Power Steering Gear Box for Railway Transmission System

I. Overview of Power Steering Gear Box

As a core component for power transmission, the railway locomotive power steering gear box, plays a crucial role in energy conversion and power distribution in rail transportation. Its technical parameters directly affect the locomotive’s operational efficiency, energy consumption, and equipment service life. It is an important technical indicator for evaluating the manufacturing level of rail transportation equipment.

II. Materials Engineering System of Power Steering Gear Box

1.Main Structural Materials

(1) Alloy Structural Steel System

20CrMnTiH carburized steel: High-quality alloy steel treated by vacuum degassing, with a carbon content of 0.17-0.23%, and a chromium-manganese-titanium composite strengthening system.

Heat treatment process: Utilizes multi-stage controllable atmosphere carburizing technology, achieving a surface hardness of HRC58-62 and maintaining a core hardness of HRC30-35 for toughness.

Microstructure characteristics: Carbides are evenly distributed, with a grain size controlled at ASTM 7-8.

(2) Application of Special Cast Iron

The housing is made of QT600-3 ductile iron, with a tensile strength of ≥600MPa and an elongation of ≥3%.

Graphite morphology control: Spheroidization rate ≥90%, with a sphere diameter of 15-50μm.

Vibration-damping characteristics: Damping coefficient is 40-60% higher than that of ordinary cast steel.

(3) Lightweight Composite Materials

Application of aluminum alloy housing cover: ZL114A cast aluminum alloy, in T6 heat treatment state.

Surface hardening treatment: Micro-arc oxidation forms a 50-80μm ceramic layer, with a hardness of ≥ 800 HV.

Structural optimization: Topology optimization design reduces weight by 35% while maintaining the same stiffness.

Auxiliary Functional Materials

(1) Sealing system: Fluororubber (FKM) and polytetrafluoroethylene (PTFE) composite seals, with a temperature range of -40°C to 200°C.

(2) Lubricating medium: Fully synthetic gear oil ISO VG 320, containing organic molybdenum extreme pressure additives.

(3) Fastening system: 12.9 grade alloy steel bolts, with a surface Dacromet coating treatment.

III. Performance Index System of Power Steering Gear Box

1.Mechanical Performance Parameters

Torque capacity: Continuous working torque ≥150kN·m, peak torque 300kN·m.

Transmission efficiency: ≥98.5% (under rated conditions).

Noise control: Sound pressure level at 1m from the housing ≤85dB(A).

2.Durability Indicators

Bench test: 5000-hour full-load durability test.

Tooth surface contact fatigue strength: ≥1100MPa.

Bending fatigue limit: ≥ 400 MPa

3.Environmental adaptability

Operating temperature range: -50°C to +120°C

Protection grade: IP67 (dustproof and waterproof)

Vibration resistance performance: meets EN 61373 Cat.I standard

IV. Functions of Power Steering Gear Box

1.Power coupling module

Adopting a quasi-hypoid gear pair design, contact ratio ≥ 2.0

2. Shaping technology:

three-dimensional topological shaping, contact spots comply with ISO 1328 standard

Misalignment compensation capability: shaft deviation ≤ 15′

3.Load distribution system

Planetary gear system load equalization mechanism: floating sun gear design

Load imbalance degree: ≤ 5%

4. Overload protection:

shear pin type safety coupling

Thermal management system

5.Forced lubrication circulation system: flow rate 80 L/min @ 3000 rpm

6. Box body heat dissipation design: finned structure, heat dissipation area increased by 40%

7.Temperature monitoring: embedded PT100 temperature sensor, accuracy ±0.5°C

V. Applications of of Power Steering Gear Box

1.High-speed EMU

Transmission ratio range: 3.5 – 5.2

Maximum input speed: 6500 rpm

Special requirements: aerodynamic shape optimization, running smoothness index W ≤ 2.5

2. Heavy-duty freight locomotive

Torque reinforcement design: reinforced planetary carrier structure

Dustproof system: multi-stage labyrinth seal + centrifugal dust removal

Maintenance cycle: first box opening inspection at 500,000 kilometers

3. Shunting operation vehicle

Compact design: axial dimension ≤ 800 mm

Frequent start-stop optimization: reinforced buffer mechanism

Corrosion protection treatment: heavy-duty anti-corrosion coating system, C5-M anti-corrosion grade

VI. Technological development trends of power steering gearbox

1. Material innovation direction

Gradient material application: surface nanocrystalline layer + gradient transition zone

Self-lubricating material: metal matrix composite (MMC) embedded solid lubricant

Intelligent material: shape memory alloy overload protection device

2.Manufacturing technology breakthrough

Near-net-shape forming technology: 3D printing of planetary carrier as a whole

Digital twin system: a health management system based on PHM

Superfinishing: mirror grinding technology (Ra ≤ 0.2 μm)

major structure	material	QT600-3 ductile iron
	strength of extension	≥600MPa
	extend rate	≥3%
technology for heating processing	Adopt multi-stage controllable atmosphere carburizing technology	The surface hardness reaches HRC58-62
		The core retains HRC30-35 toughness
performance index	operating temperature range	from -50℃～+120℃
	level of protection	IP67 (Dust and water resistant)
application scenarios	high speed train	Transmission ratio range: 3.5-5.2
	Heavy-duty freight locomotive	Torque enhancement design: Reinforced planetary carrier structure
	Shunting operation vehicle	Compact design: Axial dimension ≤800mm

Package of of power steering gearbox

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