Research on the service life and repair interval of vehicle reducer

Through calculation and statistical results, a preliminary conclusion can be drawn after synthesis: For a large hump with heavy workload, the average number of brakes in one part of the reducer is about 300,000 vehicles per year, and the maximum is up to 500,000; the second part decelerates The average number of braking vehicles per year is about 7 million, and the maximum number of vehicles is 250,000; the average number of braking vehicles per year for the three-part reducer is about 40,000, and the maximum number of vehicles is 70,000.

For small and medium hump reducers, the number of actions will be significantly reduced. Life analysis of the whole machine, wearing parts, and wearing parts. The life of the reducer. The three-part reducer generally has a design life of 100,000 vehicles. Calculated based on the number of vehicles braked by the above-mentioned reducer per year, the minimum useful life is 14 years, and the average useful life is 25 years.

In fact, except for a small amount of TJY-1 and T-2-2 which have been used for 20 years, and T”KZ-1 (A50) has a 16-year history of use, other reducers may have been identified late (for example, TJKZ-B (50) , TJKI-D (50)), there is no long-term use record; some simply can not meet the service life requirements (such as TJKI-C).

But most of the three-segment reducers, generally around 10-12 years, due to the appearance of new types of reducers and overhaul and replacement. The design life of the reducer of the first and second parts has 1 million cycles (for example, TJK (Y) 3 one (50), 2 million cycles (for example, T suit (average 3 one (50), TK4 one (50)), and 30 10,000 vehicles (such as T not K, TJK 3-B (50)). If calculated according to the number of vehicles braked by the above-mentioned reducer per year, one part of the big hump can be used for 2 years, 4 years and 6 years respectively (according to each year * more Braking 500,000 vehicles), the average can be used for 3.3 years, 6.7 years and 10 years (according to the average annual braking of 300,000 vehicles).

The second part can be used for 4, 8, and 12 years less (250,000 more braking times per year), and an average of 6.7 years, 13.3 years, and 20 years can be used (according to the average annual braking number of tens of thousands of vehicles). During the use of the reducer, the wearing parts need to be replaced frequently to ensure the normal use of the reducer. However, the life span of the wearing parts is very different, which directly affects the performance of the reducer.

The life of wear parts of the reducer The strength of the main parts of the reducer can generally meet the design life except for casting and material defects. However, the failure and performance degradation of the reducer are mostly caused by excessive wear of the wearing parts. The following analyzes several wear parts that have the greatest impact on the performance of the reducer.

In addition to TJKI-c and TJKI-D using 50kg/m rails, the other reducers are mostly 60mm steel rails. The newly produced TJK3-B50 reducer adopts 75k left m rail reform. According to statistics, the brake rail with 50k leaving m can wear 3.5 to 450,000 vehicles; the brake rail with 60 k leaving m can wear 5.0 to 600,000 vehicles; the brake rail with 75 k leaving m can wear 65 to 750,000 vehicles; in large and medium-sized For the hump, the 60kg/m brake rail can be used for 1 to 3 years in the first and second parts; 8 to 12 years in the three parts. The 50kg/m brake rail can only be used for 6 to 8 years in the three parts, and the overhaul period is too short, so it is not recommended.

Sleeper plates and rail rubber pads The reducer sleeper plate bears the impact force of the rail falling when the reducer is relieved and prevents the reducer from crawling and floating on the side. It is also subject to the positive pressure of the passing vehicle when it is not braking. The sleepers on the main line are more vulnerable to damage. In addition, the rail rubber pad of the original reducer is not easy to replace, and the rubber pad is damaged or not replaced in time after aging, which may easily cause damage to the sleeper plate. After the sleeper plate is damaged, because it is not easy to repair and replace, it will often cause the reducer to be overhauled in advance.

Therefore, the life of the sleeper plate often determines the life of the reducer. The life of ordinary sleeper plates is generally 100,000 vehicles; the life of sleeper plates with abraded sides and sleeper grooves increased by iron plates can generally reach 200,000 vehicles. If you need to increase the life of the sleeper plate, you need to use a combined sleeper plate, that is, the worn side surface and the sleeper groove as replaceable parts. According to calculation and analysis, the life of the combined sleeper plate can reach 400,000 vehicles or more. TJK3-B50 reducer adopts combined sleeper plate. The life of rail rubber pads is generally 500,000 to 600,000 vehicles, so the rubber pads need to be replaced during medium repairs. The mid-repair period of TJK3-B50 reducer exceeds 10 to 1.2 million vehicle trips, so the rubber backing plate needs to be replaced during the period. For this reason, the rubber backing plate of TIK3-B50 reducer adopts the normal-line general type for replacement.

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