A minimally invasive oral repair method for transmission gears

Abstract

This invention discloses a minimally invasive oral-style repair method for transmission gears, relating to the technical field of diesel locomotive driver controllers. First, the worn area of ​​the gear is ground down using a file. Next, a welding rod is welded to the ground worn area using gas welding. Then, rough machining is performed using a file to remove the weld beads left after welding. After pre-grinding, a milling cutter is used to machine the welded area on a milling machine. Finally, the milled area is finely machined using a file. The diameter and meshing clearance of the repaired gear are measured to determine if the repair is satisfactory. The repaired gear undergoes heat treatment, employing a low-cost repair method. By manually repairing the worn area of ​​the transmission gear using a minimally invasive oral-style repair method, the performance of the component is ensured to meet technical requirements. This reduces maintenance costs to 150 yuan per unit, ensuring the reliability and economy of the HXN5 diesel locomotive driver controller maintenance process.

Description

Technical Field

[0001] This invention relates to the field of internal combustion locomotive driver controller technology, and in particular to a minimally invasive oral cavity repair method for transmission gears. Background Technology

[0002] The HXN5 diesel locomotive driver controller (model 17KC120) is composed of components supplied by Germany and the United States and manufactured by Schalteborg GmbH in Germany. This driver controller lacks both technical support and spare parts supply for my country's locomotive maintenance system, leading to numerous limitations and technical barriers. Furthermore, the lack of necessary maintenance equipment and tooling significantly increases the difficulty of independent maintenance.

[0003] The traditional method involves replacing the entire gear assembly with a new one, requiring gear group positioning and coaxial positioning between the transmission rod and the gears. This method is costly and technically challenging. Furthermore, the transmission mechanism between the traction, braking, and drive gears in the driver controller involves linear motion (non-circular motion) via an eccentric shaft. Directly replacing the gears necessitates gear group positioning and coaxial positioning between the transmission rod and the gears. Currently, there is no relevant technical documentation in my country, creating a technical barrier, making the process difficult and expensive (approximately 48,000 RMB per unit).

[0004] Therefore, it is necessary to develop a maintenance method for driver controllers. Summary of the Invention

[0005] The purpose of this invention is to provide a minimally invasive oral repair method for transmission gears, which solves the problems existing in the prior art, is easy to operate, reduces technical difficulty, and also reduces maintenance costs.

[0006] To achieve the above objectives, the present invention provides the following solution: The present invention provides a minimally invasive oral cavity repair method for transmission gears, comprising the following steps:

[0007] Step 1: Use a file to smooth down the worn parts of the gear;

[0008] Step 2: Use gas welding to weld the welding rod to the worn part of the gear after grinding;

[0009] Step 3: Use a file to perform rough processing and grind down the weld beads left after welding;

[0010] Step 4: Use a ground profile milling cutter to machine the welding position on a milling machine;

[0011] Step 5: Use a file to perform fine finishing on the parts that have been machined by the milling machine;

[0012] Step six: Measure the diameter and meshing clearance of the repaired gear to determine whether the gear repair is qualified;

[0013] Step seven: Perform heat treatment on the repaired gear.

[0014] Preferably, in step one, a file is used to polish the surface burrs, impurities, and other debris on the worn parts of the gear.

[0015] Preferably, in step four, the profile milling cutter is a milling cutter with a gear-like shape that is pre-made according to the shape of the gear.

[0016] Preferably, in step four, when machining the welding position on the milling machine, the feed is initiated from the unworn end.

[0017] Preferably, in step six, a vernier caliper is used to measure the gear diameter.

[0018] Preferably, in step six, an outside micrometer is used to measure the gear meshing clearance.

[0019] Preferably, in step six, the acceptable range for the diameter of the repaired gear is 90.86 + 0.02 mm, and the acceptable range for the gear meshing clearance is 0.15 - 0.40 mm.

[0020] Preferably, in step seven, the repaired part of the gear needs to be polished with an electric polishing tool before heat treatment to ensure gear accuracy.

[0021] The present invention achieves the following beneficial technical effects compared to the prior art:

[0022] The oral cavity-style minimally invasive repair method for transmission gears in this invention employs a low-cost repair approach. By manually repairing the worn areas of the transmission gear using an oral cavity-style minimally invasive repair method, the performance of the component is ensured to meet technical requirements. This reduces maintenance costs to 150 yuan per unit, achieving the goal of ensuring reliability and economy in the maintenance process of the HXN5 diesel locomotive driver's controller. Attached Figure Description

[0023] none Detailed Implementation

[0024] The technical solutions will now be clearly and completely described in conjunction with embodiments of the present invention. Obviously, the described embodiments are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] The purpose of this invention is to provide a minimally invasive oral repair method for transmission gears, which solves the problems existing in the prior art, is easy to operate, reduces technical difficulty, and also reduces maintenance costs.

[0026] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to specific embodiments.

[0027] This invention provides a minimally invasive oral cavity repair method for transmission gears. Addressing the issue that the ninth tooth of the main transmission gear in the HXN5 diesel locomotive driver controller (17KC120 model) always exhibits abnormal half-tooth wear, and that the gear transmission rod is an eccentric shaft (performing non-circular motion), the following repair solution is proposed:

[0028] Step 1: Use a special file to polish the worn parts of the gear; mainly polish the burrs, impurities and rough edges on the surface.

[0029] Step 2: Use gas welding to weld the welding rod to the gear. Do not use electric welding, and only weld the worn parts.

[0030] Step 3: Use a special file for rough machining to grind away the weld beads left after welding, in preparation for milling.

[0031] Step 4: Use a specially ground profile milling cutter on a milling machine to process the gear, starting from the unworn end to ensure the original dimensions of the gear are preserved to the greatest extent possible.

[0032] Step 5: Use a special file to fine-tune the milled parts to ensure that the welded gears meet the requirements in Table 1.

[0033] Table 1

[0034] Technical standards (measurement) to be noted Complies with the standard range of the process (valid data values) Measure the gear diameter with vernier calipers 90.86 + 0.02 mm (Strictly adhere to the range standard) Use an outside micrometer to measure the gear meshing clearance. 0.15-0.40mm (Strictly adhere to the range standard)

[0035] Use a vernier caliper to measure the diameter of the machined gear (standard range: 90.86 + 0.02 mm); use an outside micrometer to measure whether the measured value of the gear meshing clearance meets the requirements (0.15-0.40 mm).

[0036] Step Six: Before heat treatment, the repaired parts of the gear need to be polished with an electric polishing tool to ensure the gear's precision. Then, the repaired gear is subjected to heat treatment.

[0037] The oral cavity-type minimally invasive repair method for transmission gears of the present invention adopts a low-cost repair method. By manually repairing the worn parts of the transmission gear using the oral cavity-type minimally invasive repair method, the performance of the component is ensured to meet technical requirements. The "oral cavity-type minimally invasive repair method for transmission gears" has been established, reducing the maintenance cost to 150 yuan / unit, thereby ensuring the reliability and economy of the maintenance process of the HXN5 diesel locomotive driver controller.

[0038] It should be noted that, for those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of the present invention is defined by the appended claims rather than the foregoing description. Therefore, it is intended that all changes falling within the meaning and scope of the equivalents of the claims be included within the present invention.

[0039] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A minimally invasive oral cavity repair method for transmission gears, characterized in that, For the HXN5 diesel locomotive, where the ninth tooth of the main drive gear of the 17KC120 driver controller always exhibits abnormal half-tooth wear, and the gear drive rod is an eccentric shaft performing non-circular motion, the repair method includes the following steps: Step 1: Use a file to polish the worn parts of the gear; Step 2: Use gas welding to weld the welding rod to the worn part of the gear after grinding; Step 3: Use a file to perform rough processing and grind down the weld beads left after welding; Step 4: Use a ground profile milling cutter to machine the welding position on a milling machine. The profile milling cutter is a milling cutter with a gear-like shape that is pre-customized according to the shape of the gear. When machining the welding position on the milling machine, the cutter enters from the unworn end of the gear. Step 5: Use a file to perform fine finishing on the parts that have been machined by the milling machine; Step 6: Measure the diameter and meshing clearance of the repaired gear to determine if the gear repair is qualified. The acceptable range for the diameter of the repaired gear is 90.86 + 0.02 mm, and the acceptable range for the meshing clearance is 0.15-0.40 mm. Step 7: Perform heat treatment on the repaired gear. Before heat treatment, the repaired part of the gear needs to be polished with an electric polishing tool to ensure the gear's precision.

2. The oral cavity-type minimally invasive repair method for transmission gears according to claim 1, characterized in that: In step one, a file is used to polish the surface burrs, impurities, and rough edges of the worn parts of the gear.

3. The oral cavity-type minimally invasive repair method for transmission gears according to claim 1, characterized in that: In step six, a vernier caliper is used to measure the diameter of the gear.

4. The oral cavity-type minimally invasive repair method for transmission gears according to claim 1, characterized in that: In step six, an outside micrometer is used to measure the gear meshing clearance.

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