A method for testing the reliability of a marine gearbox turning lock shaft device

Abstract

The present application relates to a kind of marine gear box turning lock shaft device reliability test method, comprising the following steps: turning function verification, static load verification of lock shaft, lock shaft with force release verification and turning start interlock verification;Compared to the test item coverage of the turning lock shaft device in the prior art is not complete, and the working condition simulation is not sufficient, it is difficult to fully reflect the reliability of the turning lock shaft device of marine gear box, the present application constructs the reliability test method of the turning lock shaft device of marine gear box, which covers turning function verification, static load verification of lock shaft, lock shaft with force release verification and turning start interlock verification, and the test item coverage is wide, and the working condition simulation is sufficient, can fully reflect the reliability of the turning lock shaft device of marine gear box.

Description

Technical Field

[0001] This invention relates to the field of gearbox testing technology, and specifically to a reliability testing method for a marine gearbox turning gear locking device. Background Technology

[0002] Marine gearbox turning gears are used for low-speed turning of the propeller shaft system during static maintenance of the gearbox. Shaft locking devices are used to lock the shaft system during towing or grounding. The reliability and safety of these turning and locking devices are crucial for protecting equipment from mechanical damage, ensuring the safety of maintenance personnel, maintaining equipment functionality and operational reliability, reducing downtime risks, and lowering downtime costs. Therefore, it is essential to establish an effective and comprehensive testing method to systematically verify their functional indicators.

[0003] Currently, while international organizations and industry standards have established a general testing framework for gearboxes and safety devices, specific test methods for turning gear locking devices have not yet been clearly defined. Although domestic standards have made preliminary specifications for the test methods of turning gear devices, they still suffer from incomplete coverage of test items and insufficient simulation of operating conditions, making it difficult for test results to fully reflect the reliability of marine gearbox turning gear locking devices. Summary of the Invention

[0004] The purpose of this invention is to provide a reliability testing method for marine gearbox gearbox gearbox locking devices, addressing the problem that existing technologies suffer from incomplete test coverage and insufficient simulation of operating conditions, which makes it difficult to fully reflect the reliability of the gearbox locking devices.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A reliability testing method for a marine gearbox turning gear locking device includes the following steps: Verification of the turning function: Connect the turning device to the gearbox under test and perform manual turning and electric turning respectively. If it can drive the output shaft of the gearbox under test to rotate back and forth in the clockwise and counterclockwise directions, it is qualified. Static load verification of the locking shaft: The locking shaft device is closed and locked to lock the shaft system of the gearbox under test. A predetermined torque is applied to the output end of the gearbox under test and the load is maintained. If the rotation angle of the output shaft of the gearbox under test is less than the predetermined angle, it is qualified. Lock shaft disengagement verification: Engage the turning device on the gearbox under test, and the lock shaft device closes and locks the shaft system of the gearbox under test; apply progressively increasing torque to the output end in the clockwise direction, and attempt to disengage the lock shaft device at each torque level; if disengagement is not possible at a certain torque level, maintain that torque level and attempt to disengage by manually turning the gearbox in the reverse direction; apply progressively increasing torque to the output end in the counterclockwise direction, and repeat the above disengagement attempts; if the lock shaft device can disengage under each torque level in both the clockwise and counterclockwise directions, it is deemed qualified; Turning gear start interlock verification: The working condition in which the three states of active construction turning gear device engagement, shaft locking device disengagement and gearbox clutch disengagement are not simultaneously met; send an electric turning gear start signal to the turning gear device. If the motor of the turning gear device cannot start, it is qualified.

[0006] In this invention employing the aforementioned technical solution, the turning function verification step involves verifying the turning device's forward and reverse rotation by combining manual and electric turning with clockwise and counterclockwise bidirectional reciprocating rotation. This effectively eliminates defects such as jamming and malfunction of the turning device. In the static load-bearing verification step of the locking shaft, the anti-torsional locking capability of the locking shaft device can be accurately verified by applying a predetermined torque and maintaining the load while monitoring the output shaft rotation angle. In the locking shaft force-driven disengagement verification step, the disengagement reliability of the locking shaft device under various load levels (including reverse manual turning auxiliary conditions) is verified by applying progressively increasing torques in both clockwise and counterclockwise directions. In the turning start interlocking verification step, the active... By constructing a motor interlocking logic to verify the operating conditions where three states are not simultaneously satisfied, the risk of mechanical interference caused by accidental start-up of the turning gear device can be eliminated, ensuring the safety of maintenance personnel and equipment. Compared with the existing technology where the test items for the turning gear locking device are not fully covered and the operating condition simulation is insufficient, making it difficult to fully reflect the reliability of the marine gearbox turning gear locking device, this invention constructs a reliability test method for the marine gearbox turning gear locking device that covers turning function verification, locking shaft static load verification, locking shaft force disengagement verification, and turning gear start-up interlock verification. The test items have a wide coverage and the operating condition simulation is sufficient, which can fully reflect the reliability of the marine gearbox turning gear locking device.

[0007] Furthermore, when the gearbox under test is in the first test bench position, the turning function verification, lock shaft static load verification, and turning start interlock verification are performed. The first test bench position includes a first drive motor, a first speed increaser, the gearbox under test, a second speed increaser, and a loading motor connected in sequence via couplings. A dedicated bench structure for turning function verification, lock shaft static load verification, and turning start interlock verification is defined to ensure that the loading process is stable and controllable and to improve the accuracy of test data.

[0008] Furthermore, when the gearbox under test is in the second test bench position, the locking shaft force disengagement verification is performed; the second test bench position includes a second drive motor, the gearbox under test and a third speed increaser connected in sequence via a coupling; a dedicated bench structure for locking shaft force disengagement verification is defined, which is adapted to the operation requirements of heavy load loading and facilitates the simulation of the actual stress conditions of the actual ship shafting.

[0009] Furthermore, in the manual gyratory gearbox verification procedure, the output shaft of the gearbox under test is rotated once clockwise and once counterclockwise, with each rotation angle not less than 15°; when the gearbox is rotated electrically, the output shaft of the gearbox under test is rotated three times clockwise and three times counterclockwise, each rotation being one revolution, with clockwise and counterclockwise rotations alternating. This standardizes the operational criteria for gyratory gearbox verification, and by limiting the requirements for rotation direction and angle, it fully investigates defects such as jamming in forward and reverse rotation and failure of the gyratory gearbox.

[0010] Furthermore, in the static load verification step of the lock shaft, the predetermined torque is 65% of the rated torque of the gearbox under test, the holding time is 3 minutes, and the predetermined angle is 5°; the assessment indicators of the static load verification of the lock shaft are quantified, and the anti-torsional locking performance of the lock shaft device can be accurately determined.

[0011] Furthermore, in the static load verification step of the lock shaft, a pulling force is applied at the output arm of the second speed increaser by using a hoist to apply a predetermined torque to the output end of the gearbox under test; this clarifies the low-cost loading implementation method for the static load verification of the lock shaft, which is simple and controllable to operate, and reduces the difficulty of building the test bench and the testing cost.

[0012] Furthermore, the static load-bearing verification steps of the locking shaft are repeated multiple times, and the locking shaft device must be disengaged between any two static load-bearing verification steps; by defining the repeated test rules for the static load-bearing verification of the locking shaft, the randomness of a single test is avoided, and the repeated locking reliability of the locking shaft device is fully assessed.

[0013] Furthermore, in the static load verification step of the lock shaft, electronic signal switches are installed at both the closing and disengagement points of the lock shaft device. The electronic signal switches are used to determine whether the lock shaft device is closed or disengaged in place. By setting up electronic signal switches to monitor the lock shaft status in real time, errors in manual judgment are avoided, and the accuracy of lock shaft status determination and testing efficiency are improved.

[0014] Furthermore, in the lock shaft disengagement verification step, the torque increases progressively to 5%, 10%, 15%, and 20% of the rated torque of the gearbox under test; this clarifies the progressive loading gradient of the lock shaft disengagement verification, taking into account both test comprehensiveness and experimental efficiency, and can accurately identify the lock shaft jamming risk under different load levels.

[0015] Furthermore, in the verification step of the lock shaft disengagement under force, a weight is hung on the lever arm at the output end of the third speed increaser to apply torque to the output end of the gearbox under test. The torque is applied indirectly by hanging a weight on the output end of the third speed increaser, which avoids spatial interference between the loading structure and the gearbox body and prevents accidental damage to the gearbox caused by direct loading, thus ensuring the safety and controllability of the test process.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: a reliability test method for marine gearbox gearbox gearbox locking shaft device is constructed, which covers the verification of gearbox function, static load-bearing verification of locking shaft, force disengagement verification of locking shaft, and interlocking verification of gearbox start-up. The test items have a wide coverage and the working conditions are fully simulated, which can comprehensively reflect the reliability of marine gearbox gearbox locking shaft device. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the layout of the first test bench. Figure 2 This is a schematic diagram of the layout of the second test bench. Figure 3 This is a schematic diagram of the disengagement structure of the locking shaft device; Figure 4 This is a schematic diagram of the closed structure of the locking shaft device; Figure 5 This is a schematic diagram of the load-bearing structure of the third speed increaser arm.

[0018] The markings in the diagram are: 1-First drive motor, 2-First speed increaser, 3-Test gearbox, 4-Second speed increaser, 5-Loading motor, 6-First universal coupling, 7-First high-elasticity coupling, 8-Second universal coupling, 9-Third universal coupling, 10-Second drive motor, 11-Third speed increaser, 12-Second high-elasticity coupling, 13-Fourth universal coupling, 14-Lever arm, 15-Weight, 16-Locking shaft disengagement proximity switch, 17-Locking shaft closure proximity switch, 18-Locking shaft pin, 19-Locking shaft handle, 20-Locking shaft disc, 21-Safety pin. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings.

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] This embodiment provides a reliability testing method for a marine gearbox turning gear locking device, including the following steps: Verification of the turning function: Connect the turning device to the test gearbox 3 and perform manual and electric turning respectively. If the output shaft of the test gearbox 3 can be driven to rotate back and forth in the clockwise and counterclockwise directions, it is qualified. Specifically, when turning manually, the output shaft of the test gearbox 3 is turned once in the clockwise and once in the counterclockwise direction, and the rotation angle of the output shaft is not less than 15° each time. When turning electrically, the output shaft of the test gearbox 3 is turned three times in the clockwise and three times in the counterclockwise direction, one revolution each time, and the clockwise and counterclockwise rotations are alternated. It should be noted that all the definitions of rotation direction in this application are based on the observation angle along the axial direction of the output shaft of the test gearbox 3 pointing away from the test gearbox 3.

[0022] Static load verification of the locking shaft: The locking shaft device closes and locks the shaft system of the test gearbox 3. A predetermined torque is applied to the output end of the test gearbox 3 and the load is maintained. If the rotation angle of the output shaft of the test gearbox 3 is less than the predetermined angle, it is considered qualified. Specifically, the predetermined torque is 65% of the rated torque of the test gearbox 3, the holding time is 3 minutes, and the predetermined angle is 5°. To avoid the randomness of a single test, the static load verification steps of the locking shaft need to be repeated multiple times, and the locking shaft device needs to be disengaged between any two static load verification steps. The structure of the locking shaft device is an existing structure. To avoid errors in human judgment and improve the accuracy of locking shaft status determination, this embodiment sets electronic signal switches at both the closing and disengagement points of the existing locking shaft device. The electronic signal switches determine whether the locking shaft device is closed or disengaged. The electronic signal switch at the closing point is the locking shaft closing proximity switch 17, and the electronic signal switch at the disengagement point is the locking shaft disengagement proximity switch 16. Figure 4 As shown, operating the locking shaft handle 19 of the locking shaft device causes the locking shaft pin 18 to extend. When the locking shaft closing proximity switch 17 is closed, it indicates that the locking shaft device is closed in place (at this time, the top outer edge of the locking shaft pin 18 is close to the locking shaft closing proximity switch 17, and the locking shaft pin 18 is locked in place with the locking shaft disc 20 on the gearbox 3 under test); Figure 3 As shown, operating the locking shaft handle 19 of the locking shaft device causes the locking shaft pin 18 to retract. When the locking shaft disengagement proximity switch 16 is closed, it indicates that the locking shaft device is disengaged (at this time, the top outer edge of the locking shaft pin 18 is close to the locking shaft disengagement proximity switch 16, and the locking shaft pin 18 is disengaged from the locking shaft disc 20). In addition, during the process of closing the locking shaft device, in order to align the locking shaft pin 18 with the locking shaft disc 20, the position of the locking shaft disc 20 can be adjusted by engaging the turning device and then manually turning the turning device. Verification of shaft locking release under load: connect the barring gear on the tested gearbox 3, and close the shaft locking device to lock the shaft system of the tested gearbox 3; apply stepwise increasing torque to the output end in the clockwise direction, and attempt to release the shaft locking device under each level of torque; if release cannot be achieved at a certain level of torque, maintain that level of torque and conduct release attempts with the assistance of reverse manual barring; apply stepwise increasing torque to the output end in the counterclockwise direction, and repeat the above release attempts; if the shaft locking device can be released under all levels of torque in both clockwise and counterclockwise directions, it is determined as qualified; specifically, the stepwise increasing torques are 5%, 10%, 15% and 20% of the rated torque of the tested gearbox 3; the verification of shaft locking release under load can simulate actual ship working conditions to verify whether the shaft locking device is easy to release under stress conditions.

[0023] Verification of barring start interlock: actively construct working conditions where the three states of barring gear engaged, shaft locking device released and clutch of the tested gearbox 3 disengaged are not satisfied simultaneously; send an electric barring start signal to the barring gear, if the motor of the barring gear cannot start, it is qualified; specifically, the verification scenarios include: none of the three states is satisfied, only one state is satisfied, or only two states are satisfied; if the barring motor cannot start when the electric barring start signal is sent to the barring gear in any of the above scenarios, it is qualified.

[0024] When the tested gearbox 3 is at the first test station, barring function verification, shaft locking static load bearing verification and barring start interlock verification are performed; as Figure 1 shown, the first test station comprises a first driving motor 1, a first speed-increasing gearbox 2, the tested gearbox 3, a second speed-increasing gearbox 4 and a loading motor 5 which are sequentially connected through couplings; wherein the first driving motor 1 and the first speed-increasing gearbox 2 are connected through a first universal coupling 6, the first speed-increasing gearbox 2 and the tested gearbox 3 are connected through a first high-elastic coupling 7, the tested gearbox 3 and the second speed-increasing gearbox 4 are connected through a second universal coupling 8, and the second speed-increasing gearbox 4 and the loading motor 5 are connected through a third universal coupling 9; in the step of shaft locking static load bearing verification, a hoist is used to apply a pulling force at the force arm of the output end of the second speed-increasing gearbox 4, so as to apply a predetermined torque to the output end of the tested gearbox 3; before the step of barring start interlock verification, when the tested gearbox 3 is static, disconnect the connection at its output end, and then perform the verification step; When the tested gearbox 3 is at the second test station, verification of shaft locking release under load is performed; as Figure 2 shown, the second test station comprises a second driving motor 10, the tested gearbox 3 and a third speed-increasing gearbox 11 which are sequentially connected through couplings; wherein the second driving motor 10 and the tested gearbox 3 are connected through a second high-elastic coupling 12, and the tested gearbox 3 and the third speed-increasing gearbox 11 are connected through a fourth universal coupling 13; as Figure 5As shown, in the verification step of the locking shaft disengagement under force, a weight is hung on the lever arm 14 at the output end of the third speed increaser 11 to apply torque to the output end of the gearbox 3 under test. It should be noted that since the weight 15 hanging on the lever arm 14 at the output end of the third speed increaser 11 will fall after the locking shaft pin 18 is pulled out, the following should be ensured when setting up the platform: 1) The height of the weight 15 off the ground is not more than 50mm, and a buffer should be placed below it; 2) After the locking shaft pin 18 is pulled out and the weight 15 falls, it should be prevented from rolling.

[0025] In this invention employing the aforementioned technical solution, the turning function verification step involves verifying the turning device's forward and reverse rotation by combining manual and electric turning with clockwise and counterclockwise bidirectional reciprocating rotation. This effectively eliminates defects such as jamming and malfunction of the turning device. In the static load-bearing verification step of the locking shaft, the anti-torsional locking capability of the locking shaft device can be accurately verified by applying a predetermined torque and maintaining the load while monitoring the output shaft rotation angle. In the locking shaft force-driven disengagement verification step, the disengagement reliability of the locking shaft device under various load levels (including reverse manual turning auxiliary conditions) is verified by applying progressively increasing torques in both clockwise and counterclockwise directions. In the turning start interlocking verification step, the active... By constructing a motor interlocking logic to verify the operating conditions where three states are not simultaneously satisfied, the risk of mechanical interference caused by accidental start-up of the turning gear device can be eliminated, ensuring the safety of maintenance personnel and equipment. Compared with the existing technology where the test items for the turning gear locking device are not fully covered and the operating condition simulation is insufficient, making it difficult to fully reflect the reliability of the marine gearbox turning gear locking device, this invention constructs a reliability test method for the marine gearbox turning gear locking device that covers turning function verification, locking shaft static load verification, locking shaft force disengagement verification, and turning gear start-up interlock verification. The test items have a wide coverage and the operating condition simulation is sufficient, which can fully reflect the reliability of the marine gearbox turning gear locking device.

[0026] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A reliability testing method for a marine gearbox turning gear locking device, characterized in that, Includes the following steps: Verification of the turning function: Connect the turning device to the test gearbox (3) and perform manual turning and electric turning respectively. If the output shaft of the test gearbox (3) can be driven to rotate back and forth in the clockwise and counterclockwise directions, it is qualified. Static load verification of the lock shaft: The lock shaft device closes and locks the shaft system of the test gearbox (3), applies a predetermined torque to the output end of the test gearbox (3) and holds the load. If the rotation angle of the output shaft of the test gearbox (3) is less than the predetermined angle, it is qualified. Verification of locking shaft disengagement under force: Engage the turning device on the test gearbox (3), and the locking shaft device closes and locks the shaft system of the test gearbox (3); apply progressively increasing torque to the output end in the clockwise direction, and attempt to disengage the locking shaft device at each torque level; If the device cannot disengage under a certain torque level, maintain that torque level and attempt to disengage by manually turning the gear in the opposite direction. Apply progressively increasing torque to the output end in the counterclockwise direction and repeat the above disengagement attempt. If the locking device can disengage under each torque level in both the clockwise and counterclockwise directions, it is considered qualified. Turning gear start interlock verification: The working condition in which the three states of the active construction turning gear device engagement, the locking shaft device disengagement and the clutch disengagement of the test gearbox (3) are not simultaneously satisfied; send an electric turning gear start signal to the turning gear device. If the motor of the turning gear device cannot start, it is qualified.

2. The reliability test method for the marine gearbox turning gear locking device according to claim 1, characterized in that, When the test gearbox (3) is in the first test bench position, the turning function verification, the lock shaft static load verification and the turning start interlock verification are performed; the first test bench position includes the first drive motor (1), the first speed increaser (2), the test gearbox (3), the second speed increaser (4) and the loading motor (5) connected in sequence through the coupling.

3. The reliability test method for the marine gearbox turning gear locking device according to claim 1, characterized in that, When the test gearbox (3) is in the second test bench position, the lock shaft force disengagement verification is performed; the second test bench position includes the second drive motor (10), the test gearbox (3) and the third speed increaser (11) connected in sequence by a coupling.

4. The reliability test method for the marine gearbox turning gear locking device according to claim 1, characterized in that, In the manual rotation function verification step, the output shaft of the test gearbox (3) is rotated once in the clockwise direction and once in the counterclockwise direction, and the rotation angle of the output shaft is not less than 15° each time; when rotating the gearbox (3) electrically, the output shaft of the test gearbox (3) is rotated three times in the clockwise direction and three times in the counterclockwise direction, one revolution each time, and the clockwise and counterclockwise rotations are alternated.

5. The reliability test method for the marine gearbox turning gear locking device according to claim 1, characterized in that, In the static load verification step of the lock shaft, the predetermined torque is 65% of the rated torque of the gearbox (3) under test, the holding time is 3 minutes, and the predetermined angle is 5°.

6. The reliability test method for the marine gearbox turning gear locking device according to claim 2, characterized in that, In the static load verification step of the lock shaft, a pulling force is applied at the output arm of the second speed increaser (4) by a hoist to apply a predetermined torque to the output end of the test gearbox (3).

7. The reliability test method for the marine gearbox turning gear locking device according to claim 1, characterized in that, Repeat the static load test steps of the locking shaft multiple times, and the locking shaft device must be disengaged between any two static load test steps.

8. The reliability test method for the marine gearbox turning gear locking device according to claim 7, characterized in that, In the static load verification step of the locking shaft, electronic signal switches are installed at both the closing and disengagement points of the locking shaft device. The electronic signal switches are used to determine whether the locking shaft device is closed or disengaged.

9. The reliability test method for the marine gearbox turning gear locking device according to claim 1, characterized in that, In the verification step of the lock shaft being disengaged by force, the torque is increased step by step by 5%, 10%, 15%, and 20% of the rated torque of the gearbox (3) under test.

10. The reliability testing method for the marine gearbox turning gear locking device according to claim 3, characterized in that, In the verification step of the lock shaft disengagement, a weight is hung on the lever arm (14) at the output end of the third speed increaser (11) to apply torque to the output end of the test gearbox (3).

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