Method of repair restoration of gearbox and traction motor parts of electric locomotive 2es10 (options)

Abstract

FIELD: engine building.SUBSTANCE: invention relates to the restoration of gearbox parts and traction motor parts of an electric locomotive. According to the first option: after cleaning, the area for powder spraying is determined, with the welding positioner rotation of 40 rpm, and the oscillator is set with an amplitude of 3 mm / rev for uniform application of the powder layer, a modular torch for powder spraying is installed on the stand of the oscillator and welding positioner at a distance of 150 mm from the sprayed surface of the part. It is preheated to a temperature of 100 °C and a powder alloy is sprayed, wherein first a first sublayer of the powder alloy is sprayed, and after 30-40 min a main layer of the powder alloy is applied, wherein during spraying between layers, the part heating temperature is controlled using a pyrometer, which should be no more than 200 °C. Second option: after cleaning the part surface, the welding positioner is set to 1.5 rpm and the oscillator to a current of 80 A, a protective mastic is applied and wire feed is carried out, with which a first layer is deposited, after which a break of 5-10 min is taken, wherein after each welding pass during deposition between layers, the heating temperature is controlled using a pyrometer, which should be 150 °C. After spraying or deposition, the part is cooled naturally; the treated surface of the part is cleaned and washed with water at a temperature of at least 80 °C, then dried with compressed air.EFFECT: restoration of parts to their original operational dimensions in areas of intensive wear during operation.2 cl, 1 tbl

Description

[0001] Field of technology to which the invention relates

[0002] The invention relates to methods for restoring parts of the gearbox and parts of the traction motor of the 2ES10 electric locomotive, subjected to surfacing and / or spraying to restore them to their original operating dimensions in an area of ​​intensive wear during operation.

[0003] Technology Level

[0004] A method for restoring worn surfaces of steel parts is known from the prior art, which includes mechanical treatment of the worn surface, heating, gas flame spraying of a wear-resistant layer, followed by melting of the coating surface, characterized in that electric arc surfacing of the worn surface is first carried out, taking into account an allowance for subsequent mechanical treatment, which is carried out with an underestimation of the nominal size of the part, then shot blasting activation of the treated surface is carried out, and gas flame spraying is carried out with subsequent melting of the applied coating by heating the part to a temperature of 950-1050°C (see RU2299115 C1, 20.05.2007).

[0005] From document RU 2532738 C1, 10.11.2014, a method is known for restoring worn surfaces of steel parts, including mechanical treatment of the worn surface, heating, shot blasting activation, application of a coating by flame spraying followed by melting of the coating surface and its mechanical treatment, melting of the coating surface is carried out at a temperature of 1150-1180 °C, then the parts are kept in a thermal container after cooling to a temperature of 500 °C, after which the applied coating is mechanically processed to the nominal size of the part.

[0006] From document RU 2599656 C2, 10.10.2016, a method for restoring a part by surfacing is known, which includes preliminary inspection of the restored surface for the presence of defects in the form of discontinuities in the metal, a study by a non-destructive testing method of the macrostructure of the metal of the part at the expected section of the transition from the surfacing metal to the base metal, characterized in that the boundaries of decarburization of the sections of metal bordering the identified non-metallic inclusions are determined, and the sections of the beginning and end of the surfacing process are determined at a distance from the nearest boundary of decarburization.

[0007] Disclosure of the essence of the invention

[0008] The objective of the claimed invention is to expand the arsenal of known methods for restorative repair of gearbox parts and traction motor parts of the 2ES10 electric locomotive.

[0009] The technical result consists in implementing the purpose of the method for restorative repair of parts of the gearbox and parts of the traction motor of the 2ES10 electric locomotive.

[0010] The technical result is ensured by the method of restorative repair of the gearbox parts and the traction engine parts of the 2ES10 electric locomotive, including the stages of cleaning the surface of the part from dirt, oil, rust, moisture and corrosion; after cleaning, the area for powder spraying is determined, while the illumination in the area of ​​the surfaces to be treated must be at least 300 lux, and the welding positioner is adjusted to rotate at 40 rpm, the oscillator is adjusted to uniformly apply a powder layer with an amplitude equal to the application area; then, a protective mastic from high temperatures is applied to the unused surfaces of the part, including the centers in which the part of the welding positioner is fastened; the part with the applied protective mastic is installed in the center of the three-jaw chuck of the welding positioner and the part is fastened by the inner diameter;the fixed part is heated to a temperature of 100 °C and sprayed with powder alloy, first spraying the first sublayer of powder alloy, and after 30-40 minutes applying the main layer of powder alloy, during the spraying process between layers the heating temperature of the part is monitored using a pyrometer, which should not exceed 200 °C; then the part is cooled naturally; after the part has cooled down, the treated surface of the part is cleaned and washed with water at a temperature of at least 80 °C, then dried with compressed air.

[0011] The second version of the method for restorative repair of gearbox parts and traction engine parts of the 2ES10 electric locomotive includes the following stages: cleaning the surface of the part from dirt, oil, rust, moisture and corrosion; after cleaning, determine the area for powder spraying, while the illumination in the area of ​​​​the surfaces to be treated should be at least 300 lux, and adjust the welding positioner to 1.5 rpm and the oscillator for a uniform layer of applied powder; then apply a protective mastic from high temperatures to the unused surfaces of the part, including the centers in which the part of the welding positioner is attached; install the part with the applied protective mastic in the center of the three-jaw chuck of the welding positioner and fasten the part by the inner diameter; and deposit the first layer, after which take a break of 5-10 minutes, during the deposition process between layers control the heating temperature of the part using a pyrometer, which should be 150 ° C;Afterwards, the part is cooled naturally; after the part has cooled, the treated surface of the part is cleaned and washed with water at a temperature of at least 80 °C, then dried with compressed air.

[0012] Implementation of the invention

[0013] Before carrying out the restoration repair of the gearbox parts and the traction motor parts of the 2ES10 electric locomotive, preparatory work is carried out, namely, the surface of the part, especially in the areas where the work is carried out, must be cleaned of: dirt, oil, rust, moisture, corrosion and other contaminants that interfere with the restoration work.

[0014] After washing and drying, the gearbox components and traction motor components of the electric locomotive undergo a technical inspection. The purpose of this inspection is to determine the degree of wear and tear and their suitability for future use, as well as, often, the causes of failure, such as assembly defects, improper operation, lack of lubrication, etc. During inspection and defect detection, technical specifications are developed in the form of tables or repair charts, which list the inspected dimensions and any defects present on the given component. The methods for determining them, eliminating the defect, the inspection and measuring instrument, the nominal, permissible, and maximum clearances, interference fits, etc. are also provided.

[0015] The technical condition of the gearbox parts and the traction motor parts of the electric locomotive is monitored by means of instrumental measuring control, visual measuring control, magnetic particle inspection, and capillary testing.

[0016] Instrumental and measurement inspection is performed at all stages of repair and restoration work for each component. Inspection and testing of components is performed using measuring instruments and testing devices. Inspection is initially performed upon acceptance of components, then between each stage of repair work, with the monitoring parameters recorded in the repair technical record, and culminating in control measurements at the final stage of part release from repair.

[0017] Visual measurement testing (VMT) is a non-destructive diagnostics (testing) method that allows identifying defects such as burns, build-ups, corrosion cracks, burrs, dents, deviations from geometric dimensions and other visible defects.

[0018] The method is relevant for all production operations, from the preparation of metal blanks to the step-by-step inspection of the state of readiness of products, turning and welding work, the quality of the work performed, and assembly.

[0019] Magnetic particle inspection (MPI) is a non-destructive testing method based on the attraction of magnetic indicator particles (dry powder, suspension) by the forces of non-uniform magnetic scattering fields to surface and subsurface (at a depth of up to 2–3 mm) defects.

[0020] The method allows for the detection of various subtle surface and subsurface metal defects, such as folds, pores, lack of fusion, tears, flakes, cracks, etc., both at the production and repair stages of products and during operation.

[0021] Capillary testing is a non-destructive testing method based on the penetration of indicator liquids (penetrants) into the cavities of product discontinuities under the influence of capillary pressure, resulting in artificially increased light and color contrast of the defective area relative to the undamaged one. Colored and luminescent liquids and suspensions are used as penetrants.

[0022] Next, defect detection and rejection of parts are carried out, which is carried out at a workplace equipped with a special tool, directly at the initial stage of accepting parts for work, upon arrival at the production shop.

[0023] Main signs of culling:

[0024] -violation of the geometric parameters of the part, with obvious visual inspection, it is clear that it cannot be restored;

[0025] - cracks of any type and size extending onto the seating surfaces;

[0026] - shift, chipping, crushing, breakage of gear teeth, as well as end splines;

[0027] – parts that have received emergency defects (usually have clearly visible signs (cracks, scuffs, potholes, etc.), by which it can be easily decided whether such parts can be allowed to continue working after some restoration or whether they should be completely rejected).

[0028] After washing and drying, the parts undergo a full inspection according to the repair process charts.

[0029] After cleaning the gearbox parts and traction motor parts of the electric locomotive from dirt, oil, rust, moisture and corrosion.

[0030] Preliminary preparation of the part before spraying is carried out using a turning method in accordance with the Technological Map.

[0031] Determine the area for powder spraying. Illumination in the area of ​​surfaces being treated / controlled must be at least 300 lux.

[0032] Degrease the repair surface before starting work.

[0033] Apply a protective mastic against high temperatures, oxidation and fading during powder surfacing, such as CastoMask ECO Weight, to all unused surfaces of the part, including the centers in which the welding positioner part is fixed.

[0034] Install the part in the center of the three-jaw chuck of the welding positioner (mechanical rotator). Clamp the part by its inner diameter.

[0035] Select the optimal rotation of the welding positioner using the electronic unit (40 rpm, 3 mm / rev), so that the rotation of the toothed shaft corresponds to the uniform feed and fusion of the powder alloy while maintaining a uniform layer of applied powder.

[0036] Assembly of burner components and technical gases is carried out for the application of a preliminary sublayer of powder alloy.

[0037] A CastoDyn® DS 8000 modular oxyacetylene powder spray torch is installed on the oscillator and welding positioner stand at a distance of 150 mm from the surface of the workpiece shaft to be welded.

[0038] Connect the oscillator and set it to work in such a way as to optimize the width of the powder alloy application and achieve optimal repeatability, as well as the quality of the applied alloy when re-applying the main layer of powder alloy.

[0039] Ensures a stable spraying process and high-quality formation of the powder layer.

[0040] Before starting work, heat the fixed part to a temperature of 100°C.

[0041] The spraying process is started simultaneously using the pedal to turn on the rotation of the welding positioner and the oscillator.

[0042] The spraying powder is selected depending on the type of metal the part is made of. For example, powder grade A-80-13 is used to eliminate defects in products made of aluminum and its alloys, and can also be used on steel and cast iron parts.

[0043] Control the spraying process, monitor the mode and progress of the work process.

[0044] After each pass, temperature control is performed over the entire surface of the circumference of the part.

[0045] Control the heating temperature of the welded part using a pyrometer, the interpass temperature should not exceed 200°C.

[0046] First, apply a base coat of powder alloy, with a 30-40 minute break between the base coat and the main spray. Next, apply the base coat to the part surface for subsequent powder spraying.

[0047] After powder coating, allow the part to cool slowly. Forced cooling is not permitted.

[0048] After finishing work, clean the part manually, then wash it in a Karcher stationary cleaning system. The hot water temperature should be at least 80°C. Dry with compressed air and wipe.

[0049] The second variant of the method for restorative repair of gearbox parts and traction motor parts of the 2ES10 electric locomotive is carried out as follows.

[0050] Before carrying out welding and surfacing work, the surface of the part, especially in the areas of welding (surfacing), must be cleaned of: dirt, oil, rust, moisture, corrosion, paint and other contaminants that interfere with welding work.

[0051] Illumination in the area of ​​controlled surfaces must be at least 300 lux. Preliminary preparation of the part before welding must be performed using a turning method according to the process chart.

[0052] Install the part into the clamping chuck of the welding positioner (mechanical rotator). Secure the part.

[0053] Determines the area where welding (surfacing) will take place.

[0054] Set the welding positioner rotation mode using the electronic unit to 1.5 rpm so that the rotation of the part corresponds to uniform feeding and welding of the wire, while maintaining a uniform weld bead.

[0055] The welding semiautomatic machine is installed on the oscillator stand and the welding positioner, welding holder-torch, is mounted at a distance of 150 mm from the surface of the part to be welded.

[0056] Connect the oscillator. Adjust the oscillator according to the required welding width on the part.

[0057] Using the following current parameters - 80 A, ensuring a stable welding process and high-quality formation of the weld seam.

[0058] Simultaneously by pressing the pedal to turn on the rotation of the welding positioner and oscillator, the welding process begins.

[0059] When monitoring the surfacing process, monitor the mode and progress of the work process.

[0060] After each welding pass along the entire circumference of the part (or any required section of the part), monitor the heating temperature of the welded part. Monitor the interpass temperature, which is equal to 150°C, using a pyrometer.

[0061] After depositing one weld pass, take a 5-10 minute break. Then, adjust the oscillator to the next required section of the part for further work.

[0062] After welding, allow the part to cool naturally. Forced cooling is not permitted.

[0063] After finishing the work, clean the part manually, then wash it in a Karcher stationary cleaning system. The hot water temperature should be at least 80°C. Dry the part with compressed air and wipe it dry.

[0064] List of Components of locomotive equipment subject to repair, according to the claimed invention.

[0065] № Name of products (works, services) Units of measurement 1 Gearbox housing SPRG.002.31.111.004 / SPRG.002.31.111.004R / A5E01239343A pcs. 2 Oil splash ring SPRG.002.31.111.010 / SPRG.002.31.111.010R / A5E0130327A pcs. 3 Oil splash ring SPRG.002.31.111.011 / SPRG.002.31.111.011R / A5E02360336A pcs. 4 Labyrinth ring SPRG.002.31.111.012 / SPRG.002.31.111.012P / A5E02360547A pcs. 5 External labyrinth ring SPRG.002.31.111.016 / SPRG.002.31.111.016P / D030216 pcs. 6 Labyrinth ring SPRG.002.31.111.017 / SPRG.002.31.111.017P / D030222 pcs. 7 Toothed shaft TSEV.565.064.3.02 / A5E03311032 / A5E01050512 pcs. 8 Connecting sleeve TSEV.565.064.11.10 SB / D691576 pcs. 9 Bearing ring, STMS.565.064.3.12 / STMS.565.064.3.12R / D102166 pcs. 10 Tightening ring, SPRG.002.31.111.007 / SPRG.002.31.111.007P / A5E01267814A pcs. 11 Bearing cover, STMS.565.064.5.12 / STMS.565.064.5.12R / D102160 pcs. 12 Bearing shield NP, STMS.565.064.6.10 / STMS.565.064.6.10R / D010731 / A5E00195810A pcs. 13 Bearing shield P, TSEV.565.064.4.10 / D011645 pcs. 14 Bearing cover STMS.565.064.3.24 pcs. 15 Bearing cover STMS.565.064.5.30R pcs. 16 Sealing ring СТМС.565.064.4.21Р pcs. 17 Labyrinth sealing ring TSEV.157645.064 RK, СТМС.565.064.4.30Р pcs.

Claims

1. A method for the refurbishment of gearbox parts and traction motor parts of a 2ES10 electric locomotive, including the following steps: cleaning the surface of the part from dirt, oil, rust, moisture and corrosion, and after cleaning, determining the area for powder spraying, whereby during powder spraying: - illumination in the area of ​​the surfaces being processed is provided at least 300 lux, and the rotation of the welding positioner is selected to be equal to 40 rpm, and the oscillator is adjusted with an amplitude of 3 mm / rev for uniform application of the powder layer, a modular torch for powder spraying is installed on the tripod of the oscillator and welding positioner at a distance of 150 mm from the sprayed surface of the part; - then a protective mastic against oxidation and fading is applied to the unused surfaces of the part, including the centers in which the welding positioner part is attached; - install the part with the applied protective mastic in the center of the three-jaw chuck of the welding positioner by fastening the part by the inner diameter; - heat the fixed part to a temperature of 100 °C and spray the powder alloy, first spraying the first sublayer of the powder alloy, and after 30-40 minutes applying the main layer of the powder alloy, while during the spraying process between the layers using a pyrometer, control the heating temperature of the part, which should not exceed 200 °C; - after which the part is cooled naturally; - after the part has cooled, the treated surface of the part is cleaned and washed with water at a temperature of at least 80 °C, then dried with compressed air.

2. A method for the refurbishment of gearbox parts and traction motor parts of the 2ES10 electric locomotive, including the following stages: - clean the surface of the part from dirt, oil, rust, moisture and corrosion, and after cleaning, determine the area for welding, and when welding: - illumination in the area of ​​the surfaces being processed is provided at least 300 lux, and is installed on the oscillator stand and the welding positioner at a rotation speed of 1.5 rpm, and the oscillator at a current of 80 A; - then a protective mastic against oxidation and fading is applied to the unused surfaces of the part, including the centers in which the welding positioner part is attached; - install the part with the applied protective mastic in the center of the three-jaw chuck of the welding positioner by fastening the part by the inner diameter; - feed the wire, with the help of which the first layer is deposited, after which a break of 5-10 minutes is taken, while after each welding pass in the deposition process between layers, the heating temperature of the part is monitored using a pyrometer, which should be equal to 150 °C; - after which the part is cooled naturally; - after the part has cooled, the treated surface of the part is cleaned and washed with water at a temperature of at least 80 °C, then dried with compressed air.