【作者】 张晶；

【导师】 郭常宁； 周平；

【作者基本信息】 上海交通大学 ， 机械工程， 2015， 硕士

【摘要】 齿轮箱作为地铁车辆的重要零部件,其功能性能的可靠性直接影响到地铁车辆的运行安全。在齿轮箱的所有故障模式中,油脂泄露故障可占80%以上。本文针对某时速100km/h地铁齿轮箱渗油现象,采用仿真计算、试验验证的手段在设计上改进了该齿轮箱的迷宫密封结构,从而降低了齿轮箱漏油的可能性。本课题研究的齿轮箱是为国外某地铁车辆设计的最高速度为100km/h的减速齿轮箱,该齿轮箱的密封结构借用我公司最高速度为80km/h某成熟地铁齿轮箱。在进行型式试验过程中,出现从动齿轮轴端迷宫密封处渗油现象。还未正式投入运用的齿轮箱出现渗油现象,当其随地铁车辆投入运用时,在振动、磨损等激励因素的作用下,出现漏油的可能性大大增加。必须对该问题进行深入研究。为了研究上述问题,本文首先通过对该齿轮箱及其密封结构进行设计、制造、组装等过程的分析,得知该齿轮箱在试验过程中出现渗油现象的主要原因是由于其电机转速增大后,引起温升升高,箱体内压力过大,造成密封结构不能有效密封所致,未充分考虑到齿轮箱密封结构是否适应新的工况。因此需要对齿轮箱密封结构进行改进。为了研究结构改变之后能否满足使用要求,本文对迷宫密封结构在地铁齿轮箱中的应用进行研究与探讨。采用FLUENT软件分析计算迷宫密封结构与泄漏量的关系。根据仿真分析结论,本文对该齿轮箱从动齿轮轴端迷宫密封进行结构优化,提出了新的齿轮箱密封结构,将直通式迷宫密封更改为阶梯式迷宫密封,同时减小密封间隙、增加密封空腔,从多个方面减少密封泄漏量。为进一步验证结构优化的效果,本课题采用型式试验的方式对密封结构改进后的齿轮箱进行空载试验和加载试验,验证结果表明该迷宫密封结构无渗油现象出现。更多还原

【Abstract】 Gear box, as one of the key parts of metro power bogie, the reliability of its function directly affects the safety operation of the metro vehicle and the service life of gear and bearing. Oil leakage fault can be accounted for more than 80% in all the failure mode of gear box. According to a 100km/h metro gear box oil leakage phenomenon, this paper uses the simulation calculation and test method on the design to improve the labyrinth seal structure of the gear box and reduce the possibility of a gearbox oil spill.The gear box of this research is designed for reduction gear box whose domestic metro vehicle’s top speed is 100 km/h and its sealing structure is designed from a mature subway gear box with a maximum speed of 80 km/h. When conducting type test after the trial production, oil leakage phenomenon appears on labyrinth of driven gear shaft end. Oil leakage phenomenon appears on gear box that is not officia lly put into use. When the metro vehicles put into use in vibration and wear of incentive factors, the possibility of oil spill will increase. So it is essential to study the problem.In order to study the problem, first through the analysis of the gear box design, manufacture, assemble process, we known the main reason of oil leakage phenomenon of the gear box in the test process, cause the temperature rise increases is the motor speed increases and then the pressure in the tank is too large, causing the sealing structure cannot be effectively sealed by, and not fully considering the gear box seal structure is to adapt to the new situationTherefore the seal structure of the gearbox should be improved. In order to study the structural change can meet the use requirement, the paper of labyrinth seal structure used in Metro in the gear box is studied and discussed. Frist using FLUENT software to calculation shows that the leakage of stepped labyrinth seal is considerably smal er than the straight through labyrinth seal.According to the conclusions of simulation analysis, optimizates shaft end labyrinth seal structure of the gear box driven gear, puts forward the new gear box sealing structure, changes the straight through labyrinth seal for stepped labyrinth, reduces the seal clearance and increases the sealing cavity at the same time. This paper reduces the sealing leakage in many aspects.To further verify the structure optimization effect, this topic conducts no-load test and loading test for gear box improved structure by using the type test way and verifies the function, temperature and sealing performance of the gear box which adopts the improved seal structure by the type test. Verification result shows that oil leakage phenomenon does not appear on the gear box with the labyrinth seal structure.更多还原