Wear-resistant composite material, contact and stator structure of shaft end power generation device

Abstract

The invention relates to the technical field of railway wagon shaft end power generation devices, in particular to a wear-resistant composite material, a contact and a stator structure of a shaft end power generation device.The wear-resistant composite material is prepared from, by weight, 60%-75% of modified nylon, 10%-30% of polytetrafluoroethylene, 10% of glass fiber and the balance wear-resistant auxiliary materials; the contact comprises a wear-resistant layer, and the wear-resistant layer is prepared from the wear-resistant composite material. The invention further discloses a stator structure of the shaft end power generation device comprising the contact. According to the wear-resistant composite material, the contact and the stator structure of the shaft end power generation device, the problems that in an existing shaft end power generation device, due to the fact that a gap exists between a stator rod and a bearing saddle, the vibration reduction direction of a stainless steel contact is single, and the spring rigidity is large, the contact is prone to being abraded flat, the bearing saddle is abraded, and a mechanism loses efficacy can be effectively solved; and the power supply stability of the railway wagon is influenced.

Description

Technical Field

[0001] This invention relates to the field of railway freight car axle-end power generation devices, and in particular to a wear-resistant composite material, contacts, and a stator structure for the axle-end power generation device. Background Technology

[0002] In recent years, my country's rapid economic development has propelled railway transportation towards higher speeds, heavier loads, and greater intelligence. This trend has brought tremendous opportunities to the railway freight car industry, but it has also placed numerous pressures and challenges on it. To significantly improve the economy, reliability, and safety of railway freight car operations, the development of railway freight cars towards intelligence and digitalization has become an inevitable trend. The power supply issue for railway freight cars has thus become a crucial problem that urgently needs to be addressed.

[0003] Against this backdrop, various freight car R&D departments are actively exploring effective power generation technologies. Among these, axle-end power generation devices, with their significant advantages of simple structure and convenient installation, have entered the vehicle testing and application stage, becoming one of the most promising power supply solutions. The installation method of this axle-end power generation device is as follows: it is fixed to the axle end of the railway freight car bogie, with its stator rod extending downwards to the bottom of the bogie's support saddle, thereby limiting the rotation of the stator through the support saddle. However, due to the special structure of the vehicle bogie, the stator rod and the support saddle are not fixedly connected, relying solely on their mutual contact to achieve the limiting function. Simultaneously, due to unavoidable tolerances during manufacturing and assembly, a certain gap often exists between the stator rod and the support saddle. This structural characteristic and tolerance issue, combined, cause vibrations generated during vehicle operation to induce severe friction and impact between the stator rod and the support saddle, thereby damaging the stator rod and affecting the stable operation of the device.

[0004] To address this issue, Chinese invention patent CN117267308A discloses a vibration damping structure and installation structure for fixing the stator of a shaft-end power generation device. This vibration damping structure includes a stator rod, with a limiting sleeve fixed inside. The limiting sleeve contains an axially movable elastic component and a contact. A support component is located at the rear end of the limiting sleeve, contacting the elastic component. The contact is located at the front end of the limiting sleeve and contacts the elastic component. The limiting sleeve restricts the forward movement of the contact, with the front end of the contact extending out of the stator rod. This technical solution uses a contact-based connection to the load-bearing saddle and utilizes a spring structure for vibration damping, significantly reducing friction and impact between the stator rod and the load-bearing saddle, thus improving the reliability and safety of the system.

[0005] However, in this technical solution, the contacts are made of stainless steel, and a mechanism to limit rotation is set at the front, which can only achieve vibration reduction in the direction perpendicular to the ground. However, during actual vehicle operation, due to the severe vibration and impact, the stress on the contacts is extremely complex, and the direction of the force is constantly changing. At the same time, because the spring stiffness in this structure is relatively high, serious problems have gradually emerged in actual use: the stainless steel contacts are easily worn flat, and the corresponding parts of the bearing saddle connected to them also show severe wear, leading to contact mechanism failure. The failure of the contact mechanism not only directly affects the normal power generation function of the axle-end generator and disrupts the power supply stability of railway freight cars, but also increases maintenance costs and replacement frequency due to frequent equipment failures, posing a serious threat to the efficient and safe operation of railway freight cars. Therefore, in response to the wear failure problem of the existing axle-end generator contact structure, it is urgent to develop a new contact structure solution and corresponding wear failure solution. By optimizing the contact structure, the friction coefficient can be significantly reduced, the wear resistance can be significantly enhanced, and the stress condition can be effectively improved, thereby comprehensively improving the operational reliability of the contacts and meeting the high-performance requirements of the power supply device for the intelligent development of railway freight cars. Summary of the Invention

[0006] To address the aforementioned technical problems, the present invention aims to provide a wear-resistant composite material, contact, and stator structure for a shaft-end power generation device. This solution aims to resolve issues in existing shaft-end power generation devices, such as easy wear of the contacts, wear damage to the bearing saddle, and mechanism failure caused by problems including the gap between the stator rod and the bearing saddle, the unidirectional vibration reduction direction of the stainless steel contacts, and high spring stiffness, which ultimately affect the stability of power supply to railway freight cars. To achieve the above technical effects, the present invention adopts the following technical solution: A wear-resistant composite material is composed of the following materials in the following weight ratio: 60%-75% modified nylon, 10%-30% polytetrafluoroethylene and 10% glass fiber, with the remainder being wear-resistant auxiliary materials.

[0007] Furthermore, the coefficient of friction of the wear-resistant composite material is 0.17-0.24.

[0008] Furthermore, the wear-resistant auxiliary material is at least one of molybdenum disulfide, graphite, ceramic particles, and carbon fiber.

[0009] A contact includes a wear-resistant layer, said wear-resistant layer being prepared using the aforementioned wear-resistant composite material.

[0010] Furthermore, it also includes a reinforcing layer, which is fixedly disposed on the inner wall of the wear-resistant layer, and the reinforcing layer is a metal reinforcing layer.

[0011] Furthermore, the front end of the wear-resistant layer is a planar structure; the reinforcing layer is a polygonal structure with a groove on the outer periphery and an internal thread on the inner side.

[0012] A stator structure for a shaft-end power generation device includes a stator rod with a mounting hole at one end; an axially movable elastic component is disposed within the mounting hole; a support component is disposed at the rear end of the mounting hole and contacts the elastic component; a guide limiting component is disposed at the front end of the mounting hole and contacts the elastic component, and the mounting hole restricts the forward movement of the guide limiting component, the front end of the guide limiting component extending out of the stator rod; and a contact as described in claim 6 is fitted at the front end of the guide limiting component.

[0013] Furthermore, the front end of the mounting hole is provided with a limiting boss; the guide limiting component includes a guide rod, the front end of the guide rod is provided with an external thread for threaded connection with the contact, the middle part of the guide rod is provided with a step that cooperates with the limiting boss, and the bottom of the guide rod is provided with a stepped hole for installing the elastic component.

[0014] Furthermore, the support assembly includes a spring seat, which is threadedly connected to the stator rod; an anti-loosening washer is provided between the spring seat and the stator rod.

[0015] Furthermore, the elastic component is a spring.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The contact provided by this invention is made of a high-polymer composite wear-resistant material, with a high-polymer wear-resistant layer on top. The height of this wear-resistant layer is the allowable wear height of the contact, which can adapt to the wear conditions during vehicle operation. Simultaneously, the wear-resistant layer itself has an extremely low coefficient of friction, and its upper surface can be coated with an appropriate amount of lubricating grease to further reduce the coefficient of friction, significantly reducing the friction between the contact and the bearing saddle. Furthermore, the steel reinforcement layer inside the contact enhances the connection strength of the contact, changing the original spherical contact to a planar contact, eliminating the original anti-rotation mechanism, and, in conjunction with the optimized spring design (reducing spring stiffness and increasing spring stroke), changing the force-bearing structure from point force to surface force, effectively improving the contact's stress condition. It also transforms the original unidirectional force buffering into universal buffering, significantly enhancing the contact's wear resistance, greatly reducing the frequency of contact wear-through failures, and significantly improving its reliability.

[0017] 2. The stator structure of the shaft-end power generation device provided by the present invention significantly reduces the frequency of contact and bearing saddle wear failures, reduces the risk of the shaft-end power generation device being affected by contact mechanism failure, thereby improving the safety and reliability of the entire system and providing a strong guarantee for the stable power supply of railway freight cars.

[0018] 3. The stator structure of the contact and shaft-end power generation device provided by this invention retains the advantages of simple and quick installation of the original contact and stator rod structures. While improving safety and reliability, it maintains the same contact installation method and interface, greatly saving manpower and resources during installation. In application, the system failure rate is significantly reduced, resulting in lower maintenance costs for vehicles due to related malfunctions, while also effectively increasing vehicle utilization, leading to significant economic benefits. Furthermore, this invention can also be applied to the fixing and installation of other shaft-end devices in similar applications, demonstrating good versatility. Attached Figure Description

[0019] Figure 1 A schematic diagram of the structure of the stator rod fitting on the shaft-end power generation device provided by the present invention; Figure 2 A cross-sectional view of the stator structure of the shaft-end power generation device provided by the present invention; Figure 3 A cross-sectional view of the mounting hole provided by the present invention; Figure 4 A schematic diagram of the structure of the reinforcing layer of the contact provided by the present invention; wherein, Figure 4 (a) is a top view. Figure 4 (b) is a sectional view; Figure 5 This is a schematic diagram of the contact structure provided by the present invention; wherein, Figure 5 (a) is a top view. Figure 5 (b) is a sectional view.

[0020] The attached diagram is labeled as follows: 1. Wear-resistant layer; 2. Reinforcing layer; 3. Groove; 4. Stator rod; 5. Mounting hole; 6. Elastic component; 7. Limiting boss; 8. Guide rod; 9. Spring seat; 10. Anti-loosening washer. Detailed Implementation

[0021] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore merely examples and should not be used to limit the scope of protection of the present invention. Those skilled in the art should understand that the present invention can be implemented even without certain specific details. In some other embodiments, methods, means, equipment, and steps well known to those skilled in the art are not described in detail in order to highlight the spirit of the present invention.

[0022] Unless otherwise specified, in this invention, terms such as "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," "circumferential," "x-direction," "y-direction," and "z-direction" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe orientation or positional relationships in this invention are for illustrative purposes only and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood in conjunction with the accompanying drawings and according to the specific circumstances.

[0023] Example 1 See attached Figures 1-5 This embodiment provides a wear-resistant composite material composed of the following materials in the indicated weight ratios: 60%-75% modified nylon, 10%-30% polytetrafluoroethylene (PTFE), and 10% glass fiber, with the remainder being wear-resistant auxiliary materials. Depending on the different wear-resistant auxiliary materials, the coefficient of friction of this wear-resistant composite material can be adjusted to between 0.17 and 0.24, and the wear rate ≤ 0.3 x 10⁻⁸, resulting in excellent wear resistance. The wear-resistant auxiliary materials can be at least one of molybdenum disulfide, graphite, ceramic particles, and carbon fiber.

[0024] The preparation process is as follows: the modified nylon particles are dried in an oven to remove moisture; the dried modified nylon, polytetrafluoroethylene powder, glass fiber chopped strands and wear-resistant auxiliary materials are weighed according to the above ratio and placed in a high-speed mixer to obtain a uniform mixture; the mixture is added to a twin-screw extruder, melt-blended and then extruded and granulated to obtain wear-resistant composite material particles; the particles are made into standard samples by injection molding process, and their friction coefficient is tested. For example, the test conditions are: sliding speed 0.5m / s, load 50N.

[0025] Example 2 See attached Figures 1-5 Based on Embodiment 1, this embodiment also provides a contact that can be applied to a railway freight car axle-end power generation device, such as... Figure 5 As shown, the contact includes a wear-resistant layer 1, which is prepared using the wear-resistant composite material described in Example 1. For example, it can be injection molded using the wear-resistant composite material described in Example 1. The wear-resistant layer 1 has a certain thickness and its front end has a planar structure. The wear-resistant layer 1 is used to reduce friction and wear on the material. A reinforcing layer 2 is also provided on the inner wall of the wear-resistant layer 1. The reinforcing layer 2 is used to improve the contact strength and connect the guide rod 8 and other support components. The reinforcing layer 2 is a metal reinforcing layer, for example, it can be made of steel. Figure 4As shown, the reinforcing layer 2 has a polygonal structure and a groove 3 on its outer periphery. The polygonal structure prevents relative rotation between the wear-resistant layer 1 and the reinforcing layer 2, while the groove 3 prevents vertical relative movement between them. The reinforcing layer 2 also has internal threads for connection with the guide rod 8. The wear-resistant layer 1, made of wear-resistant composite material, can be coated around the reinforcing layer 2 by injection molding or thermosetting, allowing the wear-resistant layer 1 and the reinforcing layer 2 to mechanically interlock through the groove 3. After cooling, an integrated contact is obtained.

[0026] Example 3 See attached Figures 1-5 Based on Embodiment 2, this embodiment also provides a stator structure for a shaft-end power generation device, such as... Figure 2 As shown, it includes a stator rod 4, a support assembly, an elastic assembly 6, a guide and limit assembly, and contacts. The stator rod 4 has a mounting hole 5 at its end, as shown... Figure 3 As shown, the front end of the mounting hole 5 is provided with a limiting boss 7, and the bottom of the mounting hole 5 is provided with an internal thread. Compared with the prior art, the protective cover structure is eliminated, so that the protective cover and the stator rod 4 are integrated into one piece, reducing the connection links between the two, reducing weight while increasing strength. The end of the stator rod 4 is provided with a mounting hole 5, and the mounting hole 5 is provided with a limiting boss 7, which facilitates the guide limiting component to slide up and down within the restricted area. The bottom of the mounting hole 5 is provided with a thread for easy installation and fixing with other components.

[0027] The rear end of the mounting hole 5 is provided with a support component that contacts the elastic component 6. Specifically, the support component includes a spring seat 9, which has external threads and is threadedly connected to the stator rod 4. An anti-loosening washer 10 is provided between the spring seat 9 and the stator rod 4. The elastic component 6 is disposed within the mounting hole 5 and located at the upper end of the spring seat 9. The elastic component 6 can move along its axis. Preferably, the elastic component 6 is a spring. The spring seat 9 can be used for the installation and fixing of the spring and the contact, and provides a certain preload to the spring.

[0028] The front end of the mounting hole 5 is provided with a guide limiting component that contacts the spring, and the mounting hole 5 restricts the forward movement of the guide limiting component. The front end of the guide limiting component extends out of the stator rod 4; the front end of the guide limiting component is fitted with a contact as described in Embodiment 2 above. Specifically, the guide limiting component includes a guide rod 8, the front end of which is provided with an external thread for threaded connection with the contact; the middle part of the guide rod 8 is provided with a step that cooperates with the limiting boss 7, the step is used to limit the free height of the contact, that is, the maximum working height of the contact; the bottom of the guide rod 8 is provided with a stepped hole for installing the spring, the height of the stepped hole being equal to the maximum working stroke of the spring. The spring is installed in the stepped hole of the guide rod 8. When the contact is subjected to vertical or vertical component direction vibration and impact of the bearing saddle, the guide rod 8 moves up and down vertically to compress or restore the spring to buffer and dampen vibration, protecting the contact and bearing saddle from significant damage.

[0029] The contact design incorporates a certain wear-resistant layer 1. The height of wear-resistant layer 1, specifically the height difference between the upper surface of the overall contact and the upper surface of the reinforcing layer 2, represents the contact's wear height. As the vehicle operates, the contact's wear height decreases. When the wear height approaches or equals zero, the contact assembly needs to be replaced. The contact is flexibly connected to the bottom of the support saddle under the action of a spring. During installation, a suitable amount of grease can be applied to the contact surface to further reduce friction, ensuring that vibration, impact, and friction between the support saddle and the contact are minimized during vehicle operation.

[0030] The working principle of the contacts in the stator structure of a shaft-end power generation device is as follows: During initial installation, the contact is positioned at its initial working height. At this point, the contact height is a certain distance from its free height; this distance is the spring's adjustment stroke. The contact's wear height limit is also designed to be equal to the spring's adjustment stroke. During vehicle operation, vibrations and impacts from the vehicle act on the contact surface through the load-bearing saddle. Due to friction and wear, the thickness of the contact's wear-resistant layer 1 will decrease. As the contact thickness decreases, the contact surface will rise under the spring's action, maintaining flexible contact between the contact and the load-bearing saddle. This continues until the contact wear thickness exceeds or equals the spring's adjustment stroke, at which point the contact's anti-wear and vibration-damping effects are lost. At this point, the contact structure needs to be replaced or repaired.

[0031] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications and substitutions should be covered within the scope of the claims of the present invention. Technical aspects, shapes, and structures not described in detail in this invention are all well-known technologies.

Claims

1. A wear-resistant composite material, characterized in that, It is composed of the following materials in the following weight ratio: 60%-75% modified nylon, 10%-30% polytetrafluoroethylene and 10% glass fiber, with the remainder being wear-resistant auxiliary materials.

2. The wear-resistant composite material according to claim 1, characterized in that: The friction coefficient of the wear-resistant composite material is 0.17-0.

24.

3. The wear-resistant composite material according to claim 1, characterized in that: The wear-resistant auxiliary material is at least one of molybdenum disulfide, graphite, ceramic particles, and carbon fiber.

4. A contact, characterized in that: It includes a wear-resistant layer (1), which is prepared using the wear-resistant composite material according to any one of claims 1 to 3.

5. A contact according to claim 4, characterized in that: It also includes a reinforcing layer (2), which is fixedly disposed on the inner wall of the wear-resistant layer (1), and the reinforcing layer (2) is a metal reinforcing layer.

6. A contact according to claim 5, characterized in that: The front end of the wear-resistant layer (1) is a planar structure; the reinforcement layer (2) is a polygonal structure and the outer periphery of the reinforcement layer (2) is provided with a groove (3), and the inner side of the reinforcement layer (2) is provided with an internal thread.

7. A stator structure for a shaft-end power generation device, characterized in that: The stator includes a stator rod (4), the end of which is provided with a mounting hole (5); an axially movable elastic component (6) is provided in the mounting hole (5); a support component is provided at the rear end of the mounting hole (5) to contact the elastic component (6); a guide limiting component is provided at the front end of the mounting hole (5) to contact the elastic component (6) and the mounting hole (5) restricts the forward movement of the guide limiting component, the front end of the guide limiting component extends out of the stator rod (4); and a contact as described in claim 6 is fitted at the front end of the guide limiting component.

8. The stator structure of a shaft-end power generation device according to claim 7, characterized in that: The front end of the mounting hole (5) is provided with a limiting boss (7); the guide limiting component includes a guide rod (8), the front end of the guide rod (8) is provided with an external thread for threaded connection with the contact, the middle part of the guide rod (8) is provided with a step that cooperates with the limiting boss (7), and the bottom of the guide rod (8) is provided with a stepped hole for installing the elastic component (6).

9. The stator structure of a shaft-end power generation device according to claim 7, characterized in that: The support assembly includes a spring seat (9), which is threadedly connected to the stator rod (4); an anti-loosening washer (10) is provided between the spring seat (9) and the stator rod (4).

10. The stator structure of a shaft-end power generation device according to claim 7, characterized in that: The elastic component (6) is a spring.

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