Gearbox interior cleaning device and flushing method

Abstract

The present application relates to the technical field of vehicle maintenance, and particularly relates to a gear box internal cleaning device and a flushing method. The flushing device comprises a rough cleaning part, a fine cleaning part and a flow divider valve. The rough cleaning part comprises a rough cleaning oil tank, a rough cleaning oil inlet pipe and a rough cleaning oil return pipe which are in communication with the rough cleaning oil tank. The fine cleaning part comprises a fine cleaning oil tank, a fine cleaning oil inlet pipe and a fine cleaning oil return pipe which are in communication with the fine cleaning oil tank. The flow divider valve comprises an oil inlet three-way valve and an oil return three-way valve. The rough cleaning oil inlet pipe and the fine cleaning oil inlet pipe are connected with two inlets of the oil inlet three-way valve respectively. The outlet of the oil inlet three-way valve is connected with an oil inlet of the gear box. An oil return port of the gear box is connected with an inlet of the oil return three-way valve. Two outlets of the oil return three-way valve are connected with the rough cleaning oil return pipe and the fine cleaning oil return pipe respectively. The three-stage self-adaptive switching of rough cleaning, semi-fine cleaning and fine cleaning is realized by the present application, and the thorough cleaning of the gear box is realized.

Description

Technical Field

[0001] This invention relates to the field of vehicle maintenance technology, and in particular to a gearbox internal cleaning device and rinsing method. Background Technology

[0002] When maintaining rail transit vehicles, the gearboxes need to be cleaned by circulating oil to flush away the sludge on the inner walls of the gearboxes, ensuring the cleanliness of the gearboxes before disassembly.

[0003] Existing technology discloses a circulating gearbox flushing device, including an oil tank, an oil supply line, an oil gun, and a return line. The oil tank stores cleaning oil. One end of the oil supply line is connected to the oil tank, and the other end is connected to the oil gun, delivering the cleaning oil to the inside of the gearbox. The oil gun nozzle extends into the gearbox to spray oil, flushing away sludge from the gearbox walls. One end of the return line connects to the inside of the gearbox to recover the oil, and the other end is connected to the oil tank to achieve oil circulation. A filter is installed on the return line to filter impurities in the oil. When the device is working, oil is pumped from the oil tank into the gearbox through the oil supply line, flushes, and carries impurities back to the oil tank through the return line, while the filter intercepts the impurities.

[0004] The existing technology has the following drawbacks: First, the single-tank structure leads to the accumulation of impurities after the cleaning oil is reused. After long-term operation, the filter efficiency decreases, and impurities mix into the cleaning oil, affecting the final cleaning effect.

[0005] Secondly, high-speed rinsing can easily miss residual particles in gear gaps, while low-speed rinsing cannot break up large pieces of sludge, resulting in low cleaning efficiency and potential damage to the internal structure.

[0006] Furthermore, regardless of the degree of gearbox contamination, the same cleaning time was performed, resulting in over-cleaning of lightly contaminated gearboxes and under-cleaning of heavily contaminated gearboxes. Summary of the Invention

[0007] To address the shortcomings of existing technologies, the purpose of this invention is to provide a gearbox flushing device that, through a dual-tank isolation design, achieves adaptive switching between three stages: coarse washing, semi-fine washing, and fine washing. Furthermore, by adjusting the flow rate in stages to match the stripping requirements of different contaminant layers, the device ultimately achieves the technical effects of thorough gearbox cleaning, zero pollution of the fine washing oil, and optimized energy consumption.

[0008] To achieve the above objectives, the embodiments of the present invention provide the following technical solutions: A gearbox flushing device includes a coarse washing section, a fine washing section, and a diversion valve. The coarse washing section includes a coarse washing oil tank and a coarse washing inlet pipe and a coarse washing return pipe connected to the coarse washing oil tank. The fine washing section includes a fine washing oil tank and a fine washing inlet pipe and a fine washing return pipe connected to the fine washing oil tank. The diversion valve includes an inlet three-way valve and a return three-way valve. The coarse washing inlet pipe and the fine washing inlet pipe are respectively connected to the two inlets of the inlet three-way valve. The outlet of the inlet three-way valve is connected to the inlet of the gearbox. The return port of the gearbox is connected to the inlet of the return three-way valve. The two outlets of the return three-way valve are respectively connected to the coarse washing return pipe and the fine washing return pipe.

[0009] Optionally, the flushing device further includes an oil inlet filter, which is installed on the pipeline connecting the oil inlet three-way valve and the gearbox oil inlet.

[0010] Optionally, the flushing device further includes an oil inlet motor, which is installed on the pipeline connecting the oil inlet three-way valve and the oil inlet filter.

[0011] Optionally, the flushing device further includes a return oil filter, which is installed on the pipeline connecting the gearbox return oil port and the return oil three-way valve.

[0012] Optionally, the flushing device further includes a return oil motor, which is installed on the pipeline connecting the gearbox return oil port and the return oil filter.

[0013] Optionally, the rinsing device further includes a mobile trolley with wheels installed at the bottom, and both the coarse washing section and the fine washing section are mounted on the mobile trolley.

[0014] This invention also provides a flushing method for the gearbox flushing device as described above, comprising: The oil circuit is controlled by the inlet three-way valve and the return three-way valve, so that the coarse washing oil tank and the fine washing oil tank are alternately connected to the gearbox, realizing the switching between the coarse washing stage, the semi-fine washing stage and the fine washing stage; During the coarse washing stage, the inlet three-way valve is connected to the coarse washing oil tank, and the return three-way valve is connected to the coarse washing oil tank to circulate and flush the gearbox with coarse washing oil. Real-time monitoring of gearbox oil return contamination level and calculation of contamination rate reduction; When the rate of decrease in contamination is lower than the set rate threshold and continues for the first preset time, switch to the semi-fine cleaning stage: connect the inlet three-way valve to the fine cleaning oil tank and the return three-way valve to the coarse cleaning oil tank, use fine cleaning oil to flush the gearbox and recover the return oil to the coarse cleaning oil tank. After the semi-fine cleaning stage lasts for the second preset time, switch to the fine cleaning stage: connect the oil inlet three-way valve to the fine cleaning oil tank and the oil return three-way valve to the fine cleaning oil tank, and use fine cleaning oil to circulate and flush the gearbox. During the fine cleaning stage, the degree of oil contamination is monitored in real time. The cleaning ends when the degree of contamination is lower than the cleaning threshold and continues for the third preset time.

[0015] Optional, the rough washing stage includes: The oil inlet motor operates within the first flow rate range to flush the gearbox; Calculate the rate of decrease in pollution level per unit time in real time; If the rate of decrease in contamination is lower than the set rate threshold, the flow rate will be reduced to the second flow rate range. If the pressure difference between the inlet and outlet oil lines exceeds the safety threshold, the flow rate will be increased.

[0016] Optionally, the condition for switching to the semi-fine washing stage is: the rate of decrease in contamination is lower than the set rate threshold for multiple consecutive unit time periods. During the semi-fine washing stage, the oil inlet motor operates at the third flow rate range, which is lower than the initial flow rate during the rough washing stage.

[0017] Optional, the fine washing stage includes: The oil inlet motor initially operates within the fourth flow rate range; When the contamination level of the return oil drops to the intermediate threshold, the flow rate will be reduced to the fifth flow rate range. Cleaning is terminated when the oil contamination level is consistently below the cleaning threshold.

[0018] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages: 1. The cleaning device of the present invention controls the oil circuit through an inlet three-way valve and an outlet three-way valve, allowing the coarse cleaning oil tank and the fine cleaning oil tank to alternately connect to the gearbox according to the needs of different stages. This achieves switching between the coarse cleaning stage, the semi-fine cleaning stage, and the fine cleaning stage. In the coarse cleaning stage, a coarse cleaning oil with relatively low cleanliness is used to initially rinse the gearbox, removing most of the larger, weakly adhering impurities and sludge. In the semi-fine cleaning stage, the fine cleaning oil is used to rinse and then returned to the coarse cleaning oil tank, isolating the fine cleaning oil from the impurities. In the fine cleaning stage, a fine cleaning oil with higher cleanliness is used to finely rinse the gearbox, further removing residual fine impurities and improving the cleaning quality. By setting up a coarse cleaning section, a fine cleaning section, and a diversion valve, the gearbox can be cleaned in stages, meeting the different requirements of the oil at different cleaning stages, effectively improving the cleaning effect of the gearbox, and solving the problems of incomplete cleaning and lack of staged targeted cleaning strategies in the prior art.

[0019] 2. The rinsing method of this invention reduces ineffective cleaning time through dynamic stage switching and improves sludge removal efficiency through graded flow rates, thereby enhancing cleaning efficiency. The variable frequency motor adjusts its frequency as needed, reducing overall energy consumption, and precise control of contamination levels extends the life of the cleaning oil. The low-speed penetration mode reduces impact on the internal structure of the gearbox, extending component life, and real-time pressure differential control prevents pipeline blockage and reduces the failure rate.

[0020] Advantages of additional aspects of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In addition, the spacing or dimensions between components are exaggerated to show the position of each component, and the schematic diagrams are for illustrative purposes only.

[0022] Figure 1 This is a schematic diagram of the overall cleaning device provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the oil inlet structure provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the oil return structure provided in an embodiment of the present invention; In the diagram: 1. Rough wash oil tank; 2. Rough wash return oil pipe; 3. Fine wash oil tank; 4. Fine wash return oil pipe; 5. Return oil filter; 6. Return oil motor; 7. Inlet oil filter; 8. Inlet oil motor; 9. Moving trolley; 10. Rough wash inlet oil pipe; 11. Fine wash inlet oil pipe; 12. Inlet three-way valve; 13. Return oil three-way valve; Detailed Implementation It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0023] Example 1 like Figure 1 , Figure 2 , Figure 3As shown, this embodiment proposes a gearbox flushing device, including a coarse washing section, a fine washing section, and a diversion valve. The coarse washing section includes a coarse washing oil tank 1 and a coarse washing oil inlet pipe 10 and a coarse washing oil return pipe 2 connected to the coarse washing oil tank 1. The fine washing section includes a fine washing oil tank 3 and a fine washing oil inlet pipe 11 and a fine washing oil return pipe 4 connected to the fine washing oil tank 3. The diversion valve includes an oil inlet three-way valve 12 and an oil return three-way valve 13. The coarse washing oil inlet pipe 10 and the fine washing oil inlet pipe 11 are respectively connected to the two inlets of the oil inlet three-way valve 12. The outlet of the oil inlet three-way valve 12 is connected to the oil inlet of the gearbox. The oil return port of the gearbox is connected to the inlet of the oil return three-way valve 13. The two outlets of the oil return three-way valve 13 are respectively connected to the coarse washing oil return pipe 2 and the fine washing oil return pipe 4.

[0024] During the coarse cleaning stage, cleaning oil flows from the coarse cleaning tank 1 into the gearbox via the inlet three-way valve 12. After rinsing, the oil carrying impurities flows back to the coarse cleaning tank 1 via the return three-way valve 13, effectively removing large impurities from inside the gearbox. Then, the system switches to the semi-fine cleaning stage, where fine cleaning oil is used for rinsing and then returned to the coarse cleaning tank 1, isolating the fine cleaning oil from impurities. Finally, the system switches to fine cleaning, where cleaning oil flows from the fine cleaning tank 3 into the gearbox. The rinsed oil flows back to the fine cleaning tank 3, thoroughly removing residual impurities and ensuring cleaning effectiveness. This separation of the coarse cleaning tank 1 and the fine cleaning tank 3 prevents premature contamination of the fine cleaning oil, extends service life, improves cleaning quality, achieves efficient cleaning of the gearbox interior, meets maintenance requirements, and ensures the normal operation and service life of the rail vehicle gearbox.

[0025] like Figure 2 As shown, the flushing device also includes an oil inlet filter 7, which is installed on the pipeline connecting the oil inlet three-way valve 12 and the gearbox oil inlet.

[0026] In practical applications, the internal parts of the gearbox have high precision. For example, the precision of the gear tooth surface directly affects the smoothness and accuracy of the transmission. If large particles of impurities enter, they will cause scratches and wear during gear operation, reducing the service life of the gears.

[0027] The inlet filter 7 filters the cleaning oil entering the gearbox. Whether the cleaning oil flows from the coarse cleaning tank 1 or the fine cleaning tank 3, it passes through the inlet filter 7 before entering the gearbox. This effectively intercepts larger particles of impurities in the oil, preventing them from entering the gearbox and causing wear on precision components such as gears and bearings. This protects the internal structure of the gearbox, improves cleaning safety, and, in conjunction with the coarse and fine cleaning sections and the diversion valve, further enhances the protection of the gearbox during cleaning, reducing potential damage from impurities and contributing to efficient and safe gearbox cleaning. The inlet filter 7 can be a cartridge filter, capable of comprehensively filtering various impurities. Besides conventional cartridge filters, magnetic adsorption filters can also be considered, utilizing magnetic force to attract ferromagnetic impurities in the oil.

[0028] The flushing device also includes an oil inlet motor 8, which is installed on the pipeline connecting the oil inlet three-way valve 12 and the oil inlet filter 7.

[0029] The inlet motor 8 provides power to the cleaning oil, allowing it to smoothly enter the gearbox for rinsing. The required flow rate of the cleaning oil varies at different stages: in the coarse rinsing stage, the inlet motor 8 can be controlled to operate within the first flow rate range, ensuring sufficient flushing force to powerfully remove impurities and sludge adhering to the gearbox inner walls and gear surfaces. In the subsequent semi-fine and fine rinsing stages, the flow rate can be adjusted by changing the rotation speed of the inlet motor 8 according to the needs of each stage. For example, it can operate within the third flow rate range in the semi-fine rinsing stage, and the flow rate can be adjusted according to the degree of contamination in the return oil during the fine rinsing stage. This allows for precise control of the cleaning process at different stages, improving cleaning efficiency and quality. It also works in conjunction with other components of the entire rinsing device to optimize the gearbox cleaning process.

[0030] like Figure 3 As shown, the flushing device also includes a return oil filter 5, which is installed on the pipeline connecting the gearbox return oil port and the return oil three-way valve 13.

[0031] If the return oil is not filtered and returns directly to the oil tank during the gearbox cleaning process, impurities will accumulate in the oil tank, causing the cleaning oil to become increasingly dirty. When it enters the gearbox again, it will not only fail to clean effectively but may also cause secondary pollution.

[0032] The return oil filter 5 filters the cleaning oil flowing out of the gearbox. After the cleaning oil has been flushed inside the gearbox, it carries a large amount of impurities and flows out through the return oil port. The return oil filter 5 intercepts these impurities, preventing them from re-entering the coarse cleaning oil tank 1 or the fine cleaning oil tank 3, thus ensuring the cleanliness of the oil in the tank. This allows the circulating cleaning oil to maintain a certain level of cleanliness, helping to improve the continuity and stability of the cleaning effect. Working in conjunction with the inlet filter 7, the coarse cleaning section, and the fine cleaning section, it ensures the high efficiency and reliability of the gearbox cleaning process and avoids a decrease in cleaning effect due to return oil contamination.

[0033] The flushing device also includes a return oil motor 6, which is installed on the pipeline connecting the gearbox return oil port and the return oil filter 5.

[0034] The return oil motor 6 provides power for the return oil, allowing the cleaned oil to smoothly pass through the return oil filter 5 and flow back to the corresponding oil tank. Throughout the cleaning process, the return oil motor 6 works in conjunction with the inlet oil motor 8 to maintain the circulation of the oil. In the rough cleaning stage, the return oil motor 6, in conjunction with the inlet oil motor 8, ensures that the rough cleaning oil is fully circulated and rinsed within the gearbox; in the semi-fine cleaning and fine cleaning stages, it similarly ensures that the oil in the corresponding stages can circulate normally. By controlling the return oil motor 6, the return oil speed can be adjusted to match the inlet oil speed, maintaining stable pressure inside the gearbox and preventing abnormal pressure inside the gearbox due to an imbalance between the inlet and return oil speeds, which could affect the cleaning effect or even damage the gearbox. Working together with other parts of the entire rinsing device, it ensures the smooth progress of the cleaning process.

[0035] The rinsing device also includes a mobile trolley 9, which is equipped with wheels at the bottom. Both the coarse washing section and the fine washing section are mounted on the mobile trolley 9.

[0036] In large rail vehicle maintenance plants, multiple rail vehicles are typically maintained simultaneously, with gearboxes distributed across different maintenance stations. The mobile trolley 9 provides excellent mobility for the entire gearbox washing device. In practical applications such as rail vehicle maintenance, the washing device can be easily moved to different gearbox locations for cleaning operations, eliminating the need to transport the gearboxes to a fixed cleaning facility. This saves transportation time and labor costs, and improves the convenience and efficiency of the cleaning work.

[0037] Example 2 This embodiment provides a flushing method for the gearbox flushing device as described in Embodiment 1, including: controlling the oil circuit through the inlet three-way valve 12 and the return three-way valve 13, so that the coarse washing oil tank 1 and the fine washing oil tank 3 are alternately connected to the gearbox, thereby realizing the switching between the coarse washing stage, the semi-fine washing stage and the fine washing stage. During the coarse washing stage, the inlet three-way valve 12 is connected to the coarse washing oil tank 1, and the return three-way valve 13 is connected to the coarse washing oil tank 1, so that the gearbox is flushed with coarse washing oil. Real-time monitoring of gearbox oil return contamination level and calculation of contamination rate reduction; When the rate of decrease in contamination is lower than the set rate threshold and continues for the first preset duration, switch to the semi-fine cleaning stage: connect the inlet three-way valve 12 to the fine cleaning oil tank 3 and the return three-way valve 13 to the coarse cleaning oil tank 1, use fine cleaning oil to flush the gearbox and recover the return oil to the coarse cleaning oil tank 1. After the semi-fine cleaning stage lasts for the second preset time, switch to the fine cleaning stage: connect the oil inlet three-way valve 12 to the fine cleaning oil tank 3 and the oil return three-way valve 13 to the fine cleaning oil tank 3, and use fine cleaning oil to circulate and flush the gearbox. During the fine cleaning stage, the degree of oil contamination is monitored in real time. The cleaning ends when the degree of contamination is lower than the cleaning threshold and continues for the third preset time.

[0038] The oil circuit is controlled by the inlet three-way valve 12 and the return three-way valve 13, allowing the coarse cleaning oil tank 1 and the fine cleaning oil tank 3 to alternately connect to the gearbox, thus switching between the coarse cleaning stage, the semi-fine cleaning stage, and the fine cleaning stage. In the coarse cleaning stage, the inlet three-way valve 12 is connected to the coarse cleaning oil tank 1, and the return three-way valve 13 is also connected to the coarse cleaning oil tank 1. The coarse cleaning oil circulates and flushes the gearbox, using its scouring force to remove most of the impurities. The gearbox return oil contamination level is monitored in real time, and the rate of contamination reduction is calculated. The cleaning effect can be judged based on the changes in contamination level. When the rate of contamination reduction is lower than the set threshold and remains below it for a first preset time, it indicates that the removal effect of the coarse cleaning stage on impurities is gradually weakening. At this point, the system switches to the semi-fine cleaning stage, connecting the inlet three-way valve 12 to the fine cleaning oil tank 3 and the return three-way valve 13 to the coarse cleaning oil tank 1. The gearbox is flushed with fine cleaning oil, and the returned oil is recovered to the coarse cleaning oil tank 1. The high cleanliness of the fine cleaning oil further cleans the gearbox. After the semi-fine cleaning stage lasts for a second preset time, the process switches to the fine cleaning stage. The inlet three-way valve 12 and the return three-way valve 13 are connected to the fine cleaning oil tank 3, allowing the gearbox to be circulated and flushed with fine cleaning oil, further improving cleaning precision. During the fine cleaning stage, the contamination level of the return oil is monitored in real time. When the contamination level is below the cleaning threshold and remains below it for a third preset time, the cleaning process ends, ensuring the gearbox reaches a high cleanliness standard. This phased approach, dynamically adjusting the cleaning strategy based on contamination level, effectively improves cleaning efficiency and quality, solving the problems of lack of specificity and low efficiency in existing technologies.

[0039] The coarse washing stage includes: running the oil inlet motor 8 to flush the gearbox at the first flow rate range; calculating the rate of decrease in contamination per unit time in real time; if the rate of decrease in contamination is lower than the set rate threshold, reducing the flow rate to the second flow rate range; and if the pressure difference between the oil inlet pipeline and the oil return pipeline exceeds the safety threshold, increasing the flow rate.

[0040] During the coarse washing stage, the oil inlet motor 8 operates within the first flow rate range to flush the gearbox. This flow rate range provides sufficient flushing force, allowing the coarse washing oil to powerfully impact the inside of the gearbox, effectively removing impurities and sludge adhering to the gearbox inner walls and gear surfaces. Real-time calculation of the contamination reduction rate per unit time provides a clear understanding of the cleaning effect at the current flow rate. If the contamination reduction rate falls below a set threshold, it indicates reduced cleaning efficiency at the current flow rate. The flow rate is then reduced to the second flow rate range. While the flushing force is slightly weakened, this results in a smoother flow of oil within the gearbox, promoting impurity sedimentation and facilitating subsequent oil return filtration. If the pressure difference between the inlet and return oil lines exceeds a safety threshold, it indicates potential blockages or other abnormalities in the lines. Increasing the flow rate utilizes the impact force of the oil to clear the blockages and ensure smooth cleaning. This method of dynamically adjusting the flow rate based on actual conditions during the cleaning process improves cleaning efficiency, ensures the safety and stability of the cleaning process, and optimizes the cleaning effect of the coarse washing stage.

[0041] The conditions for switching to the semi-fine washing stage are: the rate of decrease in contamination is lower than the set rate threshold for multiple consecutive unit time periods; the oil inlet motor 8 operates in the third flow rate range during the semi-fine washing stage, and the third flow rate range is lower than the initial flow rate of the coarse washing stage.

[0042] The condition for switching to the semi-fine cleaning stage is that the rate of decrease in contamination is lower than the set rate threshold for several consecutive unit time periods. This judgment method is more accurate and reliable, avoiding incorrect switching of cleaning stages due to occasional fluctuations in contamination. In the semi-fine cleaning stage, the oil inlet motor 8 operates at the third flow rate range. The third flow rate range is lower than the initial flow rate of the coarse cleaning stage. At this time, since most impurities have been removed in the coarse cleaning stage, a high flow rate is not required. The lower flow rate allows the fine cleaning oil to be distributed more evenly in the gearbox, better exerting the cleaning effect of the fine cleaning oil, further removing the fine impurities remaining in the gearbox, improving the cleaning accuracy, and at the same time, the rinsed oil is recycled to the coarse cleaning oil tank 1, which purifies the oil in the coarse cleaning oil tank 1. This works in conjunction with other stages in the entire cleaning process to improve the overall cleaning effect.

[0043] The fine cleaning stage includes: initially running the oil inlet motor 8 at the fourth flow rate range; when the return oil contamination level drops to the intermediate threshold, reducing the flow rate to the fifth flow rate range; and terminating the cleaning process when the return oil contamination level is stably below the cleaning threshold.

[0044] In the initial stage of the fine cleaning, the oil inlet motor 8 operates at the fourth flow rate range. This flow rate allows the cleaning oil to perform a preliminary fine rinse of the gearbox, removing residual fine impurities. When the return oil contamination level drops to the intermediate threshold, the flow rate is reduced to the fifth flow rate range. At this lower flow rate, the oil flows slowly within the gearbox, which is conducive to further sedimentation and adsorption of impurities, further improving cleaning precision and ensuring that the gearbox reaches a higher cleanliness standard. Cleaning is terminated when the return oil contamination level is consistently below the cleaning threshold, ensuring that the gearbox cleaning effect meets the requirements. This method of dynamically adjusting the flow rate based on the return oil contamination level during the fine cleaning stage, working in conjunction with the entire rinsing method, effectively improves the cleaning quality and solves the problem of incomplete cleaning in existing technologies.

[0045] Detailed steps and methods: Step 1: System initialization and parameter setting; 1. Install detection elements: Install a turbidity sensor in the return oil line to monitor the oil contamination level (unit: NTU). Install pressure sensors in the inlet and return oil lines to monitor the pressure difference ΔP (unit: MPa).

[0046] 2. Preset key parameters: the threshold for the rate of decrease in contamination, α, for example, 5% / minute: obtained by statistically analyzing cleaning data of gearboxes with different levels of contamination.

[0047] Flow rate classification parameters: High-speed flushing stage, frequency range 50–60Hz, to disperse loose surface impurities; medium-speed stripping stage, frequency range 30–40Hz, to strip away adhering sludge in the middle layer; low-speed penetration stage, frequency range 10–20Hz, to remove residual particles from crevices. Step 2: Dynamic control during the coarse washing stage; 1. Start the high-speed flushing mode: The oil inlet motor runs at 50-60Hz, and the coarse wash oil impacts the inner wall of the gearbox at high speed. Depending on the size of the gearbox, this lasts for about 8-12 minutes, quickly breaking up large pieces of sludge and preventing subsequent blockage.

[0048] 2. Real-time monitoring and switching logic: Turbidity value is collected every minute, and the pollution decrease rate β=(C1-C2) / C1×100% is calculated, where C1 is the turbidity value of the previous minute and C2 is the current turbidity value.

[0049] If β≥α: Maintain the current flow rate; if β<α: Switch to medium-speed stripping mode, and reduce the motor frequency to 30–40Hz.

[0050] 3. Pressure protection mechanism: If the pressure difference between the inlet and outlet oil ΔP exceeds the preset safety threshold, such as 0.5MPa, the motor frequency will be automatically increased by 10% to prevent blockage.

[0051] Step 3: Phase switching triggered by contamination level; 1. Stage switching condition: When β<α is satisfied for 3 consecutive minutes, the coarse wash is determined to be completed and the coarse wash circuit is automatically shut down.

[0052] 2. Semi-fine wash start-up: Switch the three-way valve to connect the oil inlet pipe of the fine wash tank and the oil return pipe of the coarse wash tank to enter the semi-fine wash mode. The motor runs in low-speed penetration mode (10–20Hz), and the fine wash oil flushes the gearbox. The low speed avoids oil splashing and contamination, while fully penetrating the gaps.

[0053] The semi-fine washing time is set according to the gearbox volume, about 1-2 minutes. When the turbidity of the return oil drops to 30% of the initial value of the rough washing, switch to the fine washing stage in advance.

[0054] Step 4: Coordinated control during the fine washing stage; 1. Fine cleaning start-up: Switch the three-way valve to the fine cleaning circuit, and switch the three-way valve to connect the fine cleaning oil tank inlet pipe and the fine cleaning oil tank return pipe, so that the fine cleaning oil enters and exits in a closed loop.

[0055] 2. Adaptive flow rate adjustment: Initially, the medium-speed stripping mode (30–40Hz) is used to rinse the chamber; if the turbidity value is ≤ the preset cleaning threshold for 2 consecutive minutes, such as 10 NTU, the low-speed penetration mode (10–20Hz) is switched to maintain cleaning.

[0056] 3. Termination condition: The cleaning process will automatically end when the turbidity value is consistently ≤5 NTU for 3 consecutive minutes in low-speed permeation mode.

[0057] This rinsing method reduces ineffective cleaning time through dynamic stage switching and improves sludge removal efficiency through graded flow rates, thus enhancing cleaning efficiency. The variable frequency motor adjusts its frequency as needed, reducing overall energy consumption, and precise control of contamination levels extends the life of the cleaning oil. The low-speed penetration mode reduces impact on the internal structure of the gearbox, extending component life, and real-time pressure differential control prevents pipeline blockage and reduces the failure rate.

[0058] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A flushing method for a gearbox flushing device, the gearbox flushing device comprising: The coarse washing section, the fine washing section, and the diversion valve; The coarse washing section includes a coarse washing oil tank and a coarse washing oil inlet pipe and a coarse washing oil return pipe connected to the coarse washing oil tank; The fine cleaning section includes a fine cleaning oil tank and a fine cleaning oil inlet pipe and a fine cleaning oil return pipe connected to the fine cleaning oil tank. The diverter valve includes an inlet three-way valve and a return three-way valve. The coarse wash inlet pipe and the fine wash inlet pipe are respectively connected to the two inlets of the inlet three-way valve. The outlet of the inlet three-way valve is connected to the inlet of the gearbox. The return port of the gearbox is connected to the inlet of the return three-way valve. The two outlets of the return three-way valve are respectively connected to the coarse wash return pipe and the fine wash return pipe. Its features include: The oil circuit is controlled by the inlet three-way valve and the return three-way valve, so that the coarse washing oil tank and the fine washing oil tank are alternately connected to the gearbox, realizing the switching between the coarse washing stage, the semi-fine washing stage and the fine washing stage; During the coarse washing stage, the inlet three-way valve is connected to the coarse washing oil tank, and the return three-way valve is connected to the coarse washing oil tank to circulate and flush the gearbox with coarse washing oil. Real-time monitoring of gearbox oil return contamination level and calculation of contamination rate reduction; When the rate of decrease in contamination is lower than the set rate threshold and continues for the first preset time, switch to the semi-fine cleaning stage: connect the inlet three-way valve to the fine cleaning oil tank and the return three-way valve to the coarse cleaning oil tank, use fine cleaning oil to flush the gearbox and recover the return oil to the coarse cleaning oil tank. After the semi-fine cleaning stage lasts for the second preset time, switch to the fine cleaning stage: connect the oil inlet three-way valve to the fine cleaning oil tank and the oil return three-way valve to the fine cleaning oil tank, and use fine cleaning oil to circulate and flush the gearbox. During the fine cleaning stage, the degree of oil contamination is monitored in real time. The cleaning ends when the degree of contamination is lower than the cleaning threshold and continues for the third preset time.

2. The flushing method of the gearbox flushing device as described in claim 1, characterized in that, The flushing device also includes an oil inlet filter, which is installed on the pipeline connecting the oil inlet three-way valve and the gearbox oil inlet.

3. The flushing method of the gearbox flushing device as described in claim 2, characterized in that, The flushing device also includes an oil inlet motor, which is installed on the pipeline connecting the oil inlet three-way valve and the oil inlet filter.

4. The flushing method of the gearbox flushing device as described in claim 1, characterized in that, The flushing device also includes a return oil filter, which is installed on the pipeline connecting the gearbox return oil port and the return oil three-way valve.

5. The flushing method of the gearbox flushing device as described in claim 4, characterized in that, The flushing device also includes a return oil motor, which is installed on the pipeline connecting the gearbox return oil port and the return oil filter.

6. The flushing method of the gearbox flushing device as described in claim 1, characterized in that, The rinsing device also includes a mobile trolley with wheels installed at the bottom. Both the coarse washing section and the fine washing section are mounted on the mobile trolley.

7. The flushing method of the gearbox flushing device according to claim 1, characterized in that, The rough washing stage includes: The oil inlet motor operates within the first flow rate range to flush the gearbox; Calculate the rate of decrease in pollution level per unit time in real time; If the rate of decrease in contamination is lower than the set rate threshold, the flow rate will be reduced to the second flow rate range. If the pressure difference between the inlet and outlet oil lines exceeds the safety threshold, the flow rate will be increased.

8. The flushing method of the gearbox flushing device according to claim 1, characterized in that, The condition for switching to the semi-fine washing stage is: the rate of decrease in contamination is lower than the set rate threshold for multiple consecutive unit time periods. During the semi-fine washing stage, the oil inlet motor operates at the third flow rate range, which is lower than the initial flow rate during the rough washing stage.

9. The flushing method of the gearbox flushing device according to claim 1, characterized in that, The fine washing stage includes: The oil inlet motor initially operates within the fourth flow rate range; When the contamination level of the return oil drops to the intermediate threshold, the flow rate is reduced to the fifth flow rate range; Cleaning is terminated when the oil contamination level is consistently below the cleaning threshold.

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