A disc type axial flux motor vehicle axle gear box, a middle box body and a manufacturing method thereof

Abstract

The application discloses a middle box body of a disc type axial flux motor vehicle axle gear box, which comprises a pull rod arm, and the middle box body comprises an up-down opening box structure which is composed of a middle box body side plate, a first and a second middle box body outer side plate and a middle box body top plate, the up-down opening box structure is respectively provided with a middle box body lower and upper connecting flange at the lower and upper opening, the lower part of the two middle box body side plates is respectively provided with an axle hole upper semicircular plate and a first transmission ratio gear shaft hole upper semicircular plate, the upper part of one of the middle box body side plates and the upper part of the middle box body top plate are respectively provided with a motor mounting hole lower semicircular plate and a second transmission ratio gear shaft hole lower semicircular plate, and the motor mounting hole lower semicircular plate and the second transmission ratio gear shaft hole lower semicircular plate form a middle box body lower semicircular hole connecting part; the plane where the middle box body lower connecting flange is located and the plane where the middle box body upper connecting flange is located form an acute angle; and the middle box body is further provided with a plurality of rib plates.

Description

Technical Field

[0001] The present invention relates to the technical field of locomotive bogie wheel axle structure gearboxes, and in particular to a disc-type axial flux motor axle gearbox, a middle box body and a manufacturing method thereof, which are suitable for GK locomotives. Background Art

[0002] Modern locomotives (such as GK locomotives) generally use a bogie-type running gear. The bogie on a locomotive functions like a person's legs, hence its name: the locomotive's running gear. Because bogie-type running gear is suitable for high speed, high power, various drive modes and axle types, and flexible suspension and foundation braking systems suitable for various requirements, modern locomotive running gear generally adopts a bogie structure.

[0003] The bogie primarily consists of a frame, spring system, connecting device, wheelset and axlebox, drive unit, and basic brake system. The bogie is capable of bearing the entire weight of the vehicle, including the vehicle body, frame, power unit, various auxiliary devices, and electrical and motor components. It ensures the necessary adhesion between the wheels and rails, generating circumferential traction at the wheel-rail contact point to pull the train. The frame is the bogie's skeleton, bearing and transmitting vertical and horizontal forces; the spring system ensures even axle load distribution, ensuring smooth locomotive operation; the wheelset and axlebox transmit the locomotive's weight directly to the rails; and the drive unit transmits the locomotive's power unit's traction power to the wheelset.

[0004] Currently, GK locomotives are primarily driven by internal combustion engines, which transmit traction power to the wheelsets via cardan shafts and axle gearboxes to pull the train. GK locomotives typically have two bogies on their bodies, each equipped with two axle gearboxes. This presents a challenge: With the dual pressures of oil resource depletion and severe environmental pollution, the international community is urging the development of new energy sources. Transportation energy consumption is a major contributor to environmental pollution and global warming, making the transformation of transportation energy and powertrain systems for locomotives powered by internal combustion engines a major trend. During a retrofit, to minimize the impact on the locomotive, the bogie structure typically remains unchanged. The locomotive's existing internal combustion engine drive system is converted to an electric motor drive system, rendering the existing axle gearbox unusable and requiring a redesign. To maintain consistency, the tie rod arm structure on the original locomotive's axle gearbox must be redesigned on the modified gearbox to maintain power transmission. After the retrofit, the locomotive will be driven by four electric motors, improving travel control while reducing energy consumption and pollution. However, due to the limited space on the locomotive bogie, it is difficult to use the existing gearboxes on the market directly on the bogie after minor modifications. In addition, for easy installation, the redesigned gearbox body needs to adopt a split structure and then be assembled. How to design a split gearbox body that is small in size, light in weight and easy to install and maintain has become a difficulty. Summary of the Invention

[0005] In response to the technical problems existing in the background technology, the present invention provides a disc-type axial flux motor axle gearbox, a middle box body and a manufacturing method thereof.

[0006] The technical solutions to the technical problems of the present invention are as follows:

[0007] The present invention provides a middle box body of a disc-type axial flux motor axle gearbox, including a pull rod arm, a pull rod hole is provided on the top of the pull rod arm, and the middle box body includes an upper and lower open box body structure composed of two middle box body side plates, a first outer plate of the middle box body and a second outer plate of the middle box body between the two middle box body side plates, and a middle box body top plate between the first outer plate of the middle box body and one side of the second outer plate of the middle box body. The lower opening and upper opening of the upper and lower open box body structure are respectively provided with a middle box body lower connecting flange and a middle box body upper connecting flange, and the lower parts of the two middle box body side plates are respectively provided with an upper semicircular plate of the axle hole and an upper semicircular plate of the first transmission ratio gear shaft hole, and one of the upper parts of the middle box body side plates and the upper part of the middle box body top plate are respectively provided with There is a lower semicircular plate of the motor mounting hole and a lower semicircular plate of the second transmission ratio gear shaft hole. The lower semicircular plate of the motor mounting hole and the lower semicircular plate of the second transmission ratio gear shaft hole are an integrated structure, constituting the lower semicircular hole connecting part of the middle box body. The upper semicircular plate of the axle hole and the upper semicircular plate of the first transmission ratio gear shaft hole are simultaneously connected to the lower connecting flange of the middle box body, and the lower semicircular plate of the motor mounting hole and the lower semicircular plate of the second transmission ratio gear shaft hole are simultaneously connected to the upper connecting flange of the middle box body; the plane where the lower connecting flange of the middle box body is located and the plane where the upper connecting flange of the middle box body are located form an acute angle; a number of ribs are arranged between the upper semicircular plate of the axle hole and the upper semicircular plate of the first transmission ratio gear shaft hole and the side plate of the middle box body, and between the lower semicircular hole connecting part of the middle box body and the top plate of the middle box body on the same side as it.

[0008] Furthermore, the plane where the lower connecting flange of the middle box body is located and the plane where the upper connecting flange of the middle box body is located form an angle of 25°.

[0009] Furthermore, the pull rod arm is arranged on the outer side of the upper semicircular plate of one of the axle holes.

[0010] Furthermore, the width of the upper semicircular plate of the axle hole on one side is greater than that of the upper semicircular plate of the axle hole on the other side.

[0011] Furthermore, the lower semicircular hole connection part of the middle box body composed of the upper semicircular plate of the axle hole, the upper semicircular plate of the first transmission ratio gear shaft hole, the lower semicircular plate of the motor mounting hole and the lower semicircular plate of the second transmission ratio gear shaft hole is cut and processed from 50mm steel plate, the first outer plate of the middle box body, the side plate of the middle box body, the second outer plate of the middle box body and the top plate of the middle box body are cut and processed from 30mm steel plate, the pull rod arm is cut and processed from 60mm steel plate, and the lower connecting flange of the middle box body and the upper connecting flange of the middle box body are cut and processed from 60mm steel plate.

[0012] The present invention provides a disc-type axial flux motor axle gearbox, comprising the middle box body described in the above technical solution, wherein the lower connecting flange of the middle box body and the upper connecting flange of the middle box body of the lower bottom box body are detachably connected to the lower bottom box body and the upper cover box body respectively; the middle box body is provided with an axle mounting hole and a first transmission ratio gear shaft hole through the upper semicircular plate of the axle hole and the upper semicircular plate of the first transmission ratio gear shaft hole and the lower bottom box body, the middle box body is provided with a second transmission ratio gear shaft hole and a disc-type axial flux motor mounting hole through the lower semicircular plate of the motor mounting hole and the lower semicircular plate of the second transmission ratio gear shaft hole and the upper cover box body, the axle mounting hole and the first transmission ratio gear shaft hole are commonly provided between The angle between the center line of the gear shaft hole and the center line of the second gear ratio gear shaft hole and the disc axial flux motor mounting hole is acute, and the center line of the first gear ratio gear shaft hole and the second gear ratio gear shaft hole is perpendicular to the center line of the second gear ratio gear shaft hole and the disc axial flux motor mounting hole; the wheel axle structure is installed in the axle mounting hole, the disc axial flux motor is installed in the disc axial flux motor mounting hole, the transmission mechanism is installed in the first gear ratio gear shaft hole and the second gear ratio gear shaft hole, the disc axial flux motor is meshed with the transmission mechanism through the motor shaft and gears, and the transmission mechanism is meshed with the wheel axle structure.

[0013] Furthermore, the angle between the line connecting the centers of the axle mounting hole and the first gear ratio gear shaft hole and the line connecting the centers of the second gear ratio gear shaft hole and the disc-type axial flux motor mounting hole is 25°.

[0014] The design and manufacturing method of the middle housing of a disc-type axial flux motor axle gearbox described in the above technical solution comprises the following steps:

[0015] S1. Preparation before welding:

[0016] S1.1. Welding equipment: HT400D or HT500D digitally controlled inverter DC welding machine for combined manual arc welding and argon arc welding, Φ3.2mm and φ4.0mm E5015 welding rods; Welding materials: Structural steel welding rods, carbon arc gouging ZX5-630 welding machine with plasma gouging LGK-100MA

[0017] S1.2, Heating device: H01-20 baking gun;

[0018] S1.3. Auxiliary equipment: angle grinder, file, hammer, flat shovel, mask, sample, thermometer, magnifying glass, thermal insulation cotton;

[0019] S1.4, Weldment material: body 16Mn low alloy steel;

[0020] S1.5. Requirements for surfacing before welding: Use a manual angle grinder to process and clean the welding surface to remove rust, grease, and moisture. Thick plates need to be preheated to 150 degrees.

[0021] S1.6, welding position: K groove;

[0022] S1.7, Welding requirements: All weld layers must be free of any welding defects and fused to the parent material;

[0023] S1.8. Welding process parameters: Develop welding parameters based on the welding equipment, welding materials, weldment material, and welding requirements. When welding the base layer, use an E5015 electrode with a diameter of 3.2 mm, a welding current of 90-120 A, an arc voltage of 23 ± 1 V, and a welding speed of 15 ± 1 cm / min. When welding the filler layer and cap layer, use an E5015 electrode with a diameter of 4.0 mm, a welding current of 130-160 A, an arc voltage of 26 ± 1 V, and a welding speed of 17 ± 1 cm / min.

[0024] S2. Welding production:

[0025] First, according to the designed shape and size, all the upper semicircular plates of the axle holes of the middle box, the upper semicircular plates of the first transmission ratio gear shaft holes, the first outer side plates of the middle box, the side plates of the middle box, the lower connecting flange of the middle box, the upper connecting flange of the middle box, the lower semicircular plate of the motor mounting hole and the lower semicircular plate of the second transmission ratio gear shaft hole, the middle box second outer side plate, the middle box top plate, the rib plate and the tie rod arm are machined; each side of each first outer side plate of the middle box, the side plates of the middle box, the second outer side plate of the middle box and the middle box top plate is machined with a single-sided 30° slope on both sides. The opening makes it possible to form a K-groove double-sided welding at all joints when assembling; then the processed components are welded and assembled according to the structure of the middle box body, and the upper semicircular plate of the axle hole, the upper semicircular plate of the first transmission ratio gear shaft hole and the lower semicircular plate of the second transmission ratio gear shaft hole constituting the second outer plate of the middle box body and the connection part of the lower semicircular hole of the middle box body are used as the positioning reference. The middle parts of the lower semicircular plates and the upper semicircular plates are spot welded to fix the side panels of the middle box body to form a basic frame and correct them to meet the design dimensions. Then, the first outer plate of the middle box body, the second outer plate of the middle box body and the middle box body top plate between the two are spot welded. After the whole structure frame is fixed by spot welding according to the design size, the spot welding of the tie rod arm is carried out, and finally the lower connecting flange of the middle box body, the upper connecting flange of the middle box body and the ribs are fixed by precision group; after all the structural parts are fixed by spot welding according to the design size, welding is carried out; when welding, all the outer spot welding fixed joints of the middle box body are welded first, and the welding method is manual arc welding, and the outer two sides are welded symmetrically, because the upper semicircular plate of the axle hole, the upper semicircular plate of the first transmission ratio gear shaft hole, the lower connecting flange of the middle box body, the upper connecting flange of the middle box body, the lower semicircular plate of the motor mounting hole and the lower semicircular plate of the second transmission ratio gear shaft hole constitute the lower semicircular plate of the middle box body. The hole connection and the tie rod arm plate are relatively thick. Before welding, both sides of the connection groove are preheated to about 150℃. After reaching the temperature, the digitally controlled inverter manual arc welding and argon arc welding are combined with a DC welding machine and a 3.2mm diameter E5015 structural steel welding rod is used to perform symmetrical single-sided bottom layer all-position welding. The current is 120A, and the welding rod is moved in a straight line. While the bottom is fully melted, the weld must also ensure good fusion with both sides. After the bottom layer is welded, ultrasonic stress relief is used to confirm that there are no welding defects on the surface. The interlayer temperature is controlled, and then the filling and capping layers are welded as a whole. The diameter is 4.0mm E5015 structural steel welding rod, the filling and cover layer welding current is selected between 130-140A, especially the first layer of filling layer current is too large, which is convenient for eliminating the bottom layer defects. The welding rod adopts the triangle rod method, and the welding rod angle changes according to the surfacing position. After the filling layer is fully welded, ultrasonic stress relief is used. After visual inspection or 10x magnifying glass confirms that there are no welding defects on the surface, the cover layer surface is welded. The cover layer must meet the designed weld angle size and no undercut can be generated between the two sides. After all welding is completed, ultrasonic stress relief is used, and then the maintenance All outer welds were completely covered with thermal insulation. The central box was then welded at all the inner spot welded connections. Before welding, a ZX5-630 carbon arc gouging machine and an LGK-100MA plasma gouging machine were used to clean the base of the inner spot welded connections. Only after confirming that there were no defects did welding begin. The inner welding method, process, and dimensions were identical to those used for the outer connections. After all welding was complete, ultrasonic stress relief was performed. The welds were completely covered with thermal insulation, cooled to room temperature, and then cleaned with a manual angle grinder. Finally, all welds were inspected for flaws.

[0026] Compared with the prior art, the present invention describes a disc-type axial magnetic flux motor axle gearbox, a middle box body, and a manufacturing method thereof. The middle box body and the disc-type axial magnetic flux motor axle gearbox are novel in design and reasonable in structure. By sequentially connecting the lower box body, the middle box body, and the upper cover box body, and the axle mounting hole, the first transmission ratio gear shaft hole, the second transmission ratio gear shaft hole, and the disc-type axial magnetic flux motor mounting hole formed by the three box body structures, a gear box body is formed that can be installed on the original locomotive bogie. The gear box body is small in size, light in weight, low in cost, and convenient for installation and maintenance of the axle, transmission ratio gear shaft, and motor. Combined with its manufacturing method, the stability of the gear box body during use can be effectively guaranteed, and the service life of the gear box body can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a front view structural diagram of the axle gearbox of the disc-type axial flux motor in the present invention;

[0028] Figure 2 This is a schematic diagram of the rear view of the axle gear box of the disc-type axial flux motor in the present invention;

[0029] Figure 3-Figure 7 Schematic diagram of the three-dimensional structure of the axle gear box of the disc-type axial flux motor of the present invention at different angles;

[0030] Figure 8-Figure 9 Schematic diagram of the structure of the lower bottom box at different angles in the present invention;

[0031] Figure 10-11 Schematic diagram of the structure of the middle box at different angles of the present invention;

[0032] Figure 12-13 Schematic diagram of the structure of the upper cover box at different angles in the present invention;

[0033] Figure 14-16 Schematic diagram of the structure of the gearbox at different angles in the present invention;

[0034] Figure 17 Schematic diagram of the structure of the bogie in the present invention;

[0035] Figure 18 Schematic diagram of the explosion of the gear box in the present invention;

[0036] In the figure: 1. Lower box body; 11. Lower semicircular plate for axle hole; 12. Lower semicircular plate for first gear ratio gear shaft hole; 13. Bottom plate of lower box body; 14. Side plate of lower box body; 15. Connecting flange of lower box body; 16. Lubrication device mounting plate; 161. Oil pan; 162. Lubrication device; 17. Lubrication device mounting hole; 18. Oil drain hole; 181. Oil drain plug; 2. Middle box body; 21. Upper semicircular plate for axle hole; 22. Upper semicircular plate for first gear ratio gear shaft hole; 23. First outer side plate of middle box body; 24. Side plate of middle box body; 25. Lower connecting flange of middle box body; 26. Upper connecting flange of middle box body; 27. Lower semicircular plate for motor mounting hole; 28. Lower semicircular plate for second gear ratio gear shaft hole; 29. ​​Lower semicircular plate for middle box body Hole connection part; 210, second outer side plate of middle box body; 211, top plate of middle box body; 3, upper cover box body; 32, side plate of upper cover box body; 33, top plate of upper cover box body; 34, inspection hole; 341, inspection hole flange; 36, upper cover box body connecting flange; 37, upper semicircular plate of motor mounting hole; 38, upper semicircular plate of second transmission ratio gear shaft hole; 39, upper semicircular hole connection part of upper cover box body; 4, pull rod arm; 41, pull rod hole; 5, rib plate; 6, refueling device mounting hole; 61, refueling device mounting flange; 62, oil dipstick flange; 63, oil dipstick; 7, inspection device; 71, inspection hole cover; 72, inspection hole cover sealing gasket; 73, air vent; 8, disc-type axial flux motor; 9, axle structure; 100, transmission mechanism. DETAILED DESCRIPTION

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. Unless otherwise defined, the technical terms or scientific terms used herein should be the common meanings understood by people with ordinary skills in the field to which the present disclosure belongs. The terms "upper", "lower", "left", "right", "front", "back", etc. used in the patent application specification and claims of this disclosure are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship also changes accordingly; "connected" or "connected" and similar words are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. The parts not described in detail in the present invention are all common knowledge to those skilled in the art.

[0038] Example 1:

[0039] like Figure 10-11As shown, the present invention is a middle box body of a disc-type axial flux motor axle gearbox, including a tie rod arm 4, a tie rod hole 41 for connection is provided on the top of the tie rod arm 4, and the middle box body 2 includes an upper and lower open box body composed of two middle box body side plates 24, a middle box body first outer plate 23 and a middle box body second outer plate 210 between the two middle box body side plates 24, and a middle box body top plate 211 between the middle box body first outer plate 23 and the middle box body second outer plate 210. The lower opening and upper opening of the upper and lower openings of the box structure are respectively provided with a middle box lower connecting flange 25 and a middle box upper connecting flange 26. The lower parts of the two middle box side panels 24 are respectively provided with an axle hole upper semicircular plate 21 and a first transmission ratio gear shaft hole upper semicircular plate 22. The upper part of one of the middle box side panels 24 and the upper part of the middle box top panel 211 are respectively provided with a motor mounting hole lower semicircular plate 27 and a second transmission ratio gear shaft hole lower semicircular plate 28. The lower semicircular plate 27 of the mounting hole and the lower semicircular plate 28 of the second transmission ratio gear shaft hole are an integrated structure, forming the lower semicircular hole connecting portion 29 of the middle box body. The upper semicircular plate 21 of the axle hole and the upper semicircular plate 22 of the first transmission ratio gear shaft hole are simultaneously connected to the lower connecting flange 25 of the middle box body. The lower semicircular plate 27 of the motor mounting hole and the lower semicircular plate 28 of the second transmission ratio gear shaft hole are simultaneously connected to the upper connecting flange 26 of the middle box body. The plane where the lower connecting flange 25 of the middle box body is located is connected to the upper connecting flange 26 of the middle box body. The plane where the flange 26 is located is at an acute angle, preferably 25°; a number of ribs 5 are arranged between the upper semicircular plate 21 of the axle hole and the upper semicircular plate 22 of the first transmission ratio gear shaft hole and the middle box side plate 24, as well as between the lower semicircular hole connecting portion 29 of the middle box and the middle box top plate 211 on the same side; preferably, the pull rod arm 4 is arranged on the outside of one of the upper semicircular plates 21 of the axle hole; preferably, the width of the upper semicircular plate 21 of the axle hole on one side is greater than that of the upper semicircular plate 21 of the axle hole on the other side.

[0040] In this embodiment, in order to increase the stability of the middle box body, the lower semicircular hole connecting part 29 of the middle box body composed of the upper semicircular plate 21 of the axle hole, the upper semicircular plate 22 of the first transmission ratio gear shaft hole, the lower semicircular plate 27 of the motor mounting hole and the lower semicircular plate 28 of the second transmission ratio gear shaft hole are cut and processed from 50mm steel plates, the first outer plate 23 of the middle box body, the side plate 24 of the middle box body, the second outer plate 210 of the middle box body and the top plate 211 of the middle box body are cut and processed from 30mm steel plates, the pull rod arm 4 is cut and processed from 60mm steel plates, the lower connecting flange 25 of the middle box body and the upper connecting flange 26 of the middle box body are cut and processed from 60mm steel plates, and the rib plate 5 is cut and processed from 30mm steel plates.

[0041] Example 2

[0042] As shown in the accompanying drawings, the present invention provides a disc-type axial flux motor axle gearbox, comprising the middle box body 2 described in Example 1, wherein the middle box body lower connecting flange 25 and the middle box body upper connecting flange 26 of the lower bottom box body 2 are detachably connected to the lower bottom box body 1 and the upper cover box body 3 respectively; the middle box body 2 is provided with an axle mounting hole A and a first transmission ratio gear shaft hole B between the upper semicircular plate 21 of the axle hole and the upper semicircular plate 22 of the first transmission ratio gear shaft hole and the lower bottom box body 1, and the middle box body 2 is provided with a second transmission ratio gear shaft hole C and a disc-type axial flux motor mounting hole D between the lower semicircular plate 27 of the motor mounting hole and the lower semicircular plate 28 of the second transmission ratio gear shaft hole and the upper cover box body 3, the axle mounting hole A and the first transmission ratio gear shaft hole B are provided between the middle box body 2 and the upper cover box body 3, The angle between the center line of the transmission ratio gear shaft hole B and the center line of the second transmission ratio gear shaft hole C and the disc-type axial magnetic flux motor mounting hole D is acute. The center line of the first transmission ratio gear shaft hole B and the second transmission ratio gear shaft hole C is perpendicular to the center line of the second transmission ratio gear shaft hole C and the disc-type axial magnetic flux motor mounting hole D. The wheel axle structure 9 is installed in the axle mounting hole A, and the disc-type axial magnetic flux motor 8 is installed in the disc-type axial magnetic flux motor mounting hole D. The transmission mechanism 100 is installed in the first transmission ratio gear shaft hole B and the second transmission ratio gear shaft hole C. The disc-type axial magnetic flux motor 8 is meshed with the transmission mechanism 100 through the motor shaft and gears, and the transmission mechanism 100 is meshed with the wheel axle structure 9. Figure 17 The bogie shown, the traveling frame 200, is the original locomotive traveling frame. The front and rear spaces are used to install the assembled gearbox. Tie rods 201 are provided on the front and rear of the traveling frame 200. The tie rod arms 4 on the central housing 2 are consistent with the tie rod arms on the original locomotive and are connected to the tie rods 201 through tie rod holes 41. The driving force provided by the disc axial flux motor 8 is ultimately transmitted to the axle structure 9 through the transmission mechanism 100. The axle structure 9 drives the traveling frame 200 on the track, and the tie rod arms 4 and tie rods 201 drive the traveling frame 200, ultimately driving the locomotive on the track. Preferably, the angle between the line connecting the center of the axle mounting hole A and the first gear ratio pinion hole B and the line connecting the center of the second gear ratio pinion hole C and the disc axial flux motor mounting hole D is 25°.

[0043] Example 3:

[0044] On the basis of Example 2, the lower box body 1 includes an upper open box structure consisting of a lower box body bottom plate 13 and a plurality of lower box body side plates 14. The upper opening of the upper open box structure is provided with a lower box body connecting flange 15. The upper portions of the lower box body side plates 14 on both sides thereof are respectively provided with the axle hole lower semicircular plate 11 and the first transmission ratio gear shaft hole lower semicircular plate 12. The lower box body connecting flange 15 is connected to both the axle hole lower semicircular plate 11 and the first transmission ratio gear shaft hole lower semicircular plate 12.

[0045] The upper cover box body 3 includes a lower open box structure consisting of two upper cover box body side panels 32 and an upper cover box body top panel 33 between the two upper cover box body side panels 32. The lower opening of the lower open box structure is provided with an upper cover box body connecting flange 36. The lower portions of the two upper cover box body side panels 32 are respectively provided with upper semicircular plates 37 for motor mounting holes and upper semicircular plates 38 for second transmission ratio gear shaft holes. The upper semicircular plates 37 for motor mounting holes and the upper semicircular plates 38 for second transmission ratio gear shaft holes are simultaneously connected to the upper cover box body connecting flange 36.

[0046] Among them, the lower semicircular plate 11 of the axle hole and the upper semicircular plate 21 of the axle hole constitute the axle mounting hole A, the lower semicircular plate 12 of the first transmission ratio gear shaft hole and the upper semicircular plate 22 of the first transmission ratio gear shaft hole constitute the first transmission ratio gear shaft hole B, the lower semicircular plate 28 of the second transmission ratio gear shaft hole and the upper semicircular plate 38 of the second transmission ratio gear shaft hole constitute the second transmission ratio gear shaft hole C, the lower semicircular plate 27 of the motor mounting hole and the upper semicircular plate 37 of the motor mounting hole constitute the disc-type axial flux motor mounting hole D; the lower bottom box body connecting flange 15 is adapted to the lower connecting flange 25 of the middle box body and is detachably connected by bolts, and the upper connecting flange 26 of the middle box body is adapted to the upper cover box body connecting flange 36 and is detachably connected by bolts.

[0047] In this embodiment, the line connecting the centers of the axle mounting hole A and the first transmission ratio gear shaft hole B forms an angle of 10° with the bottom surface of the lower box body 1.

[0048] In this embodiment, the bottom plate 13 of the lower box body is provided with a lubricating device mounting plate 16 and a plurality of oil drain holes 18, and the lubricating device mounting plate 16 is provided with a lubricating device mounting hole 17. Figure 16 As shown, the oil pan 161 can be installed on the lubricating device mounting plate 16, and the lubricating device can be installed on the oil pan 161. The lubricating device can be placed inside the lower bottom box 1 through the lubricating device mounting hole 17, as shown in FIG. Figure 16 As shown, an oil drain plug 181 can be provided at the oil drain hole 18 to drain the lubricating oil in the box body; a refueling device mounting hole 6 is provided on the lower bottom box side plate 14 of the lower box body 1, and a refueling device mounting flange 61 is provided on the outer side of the refueling device mounting hole 6, as shown Figure 15 As shown, an oil dipstick flange 62 and an oil dipstick 63 can be installed on the refueling device mounting flange 61, and lubricating grease can flow in here through the refueling device mounting hole 6; the pull rod arm 4 is arranged on the outside of the upper semicircular plate 21 of the axle hole; an inspection hole 34 is opened on the upper cover box body 1, and an inspection hole flange 341 is provided on the outside of the inspection hole 34, and an inspection device 7 can be installed on the inspection hole flange 341, and the detection device includes an inspection hole cover 71 and an inspection hole cover sealing gasket 72, and a ventilation hole 73 can be provided on the inspection hole cover 71.

[0049] In this embodiment, in order to facilitate design and installation, the upper semicircular plate 37 of the motor mounting hole and the upper semicircular plate 38 of the second transmission ratio gear shaft hole are an integrated structure, constituting an upper semicircular hole connecting portion 39 of the upper cover box body corresponding to the lower semicircular hole connecting portion 29 of the middle box body; the middle parts of the lower semicircular hole connecting portion 29 of the middle box body and the upper semicircular hole connecting portion 39 of the upper cover box body are correspondingly provided with mounting holes and are detachably connected by fasteners.

[0050] In this embodiment, in order to maintain the stability of the entire box body, a number of ribs 5 are also provided between the lower semicircular plate 11 of the axle hole and the lower semicircular plate 12 of the first transmission ratio gear shaft hole and the side plate 14 of the lower bottom box body. The lower semicircular plate 11 of the axle hole and the upper semicircular plate 21 of the axle hole on one side of the lower bottom box body 1 and the middle box body 2 are wider than the lower semicircular plate 11 of the axle hole and the upper semicircular plate 21 of the axle hole on the other side, and are consistent with the middle box body 2.

[0051] In this embodiment, the lower semicircular plate 11 of the axle hole and the lower semicircular plate 12 of the first transmission ratio gear shaft hole are cut and bent from 50mm steel plates, the lower bottom box bottom plate 13 is cut and processed from 40mm steel plates, the lower bottom box side plate 14 is cut and processed from 20mm steel plates, the lower bottom box connecting flange 15 is cut and processed from 60mm steel plates, and the lubrication device mounting plate 16 is cut and processed from 30mm steel plates; the upper cover box side plates 32 and the upper cover box top plate 33 are cut and processed from 20mm steel plates, the upper cover box connecting flange 36 is cut and processed from 60mm steel plates, and the upper semicircular hole connecting part 39 of the upper cover box composed of the upper semicircular plate 37 of the motor mounting hole and the upper semicircular plate 38 of the second transmission ratio gear shaft hole is cut and processed from 50mm steel plates.

[0052] Example 4:

[0053] Based on the method for manufacturing a gear box body in a disc-type axial flux motor axle gear box described in Example 3, the lower box body 1, the middle box body 2, and the upper cover box body 3 are first welded together, and then stress relief and heat treatment are performed, and finally machining is performed. The specific steps are as follows:

[0054] S1. Preparation before welding:

[0055] S1.1. Welding equipment: HT400D or HT500D digitally controlled inverter DC welding machine for combined manual arc welding and argon arc welding, Φ3.2mm and φ4.0mm E5015 welding rods; Welding materials: Structural steel welding rods, carbon arc gouging ZX5-630 welding machine with plasma gouging LGK-100MA

[0056] S1.2, Heating device: H01-20 baking gun;

[0057] S1.3. Auxiliary equipment: angle grinder, file, hammer, flat shovel, mask, sample, thermometer, magnifying glass, thermal insulation cotton;

[0058] S1.4, Weldment material: body 16Mn low alloy steel;

[0059] S1.5. Requirements for surfacing before welding: Use a manual angle grinder to process and clean the welding surface to remove rust, grease, and moisture. Thick plates need to be preheated to 150 degrees.

[0060] S1.6, welding position: K groove;

[0061] S1.7, Welding requirements: All weld layers must be free of any welding defects and fused to the parent material;

[0062] S1.8, Welding process parameters: Welding parameters are determined based on welding equipment, welding materials, weldment materials and welding requirements;

[0063] Welding process parameters

[0064]

[0065] Welding process route: component production and assembly - preheating before welding - K-groove root cleaning and symmetrical penetration welding - control of deformation and installation dimensions - local assembly - overall assembly - overall entry into the furnace for post-weld heat treatment - overall machining - local installation of spare parts - inspection and acceptance - delivery for use.

[0066] S2. Welding production:

[0067] S2.1. First, machine all the lower axle hole lower semicircular plates 11, first gear ratio gear shaft hole lower semicircular plates 12, lower box body bottom plate 13, lower box body side plates 14, lower box body connecting flange 15, lubrication device mounting plate 16 and rib plate 5 to form the lower bottom box body 1 according to the designed shape and size. Open the lubrication device mounting hole 17 on the lubrication device mounting plate 16 and the oiling device mounting hole 6 on the lower box body side plates 14. Machine a single-sided 30° bevel on both sides of each lower box body side plate 14 so that the lower bottom box body can be assembled. There are connections that can form K-groove double-sided welding; then, according to the structure of the lower bottom box body 1, the prepared plates are welded and assembled, and the lower semicircular plate 11 of the axle hole and the lower semicircular plate 12 of the first transmission ratio gear shaft hole are used as positioning references. Each lower bottom box body side plate 14 is spot welded and fixed below the lower semicircular plate 11 of the axle hole and the lower semicircular plate 12 of the first transmission ratio gear shaft hole, and the lower bottom box body bottom plate 13 and the lubrication device mounting plate 16 are installed at the bottom of the lower bottom box body side plate 14 and spot welded to form a basic frame, and then the basic frame is adjusted according to the size of the lower bottom box body 1. After the correction, the lower bottom box side panels 14 are fixed between the existing lower bottom box side panels 14, and finally the lower bottom box connecting flange 15 and each rib plate 5 are fixed by precision group spot welding; after the overall structural frame is all spot welded and fixed according to the design size, welding is carried out; when welding, all the outer spot welding fixed connections of the lower bottom box 1 are welded first, and the welding method is manual arc welding, and the outer two sides are welded symmetrically. Because the lower semicircular plate 11 of the axle hole, the lower semicircular plate 12 of the first transmission ratio gear shaft hole and the lower bottom box connecting flange 15 are relatively thick, they are connected before welding. Preheat both sides of the groove to about 150℃. After reaching the temperature, the digitally controlled inverter manual arc welding and argon arc welding are combined with a DC welding machine and a 3.2mm diameter E5015 structural steel welding rod is used to perform symmetrical single-sided bottom layer all-position welding. The current is 120A and the welding rod is moved in a straight line. While the bottom layer is fully melted, the weld must also ensure good fusion with both sides. After the bottom layer is welded, ultrasonic stress relief is used to confirm that there are no welding defects on the surface. Then, the interlayer temperature is controlled, and the filling and capping layers are welded as a whole. A diameter of 4.0mm E5015 structural steel welding rod, the filling and cover layer welding current is selected between 130-140A, especially the first layer of filling layer current is too large to facilitate the elimination of bottom layer defects, the welding rod adopts the triangle rod method, the welding rod angle changes according to the surfacing position, after the filling layer is fully welded, ultrasonic stress relief is used, visual inspection or 10x magnifying glass is used to confirm that there are no welding defects on the surface, and then the cover layer surface is welded. The cover layer must meet the designed weld angle size and no undercut can be generated between the two sides. After all welding is completed, ultrasonic stress relief is used, and then insulation All outer welds are completely covered with insulation. Next, all inner spot welds and fixed connections of the lower bottom box 1 are welded. Before welding, a ZX5-630 carbon arc gouging machine and an LGK-100MA plasma gouging machine are used to clean the base of the inner spot welds and fixed connections. Once these are confirmed to be free of defects, welding is performed. The welding method, process, and dimensions for the inner connections are the same as for the outer connections. After all welding is complete, ultrasonic stress relief is performed, and the welds are completely covered with insulation insulation. The welds are then cooled to room temperature and cleaned with a manual angle grinder. Finally, all welds are inspected for flaws.

[0068] S2.2, firstly, according to the designed shape and size, machine the upper semicircular plate 21 of the axle hole of the middle box 2, the upper semicircular plate 22 of the first transmission ratio gear shaft hole, the first outer plate 23 of the middle box, the side plate 24 of the middle box, the lower connecting flange 25 of the middle box, the upper connecting flange 26 of the middle box, the lower semicircular plate 27 of the motor mounting hole and the lower semicircular plate 28 of the second transmission ratio gear shaft hole to form the middle box lower semicircular hole connecting part 29, the middle box second outer plate 210, the middle box top plate 211, the rib plate 5 and the tie rod arm 4; on each of the first outer plate 23 of the middle box, the side plate 24 of the middle box, the second outer plate 210 of the middle box, the middle box top plate 2 Each side of 11 is machined on both sides with a single-sided 30° groove, so that all joints can form a K-groove double-sided welding when assembled; then the processed components are welded and assembled according to the structure of the middle box 2, and the upper semicircular plate 21 of the axle hole, the upper semicircular plate 22 of the first transmission ratio gear shaft hole and the lower semicircular plate 28 of the second transmission ratio gear shaft hole constituting the second outer plate 210 of the middle box and the lower semicircular hole connecting portion 29 of the middle box are used as positioning references, and each middle box side plate 24 is spot-welded in the middle of each lower semicircular plate and the upper semicircular plate to form a basic frame and correct it to meet the design size, and then the first outer plate 23 of the middle box and the second outer plate 21 of the middle box are assembled. 0 and the middle box top plate 211 between the two are spot welded and fixed, and then the tie rod arm 4 is spot welded and fixed, and finally the middle box lower connecting flange 25, the middle box upper connecting flange 26 and each rib plate 5 are spot welded and fixed by precision group; after all the overall structural parts frame are spot welded and fixed according to the design size, welding is carried out; when welding, all the outer spot welding fixed joints of the middle box 2 are welded first, and the welding method is manual arc welding, and the outer two sides are welded symmetrically, because the upper semicircular plate 21 of the axle hole, the upper semicircular plate 22 of the first transmission ratio gear shaft hole, the lower connecting flange 25 of the middle box, the upper connecting flange 26 of the middle box, the lower semicircular plate 27 of the motor mounting hole and the second transmission ratio The connecting portion 29 of the lower semicircular hole of the middle box body and the tie rod arm 4, which are formed by the lower semicircular plate 28 of the gear shaft hole, are relatively thick. Before welding, both sides of the groove of the connection are preheated to about 150°C. After reaching the temperature, the digitally controlled inverter manual arc welding and argon arc welding are combined with a DC welding machine and a 3.2mm diameter E5015 structural steel welding rod are selected to perform symmetrical single-sided bottom layer all-position welding. The current is 120A, and the welding rod is moved in a straight line. While the bottom layer is fully melted, the weld must also ensure good fusion with both sides. After the bottom layer is welded, ultrasonic stress relief is used to confirm that there are no welding defects on the surface. The interlayer temperature is controlled, and then the filling and cover layers are welded as a whole. The diameter is 4.0mm E5015 structural steel welding rod, the filling and cover layer welding current is selected between 130-140A, especially the first layer of filling layer current is too large to facilitate the elimination of bottom layer defects, the welding rod adopts the triangle rod method, the welding rod angle changes according to the surfacing position, after the filling layer is fully welded, ultrasonic stress relief is used, visual inspection or 10x magnifying glass is used to confirm that there are no welding defects on the surface, and then the cover layer surface is welded. The cover layer must meet the designed weld angle size and no undercut can be generated between the two sides. After all welding is completed, ultrasonic stress relief is used, and then insulation All outer welds are completely covered with insulation. Next, all inner spot welds and fixed joints of the central box 2 are welded. Before welding, the ZX5-630 carbon arc gouging machine and the LGK-100MA plasma gouging machine are used to clean the roots of the inner spot welds and fixed joints. Once these joints are free of defects, welding is performed. The welding method, process, and dimensions for the inner joints are the same as for the outer joints. After all welding is completed, ultrasonic stress relief is performed. The welds are completely covered with insulation insulation and cooled to room temperature. The surfaces are then cleaned with a manual angle grinder. Finally, all welds are inspected for flaws.

[0069] S2.3. First, machine all the upper cover box side panels 32, upper cover box top panel 33, upper cover box connecting flange 36, upper semicircular plate 37 of motor mounting hole, and upper semicircular plate 38 of second transmission ratio gear shaft hole to form the upper cover box upper semicircular hole connecting portion 39 according to the designed shape and size. Open an inspection hole 34 on the upper cover box top panel 33. Machine a single-sided 30° bevel on both sides of each upper cover box side panel 32 and upper cover box top panel 33 to make When all the joints are aligned, K-groove double-sided welding can be formed; then the prepared plates are welded and assembled according to the upper cover box 3, and the upper semicircular plate 37 of the motor mounting hole of the upper semicircular hole connection part 39 of the upper cover box and the upper semicircular plate 38 of the second transmission ratio gear shaft hole are used as the positioning reference. The upper part of each semicircular plate is spot welded to fix each upper cover box side plate 32 to form a basic frame and perform size correction. Then, the upper cover box top plate 33 is spot welded and fixed. Finally, the upper cover box connection flange 36 is spot welded and fixed with precision. After all the structural parts of the frame are spot welded and fixed according to the design dimensions, welding is carried out. When welding, all the outer spot welding fixed joints of the upper cover box 3 are welded first. The welding method is manual arc welding. The outer two sides are welded symmetrically. Because the upper semicircular plate 37 of the motor mounting hole and the upper semicircular plate 38 of the second transmission ratio gear shaft hole constitute the upper semicircular hole connection part 39 of the upper cover box and the upper cover box connection flange 36, the plates are relatively thick, the two sides of the connection groove are preheated to about 150℃ before welding. After the temperature reaches the temperature, the digitally controlled inverter manual arc welding and argon arc welding are combined with a DC welding machine and a 3.2mm diameter E5015 structural steel welding rod is used to perform symmetrical single-sided bottom layer full position welding. The current is 120A and the welding rod is moved in a straight line. While the bottom is fully melted, the weld must also ensure good fusion with both sides. After the bottom layer is welded, ultrasonic stress relief is used to confirm that there are no welding defects on the surface. Then the interlayer temperature is controlled and the filling and cover layer are welded as a whole. The diameter is 4.0mm E5015 structural steel welding rod, the filling and cover layer welding current is selected between 130-140A, especially the first layer of filling layer current is too large to facilitate the elimination of bottom layer defects, the welding rod adopts the triangle rod method, the welding rod angle changes according to the surfacing position, after the filling layer is fully welded, ultrasonic stress relief is used, visual inspection or 10x magnifying glass is used to confirm that there are no welding defects on the surface, and then the cover layer surface is welded. The cover layer must meet the designed weld angle size and no undercut can be generated between the two sides. After all welding is completed, ultrasonic stress relief is used, and then insulation All outer welds are completely covered with insulation. The upper cover box 3 is then welded to all inner spot welded connections. Before welding, a ZX5-630 carbon arc gouging machine and an LGK-100MA plasma gouging machine are used to clean the inner spot welded connections. Once these connections are free of defects, welding is performed. The welding method, process, and dimensions for the inner connections are the same as for the outer connections. After all welding is complete, ultrasonic stress relief is performed. The welds are completely covered with insulation insulation, cooled to room temperature, and then cleaned with a manual angle grinder. Finally, all welds are inspected for flaws.

[0070] S2.4. Connect the lower box body connecting flange 15 and the middle box body lower connecting flange 25, the middle box body upper connecting flange 26 and the upper cover box body connecting flange 36, the middle box body lower semicircular hole connecting part 29 and the upper cover box body upper semicircular hole connecting part 39 by bolts so that the lower box body 1, the middle box body 2 and the upper cover box body 3 are connected into an integral structural component frame, and then send the integral structural component frame into the furnace for overall stress elimination and deformation heat treatment, and finally use mechanical equipment to process the holes on the integral structural component frame as a whole to ensure the precision installation of the motor and various shaft components, and then install the disc-type axial flux motor, various shaft components, oiling device, lubrication device, observation device, oil drain device, etc. before delivery.

Claims

1. A middle housing of a disc-type axial flux motor axle gearbox, comprising a tie rod arm (4), a tie rod hole (41) being provided at the top of the tie rod arm (4), characterized in that: The middle box body (2) comprises an upper and lower open box body structure consisting of two middle box body side panels (24), a middle box body first outer panel (23) and a middle box body second outer panel (210) between the two middle box body side panels (24), and a middle box body top panel (211) between the middle box body first outer panel (23) and one side of the middle box body second outer panel (210), wherein the lower opening and the upper opening of the upper and lower open box body structure are respectively provided with a middle box body lower connecting flange (25) and a middle box body upper connecting flange (26), wherein the lower portions of the two middle box body side panels (24) are respectively provided with an upper semicircular plate (21) for an axle hole and an upper semicircular plate (22) for a first transmission ratio gear shaft hole, and the upper portion of one of the middle box body side panels (24) and the upper portion of the middle box body top panel (211) are respectively provided with a lower semicircular plate (27) for a motor mounting hole and a lower semicircular plate for a second transmission ratio gear shaft hole. (28), the motor mounting hole lower semicircular plate (27) and the second transmission ratio gear shaft hole lower semicircular plate (28) are an integrated structure, forming the middle box body lower semicircular hole connecting portion (29), the axle hole upper semicircular plate (21) and the first transmission ratio gear shaft hole upper semicircular plate (22) are simultaneously connected to the middle box body lower connecting flange (25), the motor mounting hole lower semicircular plate (27) and the second transmission ratio gear shaft hole lower semicircular plate (28) are simultaneously connected to the middle box body lower connecting flange (25), The upper connecting flange (26) of the middle box body is connected; the plane where the lower connecting flange (25) of the middle box body is located and the plane where the upper connecting flange (26) of the middle box body are located form an acute angle; a plurality of ribs (5) are provided between the upper semicircular plate (21) of the axle hole and the upper semicircular plate (22) of the first transmission ratio gear shaft hole and the side plate (24) of the middle box body, and between the lower semicircular hole connecting portion (29) of the middle box body and the middle box body top plate (211) on the same side thereof; The plane where the middle box lower connecting flange (25) is located and the plane where the middle box upper connecting flange (26) is located form an angle of 25°; The pull rod arm (4) is arranged on the outside of the upper semicircular plate (21) of one of the axle holes.

2. The middle housing of the disc-type axial flux motor axle gearbox according to claim 1, characterized in that: The width of the upper semicircular plate (21) of the axle hole on one side is greater than that of the upper semicircular plate (21) of the axle hole on the other side.

3. The middle housing of the disc-type axial flux motor axle gearbox according to claim 1, characterized in that: The lower semicircular hole connecting portion (29) of the middle box body, which is formed by the upper semicircular plate (21) of the axle hole, the upper semicircular plate (22) of the first transmission ratio gear shaft hole, the lower semicircular plate (27) of the motor mounting hole, and the lower semicircular plate (28) of the second transmission ratio gear shaft hole, is cut and processed from a 50 mm steel plate. The first outer side plate (23) of the middle box body, the side plate (24) of the middle box body, the second outer side plate (210) of the middle box body, and the top plate (211) of the middle box body are cut and processed from a 30 mm steel plate. The tie rod arm (4) is cut and processed from a 60 mm steel plate. The lower connecting flange (25) of the middle box body and the upper connecting flange (26) of the middle box body are cut and processed from a 60 mm steel plate.

4. A disc-type axial flux motor axle gearbox, characterized in that: The invention comprises a middle box body (2) as claimed in any one of claims 1 to 3, wherein the middle box body lower connecting flange (25) and the middle box body upper connecting flange (26) of the middle box body (2) are detachably connected to the lower box body (1) and the upper cover box body (3); the middle box body (2) is provided with an axle mounting hole (A) and a first transmission ratio gear shaft hole (B) between the upper semicircular plate (21) of the axle hole and the upper semicircular plate (22) of the first transmission ratio gear shaft hole and the lower box body (1); the middle box body (2) is provided with a second transmission ratio gear shaft hole (C) and a disc axial flux motor mounting hole (D) between the lower semicircular plate (27) of the motor mounting hole and the lower semicircular plate (28) of the second transmission ratio gear shaft hole and the upper cover box body (3); the axle mounting hole (A) and the first transmission ratio gear shaft hole (B) are provided with axle mounting hole (A) and a first transmission ratio gear shaft hole (B) between the upper semicircular plate (27) of the motor mounting hole and the lower semicircular plate (28) of the second transmission ratio gear shaft hole; The angle between the center line of the first transmission ratio gear shaft hole (B) and the center line of the second transmission ratio gear shaft hole (C) and the disc-type axial magnetic flux motor mounting hole (D) is acute, and the center line of the first transmission ratio gear shaft hole (B) and the second transmission ratio gear shaft hole (C) is perpendicular to the center line of the second transmission ratio gear shaft hole (C) and the disc-type axial magnetic flux motor mounting hole (D); the wheel axle structure (9) is installed in the axle mounting hole (A), the disc-type axial magnetic flux motor (8) is installed in the disc-type axial magnetic flux motor mounting hole (D), the transmission mechanism (100) is installed in the first transmission ratio gear shaft hole (B) and the second transmission ratio gear shaft hole (C), the disc-type axial magnetic flux motor (8) is meshed with the transmission mechanism (100) through the motor shaft and the gear, and the transmission mechanism (100) is meshed with the wheel axle structure (9).

5. The disc-type axial flux motor axle gearbox according to claim 4, characterized in that: The angle between the center line of the axle mounting hole (A) and the first gear ratio gear shaft hole (B) and the center line of the second gear ratio gear shaft hole (C) and the disc-type axial flux motor mounting hole (D) is 25°.

6. The method for designing and manufacturing a middle housing of a disc-type axial flux motor axle gearbox according to any one of claims 1 to 3, characterized in that: Here are the steps: S1. Preparation before welding: S1.

1. Welding equipment: HT400D or HT500D digitally controlled inverter DC welding machine for combined manual arc welding and argon arc welding, Φ3.2mm and φ4.0mm E5015 welding rods; Welding materials: Structural steel welding rods, carbon arc gouging ZX5-630 welding machine with plasma gouging LGK-100MA S1.2, Heating device: H01-20 baking gun; S1.

3. Auxiliary equipment: angle grinder, file, hammer, flat shovel, mask, sample, thermometer, magnifying glass, thermal insulation cotton; S1.4, Weldment material: body 16Mn low alloy steel; S1.

5. Pre-welding requirements: Use a manual angle grinder to clean the welding surface to remove rust, grease, and moisture. Thick plates must be preheated to 150 degrees. S1.6, welding position: K groove; S1.7, Welding requirements: All weld layers must be free of any welding defects and fused to the parent material; S1.

8. Welding process parameters: Develop welding parameters based on the welding equipment, welding materials, weldment material, and welding requirements. When welding the base layer, use an E5015 electrode with a diameter of 3.2 mm, a welding current of 90-120 A, an arc voltage of 23 ± 1 V, and a welding speed of 15 ± 1 cm / min. When welding the filler layer and cap layer, use an E5015 electrode with a diameter of 4.0 mm, a welding current of 130-160 A, an arc voltage of 26 ± 1 V, and a welding speed of 17 ± 1 cm / min. S2. Welding production: First, all the upper semicircular plates (21) of the axle holes of the middle box (2), the upper semicircular plates (22) of the first transmission ratio gear shaft holes, the first outer side plates (23) of the middle box, the side plates (24) of the middle box, the lower connecting flange (25) of the middle box, the upper connecting flange (26) of the middle box, the lower semicircular plates (27) of the motor mounting holes and the lower semicircular plates (28) of the second transmission ratio gear shaft holes, the middle box lower semicircular hole connecting portion (29), the middle box second outer side plates (210), the middle box top plate (211), the rib plate (5) and the tie rod arm (4) are machined according to the designed shape and size; on each of the first outer side plates (23) of the middle box, the side plates (24) of the middle box, the second outer side plates (21 0), each side of the middle box top plate (211) is machined with a single-sided 30° groove on both sides, so that all joints can form a K groove double-sided welding when assembled; then the processed components are welded and assembled according to the structure of the middle box (2), and the upper semicircular plate (21) of the axle hole, the upper semicircular plate (22) of the first transmission ratio gear shaft hole and the lower semicircular plate (28) of the second transmission ratio gear shaft hole constituting the second outer plate (210) of the middle box and the middle box lower semicircular hole connecting portion (29) are used as positioning references, and each middle box side plate (24) is spot welded and fixed at the middle part of each lower semicircular plate and the upper semicircular plate to form a basic frame and corrected to meet the design size, and then the first outer plate (23) of the middle box and the middle box are welded. The second outer plate (210) of the body and the middle box top plate (211) between the two are spot welded and fixed, and then the tie rod arm (4) is spot welded and fixed, and finally the middle box lower connecting flange (25), the middle box upper connecting flange (26) and each rib plate (5) are spot welded and fixed by precision group; after all the integral structural parts frame are spot welded and fixed according to the design size, welding is performed; when welding, all the outer spot welding fixed joints of the middle box (2) are welded first, and the welding method is manual arc welding, and the outer two sides are symmetrically welded, because the upper semicircular plate (21) of the axle hole, the upper semicircular plate (22) of the first transmission ratio gear shaft hole, the lower connecting flange (25) of the middle box, the upper connecting flange (26) of the middle box, and the lower motor mounting hole are welded. The semicircular plate (27) and the lower semicircular plate (28) of the second transmission ratio gear shaft hole constitute the middle box body lower semicircular hole connection part (29) and the tie rod arm (4) plate is relatively thick. Before welding, the two sides of the groove of the connection are preheated to about 150 ° C. After the temperature reaches the temperature, the digital control inverter manual arc welding and argon arc welding are combined with a DC welding machine and a 3.2mm diameter E5015 structural steel welding rod is selected for symmetrical single-sided bottom full position welding. The current is 120A. The welding rod is moved in a straight line. While the bottom is fully melted, the weld must also ensure good fusion with both sides. After the bottom layer is welded, ultrasonic stress relief is used to confirm that there are no welding defects on the surface. Then, the interlayer temperature is controlled and the filling and cover layer are welded as a whole. The diameter is 4.0mm E5015 structural steel welding rod, the filling and cover layer welding current is selected between 130-140A, especially the first layer of filling layer current is too large to facilitate the elimination of bottom layer defects, the welding rod adopts the triangle rod method, the welding rod angle changes according to the surfacing position, after the filling layer is fully welded, ultrasonic stress relief is used, visual inspection or 10x magnifying glass is used to confirm that there are no welding defects on the surface, and then the cover layer surface is welded. The cover layer must meet the designed weld angle size and no undercut can be generated between the two sides. After all welding is completed, ultrasonic stress relief is used, and then insulation The cotton is used to cover all the outer welds; then the welding of all the inner spot welding fixed connections of the middle box (2) is carried out. Before welding, the carbon arc air gouging ZX5-630 welding machine is used in conjunction with the plasma gouging LGK-100MA to clean the roots of the inner spot welding fixed connections. After confirming that there are no defects, welding is carried out. The welding method, process and welding size of the inner opening are the same as those of the outer connection. After all welding is completed, ultrasonic stress relief is carried out, and the welds are covered with thermal insulation cotton and then cooled to room temperature. Then, the surface is cleaned with a manual angle grinder. Finally, all welds are inspected and tested.

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