轻型卡车动力总成三壳破裂问题系统解决方案研究

【作者】 高岩；

【导师】 宋希庚； 林梅友；

【作者基本信息】 大连理工大学 ， 动力工程， 2003， 硕士

【摘要】 福田公司开发的BJ1036E2F1轻卡在1997～2000年连续发生三壳(飞轮壳、离合器壳和变速箱壳)批量破裂质量事故(约占该车型销量的1％)，一度给公司造成较大的经济损失，对该车型的市场销售和用户的生命及财产安全造成较大程度的影响。针对这一问题由本人组织策划开展了深入、系统、全面的课题研究。 在汽车运行一定时期以后其动力总成壳体在产品的使用寿命内出现批量破裂现象，说明动力总成的壳体在设计上存在一定的问题。为了从根本上解决该问题，本论文以BJ1036E2F1轻卡动力总成为研究对象，通过动力总成的动力学仿真分析，找出了三壳之间联接螺栓受力的分布规律和螺栓受力与发动机转速的关系；通过三壳的有限元模态分析，得到了动力总成壳体的固有频率与振型，从而了解了动力总成壳体的动态特性；在计算机仿真分析的基础上，通过动力总成壳体的振动测试和强度测试，得出了动力总成的试验模态，并研究了壳体受力与发动机转速和旋转部件不平衡质量的关系。通过分析与试验相结合，本论文系统性的研究了三壳发生破裂的原因，找出了解决该类问题的系统解决方案。 在分析与试验的基础上，本论文提出了系统的改进措施，通过对改进后动力总成批量装车运行情况的调查，在2000年下半年以后BJ1036E2F1轻卡基本杜绝了该类故障的发生。本论文提出的针对汽车复杂总成进行动力学仿真分析、有限元分析与试验相结合的系统研究方法，及时、有效地解决了三壳破裂问题，为公司创造了巨大的经济效益，同时该研究方法在我公司的产品开发和故障诊断与处理方面正发挥着重要作用。更多还原

【Abstract】 BJ1036E2F1 Light Truck, developed by Futian Corporation, has continuously had batch cracking accidents on three shells including flywheel shell, clutch shell and gear-box shell from 1997 to 2000. The rate of the accident is about 1%. The accident ever not only made Futian Corporation certain economic loss, but also greatly affected sale of this type truck and security of customers’ life and estate. To solve it, a deep, systemic and overall research program organized by me has been developed.After a period of vehicle’s operation, the phenomenon of batch cracking occurs on shells of power assembly in the life-span, which shows that there are some defects in the design of power assembly. In order to solve it radically, making power assembly of BJ1036E2F1 Light Truck the research object and through dynamic simulation analysis of power assembly, this thesis obtains the distribution rules of forces of the bolts linking three shells mentioned above and the relation between forces of the bolts and rotate speed of engine. After finite element mode analysis of these three shells, inherent frequency and vibration model of shell of power assembly are gained, and thus its dynamic character is realized. Based on computer simulation analysis, experimental model of power assembly is acquired by vibration test and strength test of shell of power assembly, and the relation of forces of the shell and rotate speed of engine and imbalanced mass of rotate components is studied. Through comparing simulation analysis with experiments, the thesis systemically investigates the reasons of cracking of three shells and obtains the scheme to solve this type of problem.According to the analysis and experiments, the thesis brings forward the improved method of the system. From the investigations of vehicle’s operation with improved power assembly, this type of accident occurring in BJ1036E2F1 Light Truck has almost been prevented since the late half year of 2000. In the thesis, according to the complicated assembly of vehicle, the research method of integrating dynamic simulation analysis and finite element analysis with experiment is advanced, which is utilized to solve the cracking problem of three shells effectively and in good time. It creates great economic benefit for Futian Corporation and plays a key role in production development and fault diagnose and disposal.更多还原