Improvement of adjustment process for DF4B locomotive diesel generator assembly vehicle Zhao Weining (Hangzhou Locomotive Depot Zhejiang Hangzhou B10008) loading adjustment process, the process has achieved good results in practical applications. 11 Logo Code: The proposal of B 1 questions has been put forward with the development of high-speed and high-powered diesel locomotives, and higher requirements for driving safety and reliability of locomotive equipment. The locomotive not only forms a complicated vibration system with the track, but also a complicated vibration system. The locomotive diesel generator set is one of the more important vibration sources. Therefore, in the new, overhaul and medium repair of the DF4B locomotive, the installation and adjustment of the diesel generator set is an important process. In 2000, after the locomotives that were overhauled (or repaired) by the Hangzhou Locomotive Depot, several locomotives experienced large vibrations. The radios in the cabs, horns and consoles were severely vibrated. The electrical cabinets in the electrical rooms vibrated abnormally, and the degree of vibration The engine speed is increased and the oil pipe is cracked, leaked, desoldered and loosely connected, which affects the normal operation of the locomotive. Through the addition and locomotive water block inspection, the relevant personnel analyzed the abnormal phenomenon of the vibration. Initially, the assembly of the diesel engine and the generator was considered to be problematic, and the diesel engine-generator set before and after the repair of several typical locomotives was carried out. Tracked. The results show that the assembly size and state of the diesel engine and the main generator are in line with the process requirements, and there is no problem in the bearing and assembly of the generator motor. However, it is found that the two rubber components of the diesel generator set are partially damaged. Further, it is considered to be due to the quality of the rubber component. After replacing the new product, re-install and adjust, and meet the requirements of "Technical Regulations for DF4B Diesel Locomotive Repair" (hereinafter referred to as the section specification). However, after the locomotive is put into use, the problem of excessive vibration still exists. More typical is the B886, B887, B888 B locomotives during the two repairs, all of them hanged the unit inspection due to extraordinary vibration. 2 Reasons for the occurrence of extraordinary vibration: 20004-25, with a bachelor's degree in diesel locomotives, and is mainly engaged in the inspection and management of diesel locomotives. 2.1 Elastic support structure factors The total weight of the generator set is about 28t, which is mounted on the frame by four elastic support seats, each bearing bearing about 68.6kN vertical load. The rubber bearing is used to absorb high-frequency chatter vibration, to mitigate vibration between the diesel generator set and the frame and shock vibration from the line, to avoid resonance of the diesel engine in the working speed range. See the support position of the diesel generator set on the vehicle, see elastic support structure. The static stiffness of 66.6kN/cm shows that the height difference of the seat surface of the four rubber components is less than 1mm, which corresponds to the fact that the four rubber components have a vertical force difference of no more than 6kN, and the four rubber components are evenly stressed. . Through the analysis of the field test results, it is considered that the diesel generator set only meets the requirement that the static deflection of the four rubber components is less than 2mm, and the H difference H of the four elastic support seats after installation is not more than 1mm, and cannot fully guarantee 4 The force of the elastic support is within the tolerance range, and often the force at the diagonal 2 points is larger, and the force is not evenly distributed at 4 points. When the diesel engine works, resonance occurs and abnormal vibration is generated. 2.2 Other factors From the perspective of rubber components, the original dimensions of the rubber components are different due to the different manufacturers of rubber components; at the same time, the processing of the tapered surfaces of the upper and lower support seats matched with the rubber components also has errors; The four seat plates on the frame are installed in different heights and conditions, which may cause the four elastic bearings to be inconsistent. The four elastic bearing forces are ultimately reflected in the deformation of the elastic element after it is subjected to the vertical load. 3Improved diesel generator set installation and adjustment process Generally, when the locomotive is repaired in the locomotive section, most of them do not have the conditions for testing and adjusting the level of the four supporting seats on the car body. The four seats are on the frame. The position status can only be referred to the measurement results at the time of new or overhaul. In the past, when the unit was installed and adjusted, in order to meet the requirements of the maintenance regulations, the method of adjusting the thickness and quantity of the gasket under the support seat was adopted to ensure that the 4 bearing groups after the diesel generator was assembled were not more than 1 mm, but the result affected the locomotive frame. The relative position of the four support seats. Through many practices and explorations, it is considered that the following improvements are better. 3.1 Adding the pressure test process of the rubber element The structure of the tapered elastic element can be divided into two parts: the vertical static deflection and the lower circumferential deformation when subjected to the vertical load. Therefore, the pressure test process of the rubber component can fully reflect its performance. . In the process equipment, it is necessary to make a test tire for the test pressure, and make accurate measurement when the rubber component is tested, and record the free height, the circumferential dimension S at a distance of about 50 mm from the bottom in the free state, and the load of 70 kN. Static deflection, data such as the circumferential dimension Si at a height of 50 mm from the bottom. 3.2 Adjusting the assembly work During the mid-repair operation of the locomotive, when the diesel unit is suspended, the cooperation status of the rubber element and its corresponding upper and lower support is recorded separately, and the thickness of each support seat is marked and marked. When the diesel generator set is pre-installed, the thickness of each support seat and padding is restored according to the recorded size, and assembled with a rubber component that meets the static deflection value required by the inspection regulations. After pre-installation, check the AH of the four supports should be no more than 1mm. Check the contact between the rubber element and the upper support. Uniform and no gap should be measured. Measure the corresponding circumferential dimension S/ of the rubber component and the circumferential dimension when the independent loading is 70kN. Comparing Si, the two values ​​can differ by a maximum of 8 mm, such as more than 1 of 4 supports or a bad contact of a rubber element, when there is a gap at the tapered surface, and the amount of circumferential deformation is insufficient (or a certain elastic element is in good contact, but the circumferential deformation amount is excessive Large) The rubber element with different free height can be replaced by the static deflection value at 70kN, so as to meet the requirement of 1mm, and the support position can be adjusted without cutting the support plate, thus ensuring 4 The relationship between the height difference of the support seats. The pre-assembly results are three, and the corresponding adjustment schemes are as follows: A/<1mm, uniform contact, the circumferential dimension S/ of the four supports is within 8mm, indicating that the four supports are consistent. The corresponding Si, and the difference is more than 8mm, indicating that the bearing force of 1,3 is more than 1mm, the contact is uneven, the Sr' of 2,4 support is smaller than the corresponding Si, and the difference is more than 8mm, indicating that the bearing force of 2 and 4 is small. At this time, it is possible to replace the rubber elements of the lower 2 and 4 positions with the rubber element having a large free-height value, or the rubber element of the lower 1 and 3 positions with a rubber element having a small free height value. 1. Generally, when this occurs, in the 4 supports, the joint of the H-largest support has a gap and is obvious, and its circumferential dimension S/the difference with its corresponding Si is large (Si 8mm) or the minimum support of H There is no gap at the joint of the tapered surface, and the rubber element has a large circumferential deformation (S/―S, >8mm). At this time, the rubber components of the highest and lowest support points are replaced by A/<1 mm, and then adjusted and pre-assembled, and the height of the support is adjusted without cutting the support plate. After the diesel generator set is pre-installed, four elastically supported Hs are recorded for the diesel unit installation process. 4 Conclusion This process is verified by medium repair, and the effect is remarkable. It not only effectively controls the installation state of the diesel generator set, but also reduces the replacement cost of the rubber component. The method simply reduces the operation time of the installation and adjustment process. More than two years after the implementation of this process, about 100 locomotives have never experienced such extraordinary vibrations. (Editor: Yu Huijuan)
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