An early warning device and early warning detection method for electric wheel frame fracture

Abstract

The present invention discloses an early warning device and early warning detection method for electric wheel frame fractures, belonging to the field of electric wheel frame auxiliary devices. This device is proposed to address the inability of existing detection methods to provide timely early warning of the extent of damage to the electric wheel frame. The early warning device includes: a trigger layer mounted on the inner wall of a gearbox, the trigger layer being aligned with the gear teeth clearance on the gears within the gearbox, the trigger layer including a first trigger layer composed of a solid compound capable of rendering the lubricating oil alkaline. When the electric wheel frame undergoes destructive deformation, the gear deflects toward the trigger layer and abrades against the surface of the first trigger layer. The powder mixed into the lubricating oil after abrasion changes the pH value of the lubricating oil. The detection method includes: regularly sampling and testing the pH value of the lubricating oil within the gearbox. The present invention utilizes an early warning device disposed between the inner wall of the gearbox and the gears to monitor the fracture of the electric wheel frame by detecting changes in the pH value of the lubricating oil.

Description

Technical field:

[0001] The present invention belongs to the technical field of electric wheel frame auxiliary devices, and in particular relates to an electric wheel frame fracture early warning device and an early warning detection method. Background technology:

[0002] Dump trucks are a type of engineering machinery that often work in conjunction with excavators, loaders, belt conveyors, and other engineering machinery in open-pit coal mines. Because road conditions around coal mines are often poor, dump trucks must travel on bumpy roads for extended periods of time, and the electric wheel frame, as a load-bearing structural component, is constantly subject to impact loads. While the design load of the electric wheel frame should theoretically account for the impact loads of bumpy conditions, the actual road conditions in open-pit coal mines can often be worse than ideal, significantly increasing the impact load on the frame and causing destructive deformation or even fracture of a significant portion of the electric wheel frame.

[0003] As the system that provides traction for mining dump trucks, the electric wheel frame connects the vehicle body, rim, and tire, transmits the traction and reaction force generated by the tires, and directly bears the internal and external loads of the electric wheel. The gear system is mounted within the frame and fixed relative to it. The gearbox is mounted outside the frame and gears and fixed to the vehicle body. Because the electric wheel frame is surrounded by other components after installation, cracks in the frame cannot be detected during routine inspections. Existing inspection methods can only detect electric wheels with broken frames, but cannot predict fractures or measure the extent of damage. Summary of the invention:

[0004] In order to solve the defect that the existing detection method cannot timely warn the degree of damage to the electric wheel frame, the present invention provides an early warning device and early warning detection method for the fracture of the electric wheel frame. By installing the early warning device on the existing electric wheel frame and utilizing the existing conventional inspection procedures for electric wheels, the degree of damage to the electric wheel can be judged without disassembling the external components of the electric turbine.

[0005] The technical solution adopted by the present invention is: an early warning device for electric wheel frame fracture, comprising: a trigger layer installed on the inner wall of a gear box, the trigger layer is matched with the gear tooth clearance on the gear located in the gear box, the trigger layer includes a first trigger layer, the first trigger layer is composed of a solid compound that can make the lubricating oil alkaline, when the electric wheel frame undergoes destructive deformation, the gear deflects toward the trigger layer and grinds with the surface of the first trigger layer, and the powder mixed into the lubricating oil after grinding changes the pH value of the lubricating oil.

[0006] Preferably, the gap is greater than 3.2 mm.

[0007] Preferably, the first trigger layer is massive calcium carbonate.

[0008] Preferably, the trigger layer further includes a second trigger layer, the second trigger layer is located between the inner wall of the gear box and the first trigger layer, and the second trigger layer is composed of a solid compound that can make the lubricating oil acidic.

[0009] Preferably, the second trigger layer is bulk silicon dioxide.

[0010] Preferably, the trigger layer further includes a third trigger layer, the third trigger layer is located between the inner wall of the gear box and the second trigger layer, and the third trigger layer is composed of a solid compound that can make the lubricating oil alkaline.

[0011] Preferably, the third trigger layer is massive calcium carbonate.

[0012] Preferably, the trigger layer is mounted on the inner wall of the gear box via a bracket.

[0013] A method for early warning detection of electric wheel frame fracture, specifically comprising the following detection steps:

[0014] Step 1: Take a sample of the pH value of the lubricating oil in the gearbox for the first time for testing. Since the pH value of normal lubricating oil is weakly acidic, it indicates that the electric wheel frame is in normal use. If the pH value of the lubricating oil is weakly alkaline, it indicates that the electric wheel frame has undergone slight destructive deformation, that is, the first trigger layer has been destroyed.

[0015] Step 2: After the first routine sampling and testing, the pH value of the lubricating oil in the gearbox is sampled and tested for a second time. If the pH value of the lubricating oil is weakly alkaline, it indicates that the electric wheel frame is still in a stage of slight destructive deformation. If the pH value of the lubricating oil is weakly acidic, and the acidic pH value is greater than the acidic pH value of the lubricating oil itself, it indicates that the degree of destructive deformation of the electric wheel frame has further increased, that is, the second trigger layer has been destroyed.

[0016] Step 3: After the second routine sampling and testing, the pH value of the lubricating oil in the gearbox is sampled and tested for the third time. If the pH value of the lubricating oil is still acidic, it means that the degree of destructive deformation of the electric wheel frame has not been further aggravated; if the pH value of the lubricating oil is weakly alkaline again, it means that the electric wheel frame has undergone serious fracture deformation, that is, the third trigger layer has been destroyed.

[0017] Preferably, the interval between each routine sampling and testing is at least 250 hours.

[0018] The beneficial effects of the present invention are:

[0019] 1. The present invention utilizes the fact that deformation of the electric wheel frame will reduce the gap between the gear and the inner wall of the gear box, and even cause mutual interference. An early warning device is provided between the inner wall of the gear box and the gear. The process of regular routine testing of lubricating oil by a dump truck is used to monitor the fracture of the electric wheel frame by detecting changes in the pH value of the lubricating oil, thereby achieving an early warning of different degrees of damage to the electric wheel frame.

[0020] 2. The present invention can achieve phased early warning prompts by setting up multi-level trigger layers, and the early warning function can be achieved through routine detection of lubricating oil. Compared with the existing sensor-based early warning device, the present invention has the characteristics of simple structure, no need to modify existing components, simple detection means, low monitoring cost, and strong practicality. Description of the drawings:

[0021] Figure 1 It is a structural schematic diagram of the present invention;

[0022] Figure 2 for Figure 1 Enlarged view of point A in the middle;

[0023] Figure 3 It is a structural diagram of the trigger layer;

[0024] Figure 4 This is the state diagram of the gear and trigger layer at different deformation stages at the electric wheel frame;

[0025] Figure 5 for Figure 4 Enlarged view of point B in the middle;

[0026] Among them: 1 electric wheel frame, 2 trigger layer, 3 gear, 4 gear box, 5 first trigger layer, 6 second trigger layer, 7 third trigger layer, 8 bracket. Specific implementation method:

[0027] Example 1

[0028] like Figures 1 to 3 As shown, the present invention is an early warning device for electric wheel frame fracture, comprising: a trigger layer 2 installed on the inner wall of a gear box 4, wherein the trigger layer 2 is matched with the gear tooth clearance on a gear 3 located inside the gear box 4. The clearance between the trigger layer 2 and the gear 3 is different for dump trucks of different specifications, and the clearance is greater than 3.2 mm.

[0029] A groove for mounting the trigger layer 2 is machined on the inner wall of the gear box 4, and the trigger layer 2 is mounted on the inner wall of the gear box 4 via a bracket 8. The trigger layer 2 can also be fixed to the inner wall of the gear box 4 by other means such as gluing or welding.

[0030] The trigger layer 2 includes a first trigger layer 5 , which is composed of a solid compound that can make the lubricating oil alkaline. For example, the first trigger layer 5 is a block of calcium carbonate.

[0031] Under normal design conditions, the electric wheel frame 1 is always in a state of elastic deformation and should not undergo destructive deformation. The gear 3 installed in the electric wheel frame 1 also rotates with the deflection of the electric wheel frame 1. The gear 3 and the gear box 4 fixed on the dump truck always maintain a reasonable gap and will not cause any interference. Figure 5 The location pointed to by O.

[0032] like Figure 4 As shown in the figure, F is the position where the electric wheel frame 1 breaks. When the dump truck runs for a long time under harsh working conditions, when the electric wheel frame 1 undergoes slight destructive plastic deformation (i.e. the first stage of deformation, as shown in FIG. Figure 5 The deflection of the electric wheel frame 1 increases, and since the degree of destructive deformation of the electric wheel frame 1 is relatively small, the deflection angle of the gear 3 installed in the electric wheel frame 1 also increases, causing the gear 3 to gradually approach the inner wall of the gear box 4, that is, the gear 3 deflects toward the trigger layer 2.

[0033] Since gear 3 rotates continuously at high speed during operation, it triggers the trigger layer 2 installed inside the gearbox 4. When gear 3 contacts the surface of the first trigger layer 5, it grinds it into powder, which is then mixed into the lubricating oil. During conventional lubricating oil testing procedures, since normal lubricating oil is weakly acidic, and the first trigger layer 5 is a solid compound that makes the lubricating oil alkaline, when the electric wheel frame 1 is in the first stage of deformation and the first trigger layer 5 is triggered, the pH value of the lubricating oil changes, resulting in a weakly alkaline pH test result. Therefore, if the lubricating oil test indicates alkalinity, it indicates that the electric wheel frame 1 has entered the first stage of deformation.

[0034] Example 2

[0035] Example 2 is based on Example 1, and the trigger layer 2 further includes a second trigger layer 6.

[0036] The second trigger layer 6 is mounted on the bracket 8 and is located between the inner wall of the gear box 4 and the first trigger layer 5. The second trigger layer 6 is composed of a solid compound that can make the lubricating oil acidic. For example, the second trigger layer 6 is blocky silicon dioxide.

[0037] Since the second trigger layer 6 is a solid compound that can make the lubricating oil acidic, when the electric wheel frame 1 is in severe destructive plastic deformation (i.e., the second deformation stage, Figure 5 The second trigger layer 6 is triggered, causing the pH value of the lubricating oil to change again.

[0038] Example 3

[0039] Example 3 is based on Example 2, and the trigger layer 5 further includes a third trigger layer 7.

[0040] The third trigger layer 7 is mounted on the bracket 8 and is located between the inner wall of the gearbox 4 and the second trigger layer 6 . The third trigger layer 7 is composed of a solid compound that can make the lubricating oil alkaline. For example, the third trigger layer 7 is a block of calcium carbonate.

[0041] Since the third trigger layer 7 is a solid compound that can make the lubricating oil acidic, when the electric wheel frame 1 is in a serious fracture deformation (i.e. the third deformation stage, such as Figure 5 The third trigger layer 6 is triggered, causing the pH value of the lubricating oil to change again.

[0042] Example 4

[0043] A method for early warning detection of electric wheel frame fracture, using the early warning device described in Example 3, specifically includes the following detection steps:

[0044] Step 1: Take a sample for the first time to test the pH value of the lubricating oil in the gearbox 4. Since the pH value of normal lubricating oil is weakly acidic, if the pH value after testing is its own pH value, it means that the electric wheel frame 1 is in normal use; if the pH value of the lubricating oil is weakly alkaline, it means that the electric wheel frame 1 has undergone slight destructive deformation, that is, it is in the first stage of deformation, and the first trigger layer 5 has been destroyed.

[0045] Step 2: After a period of time after the first sampling and testing, the pH value of the lubricating oil in the gear box 4 is sampled and tested again for a second time. If the pH value of the lubricating oil is weakly alkaline, it means that the electric wheel frame 1 is still in the first deformation stage; if the pH value of the lubricating oil is weakly acidic again, and the acidic pH value is greater than the acidic pH value of the lubricating oil itself, it means that the degree of destructive deformation of the electric wheel frame 1 has further increased, that is, it is in the second deformation stage, and the second trigger layer 6 has been destroyed.

[0046] Step 3: After a period of time after the second sampling and testing, the pH value of the lubricating oil in the gear box 4 is sampled and tested for the third time. If the pH value of the lubricating oil is still acidic, it means that the degree of destructive deformation of the electric wheel frame 1 has not further increased and it is still in the second stage of deformation; if the pH value of the lubricating oil is weakly alkaline again, it means that the electric wheel frame 1 has undergone serious fracture deformation, that is, it is in the third stage of deformation, the third trigger layer 7 has been destroyed, and there is a serious safety hazard.

[0047] Furthermore, the interval between each routine sampling and testing is at least 250 hours. If the dump truck encounters an unexpected abnormality during driving, temporary sampling and testing can be performed.

[0048] The foregoing are merely preferred embodiments of the present invention. These embodiments are all different implementations based on the overall concept of the present invention. The scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. An early warning device for electric wheel frame fracture, characterized in that: include: A trigger layer (2) is mounted on the inner wall of a gear box (4), the trigger layer (2) being in clearance with the gear teeth on the gear (3) located inside the gear box (4), the trigger layer (2) comprising a first trigger layer (5), the first trigger layer (5) being composed of a solid compound capable of making the lubricating oil alkaline, and when the electric wheel frame (1) undergoes destructive deformation, the gear (3) deflects toward the trigger layer (2) and grinds against the surface of the first trigger layer (5), and the powder mixed into the lubricating oil after grinding changes the pH value of the lubricating oil; The gap is greater than 3.2 mm, and the first trigger layer (5) is a block of calcium carbonate. The trigger layer (2) further includes a second trigger layer (6), the second trigger layer (6) is located between the inner wall of the gear box (4) and the first trigger layer (5), and the second trigger layer (6) is composed of a solid compound that can make the lubricating oil acidic. The second trigger layer (6) is a block of silicon dioxide. The trigger layer (2) further includes a third trigger layer (7), the third trigger layer (7) is located between the inner wall of the gear box (4) and the second trigger layer (6), and the third trigger layer (7) is composed of a solid compound that can make the lubricating oil alkaline. The third trigger layer (7) is a block of calcium carbonate. The trigger layer (2) is mounted on the inner wall of the gear box (4) through a bracket (8).

2. A method for early warning detection of electric wheel frame fracture, using the early warning device according to claim 1, characterized in that: The specific detection steps include the following: Step 1: Take a sample of the pH value of the lubricating oil in the gear box (4) for the first time for testing. If the pH value of the lubricating oil is a weak acid value, it means that the electric wheel frame (1) is in normal use. If the pH value of the lubricating oil is a weak alkaline value, it means that the electric wheel frame (1) has undergone slight destructive deformation, that is, the first trigger layer (5) has been destroyed. Step 2: After the first routine sampling and testing, the pH value of the lubricating oil in the gear box (4) is sampled and tested for a second time. If the pH value of the lubricating oil is weakly alkaline, it indicates that the electric wheel frame (1) is still in a slightly destructive deformation stage; if the pH value of the lubricating oil is weakly acidic, and the acidic pH value is greater than the acidic pH value of the lubricating oil itself, it indicates that the degree of destructive deformation of the electric wheel frame (1) has further increased, that is, the second trigger layer (6) has been destroyed; Step 3: After the second routine sampling and testing, the pH value of the lubricating oil in the gear box (4) is sampled and tested for a third time. If the pH value of the lubricating oil is still acidic, it means that the degree of destructive deformation of the electric wheel frame (1) has not been further aggravated. If the pH value of the lubricating oil is weakly alkaline again, it means that the electric wheel frame (1) has undergone severe fracture deformation, that is, the third trigger layer (7) has been destroyed. The interval between each routine sampling and testing is at least 250 hours.

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