Research progress on safety of heavy-haul locomotive and bearing stability of couple and buffer system
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摘要: 针对重载机车与钩缓装置服役安全性问题，在系统梳理相关线路试验和理论仿真基础上，阐明了钩缓装置受压稳定性、重载机车侧向过岔安全性与车钩分离的产生原因、作用机理和影响因素，提出了机车安全性与钩缓稳定性的提升技术，并展望了未来的研究重点和发展方向。研究结果表明：在列车纵向冲击载荷作用下，重载机车主要安全性问题包括直线与大半径曲线上的压钩稳定性、电制侧向通过道岔安全性和组合编组中部机车车钩分离；对于压钩稳定性问题，扁销钩缓装置在一般水平压钩力作用下依靠钩尾圆弧面摩擦作用能够保持车钩对中稳定，当遭遇极端压钩力时容易发生横向偏转失稳，可通过优化机车二系横向刚度、横向止挡间隙和刚度等方式提升系统整体受压稳定能力，圆销钩缓装置依靠具有机械止挡特性的钩尾钩肩结构，能够抵御大压钩力作用，需与机车悬挂参数合理匹配，提高机车二系横向刚度，可使车钩在更大压钩力下保持稳定状态，但当车钩必然会偏转至钩肩发挥作用时，过大二系横向刚度又会使轮轨横向约束作用增强；对于机车电制通过12号道岔侧线与小半径曲线问题，圆销车钩具有更好的随曲线方向变化的跟随性，通过控制电制力、优化操纵等方式能够有效提升机车侧向过岔安全性；组合编组中部机车车钩分离的作用机理为中部机车所受车钩力出现“过零”状态，牵引或电制力垂向分力释放引起车钩钩头向上弹跳，紧随其后的大拉钩力将连挂车钩呈倾斜状态拉开，除了优化列车操纵、控制车钩高度差等缓解性的措施，根本解决方法是增设防脱装置。该研究工作能为中国重载铁路运输安全性提升、3万吨乃至更高吨位重载组合列车的成功开行提供技术支撑，未来应进一步在系统仿真模型修正、结构参数多目标优化、精细化列车操纵优化、机车安全监测与评估方法等方面开展研究。Abstract: In response to the service safety of heavy-haul locomotive and its coupler and buffer system, based on the systematic review of relevant line tests and theoretical simulations, the causes, mechanisms, and influencing factors of three main problems were systematically summarized, including the compressed stability of coupler, the safety of lateral crossing turnout for heavy-haul locomotive and the coupler separation, the improvement technologies for locomotive safety and coupler and buffer system stability were proposed, and the future research focus and development direction were forecast. Research results indicate that under the in-train longitudinal forces, the main safety issues of locomotive are the stability of coupler under compression on straight line or large curve, the safety of lateral crossing turnout for heavy-haul locomotive during electric braking, and the coupler separation in the middle of combined train. For the stability of coupler and buffer system, flatten pin coupler can maintain alignment stability by relying on the contact friction effect between coupler tail and follower plate under general longitudinal forces, but will be prone to lateral deflection instability under extreme compressed forces. The stability of coupler and buffer system can be improved by optimizing the secondary lateral stiffness, lateral stop clearance and stiffness of locomotive. The coupler with circular pin can resist the large longitudinal forces by relying on the mechanical stopper from coupler tail and shoulder, and will maintain a stable state by improving the secondary lateral stiffness of locomotive and reasonably matching with the suspension parameters. However, when coupler deflects to shoulder to play a role, excessive secondary lateral stiffness will strengthen the lateral constraint effect of wheel and rail. For the safety problem that locomotive crosses the branch line of 12-type switch or small curve, the coupler with circular pin can follow curve direction, and the safety of locomotive can be effectively improved by controlling electric braking force and optimizing operation. For the coupler separation in the middle of combined train, the mechanism is that the coupler force of middle locomotive experiences a "zero crossing" state, the releasing of vertical component of traction or electric braking force causes coupler head to bounce upwards, and following large pulling force immediately separates trailer coupler at an angle. Although some measures such as optimizing train operation and controlling coupler height difference can be taken to mitigate coupler separation, the fundamental measure is still adding anti-detachment device. The research work provides technical support for the safety improvement of China's heavy-haul railway transportation and the successful operation of 30 000-ton or even higher heavy-haul combined train. The further research should be carried out in the aspects of system simulation model correction, multi-objective optimization of structural parameters, refined train handling optimization, and safety monitoring and evaluation methods of locomotive. 27 figs, 81 refs.
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图 2 不同试验工况下重载机车运行安全性参数
Figure 2. Running safety parameters of heavy haul locomotives under different test conditions
图 4 12号道岔侧向通过时实测轮轴横向力回归分析结果
Figure 4. Regression analysis results of measured wheelset lateral forces during lateral passing 12-type turnout
图 8 102型钩缓装置受压和受拉状态下结构位置关系
Figure 8. Structure position relationship of 102-tpye coupler and buffer system under tension and compression
图 9 安装100钩缓装置机车安全性指标随车钩偏转角的变化
Figure 9. Change of running safety indexes with coupler rotation angle for locomotive with 100-tpye coupler and buffer system
图 11 基于曲面-曲面接触摩擦的扁销钩缓装置动力学模型
Figure 11. Dynamics model of flatten pin coupler and buffer system based on surface-surface contact friction
图 12 基于多边形接触方法的扁销钩缓装置动力学模型
Figure 12. Dynamics model of flatten pin coupler and buffer system based on polygonal contact method
图 15 机车电制侧向通过12号道岔时的动力学响应
Figure 15. Dynamics responses of locomotive with electric braking during lateral passing 12-type turnout
图 16 摩擦因数对扁销车钩偏转角的影响
Figure 16. Influence of friction coefficient on deflection angle of coupler with flat pin
图 17 新型高稳前从板及其改进效果
Figure 17. New high-stability front following plate and its improved effect
图 18 二系横向止挡参数对车钩偏转角的影响
Figure 18. Influence of secondary lateral stop parameters on coupler rotation angle
图 19 FXD1B机车试验动力学响应随车钩力变化
Figure 19. Variation of tested dynamic responses with coupler force for FXD1B locomotive
图 20 不同二系悬挂横向刚度下2种型号机车动力学响应随里程分布
Figure 20. Distributions of dynamics responses with distance for two locomotives with different secondary lateral stiffnesses
图 21 圆销钩缓装置动力学模型
Figure 21. Dynamics model of cylindrical pin coupler and buffer system
图 22 圆销钩缓装置计算与试验结果对比
Figure 22. Comparison of simulation result and test data for cylindrical pin coupler and buffer system
图 23 机车动力学响应最大值随车钩受压最大自由转角变化曲线
Figure 23. Variation curves of maximum locomotive dynamics responses with maximum coupler free rotation angle under compression
图 24 机车电制侧向通过12号道岔时的实测动力学响应
Figure 24. Tested dynamic responses of locomotive with electric braking during lateral passing 12-type turnout
图 25 两种机车轮轴横向力随电制级位变化
Figure 25. Variation of wheelset lateral forces of two kinds of locomotives with different electric braking level
图 26 轮轴横向力随机车电制力和钩尾摩擦因数变化曲线
Figure 26. Variation curves of wheelset lateral forces with electric braking force and coupler-tail friction coefficient
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