Abstract
In this paper, a numerical simulation model of the flow field in a gearbox with an oil volume adjusting device is established for the first time to study its influence on the lubrication characteristics of a high-speed electric multiple unit (EMU) gearbox. The moving particle semi-implicit (MPS) method is used to numerically simulate the internal flow field of the gearbox of the high-speed EMU under working conditions. The effects of the velocity of the high-speed EMU, the immersion depth, and the oil sump temperature on the power loss of the gears and the lubricant quantity of each bearing are studied and provide an effective tool for the quantitative evaluation of the lubrication characteristics of the gearbox. The lubrication characteristics of the gearbox under different working conditions are studied when the oil volume adjusting device is closed and opened. The results show that the oil volume adjusting device mainly changes the amount of lubricant stirred by the output gear by changing the flow rate of lubricant from the cavity pinion (Cavity P) to the cavity gear (Cavity G), and thus affects the power loss of gears and the lubricant quantity of each bearing.
Abstract
目的
油量调节装置作为高速动车组齿轮箱的一个重要零部件，可实现不同油温环境下自动调节从动齿轮搅油的油位。本文旨在探讨油量调节装置在不同工作状态下对齿轮功率损失和各轴承润滑油量的影响，为定量评估齿轮箱润滑特性提供有效依据。
创新点
1. 建立实际工况下高速动车组齿轮箱的高保真三维模型，并探讨油量调节装置的不同工作状态对齿轮箱润滑特性的影响；2. 在齿轮箱各轴承位置设置监测环，并从各轴承的润滑油油量和覆盖率的角度分析轴承润滑特性。
方法
1. 应用移动粒子半隐式（MPS）方法，对比分析油量调节装置的不同工作状态对齿轮箱润滑特性的影响；2. 通过与德国齿轮研究中心（FZG）的试验结果进行对比，验证数值仿真方法的准确性和适用性；3. 通过数值仿真，分析不同转速、不同浸油深度、不同油温等实际工况下的齿轮箱搅油功率损失和各轴承的润滑油油量。
结论
1. MPS方法非常适用于分析复杂结构的齿轮箱的润滑特性；2. 齿轮功率损失和各轴承润滑油油量与齿轮转速、浸油深度和润滑油油温呈正相关；3. 油量调节装置主要通过减少输出齿轮搅拌的润滑油油量来减少齿轮的功率损失和参与轴承润滑的润滑油油量。
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Acknowledgments
This work is supported by the Natural Science Foundation of Sichuan Province, China (Nos. 2022NSFSC0034 and 2022NSFSC1901), the National Railway Group Science and Technology Program (No. N2021J028), the Independent Research and Development Projects of State Key Laboratory of Heavy Duty AC Drive Electric Locomotive Systems Integration (No. R111720H01385), and the Independent Research and Development Projects of State Key Laboratory of Traction Power (No. 2022TPL-T02), China.
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Shuai SHAO and Yuan YAO designed the research. Shuai SHAO and Yi LIU processed the corresponding data. Shuai SHAO wrote the first draft of the manuscript. Kai-lin ZHANG helped to organize the manuscript. Jun GU contributed to the simulation technology of the study. Shuai SHAO, Yuan YAO, and Kai-lin ZHANG revised and edited the final version.
Conflict of interest
Shuai SHAO, Kai-lin ZHANG, Yuan YAO, Yi LIU, and Jun GU declare that they have no conflict of interest.
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Investigations on lubrication characteristics of high-speed electric multiple unit gearbox by oil volume adjusting device
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Shao, S., Zhang, Kl., Yao, Y. et al. Investigations on lubrication characteristics of high-speed electric multiple unit gearbox by oil volume adjusting device. J. Zhejiang Univ. Sci. A 23, 1013–1026 (2022). https://doi.org/10.1631/2023.A2200274
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DOI: https://doi.org/10.1631/2023.A2200274
Key words
- High-speed electric multiple unit (EMU)
- Splash lubrication
- Mesh-free moving particle semi-implicit (MPS) method
- Bearing lubrication
- Churning power loss
- Oil volume adjusting device