High Precision Power Transmission Automatic Transmission Gearbox for Rail Vehicle

Introduction of Automatic Transmission Gearbox for Rail Vehicle

Track vehicles are mainly used in railway maintenance, railway construction and inspection. The power output by the traction motor of the rail vehicle is transmitted to the wheels through the gearbox, driving the rail vehicle to move. Therefore, the gearbox is a key transmission component in the rail vehicle.

The Core Features of Automatic Transmission Gearbox for Rail Vehicle

(1) an efficient power transmission system adopts a three-level structure of planetary gear design, with a transmission efficiency in the 96.2% – 98.5% range. Through the precisely calculated tooth profile contour curve, the optimization effect of reducing the contact stress by 23% is achieved. Equipped with a self-developed double-circulation forced lubrication system, it ensures stable operation under extreme working conditions ranging from -40
℃to 120℃
(2) strong carrying capacity of the box using ductile iron QT600, 3 whole casting processes, with a yield strength of 370 MPa or higher. The gear set undergoes carburizing and quenching treatment, with a surface hardness of HRC58-62 and the core maintaining toughness of HRC30-35. Verified by bench tests, the maximum input torque carrying capacity reaches 32,000 Nm, meeting the requirements of the UIC standard.

(3) Intelligent monitoring integrated vibration spectrum analysis module operation, set up eight monitoring axial/radial vibration data in real time. It is equipped with an internal oil metal particle detection system and will automatically alarm when the concentration of ferromagnetic substances exceeds 15 ppm. Equipped with a temperature compensation device to ensure that the viscosity of the lubricating oil is stable within the range of ISO VG220±5%.

The Functions of Automatic Transmission Gearbox for Rail Vehicle

(1)the power adapter is central by 2:1 to a variable speed ratio of 6:1, perfect matching the diesel engine work 1500-2100-RPM range and 200-350-RPM wheel speed requirements. The unique torque-doubling mechanism can increase the output torque to 3.8 times the input torque, ensuring the power reserve when starting under heavy load.

(2) The three-step synchronizer switch operation mode innovation design structure implements moving shift time 1.2 seconds or less. Equipped with an electronic pre-selection file system, it supports both manual and automatic dual-mode operation. Under emergency braking conditions, the reverse torque transmission efficiency can reach 82% of the forward torque, significantly shortening the braking distance. (3) The inertial energy storage device for the energy management optimization, recycled 15% to 18% kinetic energy in the deceleration phase. The intelligent lubrication flow distribution system automatically adjusts the oil supply volume according to different working conditions, saving 7.3% energy compared with the traditional design. The heat sink type oil cooling system keeps the continuous working temperature stable within the optimal range of 85±5℃.

The Applications of Automatic Transmission Gearbox for Rail Vehicle

(1) the main force of railway transportation in shunting locomotive DF4D type, double gear box configuration implementation, 0 to 40 km/h stepless variable speed. In the application of freight locomotives, the tractive force is increased to 245kN through a combined reduction mechanism. The high-speed EMU adopts a parallel shaft-planetary compound transmission to ensure the smoothness of transmission at a speed of 350 kilometers per hour.

(2) special engineering tunnel construction, track car configuration, heavy-duty gearbox, box body wall thickness increased to 25 mm, to deal with frequent start-stop conditions. The modified model of the mine transport vehicle is equipped with a dust-proof labyrinth structure, and the dust protection level reaches the IP6K-9K standard. The polar exploration vehicles are equipped with low-temperature starting kits, and the success rate of cold starting in an environment of -50℃reaches 100%.

(3) Intelligent predictive maintenance system upgrade direction of the latest research and development, and build a digital twin model by collecting 200 + operation parameters. By applying deep learning algorithms, a 200-hour early warning of faults is achieved. The magnetorheological fluid clutch device in the pilot application has shortened the power engagement time to 0.08 seconds and reduced the impact by 65%.

The Technology Breakthrough of Automatic Transmission Gearbox for Rail Vehicle

(1) the application of nano composite material technology innovation penetration technology, the contact fatigue life of the gear up to 2.1 * 10 ^ 7 loops. Develop a new type of aluminum matrix composite material box, reducing the weight by 18% while maintaining the same strength. The theoretical service life of ceramic rolling bearings in the test stage can reach 100,000 hours.

(2) manufacturing accuracy control the grinding-compound gear honing processing technology, tooth surface roughness Ra 0.4 microns or less. The processing of the box body adopts five-axis linkage CNC machine tools, and the shape and position tolerance are controlled within 0.015mm. The assembly process uses a laser alignment system to ensure that the concentricity error of each shafting is
≤0.01mm.

(3) The environmental adaptability of the plateau type product configuration design pressurization compensation device ensures power with no attenuation, 5000 meters above sea level. The coastal dedicated version is equipped with multi-layer composite coating protection and has passed the 3,000-hour salt spray test. In desert areas, a cyclone dust removal system has been modified and added, which can operate continuously for 48 hours during sandstorm weather.

Package of Automatic Transmission Gearbox for Rail Vehicle

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