导轨式胶轮车辆传动轴失效原因分析与优化设计
杨怡谭志成康飞张鑫刘赛武
Failure Cause Analysis and Optimization Design of the Transmission Shaft for Guideway Rubber-tyred Vehicle
YANG YiTAN ZhichengKANG FeiZHANG XinLIU Saiwu
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作者信息:比亚迪机电设备有限公司， 518118， 深圳
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Affiliation:BYD Electro-Mechanical Equipment Co., Ltd., 518118, Shenzhen, China
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关键词:
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Key words:
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DOI:10.16037/j.1007-869x.2024.03.012
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中图分类号/CLCN:U270.332
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栏目/Col:研究报告
摘要:
［目的］导轨式胶轮车辆传动轴的结构可靠性对列车运行安全性至关重要。该车辆在某条城市轨道交通线路上进行冰雪试验时，多次出现传动轴断裂现象而导致失效。因此需分析传动轴失效原因，并对其进行优化设计。［方法］从传动轴失效断面宏观检测及失效件材料理化检测两方面分析了传动轴断裂的原因。采用无线扭矩测试系统对该条线路五号站—六号站、五号站—七号站区间传动轴的实时载荷进行了测试，并分析其测试结果。优化了传动轴结构设计。对优化后的传动轴台架进行了强度测试，以及对优化后的传动轴进行了疲劳试验。［结果及结论］传动轴断裂的原因为：十字轴的过载脆性断裂和双联轴套的疲劳断裂。两个区间的测试结果显示：传动轴的最大扭矩均出现在车辆打滑状态下，其实际扭矩虽小于设计的最大工作扭矩，但由于扭矩短时间内发生变化时，其受到的冲击能量远大于正常工况下的扭矩变化值。传动轴结构的优化措施为：增大十字轴的轴径，在十字轴圆弧过渡处增大倒圆角，进一步减小应力集中；通过在双联轴套上增加加强筋，提高双联轴套轴肩部的强度。优化后的传动轴台架强度测试表明，满足设计要求；优化后的传动轴疲劳试验表明，试验合格。
Abstracts:
［Objective］ The structural reliability of the transmission shaft of guideway rubber-tyred train is crucial to the safety of train operation. During the ice and snow test on a certain urban rail transit line, the guideway rubber-tyred train failed several times resulting from the fracture of the transmission shaft. Therefore, it is necessary to analyze the fracture causes of the transmission shaft and optimize its design. ［Method］ The causes of the fracture of the transmission shaft are analyzed from two aspects: macroscopic detection of the failure shaft section, physical and chemical detection of the failure material. A wireless torque test system is used to test the real-time load of the transmission shaft between stations 5-6 and stations 5-7 on the line. The test results are analyzed, and the structure of the transmission shaft is optimized. The strength test on the optimized transmission shaft bench and the fatigue test on the optimized transmission shaft are carried out respectively. ［Result & Conclusion］ The causes of transmission shaft fracture are identified as the overload brittle fracture of cross shaft and fatigue fracture of double coupling bushing. The test results from the above two line sections show that all the maximum torques of the shaft occur when the vehicle is slipping. Though the actual torque of transmission shaft is less than the designed maximum working torque, the impact energy on the shaft is much larger than the torque change value under normal working conditions because the torque changes within a very short time. The measures that are taken to optimize the transmission shaft structure are as follows: increasing the shaft diameter of the cross shaft, increasing the chamfer angle of the cross shaft arc transition, and further reducing the stress concentration. The strength of the shaft shoulder of the double coupling bushing is increased by adding the reinforcing rib on it. The strength test on the optimized transmission shaft bench shows that it meets the design requirements and passes its fatigue test.
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