速箱設(shè)計技術(shù)和方法。在其理論基礎(chǔ)上,收集其常見故障模式,分析其失效因素,為設(shè)計改進提供原始素材。 2)改進型變速箱關(guān)鍵零部件結(jié)構(gòu)優(yōu)化及強度分析。 結(jié)合裝載機實際工作情況和工程機械實際制造情況,工作泵、轉(zhuǎn)向泵、變速泵的使用和制造情況按中等情況考慮,工作泵、轉(zhuǎn)向泵、變速泵花鍵聯(lián)接的擠壓應力都小于許用值;超越離合器采用變矩器失速輸出的最大力矩進行接觸應力計算,其余工況下均應低于此值;通過三合一螺栓聯(lián)接結(jié)構(gòu)、直接檔軸與二檔齒圈聯(lián)接螺栓結(jié)構(gòu)、直接檔連接盤聯(lián)接結(jié)構(gòu)的優(yōu)化設(shè)計,計算分析其強度足夠;通過碟形彈簧結(jié)構(gòu)的優(yōu)化設(shè)計,計算分析其壽命足夠;通過二檔摩擦片傳遞扭矩的計算,顯示該處摩擦片傳遞的扭矩足夠。通過對比可知,設(shè)計理論強度、壽命等關(guān)鍵技術(shù)參數(shù)改進型變速箱均優(yōu)于原ZL50行星式變速箱。 3)對變速箱箱體結(jié)構(gòu)進行優(yōu)化設(shè)計,并進行強度分析。 通過一檔工況下改進型變速箱箱體變形有限元分析,得到V軸軸承座位移響應曲線,且計算結(jié)果和模型位移分布與實際情況相符,證明了本文所建立的變速箱位移響應模型與計算的正確性。該箱體總體結(jié)構(gòu)布局比較合理,在大應力區(qū)域嚴格控制鑄造缺陷;改變區(qū)域的筋板分布對振動改善最好,對前輸出法蘭而言,其上的只是局部降低振動,建議維持原前輸出法蘭固定筋板布局不變,采用反變形措施,在裝載機后車架增加剛性固定支架與五軸箱下環(huán)面約束考慮工藝實施方案的困難程度,兼顧成本與改進,在總體結(jié)構(gòu)布局已定的情況下,為減少五軸箱前輸出端漏油故障,改進薄弱處的結(jié)構(gòu)和筋板分布,減少其變形是較為成熟的方向并借鑒國內(nèi)外箱體密封結(jié)構(gòu)特點,采用“背靠背”安裝方式,采用進口油封材料,采用合理工藝裝配手段。 4)變速箱試驗研究 根據(jù)改進后變速箱試驗件的技術(shù)指標,應用變速箱試驗系統(tǒng)對改進型變速箱樣件進行空載功率損失、工作油壓、換擋過程、傳動效率、溫升特性等性能試驗和總成可靠性試驗,對其性能及可靠性進行評估,并與原ZL50變速箱進行對比分析,為優(yōu)化設(shè)計提出改進建議。 (1)變速箱空載功率損失偏大、效率偏低,主要原因可能是變矩器效率偏低,以及變速箱內(nèi)的齒輪加工精度較低,建議適當提高齒輪件的加工精度等級,以提高效率、降低振動噪聲; (2)改進型超越離合器在重載試驗及帶載循環(huán)可靠性試驗中,運轉(zhuǎn)狀況良好; (3)變速箱前輸出軸漏油,應加強油封及密封圈的裝配質(zhì)量控制; (4)其余各改進件經(jīng)強化試驗未見異常,建議小批量裝配試用。 通過廣泛了解和借鑒國內(nèi)外裝載機變速箱制造技術(shù),仔細分析5t裝載機變速箱易出現(xiàn)故障件的理論機理,依據(jù)理論計算和測試分析結(jié)果,提出并且實施了積極有效的結(jié)構(gòu)優(yōu)化、制造過程控制。經(jīng)過試驗驗證變速箱的各項指標均優(yōu)于原ZL50行星式變速箱,達到預期效果。
[Abstract]:In this paper, combined with the special technology research project of a loader production enterprises, the current domestic 5T class loaders usually use ZL50 planetary gearbox as the research object, in carries on the analysis of the common fault, based on the related parameters of checking, propose and implement some effective improvement measures, reduce the frequency of gearbox fault. To improve its reliability, prolong the service life, is to improve the engineering application in loader products of the transmission technology. This paper follows the theoretical analysis and experimental research.
1) the present situation of the loader gearbox and the purpose and content of the research on this subject are summarized.
Widely understand and learn from the existing 5T gearbox design technology and methods. On the basis of its theory, collect its common failure modes, analyze its failure factors, and provide raw materials for design improvement.
2) the structure optimization and strength analysis of the key parts of the improved gearbox.
Combined with the actual situation of loader and engineering machinery manufacturing actual situation, working pump, steering pump, the use and manufacture of transmission pump, according to the working medium pump, steering pump, variable speed pump spline extrusion stress is less than the allowable value; the maximum torque of clutch torque converter stall output contact the stress calculation, other conditions should be lower than this value by three; a bolt connection structure, gear shaft and gear tooth ring direct bolt structure, optimization design of connecting plate connecting structure of direct file, calculate the sufficient strength; through disc spring structure optimization design, calculation and analysis of its life enough calculation; friction torque is transmitted through the second gear, the friction torque shows enough. By contrast, the strength design theory and the improvement of the key technical parameters of life are better than the original ZL50 type gear box planetary Transmission case.
3) the structure of the gearbox is optimized and the strength analysis is carried out.
Through a case of improved gearbox finite element analysis of deformation, displacement response curve of V shaft bearing seat, and the calculation results and the model of displacement distribution is consistent with the actual situation, proved that the gearbox the displacement response model is correct and calculation. The overall structure of the box layout is reasonable, in the area of strict control of casting defects should be changed; the regional distribution of stiffened plate vibration and improve the best on the output flange, which is part of reducing vibration, to maintain the original proposal before the output flange fixed plate layout unchanged, with anti deformation measures, increase the rigid fixation and five axle under the torus constraints consider the degree of difficulty of implementation process in the rear frame of loader, taking into account the cost and improvement in the overall layout, the structure has been established, in order to reduce the five box front output leakage fault, the weak structure improvement It is a more mature direction to distribute and reduce the deformation of the stiffeners, and draw lessons from the characteristics of the sealing structure at home and abroad, adopt the way of "back to back" installation, adopt imported oil seal materials, and adopt reasonable process assembly methods.
4) experimental study of gearbox
According to the improved gearbox test technical index of the test system for gear box no-load power loss, the improved gearbox shifting process, sample working pressure, transmission efficiency, temperature rise characteristics and reliability test, evaluate its performance and reliability, and compared with the original strain ZL50 the box, the suggestion is put forward for optimizing design.
(1) the gearbox's no load power loss is too large and the efficiency is low. The main reason may be the low efficiency of the torque converter, and the low gear machining accuracy in the gearbox. It is suggested that the machining accuracy level of the gear parts should be increased appropriately, so as to improve efficiency and reduce vibration and noise.
(2) the improved overrunning clutch is in good condition in the heavy load test and the carrying cycle reliability test.
(3) the oil leakage in the front output shaft of the gearbox should be strengthened, and the assembly quality control of the oil seal and the seal ring should be strengthened.
(4) the rest of the improved parts have not been abnormally tested by the intensifying test. It is suggested that a small batch assembly should be tried.
Through a broad understanding of domestic and abroad loading machine gearbox manufacturing technology, careful analysis of 5t loader gearbox failure prone mechanism, theoretical calculation and test results, and put forward the implementation of structural optimization of active and effective manufacturing process control. After each index test of the gearbox are better than the original planet ZL50 gearbox, to achieve the desired effect.

【學位授予單位】：吉林大學
【學位級別】：碩士
【學位授予年份】：2011
【分類號】：TH243.1

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