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摘要: 针对国内400 km·h-1变轨距动车组转向架的研发和设计问题，在借鉴国外成熟变轨距转向架技术的基础上，重点研究了国内高速变轨距动车组转向架的5个关键问题，即牵引电机布置方式、轮对驱动方式、轴箱轴承、变轨机构、基础制动及撒砂装置，对研究中发现的问题提出了相应的解决措施。研究结果表明：电机架悬和体悬都可以给制动盘的安装让出空间，但是电机与所驱动的车轴之间都会产生相对位移，需要采取运动补偿措施；为了满足400 km·h-1变轨距动车组车轴尺寸和转速要求，需研发新型轴箱轴承；变轨机构的存在会使转向架簧下质量增大，所以研制的变轨距转向架应尽量采用轻量化设计；考虑到制动效率和夹钳随动问题对变轨距转向架制动效果的影响，基础制动应优先采用轴盘制动，其次为轮盘制动；动车组转向架尽量不采用撒砂装置，若非用不可，考虑在砂箱和喷砂嘴之间采用软管连接，以适应变轨距时的运动补偿；在对变轨距转向架进行研发的同时，应注意地面变轨设施的广泛使用，使之达到简统化、标准化的要求；变轨距转向架的研制必须考虑不同轨距铁路的限界要求，轨距相差越大，对限界要求也就越高。所研发的动车组整车于西南交通大学滚振试验台上，在施加中国客运专线线路谱激扰的情况下，最高运行速度达到了602 km·h-1，并于2020年10月21日成功下线。Abstract: To address the problems in the development and design of 400 km·h-1 variable gauge EMUs bogies in China, five important problems for Chinese high-speed variable gauge EMUs bogies (i.e., traction motor mounting, type of wheel set drive, axle box bearing, track changing mechanism, foundation brake, and sanding device) were studied based on the mature variable gauge bogie technologies developed in other countries. Corresponding solutions to the problems discovered in this study were also proposed. Research result shows that both the electric motor suspension and body suspension can make room for the installation of brake disc, but those will be relative displacements between the motor and the driven axles, which requires motion compensation measures. To meet the requirements of axle size and rotating speed of 400 km·h-1 variable gauge EMUs, it is necessary to develop new axle box bearings. The existence of track changing mechanism will increase the unsprung mass of bogie, so the developed variable gauge bogie should adopt a lightweight design as much as possible. Considering the effects of braking efficiency and caliper follow-up on the braking effect of variable gauge bogie, the basic braking should be given priority to the axle disc braking, followed by the wheel disc braking. Sanding device shall not be used for bogie of EMU, if it is absolutely necessary, considering using a hose connection between the sandbox and the sandblasting nozzle to adapt to the motion compensation when the gauge changes. While researching and developing the variable gauge bogie, attention should be paid to the wide use of ground track changing device, so that they can also meet the requirements of simplicity and standardization. The development of variable gauge bogie must consider the clearance requirements of different gauge railways, the greater the gauge difference, the higher the clearance requirement. On the rolling vibration test-bed of Southwest Jiaotong University, the maximum running speed of the developed EMU reaches 602 km·h-1 under the condition of applying line spectrum excitation of Chinese passenger dedicated line and it was successfully launched in October 21, 2020. 2 tabs, 10 figs, 36 refs.
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Key words:
- EMUs /
- variable gauge bogie /
- axle box bearing /
- ground track changing device /
- motor suspension mode /
- clearance
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图 3 DB AG/Rafil Type V变轨距转向架轮对结构
Figure 3. Wheelset structure of variable gauge bogie of DB AG/Rafil Type V
图 4 E30A和E30B变轨距转向架轮对结构
Figure 4. Wheelset structures of E30A and E30B variable gauge bogies
图 6 轴承类型、润滑情况与其转速的关系
Figure 6. Relationship among bearing type, lubrication and rotating speed
图 7 德国变轨距轮对的锁紧/解锁机构
Figure 7. Locking/unlocking mechanism of variable gauge wheelset in Germany
图 8 E30B型变轨距转向架锁紧/解锁机构
Figure 8. Locking/unlocking mechanism of E30B variable gauge bogies
图 9 日本第三代变轨距转向架轮对结构
Figure 9. Wheelset structure of third generation variable gauge bogies in Japan
图 10 国外典型变轨距转向架地面变轨设施
Figure 10. Foreign typical ground track changing device for variable gauge bogies
表 1 各国变轨距转向架特点对比
Table 1. Comparison of characteristics of variable gauge bogies in different countries
国家名称 变轨距转向架名称 运行轨距/mm 轮对旋转方式 最高运行速度/(km·h-1) 适用车型 主要特点 西班牙 Talgo RD 1 668/1 435 独立式 260 客/货 轮对由2个半轴组成，车轮独立旋转，锁紧机构安装于短车轴 CAF BRAVA 1 668/1 435 独立式 250 客 扭矩的传递不通过车轴，车轴不旋转，齿轮箱通过万向轴与体悬电机相连 波兰 SUW2000 1 520/1 435
1 668/1 435
1 668/1 520/1 435整体式 200 客/货 车轮采用整体式旋转，依靠与车轴一体的固定套筒和轮毂加长区域的对插结构传递扭矩 德国 DB AG/Rafil Type V 1 524/1 435 整体式 160 货 锁紧机构设计在车轮轮毂处，左右车轮以整体式旋转，设计速度较低 日本 E30A 1 435/1 067 独立式 210 客 采用独立旋转车轮，牵引电机采用外转子式，转子和车轮直接相连来传递扭矩 E30B 1 435/1 067 整体式 210 客 采用整体式旋转车轮，曲线通过性能良好，牵引电机架悬，采用平行万向轴驱动方式并用滚子花键传递扭矩 
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表 2 几款标准轴承相关参数
Table 2. Relevant parameters of several standard bearings
轴承类型 轴承型号 轴承内径/mm 轴承外径/mm 轴承宽度/mm 额定载荷/kN 极限载荷/kN 参考转速/(r·min-1) 极限转速/(r·min-1) 圆柱滚子轴承 NJ 238 ECML 190 340 55 800 965 2 000 3 400 圆柱滚子轴承 NJ 238 ECM 190 340 55 800 965 2 000 2 000 圆柱滚子轴承 NUP 238 ECML 190 340 55 800 965 2 000 3 400 圆柱滚子轴承 NUP 238 ECM 190 340 55 800 965 2 000 2 000 圆柱滚子轴承 NU 2238 ECML 190 340 92 1 220 1 600 2 000 3 400 圆柱滚子轴承 NU 2238 ECM 190 340 92 1 220 1 600 2 000 2 000
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