马来西亚项目培训教材c

1、编制： 转向架设计部prepared by: bogie design department属性：attribute:南车南京浦镇车辆有限公司csr nanjing puzhen rolling stock co.,ltd.项目：马来西亚dmu项目project:malaysian dmu project类别：设计文件cate. design docu. 文件名称/title马来西亚转向架培训教材/cd(中文)xxxxxxxxxxxxxxxxx/cd（英文）姓名/name签字/visa日期/date编制prepared 审核checked 审核checkedrams 审核rams checke

2、d 审核checked批准approved目 录table of contents 1.1xxx51.1.1xxx51.1.2xxx51.1.3xxx51.2xxx51.2.1xxx51.2.2xxx51.2.3xxx61.2.4xxx61 目的/ purpose 该文件主要介绍了马来西亚转向架的主要结构、主要组装过程、转向架落成找平要求、转向架常见的分解过程以及转向架运用维护要求。该文件的主要目的使用户对转向架的结构和日常使用维护有一定的了解，便于后期的日常维护。this document mainly gives an introduction to the primary structu

3、re, the basic assembly process, the requirements for installation and assemble of bogie and for its adjustment, the common dismantling process and the requirements for operation and maintenance of the bogie. it aims to providing the users a better understanding of bogie structure and the routine ope

4、ration and maintenance for their later use.2 概要/general pw15型转向架是为了适应马来西亚沙巴州铁路的运用环境及使用要求，本着采用成熟、可靠的原则，以工厂成熟产品pw200k型转向架及庞巴迪am96转向架为设计原形，根据多年的转向架设计经验和转向架研制技术储备为基础进行改进设计而成的新型米轨客车转向架。转向架的设计吸收我公司与国际知名车辆制造商多年合作经验，采用国际上先进的设计理念和技术，最大限度采用了成熟、可靠的结构，并充分考虑运行安全性、乘坐舒适性、互换性以及运用维护方便等技术要求。该转向架采用无摇枕、无摇动台和无旁承的“三无”结构，

5、结构简单紧凑，使用维修方便。主要由构架装置、轮对轴箱定位装置、二系悬挂装置及基础制动装置等组成。该转向架采用了现代高速客车转向架较为经典的u型构架、转臂式轮对轴箱定位装置、二系悬挂装置采用无摇枕高舒适度的空气弹簧悬挂；基础制动装置采用每轴两套盘形制动单元、加装电子防滑器，且每轴有2套盘形制动单元均具有停放功能。pw15 bogie is of a new type used for the meter-gage passenger car, which is improved and designed based on years of bogie design experiences and

6、 r & d technology, and to meet the requirements for operating in the environment of sabah, malaysia. in the principle of being well-proven and reliable, the design of this bogie adopts the prototype of the mature product pw200k bogie and the am96 bogie from bombardier. through years of cooperation w

7、ith international renowned vehicle manufacturers, taking advanced design philosophy and technology around the world, this bogie is designed with the maximum use of mature and reliable structures, and with adequate consideration to operation safety, riding comfort, interchangeability and easy operati

8、on and maintenance. with a simple and compact structure but without such parts as bolsters, swing bolsters and side bearings, it is easy to operate and maintain. its primarily made up of the frame assembly, the wheel-set axle box positioning device, the secondary suspension system and the foundation

9、 brake rigging. it uses the u-frame which is typical on the bogie for modern high-speed trains, and the rocker type wheel-set axle box positioning device. the secondary suspension system uses bolsterless air spring suspension with high comfort level while the foundation brake rigging has two disc br

10、ake units for each axle, and is provided with the electronic anti-skid device. the two disc brake units both have the parking function.pw15型转向架主要特点如下：pw15 bogie has the following characteristics:a) 采用连杆外置式抗侧滚扭杆技术，大大提高了抗侧滚扭杆的整体可靠性，并且便于抗侧滚扭杆的安装和维护。 it uses the technology of anti-roll bar with external

11、 rod, which greatly improves the reliability of the whole anti-roll bar and provides easy mounting and maintenance of it.b) 采用了“z”型双牵引拉杆结构，能可靠地传递牵引力和制动力，在保证合适的纵向刚度前提下，尽可能的减小了垂向和横向刚度，较好的适应了车体和转向架间的相对运动。 it adopts the structure of z-shape duplex-drawbar, which can transmit tractive force and brake for

12、ce reliably, and can reduce as much as possible the vertical and lateral stiffness while ensuring proper longitudinal stiffness, thus provides a good accommodation of the relative movement between the carbody and the bogie.c) 组成构架的板材和无缝钢管，焊缝均采用进口材料；构架以及其上铸件的制造和检验均采用uic、en等标准。 all the plates and seam

13、less steel pipes which make up the frame use imported materials; the frame and the castings on it are manufactured and tested in accordance with the uic, en standards.d)轮对轴箱组成采用现有成熟的结构,轴箱弹簧组成设有了工艺定位螺栓，弹簧上夹板上加了绝缘垫，增加了构架与轮对轴箱绝缘性能，简化了结构，方便后期的维修和保养。 the wheel-set axle box assembly adopts current mature

14、structures. the axle box spring assembly is equipped with jack bolts, and the upper plate of the spring is fitted with the insulation washer, which promotes the insulation performance of the frame and the wheel-set axle box and also simplifies the structure so that easy repair and maintenance are to

15、 be achieved.e)采用无摇枕全空气弹簧支重不仅简化了悬挂结构，空气弹簧内设有截流阻尼器，简化了二系悬挂结构，减轻了重量，还提高了安全性和可靠性，并减少了运用中的检修工作量。the use of bolsterless and full air spring support not only simplifies the suspension structure, the cut-off damper installed in the air spring simplifying the secondary suspension structure and reducing the

16、weight, but enhances safety and reliability so as to reduce the repair work to be encountered in operation.f)结构简单、安全可靠，便于制造、维修。the simplified structure with safety and reliability is easy for manufacture and repair.3 转向架结构特点/ structural characteristics of the bogie3.1 转向架主要技术参数/basic technical param

17、eters of the bogie ：n 轨距/ gauge（mm）： 1000n 最高运营速度/maximum operation speed（km/h) ： 100n 最高试验速度/maximum test speed (km/h ) : 110 n 轴重/axle weight（t）： 14 n 最小平面曲线半径/minimum plane curve radius(m) 正线/main line 100站场/station yard 80n 固定轴距/rigid wheelbase(mm)： 2300n 空气弹簧中心距/distance between air spring cent

18、ers(mm)： 1700n 空簧上平面距轨面高度 (mm) upper plane of the air spring above the top of the rail(mm) 935n 轴颈中心距/distance between journal centers（mm）: 1600n 轮对内侧距/distance between backs of wheel flanges（mm）: 9231 n 轮径/wheel diameter（mm）： 新轮/new 851 磨耗到限/fully worn 781 n 车轮踏面外形/wheel tread profile： br p8n 自重/de

19、adweight (t) : 约/approximately 5.2n 限界： 沙巴州铁路车辆下部限界gauge: underneath gauge of the rolling stock of sabah3.2 转向架总体结构/ overall structure of the bogie：转向架采用无摇枕结构。构架采用焊接构架；一系悬挂采用钢弹簧转臂定位；二系采用空气弹簧承载，“z”型双拉杆牵引及抗侧滚扭杆；制动采用盘形制动。转向架结构见图1。the bogie is bolsterless with its welded frame. steel spring rocker locat

20、ing is used for the primary suspension while the air spring load and the z-shape duplex-drawbar and anti-roll bar are for the secondary suspension. and the disc brake is applied. the structure of the bogie is seen in fig. 1. 图1 转向架结构fig.1 bogie structure3.2.1 构架装置/frame assemby：构架装置采用钢板拼焊而成的“h”型构架。主

21、要由侧梁、横梁和中心框架等部件组成。 侧梁封闭内腔及横梁内腔作为空气弹簧的附加气室。 the frame is h-shape assembly soldered with steel plates. it mainly consists of side sills, crossbeams and central frames. the enclosed cavity of the side sill and the crossbeam cavity work as the additional air chambers of the air spring. 横梁/crossbeam中心框架/

22、central frame侧梁/side sill图2 构架装置fig. 2 frame assembly3.2.1.1 材料属性/material property： n 组成构架所用的钢板采用en10028-3的p355nl1p355nl1 steel plates complying with en10028-3 are used.n 铸钢件采用nf a 32-054的ge280ge280 steel castings complying with nf a 32-054 are used.n 无缝钢管采用s355j2h，符合en 10210 s355j2h seamless steel

23、 pipes complying with en 10210 are adopted.3.2.1.2 构架制造要求/requirements for frame manufacture： u 焊工资质符合en287-1 the qualification of the welder accords with en287-1u 无损探伤操作人员资质符合en473。qualification of the non-destructive inspection operator accords with en473.u 焊缝缺陷的验收标准按照iso 5817。the acceptance crite

24、ria of seam defects comply with iso 5817.u 构架焊接后，根据nf f 01-810要求进行消除应力退火。once the frame has been welded, stress-relief annealing should be conducted according to nf f 01-810 requirements.u 构架在有平台的数控铣床进行机加工，机加工后，在3维检测仪上检测构架各关键尺寸，尺寸公差符合设计要求。the frame is machined by the cnc milling machine with a platf

25、orm. afterwards, all the key dimensions of the frame should be detected by the three-dimensional detector, and their tolerance meets the design requirements.u 对检查合格的构架装置进行油漆保护，使构架装置符合马来西亚的特殊使用环境要求。paint the frame assembly which has been qualified in tests to meet the special operational environment

26、of malaysia.3.2.1.3 构架强度计算及试验按uic515-4执行/fatigue calculation and test on the frame is carried out in accordance with uic515-43.2.2 一系悬挂/ primary suspension一系悬挂采用钢弹簧转臂式定位结构，垂向刚度由钢弹簧提供，纵向、横向定位刚度由弹性定位套组成提供，定位精度较高。钢弹簧采用双卷螺旋弹簧。垂直方向上设轮对提吊装置，在起吊转向架时吊起轮对。定位转臂采用铸造结构，一端通过弹性定位套组成与构架相连，另一端与轴箱相连并用夹紧箍紧固，并在端部设置一系垂

27、向减振器的安装座。一系悬挂装置结构见图3。the primary suspension has the steel spring rocker locating structure which enjoys a high locating accuracy as the vertical stiffness is provided by the steel spring while the longitudinal and the lateral locating stiffness are provided by elastic locating sleeve. the steel spri

28、ng uses the dual coil spring. the wheel-set lifts are provided vertically to lift the wheel-set for the purpose of bogie lifting. the positioning rocker adopts cast structure, one end of which is connected to the frame via flexible locating sleeve, and the other end, where the mounting seat for the

29、primary vertical damper is installed, is connected to the axle box while fastened with bail. the structure of the primary suspension system is seen in fig.3.1) 钢弹簧按gb1239的要求进行设计计算，并按tb/t1025的要求进行制造和采购。steel springs are designed and calculated in accordance with gb1239, while manufactured and purchas

30、ed according to tb/t1025.2) 定位转臂及夹紧箍采用熔模铸造，材质为c级钢，符合tb/t2942的要求，并对关键部位进行探伤检查。positioning rockers and bails are investment castings with class c steel as its material which meets the requirement of tb/t2942. its capable of flaw detection on key positions.3) 弹性定位套组成为橡胶与金属硫化而成，压装于定位转臂内，并通过定位轴固定于构架上。节点的

31、纵向刚度kpx=7.5mn/m，横向定位刚度kpy=5mn/m。为了保证构架与车轮之间的绝缘电阻要求，定位节点的绝缘电阻不小于50m。定位节点的制造和采购按nf f01-815执行。the flexible locating sleeve assembly, which is vulcanized with rubber and metal, is press fit into the rocker and fixed on the frame through the locating axle. longitudinal stiffness of the node kpx=7.5mn/m,

32、lateral locating stiffness kpy=5mn/m. to meet the requirement for the insulation resistance between the frame and the wheels, the insulation resistance of the locating node shall be no less than 50m. the locating node is manufactured and purchased according to nf f01-815.绝缘垫/insulation washer为便于后期维修

33、，在钢簧上下夹板处设置了弹簧预紧工艺螺栓接口in order to be maintained easily, bolt interfaces for spring preloading are set at the upper and lower plates of the spring转臂/rocker缓冲垫/cushion pad弹簧下夹板/lower plate of the spring一系钢弹簧/steel spring of the primary suspension弹簧上夹板/upper plate of the spring轮对提吊/wheel-set lift上夹板 一系

34、减振器/ primary damper 夹紧箍/bail286弹性定位套/flexible locating sleeve 图3 一系悬挂装置fig.3 primary suspension system3.2.3 轮对轴箱装置/wheel-set axle box device轮对轴箱装置主要由车轮、车轴、制动盘、轴箱装置等组成。轴箱采用外置式轴箱，轴颈中心距为1600mm，根据业主要求轮对内侧距设置为923mm。轮对轴箱装置结构如图4the wheel-set device mainly consists of wheels, axles, brake discs, and axle bo

35、xes. the axle box is of external type. the distance between journal centers is 1600mm. as is required by the employer, the distance between inner sides of the wheel-sets is 923mm. the wheel-set axle box device has the structure shown in fig.4.轴箱axle box制动盘brake disc车轴axle车轮wheel图4 轮对轴箱装置fig.4 wheel-

36、set axle box device3.2.3.1 车轮/wheels车轮采用整体辗钢车轮，新轮直径为851 mm，磨耗到限为781 mm，根据业主要求，车轮踏面外形为br p8，车轮上设置注油退轮的注油孔。monobloc rolled steel wheel is used, whose diameter is851 mm when new and 781 mm when fully worn. in the employers requirement, the outline of the wheel tread is br p8, and the oil filler hole is

37、 provided on the wheel to remove the wheel by filling oil.3.2.3.2 车轴/axle车轴轴颈直径为130mm;车轴的制造应符合tb 2945 的要求，材质为lzw。the diameter of axle journal is130mm;the axles manufacture comply with tb 2945 witch material is lzw.3.2.3.3 制动盘/brake disc采用轴装式制动盘，毎条轮对上安装2个制动盘。直径为610。the brake disc is installed on the

38、axle, and each wheel-set is fitted with two brake discs whose diameter is610.1) 轮对采用过盈压装，压装力和压装曲线符合en13260的要求。车轮和轴装制动盘的拆卸均采用注油拆卸。the wheel-set is interference pressfit. the pressfit force and curve meet the requirements specified in en13260. dismantling of wheels and brake discs on the axle are both

39、 accomplished through filling oil.2) 轴端布置根据列车总体设计要求进行布置。在车辆2、4、6、8位轴端安装测速传感器，2、3、6、7位轴端连接接地线。axle end arrangement is compliant with the general design requirements of the train. tacho-generators are provided on axle ends 2, 4, 6, and 8 while axle ends 2, 3, 6, and 7 are connected with grounding wire

40、s.3.2.3.4 轴箱装置/axle box arrangement轴箱装置由防尘板、轴箱体、分体轴承及轴端压盖组成；（见图5 ）the axle box is made up of dust shield, axle box body, split bearings and shaft glands;(see fig.5)n 采用skf分体轴承，型号：bc1b322880/bc1b322881 ； skf split bearings are used, whose type is bc1b322880/bc1b322881;n 国内成熟的轴箱迷宫密封方式； domestically we

41、ll-proven labyrinth seal for the axle box n 易于维护检修； easy maintenance and repair;防尘板/dust shield 轴箱体/axle box body 分体轴承/split bearing 轴端压盖/shaft gland图5 轴箱装置fig.5 axle box assembly3.2.4 二系悬挂装置/secondary suspension system二系悬挂装置采用无摇枕结构，由空气弹簧全承载。主要由空气弹簧、二系横向减振器、横向挡、防过充钢丝绳、高度阀、差压阀等组成。二系悬挂装置结构见图6。二系横向减振器/

42、secondary lateral damper防过充钢丝绳/anti-overinflating steel cable空气弹簧/air spring差压阀/differential valve横向挡/lateral stop高度阀/leveling valve图6 二系悬挂装置fig.6 secondary suspension system1) 空气弹簧主要由胶囊和应急橡胶弹簧组成。应急橡胶弹簧应保证当空气弹簧无气时，能限速运行到站。转向架上为每个空气弹簧设置一个附加气室（约70l），降低空气弹簧的垂向刚度。见图7the air spring is composed of rubber

43、air bag and emergency rubber spring. the emergency rubber spring shall ensure the train to run into the station at limited speed when the air spring is out of air. one air chamber (about 70l) is attached to each air spring on the bogie to reduce the vertical stiffness of the air spring. (see fig.7)与

44、附加气室相连/connected to the attached air chamber节流阀/baffler空气弹簧进风/air spring air intake图7 空气弹簧fig.7 air spring2) 横向挡作用是抑制车体横向运动；横向挡与牵引销上的横向挡座之间有20mm间隙，当车体横向运动超过20mm时，横向挡与安装在车体上牵引销接触从而抑制车体横向运动。横向挡是由橡胶和金属硫化而成，具有一定的弹性，能提供一个非线性的横向刚度。the lateral stop functions to suppress the lateral movement of the carbody;

45、 the gap between the lateral stop and the lateral block on the towing pin is 20mm. once it is exceeded, the lateral stop gets to the towing pin on the carbody so as to suppress the carbody movement. the lateral stop, which is elastic to some extent, is vulcanized with rubber and metal to provide a n

46、onlinear lateral stiffness.3) 每个空簧设置高度控制阀，保证车辆在不同载重状态下，车体地板面保持相同的高度；两附加气室之间设置差压阀，使两个空气弹簧的压力差保持在设定范围内。each air spring is fitted with the leveling valve to ensure the floor is at the same height under different loading conditions; the differential valve is provided between two attached air chambers to

47、 keep the pressure difference of the two air springs staying in the setting range.高度阀的主要工作状态有一下3种：the lvevling valve has three work conditions:u 平衡位置/equilibrium position：该状态下作用在空簧的载荷是稳定的或者说空簧上平面距轨面高度（935mm）是不变的，此时高度阀调节杆的水平杆处于中间位置，如a图所示；under this condition, load applied on the air spring is stable,

48、 or to say the upper plane of the air spring above the top of the rail (935mm) is constant, and the horizontal bar of the leveling valve adjuster bars is in the middle, as shown in fig.a .u 充气位置/inflating position：当由于车体上载荷的增加或其他原因使得平衡位置状态下的空簧上平面距轨面高度降低时，高度阀调节杆的水平杆处于充气位置，如b图所示；此时风源与空簧之间的管路是打开的，风压将从风源

49、向空簧充气，从而使空簧上平面上升，当空簧上平面上升到距轨面高度935mm时，风源与空簧之间的管路将会关闭，充气完成。when increase of the load on the carbody or other factors cause reduction in the height of the air spring upper plane above the rail top on equilibrium position, the horizontal adjuster bar is at inflating position, as shown in fig. b;here th

50、e pipe of the air source and air spring are open,the air pressure will flow from air source to the air spring,thereby the air spring upper plane will lift,when the air spring upper plane lift to 935mm above the top of the rail, the pipe of the air source and air spring are close,the inflating is fin

51、ish.u 排气位置/ exhaust position：当由于车体上载荷的减少或其他原因使得平衡位置状态下的空簧上平面距轨面高度上升时，高度阀调节杆的水平杆处于排气位置，如c图所示；此时外界（环境气压）与空簧之间的管路是打开的，风压将从空簧向外界排气，从而使空簧上平面下降，当空簧上平面下降到距轨面高度935mm时，外界与空簧之间的管路将会关闭，排气完成。when the reduction in the load applied to the carbody or other factors lead to the height increase of the air spring uppe

52、r plane above rail top on equilibrium position, the horizontal adjuster bar of the leveling valve is placed on the exhaust position, as shown in fig.c, and the pipelines connecting the environment (ambient air pressure) to the air spring are open, which enables the air pressure to exhaust from the a

53、ir spring to the environment, as a result, the air spring upper plane descends until its 935mm over the rail top. then the pipelines connecting the air spring to the atmosphere are closed and exhaust is done.空气弹簧/air spring风源/air supply调节杆水平杆处于水平位置/horizontal adjuster bar is on horizontal position进气

54、口/air inlet出气口/air outleta图 平衡位置出气/air outletfig.a equilibrium position风源/air supply调节杆水平杆处于充气位置/the horizontal adjuster bar is on inflating position空气弹簧/air spring进气口/air inlet进气/air inletb图 充气位置fig.b inflating position调节杆水平杆处于充气位置/ the horizontal adjuster bar is on inflating position风源/air supply空

55、气弹簧/air spring大气（外界）/ atmosphere(external)c图 排气位置 差压阀的作用是当左右空簧的压力差大于一定的数值（150kp）时，差压阀两边管路将开通，气体将从高压区流向低压区，从而使得同一转向架左右空簧的压力差保持在一定范围内（150kp），以防止由空簧压力过高而出现空簧过冲现象。when the pressure difference between left and right air springs is over a certain value (150kp), the pipelines on both sides of the differential valve shall be open, and air flow shall be from higher pressure zone to lower pressure zone, which maintains the pressure difference between left and right air springs of the sa