High Precision Power Steering Gear Box in Railway

Introduction of Power Steering Gear Box in Railway

In the moment when the steel dragon roars past, the gearbox housing is like a silent guardian, carrying the core transmission system of the rail locomotive. This precision container, cast from a special alloy, is not only a central fortress for power transmission but also a concentrated manifestation of the manufacturing level of modern rail transit equipment. As a key carrier connecting the wheel-rail power system, the manufacturing process of the gearbox housing embodies the cutting-edge achievements of the three major fields of materials science, structural mechanics, and precision manufacturing.

The Features of Power Steering Gear Box in Railway

The modern gearbox housing adopts the “pressure vessel” design concept, and its unique double-layer vibration isolation structure can be regarded as a model of mechanical engineering. The outer wall is made of high-strength ductile iron through vacuum high-pressure casting, and the surface of industrial gearbox is treated with a gradient quenching process to form a hardened layer of 0.8-1.2mm. This bionic design simulates the layered structure of a shell, ensuring impact resistance (up to 800MPa) while optimizing the overall weight to 65% of that of traditional cast steel parts. The aluminum alloy bushing in the inner cavity precisely fits with the casing through a hydraulic expansion process, with an error controlled within ±0.02mm. This “combination of rigidity and flexibility” effectively resolves the harmonic vibration generated by gear meshing.

The Function of Power Steering Gear Box in Railway

（1）In the design of the heat dissipation system, engineers innovatively introduced the turbine flow guiding principle of aero engines into the shell structure. The 128 spiral guide channels distributed on the outer surface are not simple decorations but heat dissipation channels optimized through fluid mechanics simulation. When the train speed reaches 350km/h, these microstructures can increase the air flow rate to 3.2 times that in the static pressure state. Combined with the built-in phase change energy storage material, the internal temperature rise of the power steering gear box does not exceed 45℃ during continuous operation. Compared with the traditional forced air cooling system, this passive cooling solution reduces energy consumption by 78% and eliminates the wear of moving parts.

(2)Modern motor gearbox housings have evolved into the carriers of intelligent monitoring systems. The 32 embedded MEMS sensors collect key parameters such as vibration spectrum, temperature gradient and stress distribution in real time. Feature extraction is carried out through the edge computing module, which can warn of potential faults 1,200 hours in advance. The intelligent anti-corrosion coating applied on the surface of the shell is more innovative. When the chloride ion concentration exceeds the threshold, the microcapsules in the coating automatically release corrosion inhibitors. This technology extends the maintenance cycle of key components from the traditional 2 years to 5 years.

(3)In the dimension of maintenance and repair, the modular design concept is fully reflected. Adopting the patented dovetail tenon-conical locking structure, a single technician can complete the replacement of the shell assembly within 45 minutes. All fasteners adopt a unified standard maintenance-free design, combined with an intelligent lubrication system, truly achieving an industry breakthrough of “maintenance-free for one million kilometers”.

The Manufacturing Techniques of Power Steering Gear Box in Railway

From raw material smelting to the finished product coming off the production line, the manufacturing of the industrial gear box housing involves 27 core processes. The casting process adopts the internationally leading V-process vacuum molding technology. Alloy molten liquid at 1650℃ is injected under a negative pressure of 0.08MPa to ensure that the density of the casting reaches over 99.3%. The cryogenic treatment carried out after rough machining is a highlight of the process: the components are kept in a liquid nitrogen environment at -196℃ for 72 hours. This extreme treatment enables the metal lattice to complete directional reorganization, increasing the material’s fatigue strength by 40% and improving dimensional stability by three grades.

In terms of sealing performance, the assembly process introduces in-situ curing technology originated from the aerospace field. The nano-scale sealant coated on the bonding surface forms a molecular-level bond under ultraviolet radiation, and its air-tightness reaches the IP68 protection grade standard. The specially designed labyrinth sealing structure includes three 90° interlaced oil seals, combined with a magnetic fluid sealing device, which can completely prevent external dust and water vapor from entering. It has demonstrated astonishing environmental adaptability in actual tests in desert and coastal environments.

The Package of Power Steering Gear Box in Railway

Polybag+Carton box+Wooden case/Pallet, according to customer’s request

Company Profile

Luoyang Fonyo Heavy Industries Co., Ltd. was founded in 1998, covers an area of 72,600㎡, with more than 300 employees, 32 technicians, including 5 senior engineers, 11 assistant engineers, and 16 technicians. It has been rated as Luoyang Engineering Technology Center, Luoyang Technology R&D Center, and National High-tech Enterprise for many times.
Our production capacity is 30,000 tons per year. Currently, we mainly produce cast steel, cast iron (gray iron, ductile iron, etc.), processing of finished product and component assembly for locomotive,railcar,high-speed trains, mining equipment,wind power,etc.Our products have been exported to Russia, the United States, Germany, Argentina, Japan, France, South Africa,Italy and other countries.

FAQS

Q1: Are you a manufacturer or trading company?
A:We are a manufacturer.Our company was founded in 1998, with nearly 30 years in casting industry, a total area of 72,600㎡, with a factory building area of 51,000㎡.
Q2. What are your main products?
A: We primarily focus on steel casting, iron casting, finished product machining, and component assembly production for locomotive,railcar,high-speed trains, mining equipment,wind power,etc.
Q3: How precision can you produce casting parts?
A: We have the capability of producing casting parts with different casting processes. The production is strictly comply with ISO 9001, ISO 14001 and ISO45001,EN15085, IRIS.
Q4. Can you produce according to the samples?
 Yes, we can produce by your samples or technical drawings. We can build drawings for you after we get your samples too.
Q5: How do you do Quality Control before delivery?
A: Quality inspection is a very important factor to guarantee the quality of steel casting parts. We follow 3 times of inspection during the whole production process. And we will provide material testing report, dimensional testing report, and mechanical properties testing report to our clients before delivery.

It you are interested in any products,please feel free to contact us.
Contact:Cathy Xu
Email:sales@railwaypart.com
Mobile:008615515321683