Assembly process for reducing vibration fault of diesel engine 16V240ZJ during overhaul

Abstract

This invention proposes an assembly process to reduce vibration faults in a 16V240ZJ diesel engine during maintenance, comprising the following steps: Step S1, pre-assembly component inspection; Step S2, measurement during assembly; Step S3, post-assembly measurement; After the main generator is installed, the radial runout M of the driven disc of the flexible coupling and the runout N of the main generator slip ring are measured, with M ≤ 0.30 mm and N ≤ 0.15 mm; if both parameters M and N meet the requirements, the maintenance is completed. In the diesel engine maintenance assembly process, based on the connection method and structural principle of the components, combined with practical operating experience and data accumulation, this invention, after assembly, measures and controls these two parameters—radial runout M of the driven disc of the flexible coupling and runout N of the main generator slip ring—to predict the risk of diesel engine vibration faults in advance, thereby improving maintenance assembly efficiency.

Description

Technical Field

[0001] This invention relates to railway vehicle maintenance technology, specifically an assembly process for reducing vibration faults in the 16V240ZJ diesel engine of a diesel locomotive during maintenance. Background Technology

[0002] Diesel engines are the power source for diesel locomotives. In railway vehicle operation, diesel engine vibration, as a comprehensive quality issue, significantly impacts the reliability and service life of vehicle components. One of the main causes of diesel engine vibration is excessive rotational torque resulting from poor coaxiality of shaft system components. While ensuring the coaxiality of assembled diesel engine shaft system components typically relies on the shape and dimensions of each component during maintenance, accumulated dimensional deviations after assembly can still lead to vibration detected during diesel engine bench testing. Further troubleshooting requires disassembling and inspecting a large number of components, resulting in significant rework and repair work, making fault diagnosis and troubleshooting difficult. Summary of the Invention

[0003] In response to the problems raised in the background art, the purpose of this invention is to propose an assembly process to reduce vibration faults in the 16V240ZJ diesel engine of a diesel locomotive during maintenance. This process, combined with practical operating experience and data accumulation, can reduce the vibration risk of the diesel engine caused by the difference in shaft coaxiality during the maintenance and assembly stage, avoid rework caused by vibration faults reported from bench tests, and greatly improve the efficiency of maintenance and assembly.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] An assembly process for reducing vibration faults in a 16V240ZJ diesel engine of an internal combustion locomotive during maintenance includes the following steps:

[0006] Step S1: Pre-assembly component inspection; Connect the crankshaft and the flexible coupling, and measure and control the following parameters: Radial runout A of the flange on the flexible coupling relative to the crankshaft center axis; Radial runout B of the driving disc stop of the flexible coupling relative to the crankshaft center axis; Radial runout C of the driven disc stop of the flexible coupling relative to the crankshaft center axis; Check the flatness D of the two mounting surfaces of the connecting box along its entire length, the end runout E of the mounting surface connecting the connecting box to the diesel engine block to the main bearing hole axis 7 of the connecting box, and the radial runout F of the main generator slip ring relative to the rotor center axis; Ensure that parameters A, B, C, D, E, and F all meet the assembly requirements;

[0007] Step S2, Measurements during assembly: Connect the flexible coupling to the main generator and measure the following parameters: Detect the radial runout G1 and end face runout G2 of the driving disc stop of the flexible coupling, ensuring that parameters G1 and G2 meet the assembly requirements; Install the connecting box and adjust the coaxiality of the connecting box main bearing hole axis and the crankshaft center axis to create a two-dimensional offset between the connecting box main bearing hole axis and the crankshaft center axis. Use a dial indicator to measure the two-dimensional offset between the connecting box main bearing hole axis and the crankshaft center axis, and set the Z-axis offset F. 上 -F 下 =0.12~0.20mm, Y-axis offset F 左 -F 右 = ±0.05mm;

[0008] Step S3: Measurement after assembly; After the main generator is installed, check the radial runout M of the driven disc of the flexible coupling and the runout N of the main generator slip ring. Set M≤0.30mm and N≤0.15mm. If both parameters M and N meet the requirements, the overhaul is complete; otherwise, return to step S1 and perform the pre-assembly component overhaul again.

[0009] In step S1, the measured values ​​of each parameter must meet the following requirements: A≤0.05mm, B≤0.25mm, C≤0.25mm, D≤0.10mm, E≤0.30mm, F≤0.15mm.

[0010] In step S2, the radial runout G1 and the end face runout G2 of the active disc stop meet the following requirements: G1≤0.25mm, G2≤0.03mm.

[0011] The principle of this invention: Based on practical experience and data accumulation, this invention determines two parameters, M and N, as threshold values. M refers to the coaxiality of the driven disc center axis with the crankshaft center axis after the assembly of all components of the feedback shaft system. N refers to the coaxiality of the main generator rotor center axis with the crankshaft axis after the main generator slip ring is installed through the connecting box and coupling. If both of the above two parameters are controlled within the threshold values ​​given in step S3, and the maintenance process of each component of the shaft system also meets the process requirements, the probability of the vibration value exceeding the standard during the diesel engine test is zero.

[0012] The beneficial effects of the present invention are as follows: The process proposed in this invention combines practical experience and data accumulation, and uses two specific threshold values ​​as evaluation parameters for the final inspection of maintenance. It can predict the vibration fault of the 16V240ZJ diesel engine of the internal combustion locomotive in advance. The maintenance process is highly operable and easy to execute, which greatly improves the maintenance and assembly efficiency. Attached Figure Description

[0013] Figure 1A schematic diagram showing the connection between the crankshaft output end of a 16V240ZJ diesel engine and the main generator via a flexible coupling.

[0014] Figure 2 A front view of the 16V240ZJ diesel engine and main generator after assembly;

[0015] Figure 3 This is an assembly diagram of the 16V240ZJ diesel engine block and its connecting box.

[0016] Figure 4 This is a schematic diagram showing the offset between the main bearing bore axis of the connecting box and the crankshaft center axis during assembly.

[0017] Figure 5 This is the front view of the connecting box;

[0018] Figure 6 This is the left side view of the connecting box.

[0019] In the diagram, 1 is the crankshaft, 2 is the flexible coupling, 3 is the flange, 4 is the driving disc stop, 5 is the driven disc stop, 6 is the connecting box, 7 is the main bearing hole axis, 8 is the main generator slip ring, 10 is the main generator, 11 is the driven disc, 12 is the diesel engine block, and 13 is the dial indicator. Detailed Implementation

[0020] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings.

[0021] like Figures 1 to 6 As shown, this invention provides an assembly process for reducing vibration faults in the 16V240ZJ diesel engine of an internal combustion locomotive during maintenance, comprising the following steps:

[0022] Step S1: Pre-assembly component inspection; Connect crankshaft 1 and flexible coupling 2, and measure and control the following parameters: radial runout A of the flange 3 on the flexible coupling 2 relative to the central axis of crankshaft 1; radial runout B of the driving disc stop 4 of the flexible coupling 2 relative to the central axis of crankshaft 1; radial runout C of the driven disc stop 5 of the flexible coupling 2 relative to the central axis of crankshaft 1; check the flatness D of the two mounting surfaces of the connecting box 6 along its entire length, the end runout E of the mounting surface connecting the connecting box 6 and the diesel engine block 12 to the main bearing hole axis 7 of the connecting box 6, and the radial runout F of the main generator slip ring 8 relative to the rotor central axis; ensure that parameters A, B, C, D, E, and F all meet the assembly requirements; if any of parameters A, B, C, D, E, or F does not meet the assembly requirements, the corresponding parts of the components must be repaired; regarding the testing methods, all are existing technologies, such as the measurement of D and E, for example... Figure 6 As shown, it is measured using dial indicator 13. The fixed position of dial indicator 13 and the corresponding position of the measuring head are both existing technologies.

[0023] Step S2, Measurement during assembly: Connect the flexible coupling 2 to the main generator 10 and measure the following parameters: Detect the radial runout G1 and end face runout G2 of the driving disc stop 4 of the flexible coupling 2, ensuring that parameters G1 and G2 meet the assembly requirements; Install the connecting box 6 and adjust the coaxiality of the main bearing hole axis 7 of the connecting box 6 and the central axis of the crankshaft 1, causing a two-dimensional offset between the main bearing hole axis 7 of the connecting box 6 and the central axis of the crankshaft 1. Use a dial indicator to measure the two-dimensional offset between the main bearing hole axis 7 of the connecting box 6 and the central axis of the crankshaft 1, and set the Z-axis offset F... 上 -F 下 =0.12~0.20mm, Y-axis offset F 左 -F 右 =±0.05mm; such as Figure 4 As shown, the axis 7 of the main bearing hole of the connecting box 6 is 0.12 to 0.20 mm higher than the crankshaft centerline;

[0024] Step S3: Measurement after assembly; After the main generator is installed, check the radial runout M of the driven disc 11 of the flexible coupling 2 and the runout N of the slip ring 8 of the main generator. Set M≤0.30mm and N≤0.15mm. If both parameters M and N meet the requirements, the overhaul is complete; otherwise, return to step S1 and perform the pre-assembly component overhaul again.

[0025] In step S1, the measured values ​​of each parameter must meet the following requirements: A≤0.05mm, B≤0.25mm, C≤0.25mm, D≤0.10mm, E≤0.30mm, F≤0.15mm.

[0026] In step S2, the radial runout G1 and the end face runout G2 of the active disc stop 4 meet the following requirements: G1≤0.25mm, G2≤0.03mm.

[0027] The assembly of the 16V240ZJ diesel engine is as follows: Figure 1-3 As shown, it includes a diesel engine block 12 ( Figure 1 For the purpose of illustration, neither the diesel engine body 12 nor the connecting box 6 is shown in order to clearly show the connection relationship within the connecting box 6. The connecting box 6 and the main generator 10 are connected. The main shaft (rotor part) of the main generator 10 is connected to the crankshaft 1 in the diesel engine body 12 through the flexible coupling 2. The stator part of the main generator 10 is installed on the diesel engine body 12 through the connecting box 6. The flexible coupling 2 is located inside the connecting box 6.

[0028] The flexible coupling 2 connects to the crankshaft 1 of the diesel engine on the driving side (drive plate 11) and to the main generator 10 on the driven plate 11 (driven plate 11). The driving and driven plates 11 are positioned by a stop and connected by bolts. The flexible coupling 2 is located inside the connecting housing 6. Figure 5 , Figure 6As shown, the side wall of the connecting box 6 has a window, through which various positions on the flexible coupling 2 can be detected.

[0029] The process proposed in this invention is derived from extensive data accumulation and actual observation. The radial runout M of the driven disc 11 provides feedback on the coaxiality of the driven disc center axis of the flexible coupling 2 with the crankshaft center axis after the assembly of all components in the shaft system. The radial runout N of the main generator slip ring 8 provides feedback on the coaxiality of the rotor center axis of the main generator with the crankshaft axis after installation via the connecting box 6 and the flexible coupling 2. If both parameters are controlled within the threshold values, and the maintenance process of each component in the shaft system also meets the process flow requirements, the probability of the vibration value exceeding the standard during diesel engine testing is zero. If either parameter exceeds the standard, the cause of the abnormality must be traced back and dealt with during assembly. The handling methods include retesting and verifying the process parameters during the maintenance of each component and re-repairing the parts.

[0030] The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solution based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. An assembly process for reducing vibration faults in the 16V240ZJ diesel engine of a diesel locomotive during maintenance, characterized by: Includes the following steps: Step S1: Inspection of components before assembly; Connect the crankshaft (1) and the flexible coupling (2), and measure and control the following parameters: the radial runout A of the flange (3) on the upper flange (2) relative to the central axis of the crankshaft (1); the radial runout B of the driving disc stop (4) of the flexible coupling (2) relative to the central axis of the crankshaft (1); the radial runout C of the driven disc stop (5) of the flexible coupling (2) relative to the central axis of the crankshaft (1); check the flatness D of the two mounting surfaces of the connecting box (6) along the entire length, the end runout E of the mounting surface connecting the connecting box (6) and the diesel engine block (12) to the main bearing hole axis (7) of the connecting box (6), and the radial runout F of the main generator slip ring (8) relative to the central axis of the rotor; ensure that parameters A, B, C, D, E, and F all meet the assembly requirements; Step S2, Measurement during assembly; Connect the flexible coupling (2) to the main generator (10) and measure the following parameters: Detect the radial runout G1 and end face runout G2 of the drive disc stop (4) of the flexible coupling (2), and ensure that parameters G1 and G2 meet the assembly requirements; Install the connecting box (6), adjust the coaxiality of the main bearing hole axis (7) of the connecting box (6) and the central axis of the crankshaft (1), so that the main bearing hole axis (7) of the connecting box (6) and the central axis of the crankshaft (1) produce a two-dimensional offset, use a dial indicator to measure the two-dimensional offset of the main bearing hole axis (7) of the connecting box (6) and the central axis of the crankshaft (1), and let the Z-direction offset F 上 -F 下 =0.12~0.20mm, Y-axis offset F 左 -F 右 = ±0.05mm; Step S3, Measurement after assembly; After the main generator is installed, the radial runout M of the driven disc (11) of the flexible coupling (2) and the runout N of the slip ring (8) of the main generator are detected. M is set to ≤0.30mm and N to ≤0.15mm. If both parameters M and N meet the requirements, the maintenance is completed; otherwise, return to step S1 and perform the pre-assembly component maintenance again.

2. The assembly process for reducing vibration faults in the 16V240ZJ diesel engine of a diesel locomotive during maintenance, as described in claim 1, is characterized by: In step S1, the measured values ​​of each parameter must meet the following requirements: A≤0.05mm, B≤0.25mm, C≤0.25mm, D≤0.10mm, E≤0.30mm, F≤0.15mm.

3. The assembly process for reducing vibration faults in the 16V240ZJ diesel engine of an internal combustion locomotive during maintenance, as described in claim 1, is characterized by: In step S2, the radial runout G1 and end face runout G2 of the active disc stop (4) meet the following requirements: G1≤0.25mm, G2≤0.03mm.

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