High-speed train gearbox housing vibration test based on small roller high-frequency excitation
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摘要: 为探究高速列车齿轮箱箱体振动特性和疲劳损伤, 应用小滚轮高频激励台架试验, 将滚轮表面加工成径跳量幅值为0.05 mm的13阶多边形, 可等效成20阶车轮多边形, 研究了某型齿轮箱箱体在不同垂向载荷与速度工况下的振动特性; 通过雨流计数法及Miner线性损伤法则, 分析了齿轮箱箱体单位时间应力累计损伤。研究结果表明: 受齿轮箱箱体共振影响, 不同垂向载荷与速度工况下, 高速列车运行速度为200 km·h-1时, 齿轮箱箱体各测点的垂、横向加速度均方根值均为最小; 当垂向载荷为23 t时, 大部分测点的垂、横向加速度均方根值均为最大; 齿轮箱箱体存在573 Hz的局部固有频率被激发共振, 其原因是试验速度为100 km·h-1时试验台发生共振, 以及试验速度为300 km·h-1时, 受到20阶多边形车轮转频约580 Hz的主频激扰; 车轮初始速度从0加速到200 km·h-1及从300 km·h-1减速至0的速度等级之间时, 齿轮箱箱体各测点的单位时间应力累计损伤波动较大, 其余速度等级段各测点的单位时间应力累计损伤波动很小; 单位时间应力损伤最大值出现在大齿轮箱齿面观察孔, 为3.72×10-10, 损伤最小值位于小齿轮箱轴承正上方, 仅为8.29×10-18。可见, 箱体共振、试验台减速运行、速度等级对齿轮箱箱体振动加速度影响较大; 非共振、试验台不减速运行、相同速度等级下, 垂向载荷对单位时间应力累计损伤影响甚微。Abstract: To analyze the vibration characteristics and fatigue damage of a high-speed train gearbox housing, a small roller high-frequency excitation test stand was applied to study the vibration characteristics of gearbox housing under different vertical loads and speeds. In the test, the surface of roller was processed to the 13 th-order polygon with a radial jump amplitude of 0.05 mm, which could be equaled to a 20 th-order actual wheel polygon. The stress accumulation damage of gearbox housing per unit time was analyzed by the rain flow counting method and Miner linear damage rule. Analysis result indicates that effected by the resonance of the gearbox housing, the root mean square(RMS) values of transverse and vertical accelerations of each measuring point of the gearbox housing are minimal under different vertical loads and speeds at a running speed of the high-speed train of 200 km·h-1. The RMS values of transverse and vertical accelerations of most measurement points are maximal when the vertical load is 23 t. The resonance of gearbox at the natural frequency of 573 Hz can be stimulated by the resonance frequency of test bench at a test speed of 100 km·h-1 and main excitation frequency of the 20 th-order wheel polygon frequency shift of approximately 580 Hz at a test speed of 300 km·h-1. The cumulative stress damage per unit time at each measuring point of gearbox housing largely fluctuates when the initial speed of wheel is between the speed grades of acceleration from 0 to 200 km·h-1 and deceleration from 300 to 0 km·h-1. The stress cumulative damage per unit time of each measuring point in the other speed grades has small fluctuations. The maximum value of stress damage per unit time is obtained in the tooth surface observation hole of a large gearbox housing, 3.72×10-10, while the minimum damage is located above the bearing of a small gearbox housing, only 8.29×10-18. Thus, the vibration acceleration of gearbox housing is largely affected by the resonance of gearbox and the deceleration operation and speed grades of test stand. However, the vertical load has a small influence on the stress cumulative damage per unit time under the conditions of non-resonance of gearbox housing, without deceleration operation, and the same speed grade of test stand.
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图 8 齿轮箱箱体振动模态试验测点布置
Figure 8. Layout of measuring points for vibration modal test of gearbox housing
图 9 10t载荷作用下齿轮箱箱体测点加速度均方根值
Figure 9. Acceleration RMS values of gearbox housing measuring points under 10 t load
图 10 18t载荷作用下齿轮箱箱体测点加速度均方根值
Figure 10. Acceleration RMS values of gearbox housing measuring points under 18 t load
图 11 小齿轮箱箱体轴承正上方加速度均方根值
Figure 11. Acceleration RMS values of bearing directly above small gearbox housing
图 12 大齿轮箱箱体轴承正上方加速度均方根值
Figure 12. Acceleration RMS values of bearing directly above large gearbox housing
图 13 大齿轮箱齿面观察孔加速度均方根值
Figure 13. Acceleration RMS values of tooth surface observation hole of large gearbox
图 14 大齿轮箱油位观察孔加速度均方根值
Figure 14. Acceleration RMS values of oil level observation hole of large gearbox
图 15 10t载荷工况下大齿轮箱油位观察孔振动加速度时频
Figure 15. Vibration acceleration time-frequency of oil level observation hole of large gearbox under 10 t load condition
图 16 10t载荷工况下大齿轮箱齿面观察孔振动加速度时频
Figure 16. Vibration acceleration time-frequency of tooth surface observation hole of large gearbox under 10 t load condition
图 17 18t载荷工况下大齿轮箱油位观察孔振动加速度时频
Figure 17. Vibration acceleration time-frequency of oil level observation hole of large gearbox under 18 t load condition
图 18 18t载荷工况下大齿轮箱齿面观察孔振动加速度时频
Figure 18. Vibration acceleration time-frequency of tooth surface observation hole of large gearbox under 18 t load condition
图 19 大齿轮箱齿面观察孔应力时域
Figure 19. Stress time-domain of tooth surface observation hole of large gearbox
图 20 大齿轮箱油位观察孔应力时域
Figure 20. Stress time-domain of oil level observation hole of large gearbox
图 21 小齿轮箱轴承正上方应力时域
Figure 21. Stress time-domain of bearing directly above small gearbox
图 22 大齿轮箱轴承正上方应力时域
Figure 22. Stress time-domain of bearing directly above large gearbox
图 23 齿轮箱箱体动应力累计损伤演化
Figure 23. Dynamic stress accumulated damage evolution of gearbox housing
图 24 齿轮箱箱体每秒应力累计损伤演化
Figure 24. Evolution of gearbox housing stress accumulated damage per second
表 1 传感器测量参数
Table 1. Measurement parameters of sensors
传感器类型 量程 采样频率/kHz 测试方向 测试对象 BK传感器 0~700g 5 垂、横向 齿轮箱箱体 应变片传感器 应变极限2% 5 纵向 齿轮箱箱体 
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表 2 滚轮试验工况
Table 2. Roller test condition
参数 滚轮阶数 车轮阶数 径跳量幅值/mm 作动器垂向载荷/t 轮对速度/(km·h-1) 数值 13 20 0.05 10、18、23 0~300
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表 3 齿轮箱箱体模态试验频率
Table 3. Modal test frequencies of gearbox housing
阶次 1 2 3 4 5 6 7 8 频率/Hz 573 643 665 762 835 864 889 946
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表 4 齿轮箱箱体测点位置应变片信息
Table 4. Strain gauge information for measuring point positions of gearbox housing
位置 材料 方向 采样频率/kHz 编号 通道号 应变片系数 大齿轮箱齿面观察孔 铝合金 纵向 5 ZFB10 Smstr6448 0.138 大齿轮箱轴承正上方 铸钢 纵向 5 ZFB20 Smstr6334 0.412 小齿轮箱轴承正上方 铝合金 纵向 5 ZFB12 Smstr6263 0.138 大齿轮箱油位观察孔 铝合金 纵向 5 ZFB09 Smstr6467 0.138
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表 5 23 t载荷工况下各测点速度等级与测试时间
Table 5. Speed grades and test times of each measuring point under 23 t load condition
速度等级 速度/(km·h-1) 测试时间/s 1 0~100 0~133 2 100 133~200 3 100~200 200~263 4 200 263~328 5 200~250 328~361 6 250 361~436 7 250~300 436~468 8 300 468~541 9 300~0 541~700
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表 6 23 t垂向载荷齿轮箱箱体测点应力累计损伤
Table 6. Stress accumulated damages of gearbox housing measuring points under 23 t vertical load
速度等级 大齿轮箱轴承正上方/10-10 大齿轮箱齿面观察孔/10-10 小齿轮箱轴承正上方/10-14 大齿轮箱油位观察孔/10-14 1 9.7 78.1 70.9 155.3 2 48.1 249.3 141.1 241.9 3 13.5 58.5 32.1 23.7 4 0.9 6.7 0.3 27.3 5 0.5 3.3 0.3 4.5 6 2.3 16.6 0.3 18.3 7 0.6 6.8 2.9 3.7 8 2.9 16.8 10.3 14.8 9 18.4 135.7 85.3 1 560.6
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表 7 18 t垂向载荷齿轮箱箱体测点应力累计损伤
Table 7. Stress accumulated damages of gearbox housing measuring points under 18 t vertical load
速度等级 大齿轮箱轴承正上方/10-10 大齿轮箱齿面观察孔/10-10 小齿轮箱轴承正上方/10-14 大齿轮箱油位观察孔/10-14 1 51.8 128.9 201.7 49.1 2 1.5 5.4 0.2 0.9 3 4.8 12.6 1.1 1.2 4 3.7 12.7 1.3 0.9 5 2.3 9.2 4.8 1.1 6 2.4 10.3 3.1 1.2 7 1.4 5.5 0.4 0.8 8 14.3 45.8 121.6 4.4 9 17.4 63.8 123.9 6.4
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表 8 10 t垂向载荷齿轮箱箱体测点应力累计损伤
Table 8. Stress accumulated damages of gearbox housing measuring points under 10 t vertical load
速度等级 大齿轮箱轴承正上方/10-10 大齿轮箱齿面观察孔/10-10 小齿轮箱轴承正上方/10-14 大齿轮箱油位观察孔/10-14 1 9.3 94.8 153.6 2 909.3 2 15.8 124.5 62.5 3.9 3 3.4 37.1 6.2 1.4 4 0.4 2.4 0.1 0.8 5 7.1 2.8 0.2 0.7 6 1.1 6.4 0.5 0.9 7 0.8 4.7 1.3 0.6 8 0.9 5.8 5.2 1.1 9 7.5 93.7 98.8 9.1
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表 9 23 t垂向载荷齿轮箱箱体测点每秒应力累计损伤
Table 9. Stress accumulated damages per second of gearbox housing measuring points under 23 t vertical load
速度等级 大齿轮箱轴承正上方/10-12 大齿轮箱齿面观察孔/10-11 小齿轮箱轴承正上方/10-16 大齿轮箱油位观察孔/10-16 1 7.3 5.9 53.3 117.0 2 71.9 37.2 211.0 361.0 3 21.4 9.3 50.9 37.6 4 1.4 1.1 0.5 42.0 5 1.4 1.0 0.8 13.6 6 3.1 2.2 3.9 24.4 7 2.1 2.1 5.2 11.4 8 3.9 2.3 14.1 20.3 9 25.1 18.6 117.0 2 140.0
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表 10 18 t垂向载荷齿轮箱箱体测点每秒应力累计损伤
Table 10. Stress accumulated damages per second of gearbox housing measuring points under 18 t vertical load
速度等级 大齿轮箱轴承正上方/10-12 大齿轮箱齿面观察孔/10-11 小齿轮箱轴承正上方/10-16 大齿轮箱油位观察孔/10-16 1 43.2 10.8 168.0 41.0 2 2.3 0.8 0.3 1.4 3 4.8 1.3 1.1 1.3 4 6.8 2.3 2.4 1.7 5 2.7 1.1 5.7 1.2 6 3.7 1.6 4.8 1.9 7 1.8 0.7 0.5 1.1 8 20.5 6.6 174.0 6.3 9 9.4 3.5 67.0 3.5
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表 11 10 t垂向载荷齿轮箱箱体测点每秒应力累计损伤
Table 11. Stress accumulated damages per second of gearbox housing measuring points under 10 t vertical load
速度等级 大齿轮箱轴承正上方/10-12 大齿轮箱齿面观察孔/10-11 小齿轮箱轴承正上方/10-16 大齿轮箱油位观察孔/10-16 1 3.2 3.3 53.0 1 000.0 2 19.8 15.6 78.1 4.9 3 3.4 3.7 6.2 1.4 4 0.5 0.3 0.1 1.0 5 10.1 0.4 0.2 0.9 6 1.4 0.9 0.6 1.2 7 1.1 0.6 1.7 0.8 8 1.3 0.8 6.9 1.5 9 3.8 4.6 48.2 4.4
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