Novel hump speed reducer air cylinder convenient to maintain

Abstract

The utility model belongs to the technical field of air cylinders, and particularly relates to a novel hump speed reducer air cylinder convenient to maintain, which comprises a cylinder barrel, two air connecting pipes are sequentially arranged on the same horizontal plane of the cylinder barrel at intervals, and the air connecting pipes are communicated with the inside of the cylinder barrel; the rear cover is connected to one end of the cylinder barrel, and the other end of the cylinder barrel is sleeved with a fixing disc; the front cover is connected with the fixing disc through a plurality of bolts, and the bolts are evenly distributed in the circumferential direction of the front cover; a clamping assembly is arranged between the fixing disc and the front cover and used for stably fixing the fixing disc and the front cover to the cylinder barrel. The piston is located in the cylinder barrel, and the rear end of the piston body is connected with a piston rod in sliding fit with the front cover. The hydraulic cylinder has the beneficial effects that the service life of the sealing ring is prolonged, the maintenance process is simplified, and the maintenance efficiency is improved.

Description

Technical Field

[0001] This utility model belongs to the technical field of cylinders, specifically a new type of hump reducer cylinder that is easy to maintain. Background Technology

[0002] In hump yard operations at railway marshalling yards, the hump reducer cylinder is a key component ensuring the safe disassembly of vehicles and their entry into designated tracks. However, traditional hump reducer cylinders have revealed numerous problems in actual use, seriously affecting the efficiency and cost of railway transportation. The following are some of the current technical shortcomings:

[0003] The maintenance workload is large and the process is complicated: When replacing the seal ring, the cylinder itself weighs 30 kg, requiring laborious disassembly from the site and transportation back to the repair shop for replacement by specialized personnel. After replacement, it is then returned to the site for installation. This process not only consumes a lot of manpower and resources, but also poses safety risks during round-trip transportation. Moreover, replacing the seal ring requires specialized disassembly and testing equipment, which has high requirements for the operating environment, lacks flexibility, and cannot be completed quickly on-site, seriously affecting the efficiency of hump yard operations.

[0004] There is a shortage of skilled operators and a disconnect between maintenance and repair: Replacing a sealing ring requires specialized skills and high technical expertise. Improper installation can easily scratch the seal and reduce its service life. Currently, most of the personnel who have mastered the replacement skills are older employees facing retirement, while younger people are unwilling to do this work, resulting in a shortage of skilled personnel. In addition, the personnel who return cylinders for repair have little understanding of the on-site cylinder operating conditions and environment, and the repair work is disconnected from the actual needs on site.

[0005] High daily maintenance costs: Traditional hump reducer cylinders require monthly lubrication. Frequent lubrication increases maintenance workload. Moreover, ordinary lubricating oil corrodes polyurethane seals, accelerating seal aging and further reducing their service life, creating a vicious cycle that increases equipment maintenance costs. Utility Model Content

[0006] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a new type of hump reducer cylinder that is easy to maintain, which solves the technical problems of large maintenance workload and complicated process, lack of operators, disconnect in maintenance, and high daily maintenance costs.

[0007] The solution adopted in this utility model is: a novel hump reducer cylinder that is easy to maintain, characterized in that it includes:

[0008] The cylinder is hollow and has a through-hole design. On the same horizontal plane of the cylinder, two air inlet pipes are arranged at intervals and are connected to the inside of the cylinder.

[0009] The rear cover is connected to one end of the cylinder, and a fixing plate is fitted on the other end of the cylinder;

[0010] The front cover is connected to the fixing plate by several bolts, which are evenly distributed along the circumference of the front cover.

[0011] A snap-fit ​​assembly is provided between the fixed plate and the front cover, which is used to securely fix the fixed plate and the front cover to the cylinder.

[0012] The piston is located inside the cylinder, and the rear end of the piston body is connected to a piston rod that slides with the front cover.

[0013] Preferably, a retaining ring is used, with an opening at one point.

[0014] The cylinder barrel has a groove that fits the fixed retaining ring;

[0015] The fixed plate has a first placement groove corresponding to the fixed retaining ring;

[0016] The front cover has a second placement groove corresponding to the fixing retaining ring.

[0017] Preferably, it also includes:

[0018] An oil storage container is provided on the inner wall of the fixed plate;

[0019] The cylinder has an oil hole running through it, which is connected to the oil storage naan.

[0020] The front cover has a first boss and a second boss arranged sequentially along the inside of the cylinder. The first boss is matched with the oil hole to ensure that the oil inside the oil storage container flows into the cylinder.

[0021] Preferably, it also includes:

[0022] A sealing groove is provided on the first protrusion, and a sealing ring is provided inside the sealing groove. The sealing groove is connected to the oil hole.

[0023] Preferably, it also includes:

[0024] Wear-resistant strips are provided on the outer wall of the piston;

[0025] Two piston rings, with a wear-resistant band located between the two piston rings.

[0026] Preferably, the rear cover and the cylinder are cold-metal transition welded.

[0027] Preferably, the cylinder is made of alloy steel.

[0028] Preferably, the retaining ring is made of 304 stainless steel.

[0029] Preferably, the oil added to the oil storage naan is solid iteflon polyester oil.

[0030] Preferably, the sealing ring is made of thermoplastic polyurethane composite material.

[0031] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0032] I. Extending the service life of the sealing ring: In the cylinder of the hump reducer of this utility model, the sealing ring is made of thermoplastic polyurethane composite material. Compared with the traditional ordinary polyurethane sealing ring, its anti-aging and corrosion resistance are improved by 2-3 times. It has good sealing and wear resistance in a wide temperature range of -40℃ to 180℃. The service life of the sealing ring can be increased by more than 2 times, reducing the replacement frequency and reducing maintenance costs.

[0033] II. Simplified Maintenance Process and Improved Efficiency: By incorporating special snap-fit ​​components—namely, the retaining ring engaging with the groove on the cylinder, the first placement groove on the mounting plate, and the second placement groove on the front cover—the installation and removal of the mounting plate and front cover become significantly easier. No complex specialized equipment is required; ordinary maintenance personnel can quickly complete the operation on-site, avoiding the hassle and risks of transporting cylinders back and forth, thus greatly saving maintenance time and labor costs. Simultaneously, this design reduces reliance on specialized technicians, addressing the issue of a shortage of skilled operators.

[0034] III. Improved Cylinder Performance and Reduced Production Costs: The cylinder barrel is made of alloy steel. By adding alloying elements such as Mn, Mo, and Cr, and through solid solution strengthening, grain boundary strengthening, and second-phase strengthening, the strength and toughness of the steel are improved, making the alloy steel tensile strength greater than 700MPa, hardness up to HRC55, and wear resistance increased by 3-5 times. In addition, the back cover and cylinder barrel adopt a cold metal transition welding process, with less heat output and minimal deformation after welding. No subsequent boring and grinding processing is required, which improves production efficiency and reduces production costs.

[0035] IV. Optimized Lubrication System, Extending Component Life: An oil reservoir is installed on the inner wall of the fixed plate, communicating with the cylinder through an oil hole. The front cover has a first and second protrusion to guide the oil from the reservoir into the cylinder. The solid ETEFL polyester oil added to the reservoir has strong adhesion and lubricity, and does not chemically react with the seals, thus preventing corrosion. Simultaneously, the automatic oiling device eliminates the need for frequent lubrication, reducing oil evaporation and extending the lifespan of the seals by 3-5 times, further lowering maintenance costs and improving equipment operational stability. Attached Figure Description

[0036] Figure 1 This is one of the perspective views of this utility model.

[0037] Figure 2This is one of the perspective views of the three-dimensional cross-section of this utility model.

[0038] Figure 3 yes Figure 2 A magnified view of part A.

[0039] Figure 4 This is the second perspective of the three-dimensional cross-sectional view of this utility model.

[0040] Figure 5 yes Figure 4 A magnified view of part B.

[0041] Figure 6 This is the third perspective view of the three-dimensional cross-sectional view of this utility model.

[0042] Reference numerals in the attached diagram: 1. Cylinder; 2. Air inlet pipe; 3. Rear cover; 4. Fixing plate; 5. Front cover; 6. Bolt; 7. Piston; 8. Piston rod; 9. Fixing retaining ring; 10. Ring groove; 11. First placement groove; 12. Second placement groove; 13. Oil reservoir; 14. Oil hole; 15. First boss; 16. Second boss; 17. Sealing groove; 18. Sealing ring; 19. Wear-resistant band; 20. Piston ring. Detailed Implementation

[0043] The foregoing and other technical contents, features and effects of this utility model are described in conjunction with the appendix below. Figure 1-6 The detailed description of the embodiments will clearly demonstrate this. All structural details mentioned in the following embodiments are based on the accompanying drawings.

[0044] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings.

[0045] Example 1: A novel hump reducer cylinder that is easy to maintain, characterized in that it comprises:

[0046] The cylinder 1 is hollow and has a through-hole structure. On the same horizontal plane of the cylinder 1, two air inlet pipes 2 are arranged at intervals and are connected to the inside of the cylinder 1.

[0047] The rear cover 3 is connected to one end of the cylinder 1, and a fixing plate 4 is fitted on the other end of the cylinder 1;

[0048] The front cover 5 is connected to the fixed plate 4 by several bolts 6, which are evenly distributed around the circumference of the front cover 5.

[0049] A snap-fit ​​assembly is provided between the fixed plate 4 and the front cover 5 to securely fix the two to the cylinder 1;

[0050] Piston 7 is located inside cylinder 1, and piston rod 8, which slides with front cover 5, is connected to the rear end of piston 7.

[0051] As an optional solution of Embodiment 1, the retaining ring 9 is fixed with an opening at one point;

[0052] The cylinder barrel 1 is provided with a groove 10 that is adapted to the fixed retaining ring 9;

[0053] The fixed plate 4 has a first placement groove 11 corresponding to the fixed retaining ring 9;

[0054] The front cover 5 has a second placement groove 12 corresponding to the fixed retaining ring 9.

[0055] Example 2: An oil storage container 13 is provided on the inner side wall of the fixed plate 4;

[0056] The cylinder 1 has an oil hole 14 through it, and the oil hole 14 is connected to the oil storage naan 13;

[0057] The front cover 5 is provided with a first protrusion 15 and a second protrusion 16 in sequence along the inside of the cylinder 1. The first protrusion 15 is matched with the oil hole 14 to ensure that the oil inside the oil storage 13 flows into the inside of the cylinder 1.

[0058] As an optional embodiment of Example 1, a wear-resistant strip 19 is provided on the outer side wall of the piston 7;

[0059] Two piston rings 20, with a wear-resistant band 19 located between the two piston rings 20.

[0060] As an optional embodiment of Example 1, the rear cover 3 and the cylinder 1 are cold-metal transition welded.

[0061] As an optional embodiment of Example 1, the cylinder 1 is made of alloy steel.

[0062] As an optional embodiment of Example 1, the retaining ring 9 is made of 304 stainless steel.

[0063] As an optional embodiment of Example 1, the grease added to the oil storage naan 13 is solid ETEFL polyester oil.

[0064] As an optional embodiment of Example 1, the sealing ring 18 is made of thermoplastic polyurethane composite material.

[0065] I. Manufacturing and assembly of cylinder barrel and related components

[0066] Cylinder Manufacturing: Cylinder 1 is made of alloy steel. According to design requirements, machining equipment is used to machine the interior of cylinder 1 into a hollow, through-hole structure. During machining, the dimensional accuracy of the inner and outer diameters of cylinder 1, as well as the surface roughness of the inner wall, are strictly controlled to ensure that piston 7 can slide smoothly within cylinder 1. Simultaneously, on the same horizontal plane of cylinder 1, two air inlet mounting holes communicating with the interior of cylinder 1 are machined sequentially and at intervals using drilling and reaming processes. The dimensions of the mounting holes are adapted to the air inlet pipe 2 to ensure a tight seal.

[0067] Air inlet pipe installation: Select an air inlet pipe 2 of appropriate specifications, insert one end of it into the corresponding mounting hole on the cylinder 1, and seal it using welding or sealant to ensure a secure and leak-free connection between the air inlet pipe 2 and the cylinder 1. The other end of the air inlet pipe 2 is used to connect to an external air source or other related equipment to provide power to the cylinder.

[0068] Rear cover and mounting plate installation: The rear cover 3 is welded to one end of the cylinder 1 using a cold metal over-welding process. This welding process has a small heat input, which can effectively reduce welding deformation and ensure the overall accuracy of the cylinder 1. At the other end of the cylinder 1, the mounting plate 4 is fitted onto it, so that the mounting plate 4 fits tightly against the outer wall of the cylinder 1, and the position of the mounting plate 4 on the cylinder 1 is ensured to be accurate by appropriate positioning.

[0069] Front cover installation and snap-fit ​​assembly: Drill several threaded holes evenly on the mounting plate 4 to match the bolts 6, and drill through holes at corresponding positions on the front cover 5. Connect the front cover 5 and the mounting plate 4 by passing several bolts 6 through the through holes of the front cover 5 and screwing them into the threaded holes of the mounting plate 4. During the tightening of the bolts 6, operate according to a specific tightening sequence and torque requirements to ensure a tight connection and even force distribution between the front cover 5 and the mounting plate 4.

[0070] For the snap-fit ​​assembly, a groove 10 that matches the fixed retaining ring 9 is first machined on the cylinder 1. The depth, width and shape of the groove 10 match the fixed retaining ring 9 to ensure that the fixed retaining ring 9 can be stably embedded in it.

[0071] A first placement groove 11 and a second placement groove 12 corresponding to the fixed retaining ring 9 are respectively machined on the fixed plate 4 and the front cover 5. The position and size of the first placement groove 11 and the second placement groove 12 should ensure that when the fixed retaining ring 9 is installed in place, it can be tightly locked between the fixed plate 4 and the front cover 5, thereby firmly fixing the fixed plate 4 and the front cover 5 to the cylinder 1. When installing the fixed retaining ring 9, align its opening with one side of the ring groove 10, and then gently insert the fixed retaining ring 9 into the ring groove 10, so that its two ends fall into the first placement groove 11 and the second placement groove 12 respectively.

[0072] Piston and piston rod assembly: A mounting structure, such as a threaded hole or groove, is machined at the rear end of the piston body 7 to connect with the piston rod 8. One end of the piston rod 8 is installed at the rear end of the piston body 7 according to the design requirements, ensuring a firm and reliable connection. Then, a wear-resistant band 19 and two piston rings 20 are installed on the outer wall of the piston 7, with the wear-resistant band 19 positioned between the two piston rings 20. The wear-resistant band 19 and piston rings 20 must fit tightly against the outer wall of the piston 7, ensuring good sealing performance. The assembled piston assembly is carefully placed into the cylinder 1, allowing the piston rod 8 to pass through the corresponding hole on the front cover 5, ensuring the sliding fit accuracy between the piston rod 8 and the front cover 5, and ensuring smooth reciprocating motion of the piston 7 within the cylinder 1.

[0073] II. Material Selection

[0074] The cylinder barrel 1 is made of alloy steel. This alloy steel is treated with alloying elements such as Mn, Mo, and Cr, and is strengthened by solid solution strengthening, grain boundary strengthening and second phase strengthening processes. This makes its tensile strength greater than 700MPa, hardness up to HRC55, and wear resistance improved by 3-5 times, effectively extending the service life of the cylinder barrel 1.

[0075] The retaining ring 9 is made of 304 stainless steel. 304 stainless steel has good toughness and corrosion resistance. While ensuring the fixing effect, it is easy to disassemble and install multiple times and is not easily damaged. It can ensure the stable connection between the fixing plate 4 and the front cover 5 during long-term use.

[0076] The sealing ring 18 is made of thermoplastic polyurethane composite material, which has 2-3 times better anti-aging and corrosion resistance than ordinary polyurethane material. It has good sealing and wear resistance in the operating temperature range of -40℃ to 180℃. The service life of the sealing ring 18 can be increased by more than 2 times, effectively preventing gas leakage and ensuring the working performance of the cylinder.

[0077] As an optional embodiment 2, a sealing groove 17 is provided on the first boss 15, and a sealing ring 18 is provided in the sealing groove 17. The sealing groove 17 is connected to the oil hole 14.

[0078] I. Manufacturing and Installation of Lubrication Structures

[0079] Oil storage naan installation: Install the oil storage naan 13 on the inner wall of the fixed plate 4 according to the design dimensions and shape requirements. The oil storage naan 13 can be installed by welding, bonding or snap-fitting to ensure that it is firmly connected to the fixed plate 4 and has a good seal to prevent grease leakage.

[0080] Oil hole machining and connection: Several oil holes 14 are drilled on the cylinder 1 at positions corresponding to the oil reservoir 13. The diameter, number, and distribution of the oil holes 14 should be designed according to the actual lubrication requirements to ensure that the oil holes 14 are connected to the oil reservoir 13, allowing the grease in the oil reservoir 13 to flow smoothly into the cylinder 1. After machining the oil holes 14, the inner walls of the oil holes 14 are appropriately polished to remove burrs and impurities, ensuring smooth grease flow.

[0081] Machining of the front cover boss and sealing groove: Along the internal direction of the cylinder 1, the front cover 5 is machined sequentially with a first boss 15 and a second boss 16. The position of the first boss 15 corresponds to the oil hole 14, and its height, diameter, and other dimensions must ensure effective guidance of oil from the oil reservoir 13 into the cylinder 1. A sealing groove 17 is machined on the first boss 15, and the depth and width of the sealing groove 17 are adapted to the sealing ring 18. The sealing ring 18, made of thermoplastic polyurethane composite material, is installed in the sealing groove 17, ensuring that the sealing groove 17 communicates with the oil hole 14 to prevent grease leakage.

[0082] Adding grease: Open the oil inlet of oil storage container 13 and slowly inject solid Eteflon polyester oil into oil storage container 13. Solid Eteflon polyester oil has strong adhesion and lubricity, and does not react chemically with the seals and will not corrode the seals. During the oil injection process, pay attention to controlling the amount of oil injected. After reaching the designed amount of oil, seal the oil inlet.

[0083] II. Overall Debugging and Inspection

[0084] After completing the installation of all components in Example 2, a comprehensive debugging and inspection of the entire hump reducer cylinder is carried out.

[0085] Sealing performance check: Introduce gas at a certain pressure into cylinder 1 through air inlet pipe 2, and check all connections, including the connection between air inlet pipe 2 and cylinder 1, the connection between front cover 5 and fixed plate 4, the mating point between piston 7 and cylinder 1, and the oil hole connection between oil reservoir 13 and cylinder 1, to ensure there is no gas leakage. If a leak is found, locate the leak point and repair it promptly, such as tightening bolts or replacing seals.

[0086] Lubrication performance check: Start the cylinder to make piston 7 reciprocate within cylinder 1. Observe whether the grease in oil reservoir 13 can flow smoothly into cylinder 1 through oil hole 14, and ensure proper lubrication of piston 7, piston rod 8, and other components. Check whether the movement of piston 7 is smooth and free from jamming, and at the same time check the wear of each component to ensure the lubrication system is working properly.

[0087] Overall performance testing: Simulating the actual working conditions of the hump reducer cylinder, performance tests are conducted on the cylinder. Tests include parameters such as the movement speed of piston 7, the output force of piston rod 8, and the cylinder's response time, ensuring that all performance indicators of the cylinder meet design requirements. If the test results do not meet the requirements, relevant components are adjusted or optimized until the design standards are met.

[0088] The above description is only for illustrating the present utility model. It should be understood that the present utility model is not limited to the above embodiments, and various modifications that conform to the concept of the present utility model are within the protection scope of the present utility model.

Claims

1. A novel hump reducer cylinder that is easy to maintain, characterized in that, include: The cylinder (1) is hollow and has a through-hole structure. On the same horizontal plane of the cylinder (1), two air inlet pipes (2) are arranged at intervals and are connected to the inside of the cylinder (1). The rear cover (3) is connected to one end of the cylinder (1), and a fixing plate (4) is fitted on the other end of the cylinder (1); The front cover (5) is connected to the fixed plate (4) by several bolts (6), and the bolts (6) are evenly distributed around the front cover (5). A snap-fit ​​assembly is provided between the fixed plate (4) and the front cover (5) to securely fix the two to the cylinder (1); The piston (7) is located inside the cylinder (1), and the rear end of the piston (7) is connected to a piston rod (8) that slides with the front cover (5).

2. The hump reducer cylinder according to claim 1, characterized in that, The snap-fit ​​assembly includes: A retaining ring (9) is provided with an opening at one point; The cylinder (1) has a groove (10) that is compatible with the fixed retaining ring (9); The fixed plate (4) is provided with a first placement groove (11) corresponding to the fixed retaining ring (9); The front cover (5) has a second placement groove (12) corresponding to the fixed retaining ring (9).

3. The hump reducer cylinder according to claim 1, characterized in that, Also includes: Oil storage naan (13) is provided on the inner wall of the fixed plate (4); The cylinder (1) has an oil hole (14) running through it, and the oil hole (14) is connected to the oil storage naan (13); The front cover (5) is provided with a first boss (15) and a second boss (16) in sequence along the inside direction of the cylinder (1). The first boss (15) is matched with the oil hole (14) to ensure that the oil inside the oil storage naan (13) flows into the cylinder (1).

4. The hump reducer cylinder according to claim 3, characterized in that, Also includes: A sealing groove (17) is provided on the first boss (15), and a sealing ring (18) is provided in the sealing groove (17). The sealing groove (17) is connected to the oil hole (14).

5. The hump reducer cylinder according to claim 1, characterized in that, Also includes: Wear-resistant bands (19) are provided on the outer side wall of the piston (7); Two piston rings (20), with a wear-resistant band (19) located between the two piston rings (20).

6. The hump reducer cylinder according to claim 1, characterized in that, The rear cover (3) and the cylinder (1) are cold-metal transition welded together.

7. The hump reducer cylinder according to claim 1, characterized in that, The cylinder (1) is made of alloy steel.

8. The hump reducer cylinder according to claim 2, characterized in that, The retaining ring (9) is made of 304 stainless steel.

9. The hump reducer cylinder according to claim 3, characterized in that, The oil added to the oil storage naan (13) is solid iteflon polyester oil.

10. The hump reducer cylinder according to claim 4, characterized in that, The sealing ring (18) is made of thermoplastic polyurethane composite material.

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