車鉤緩沖裝置檢修hecoupleranddraftgear

車鉤緩沖裝置檢修Thecoupleranddraftgeartogether一、車鉤緩沖裝置簡(jiǎn)介Introductiontothecoupleranddraftgear二、車鉤檢修工藝線設(shè)施Coupleroverhaulprocesslinefacilities三、車鉤緩沖裝置損傷形式與檢修Couplerbufferdamageandoverhauling四、車鉤三態(tài)故障分析 Thecouplerthreestatefailureanalysis五、車鉤分離故障的原因分析及防止措施Analysisofthecausesofcouplerseparationfailureandpreventivemeasures車鉤緩沖裝置簡(jiǎn)介Introductiontothecoupleranddraftgear車鉤緩沖裝置是鐵路貨車的重要組成部分，是連接列車中機(jī)車和車輛、車輛和車輛，使之彼此保持一定距離，并且傳遞和緩和列車在運(yùn)行中或在調(diào)車時(shí)所產(chǎn)生的牽引力和沖擊力。Thecoupleranddraftgearsareanimportantpartofrailroadwagons,whichisusedtoconnectLocomotivesandvehicles,variousvehiclesinthetraintomaintainacertaindistancefromeachother,andtotransmitandalleviatethelongitudinalandimpactforcesgeneratedbythetrainduringoperationorshunting.我國(guó)鐵路貨車使用的車鉤緩沖裝置主要有13系列、16、17型車鉤緩沖裝置，在大秦線一些重載貨車上采用了RFC型牽引桿裝置,同時(shí)少量舊型鐵路貨車上仍然使用2號(hào)車鉤。Atpresent,themaintypesoffreightcarsusedinChinaare:No.13coupler,No.16couplerandNo.17coupler.TheRFC-typetractionbardevicehasbeenadoptedonsomeheavywagonsoftheDaqinLine,whileasmallnumberofoldrailroadwagonsstilluseNo.2couplers.車鉤緩沖裝置簡(jiǎn)介Introductiontothecoupleranddraftgear我國(guó)60t級(jí)鐵路貨車基本采用13號(hào)、13A、13B型車鉤。隨著列車運(yùn)行速度提高和牽引噸位的增加，13系列車鉤強(qiáng)度已不能滿足鐵路貨車高速、重載發(fā)展的需要，將逐漸進(jìn)行淘汰，目前新造載重70t及以上鐵路貨車已全部采用高強(qiáng)度的16、17型車鉤。鐵路貨車車鉤正向著可靠性高、強(qiáng)度高和耐磨性能好的方向發(fā)展。China's60t-classrailroadwagonsbasicallyuse13,13A,13Btypecouplers.Withtheincreaseoftrainspeedandtractiontonnage,13seriesofcouplerstrengthcannotmeettheneedsofhigh-speedrailroadwagons,heavy-dutydevelopment,willbegraduallyeliminated,atpresent,thenew70tandaboverailroadwagonshavebeenusedinallthehigh-strength16,17-typecouplers.Railroadwagoncouplersaredevelopinginthedirectionofhighreliability,highstrengthandgoodwearresistance.13系列車鉤No.13coupler13號(hào)車鉤是在二十世紀(jì)60年代初研制的，70年代初開始在鐵路貨車上推廣使用，2002年停止生產(chǎn)。13號(hào)車鉤鉤體、鉤舌及鉤尾框采用牌號(hào)為ZG25的普通碳素鑄鋼制造，從1996年起推廣使用C級(jí)鋼13號(hào)車鉤及鉤尾框。自2002年開始在新造及檢修貨車上推廣使用13A型車鉤，近年來，為解決13號(hào)車鉤鉤尾銷螺栓折斷造成鉤尾銷脫落而引起的車鉤分離問題，在13A型車鉤基礎(chǔ)上改進(jìn)設(shè)計(jì)了13B型車鉤。No.13couplerwasdevelopedintheearly1960s,andbegantopromotetheuseofrailroadwagonsintheearly1970s,andceasedproductionin2002.13couplerbody,couplertongueandcouplertailframeismadeofordinarycarboncaststeelwithgradeZG25,andfrom1996onwards,theuseofC-gradesteelNo.13couplersandcouplertailframewaspromoted.Since2002,theuseof13Atypecouplershasbeenpromotedonnewly-builtandoverhauledwagons.Inrecentyears,inordertosolvetheproblemofcouplerseparationcausedbythesheddingofcouplertailpinsduetothebreakingofcouplertailpinboltsofNo.13couplers,13Btypecouplershavebeenimprovedanddesignedonthebasisof13Atypecouplers.

13B型車鉤13B-typecoupler

13B型鉤體主要在13A型車鉤鉤體基礎(chǔ)上對(duì)鉤體尾部結(jié)構(gòu)進(jìn)行了改進(jìn)，連接輪廓等外形尺寸保持一致，主要區(qū)別有：13B型鉤體尾部取消鉤尾端部工藝孔，改進(jìn)了鉤尾銷孔處內(nèi)腔結(jié)構(gòu)，提高了結(jié)構(gòu)強(qiáng)度；增加鉤尾銷的承載面積，改善鉤尾銷的受力狀態(tài)；提高車鉤的制造精度要求；材質(zhì)由C級(jí)鋼提高為E級(jí)鋼，進(jìn)一步提高車鉤強(qiáng)度。13B-typecouplerbodyismainlyin13A-typecouplerbodyonthebasisofthecouplerbodyonthetailstructureofthecouplerbodyhasbeenimproved,connectingcontoursandotherexternaldimensionsremainconsistent,themaindifferencesare:13B-typecouplerbodytailtocanceltheendofthecouplertailendoftheprocessholes,improvethecouplertailpinholesintheinnercavitystructure,improvethestructuralstrength;increasethetailofthecouplertailpinload-bearingarea,toimprovetheforcestateofthecouplertailpin;toimprovethecoupler'smanufacturingaccuracyrequirements;materialfromC-gradesteeltoimprovetheE-gradesteel,tofurtherincreasethestrengthofthecoupler.13B型與13A、13號(hào)鉤體尾部結(jié)構(gòu)對(duì)比

ComparisonofModel13Bwith13Aand13couplerBodyTailStructure13B型車鉤13B-typecoupler

13B型鉤舌是在13A型鉤舌的基礎(chǔ)上改進(jìn)的鉤舌。主要區(qū)別有：重新設(shè)計(jì)了鉤舌鼻部?jī)?nèi)腔加強(qiáng)筋結(jié)構(gòu)，加強(qiáng)筋數(shù)量由2條增加為3條，同時(shí)增加加強(qiáng)筋厚度；增加了牽引S面無起模斜度的要求；增加了沿座鎖面分型，規(guī)定了鎖面的起模斜度；材質(zhì)有C級(jí)鋼和E級(jí)鋼兩種，同時(shí)滿足新造和檢修貨車的需要。13Btypecouplertongueisimprovedonthebasisof13Atypecouplertongue.Themaindifferencesare:re-designedtonguenosecavityreinforcementstructure,thenumberofreinforcementfrom2to3,whileincreasingthethicknessofthereinforcement;increasedtractionSsurfacewithoutmoldsloperequirements;increasedalongtheseatofthelocksurfaceparting,theprovisionsofthelocksurfaceofthemoldslope;thematerialhastwokindsofC-gradesteelandE-gradesteel,andatthesametime,tomeettheneedsofthenewandoverhauloftrucks.13B型與13A型鉤舌鼻部結(jié)構(gòu)對(duì)比

ComparisonofModel13BandModel13AcouplerandTongueNasalStructures13系列車鉤上鎖銷組成

13SeriescouplerUpperLockingPinComposition

為進(jìn)一步提高13系列車鉤的防分離可靠性，對(duì)13系列上作用式車鉤的防跳裝置進(jìn)行了改造。將原上鎖銷組成的兩連桿機(jī)構(gòu)更改為三連桿機(jī)構(gòu)，新型上鎖銷由上鎖提、上鎖銷和上鎖銷桿組成。裝用新型上鎖銷組成后，車鉤的解鉤方式、作業(yè)程序與裝用原上鎖銷組成的車鉤相同，僅開鉤角度有所增加，有效的提高了車鉤防分離的可靠性。Inordertofurtherimprovethereliabilityofanti-separationof13seriescouplers,theanti-jumpingdeviceof13seriesup-actingcouplershasbeenmodified.Thetwo-linkmechanismoftheoriginalupperlockingpinischangedtoathree-linkmechanism,andthenewupperlockingpiniscomposedofupperlockinglift,upperlockingpinandupperlockingpinrod.Afterinstallingthenewtypeofupperlockingpin,theuncoupleringmethodandoperationprocedureofthecouplerarethesameasthoseoftheoriginalupperlockingpin,butonlytheopeningangleofthecouplerisincreased,whicheffectivelyimprovesthereliabilityoftheanti-separationofthecoupler.新型上鎖銷組成與原上鎖銷組成對(duì)比

Comparisonofthenewlatchcompositionandtheoriginallatchcomposition

16型車鉤16typeCoupler16型車鉤16typeCoupler由16型車鉤鉤體、鉤舌、鉤舌推鐵、鉤舌銷、鉤鎖組成、下鎖銷轉(zhuǎn)軸和下鎖銷組成等零部件組成。Itconsistsof16-typecouplerbody,couplertongue,couplertonguepushiron,couplertonguepin,couplerlockcomposition,lowerlockingpinspindleandlowerlockingpincompositionandotherparts.為了使車鉤在進(jìn)行翻卸作業(yè)時(shí)轉(zhuǎn)動(dòng)靈活，16型車鉤鉤體的鉤身為圓柱形，鉤身下面的磨耗板為嵌入式磨耗板，減小了車鉤轉(zhuǎn)動(dòng)時(shí)的阻力。鉤體尾部與從板接觸的部位為半徑133.5mm的球面。Inordertomakethecouplerrotateflexiblyduringthetippingandunloadingoperation,thecouplerbodyofType16coupleriscylindrical,andthewearplateunderthecouplerbodyisanembeddedwearplate,whichreducestheresistancewhenthecouplerrotates.Thepartofthecouplerbodyincontactwiththefollowerplateisasphericalsurfacewitharadiusof133.5mm.17型車鉤17typeCoupler

17型車鉤17typeCoupler由17型車鉤鉤體、鉤舌、鉤舌推鐵、鉤舌銷、鉤鎖組成、下鎖銷轉(zhuǎn)軸和17型車鉤下鎖銷組成等零部件組成，所有鑄件均為E級(jí)鋼制造。The17typecoupler,asshowninthefigure,consistsof17typecouplerbody,couplerknuckle,couplerknucklepushiron,couplerknucklepin,lockiron,lowerlockpinshaft,andlowerlockpincomponents.ThecastingsareallmadeofEgradesteel.其中鉤舌、鉤舌推鐵、鉤舌銷和下鎖銷與16型車鉤組成完全通用，17型車鉤的所有零件與13B型、13A型和13號(hào)車鉤的零件均不能互換。Thecomponentsofthe16typecouplerincludethecouplerknuckle,couplerknucklepushiron,lowerlockpin,couplerknucklepin.AllpartsoftheModel17hitcharenotinterchangeablewithpartsoftheModel13B,Model13A,andNo.13hitch.16、17型采用了E級(jí)鋼制造，強(qiáng)度大大提高，鉤體、鉤舌最小靜拉破壞載荷分別為≥4005kN和≥3430kN，而13A鉤體、鉤舌分別為≥3225kN和≥2950kN，同時(shí)增強(qiáng)了鉤體和車鉤等部件的耐磨性。Type16and17aremadeofE-gradesteel,thestrengthisgreatlyimproved,theminimumstatictensilebreakingloadofthecouplerbodyandtongueare≥4005kNand≥3430kNrespectively,whilethecouplerbodyandtongueof13Aare≥3225kNand≥2950kNrespectively,andatthesametime,ithasstrengthenedtheabrasionresistanceofthecouplerbodyandthecouplersandotherparts.17型車鉤相對(duì)13號(hào)系列車鉤的優(yōu)點(diǎn)

AdvantagesofType17couplersoverSeries13couplers

1、防分離可靠性高：Highreliabilityinpreventingseparation

具有下鎖銷防跳和下鎖銷桿防跳兩級(jí)防跳功能，與上作用車鉤的一次防跳相比，具有更好的防跳性能。同時(shí)，17型車鉤的提桿裝置加裝了復(fù)位彈簧，進(jìn)一步提高了車鉤的防分離可靠性。The17typecouplerhastwolevelsofanti-jumpfunctions:lowerlockpinantijumpandlowerlockpinbarantijump,whichhasbetteranti-jumpperformancecomparedtotheonetimeantijumpoftheupperactingcoupler.

Atthesametime,theleverliftingdeviceofthe17typecouplerisequippedwitharesetspring,furtherimprovingtheanti-separationreliabilityofthecoupler.2、車鉤強(qiáng)度高：

Thestrengthofthecouplerishigh

結(jié)構(gòu)合理，鉤體、鉤舌及鉤尾框均采用了E級(jí)鑄鋼制造，增加了車鉤強(qiáng)度；同時(shí)，鉤體最小破壞載荷4005kN與AAR標(biāo)準(zhǔn)規(guī)定相同，鉤舌的最小破壞載荷為3430kN，鉤尾框由E級(jí)鑄鋼改為E級(jí)鍛鋼，具有較高的強(qiáng)度儲(chǔ)備。Thestructureisreasonable,andthecouplerbody,knuckle,andtailframeareallmadeofEgradesteel,whichincreasesthestrengthofthecoupler;Atthesametime,theminimumfailureloadofthecouplerbodyis4005kN,whichisthesameastheAARstandard.Theminimumfailureloadofthecouplerknuckleis3430kN,ThecouplertailframehasbeenchangedfromEgradecaststeeltoE-gradeforgedsteel,whichhasahighstrengthreserve.3、耐磨性能好：Goodwearresistance

采用高強(qiáng)度的E級(jí)鋼材質(zhì)，提高了鉤體、鉤舌和鉤尾框的硬度和耐磨性，并對(duì)鉤尾端面及鉤尾銷孔后圓弧面進(jìn)行了提高表面硬度的特殊處理，具有更高的硬度和更好的耐磨性；鉤體下方增設(shè)了磨耗板，防止鉤體磨耗，降低檢修的工作量和成本。Itismadeofhigh-strengthE-gradesteelmaterial,whichimprovesthehardnessandwearresistanceofthecouplerbody,couplerknuckleandcoupleryoke.Specialtreatmenthasbeencarriedouttoimprovethesurfacehardnessofthecoupleryokeendfaceandthecircularsurfacebehindthecoupleryokepinhole,achievinghigherhardnessandbetterwearresistance;Awearplateisaddedbelowthecouplerbodytopreventwearandreducetheworkloadandcostofmaintenance.17型車鉤相對(duì)13號(hào)系列車鉤的優(yōu)點(diǎn)

AdvantagesofType17couplersoverSeries13couplers

4、連掛間隙?。篢hecouplingclearanceissmall連掛間隙為9.5mm，比13號(hào)車鉤的19.5mm減少了52%，比13A型小間隙車鉤的11.5mm間隙減少了17%，可降低列車的縱向沖動(dòng)、改善列車縱向動(dòng)力學(xué)性能，延長(zhǎng)貨車及其零件的使用壽命。

Thecouplingclearanceofthe17typecoupleris9.5Mm,whichis52%lessthanthe19.5%clearanceoftheNo.13couplerand17%lessthanthe11.5mmclearanceofthetype13Asmallclearancecoupler.Itcanreducethelongitudinalimpulseofthetrain,improvethelongitudinaldynamicperformanceofthetrain,andextendtheservicelifeofthevehicleanditscomponents.5、曲線通過性能好：Goodcurvepassingperformance尾部設(shè)有自動(dòng)對(duì)中凸肩和球型端面，可以使車鉤在運(yùn)行中經(jīng)常保持正位，同時(shí)改善了貨車及列車的曲線通過性能；采用豎圓銷與鉤尾框垂直聯(lián)接，提高了貨車的曲線通過能力。Therearofthe17typecouplerisequippedwithanautomaticcenteringshoulderandasphericalendface,whichcankeepthecouplerinregularpositionduringoperationandimprovethecurvenegotiationperformanceofvehiclesandtrains;Theverticalcircularpinisusedtoverticallyconnectwiththecoupleryoke,improvingthevehicle'scurvepassingability.6、連掛性能好：Goodhangingperformance可與現(xiàn)有貨車使用的13號(hào)、13A型車鉤正常連掛使用。ItcanbeusednormallyinconjunctionwiththeNo.13andNo.13Acouplersusedinexistingtrucks.

7、具有聯(lián)鎖功能：Equippedwithinterlockingfunction鉤體頭部設(shè)有聯(lián)鎖裝置，車鉤連掛后可自動(dòng)實(shí)現(xiàn)聯(lián)鎖，減少車鉤的相對(duì)運(yùn)動(dòng)，具有類似牽引桿裝置的作用；聯(lián)鎖裝置還可以在車鉤轉(zhuǎn)動(dòng)作業(yè)中起到附加旋轉(zhuǎn)功能以降低對(duì)車鉤的損壞。Theheadofthe17typecouplerisequippedwithaninterlockingdevice,whichcanautomaticallyachieveinterlockingaftercoupling,reducingtherelativemovementofthecouplerandhavingasimilarfunctionasatractionroddevice;Theinterlockingdevicecanalsoplayanadditionalrotationfunctioninthecouplerrotationoperationtoreducedamagetothecoupler.牽引桿tractionrod鉤尾框coupleryoke

鉤尾框的種類按型別分有13號(hào)、13A型、13B型、16型、17型鉤尾框，按制造方式分有鑄造鉤尾框和鍛造鉤尾框，鍛造鉤尾框有13B型、16型、17型鍛造鉤尾框。13號(hào)普碳鋼鉤尾框已停止生產(chǎn)，從1996年開始生產(chǎn)的13號(hào)鉤尾框和2001年開始生產(chǎn)的13A型鉤尾框的材質(zhì)為C級(jí)鋼。Thetypesofcoupleryokearedividedinto13,13A,13B,16,17coupleryokeaccordingtotype,castingcoupleryokeandforgingcoupleryokeaccordingtothemanufacturingmethod,forgingcoupleryoke13B,16,17forgingcoupleryoke.13plaincarbonsteelcoupleryokehasbeendiscontinuedfromtheproductionof13coupleryokesince1996,and13Acoupleryokefromthebeginningofproductionin2001.ThematerialisCgradesteel.

13B型鉤尾框Type13Bcoupleryoke

13B型鉤尾框Type13Bcoupleryoke

主要特點(diǎn)：Mainfeatures:1、螺栓安裝座由原來的一個(gè)螺栓承載更改為一個(gè)螺栓承載、兩個(gè)螺栓防護(hù)的結(jié)構(gòu)，避免了鉤尾銷螺栓折斷而造成鉤尾銷脫落；boltmountingseatfromtheoriginaloneboltbearingchangedtoaboltbearing,twoboltsprotectionstructure,toavoidthecouplertailpinboltsbrokenandcausedbythecouplertailpinfalloff;2、提高鉤尾框的制造精度要求；Improvethemanufacturingprecisionofthecoupleryoke;3、材質(zhì)由C級(jí)鋼提高為E級(jí)鋼，進(jìn)一步提高鉤尾框強(qiáng)度。ThematerialisimprovedfromCgradesteeltoEgradesteeltofurtherimprovethestrengthofthecoupleryoke.

13B型鍛造鉤尾框Type13Bforgedcoupleryoke

13B型鍛造鉤尾框Type13Bforgedcoupleryoke

13B型鍛造鉤尾框是在16、17型鍛造鉤尾框成功應(yīng)用基礎(chǔ)上研制的，采用插入式銷托組裝結(jié)構(gòu)，可預(yù)防鉤尾銷脫落后引起的列車分離事故，滿足提速、重載后鐵路運(yùn)輸安全的需要。13B型鍛造鉤尾框、鉤尾框插托見下圖。17型鉤尾框Type17CouplerYoke16型鉤尾框Type16CouplerYoke緩沖器Buffer

現(xiàn)在我國(guó)鐵路貨車常用的車鉤緩沖器有：2號(hào)、ST型、MT-2型和MT-3型緩沖器。其中2號(hào)緩沖器也只是少量非提速車裝用。近年來，我國(guó)又新研制了HM－1型和HM-2型大容量緩沖器。NowChina'srailroadwagonscommonlyusedcouplerbuffer:No.2,STtype,MT-2typeandMT-3typebuffer.Amongthem,theNo.2bufferisonlyasmallnumberofnon-railwaycarsinstalled.Inrecentyears,ChinahasnewlydevelopedHM-1typeandHM-2typehigh-capacitybuffer.HM-1型緩沖器HM-1bufferHM-1型緩沖器是新型摩擦膠泥組合式緩沖器，由摩擦系統(tǒng)、彈性元件、箱體及縮短裝置組成。摩擦系統(tǒng)主要由中心楔塊、動(dòng)板、楔塊等組成；彈性元件由圓鋼彈簧和彈性膠泥體組成。HM-1型緩沖器是通過摩擦副和彈性膠泥來吸收和消耗沖擊能量。HM-1bufferisanewtypeoffrictioncementcombinationbuffer,whichiscomposedoffrictionsystem,elasticelement,boxandshorteningdevice.Thefrictionsystemmainlyconsistsofcenterwedge,movingplate,wedgeandsoon;theelasticelementconsistsofroundsteelspringandelasticcementbody.HM-1bufferistoabsorbandconsumetheimpactenergythroughthefrictionviceandelasticcement.HM-2型緩沖器HM-2buffer

HM-2型緩沖器是新型摩擦彈性體組合式大容量緩沖器，由摩擦系統(tǒng)、彈性元件、箱體及縮短裝置組成。HM-2typebufferisanewtypeoffrictionelastomercombinedlargecapacitybuffer,whichiscomposedoffrictionsystem,elasticelement,boxandshorteningdevice.

幾種緩沖器主要性能參數(shù)比較

Comparisonofthemainperformanceparametersofseveraltypesofbuffers

ST型MT-2型MT-3型HM－1型HM－2型額定阻抗力kN≤2000≤2270≤2000≤2450≤2450額定沖擊速度km/h7881010額定行程mm約68約83約83約83約83吸收率%＞80≥80≥80≥80≥80外形尺寸mm

230×318×568227×320×561227×320×561227×320×561227×320×561質(zhì)量kg132178178180160車鉤檢修工藝線設(shè)施

CouplerMaintenanceProcessLineFacility

一般具有車鉤、鉤尾框、鉤舌、緩沖器檢修流水線，車鉤檢修流水線一般進(jìn)行鉤體的檢測(cè)、工作量較小的加修、車鉤組裝及三態(tài)作用試驗(yàn)；鉤尾框檢修線一般進(jìn)行鉤尾框的檢測(cè)、探傷，鉤尾框的拋丸除銹大部分為下線進(jìn)行；鉤舌檢修線進(jìn)行鉤舌檢測(cè)、探傷，鉤舌的拋丸除銹下線進(jìn)行，鉤體、鉤尾框、鉤舌較大的故障下線檢修；緩沖器檢修線進(jìn)行緩沖器檢查、檢測(cè)，緩沖器的檢修下線進(jìn)行。車鉤緩沖裝置的其他配件如：鉤腔配件、鉤舌銷、鉤尾銷、從板等實(shí)行異地檢測(cè)、集中加修。Generallyhavethecoupler,couplertailframe,couplerknuckle,buffermaintenanceline,couplermaintenancelinegenerallyforthecouplerbodyinspection,workloadsmallerrepair,couplerassemblyandthree-stateactiontest;couplertailframemaintenancelinegenerallyforthecouplertailframeinspection,flawdetection,thecouplertailframeoftheshotblastingdescalingmostoftheline;couplerknucklemaintenancelineforthecouplerknuckledetection,flawdetection,thecouplertongueoftheshotblastingdescalingdowntheline,thecouplerbody,couplers,couplers,andlargerfaultsdownthelinemaintenance;buffermaintenancelineforbufferinspection,testing,buffermaintenancedowntheline;buffermaintenancelineforbufferinspection,testing,buffermaintenancedowntheline.Tailframe,coupleryoke,couplerknucklelargerfailuresofflinemaintenance;buffermaintenancelineforbufferinspection,testing,buffermaintenanceoffline.Otheraccessoriesofcouplerknucklecushioningdevicesuchas:couplercavityaccessories,couplerknucklepin,couplertailpin,fromtheplate,etc.areimplementedoff-siteinspectionandcentralizedrepair.主要工藝裝備Mainprocessequipment成套鉤緩裝置分解機(jī)，車鉤儲(chǔ)存檢修架（線），緩沖器分解組裝壓力機(jī)，鉤舌、鉤尾框及鉤腔內(nèi)配件拋丸除銹機(jī)，復(fù)合磁化鉤尾框濕法探傷機(jī)，復(fù)合磁化鉤舌濕法探傷機(jī)，車鉤三態(tài)試驗(yàn)裝置，鉤舌自動(dòng)焊機(jī)，鉤舌S面數(shù)控刨床（銑床），二氧化碳?xì)怏w保護(hù)焊機(jī)，配件熱處理裝置，鉤尾及鉤尾框銷孔加工機(jī)具，鉤耳孔及鉤舌銷孔鏜孔機(jī)，鉤耳孔及鉤舌銷孔鑲套機(jī)，成套鉤緩裝置組裝機(jī)等主要設(shè)施。Completesetsofcouplerandslowdevicedecompositionmachine,couplerstorageandmaintenanceframe(line),bufferdecompositionandassemblypress,couplertongue,couplerknuckleandcouplercavityfittingsshotblastingandrustremovalmachine,compositemagnetizationofthecouplertailframewetdetectionmachine,compositemagnetizationofthecouplertonguewetdetectionmachine,thecouplerthree-statetestdevice,couplerandtongueautomaticwelder,couplerknuckleS-surfacenumericalcontrolplaner(millingmachine),carbondioxidegasshieldedwelder,fittingsheattreatmentequipment,couplerknuckleandcouplerknuckleframepinHoleprocessingmachinery,couplerknuckleholeandcouplerknucklepinholeboringmachine,couplerknuckleholeandcouplerknucklepinholesettingmachine,completesetsofcouplersandslowdeviceassemblymachineandothermajorfacilities.主要檢測(cè)量具M(jìn)aintestinggauges

鉤身彎曲檢查器，緩沖器自由高檢測(cè)量規(guī)，鉤舌與鉤腕內(nèi)側(cè)距離檢測(cè)量規(guī)，車鉤鉤鎖移動(dòng)量間隙塞尺及鎖鐵托具、鉤舌厚度檢測(cè)量規(guī)，鉤舌鎖面檢測(cè)量規(guī)，鉤舌鉤鎖坐入量檢測(cè)量規(guī)，鉤舌銷孔直徑檢測(cè)量規(guī)，鉤尾框檢測(cè)量規(guī)、鋼卷尺、塞尺等。couplerbodybendingchecker,bufferfreeheightcheckgauge,couplertongueandcouplerwristinsidedistancedetectiongauge,couplercouplerlockmovementgaprulerandlockironbracket,couplertonguethicknessdetectiongauge,couplertonguelockingsurfacedetectiongauge,couplertonguecouplerlockingseatedintotheamountofdetectiongauge,couplerknucklepinholediameterdetectiongauge,couplerknuckledetectiongauge,steeltapemeasure,tapemeasure,andsoon.13號(hào)、13A型、13B型：鉤腕內(nèi)側(cè)面樣板，鉤腔上防跳臺(tái)磨耗檢測(cè)量規(guī)，鉤腔前導(dǎo)向角凸臺(tái)樣板，鉤腔內(nèi)下防跳臺(tái)檢測(cè)量規(guī)，磨耗板定位量規(guī)，鉤舌外脹檢測(cè)量規(guī)，鉤耳孔鉤舌銷孔檢測(cè)量規(guī)等。No.13,Type13A,Type13B:couplerwristinnersidesampleplate,couplercavityupperanti-jumpingplatformweardetectiongauge,couplercavityfrontguideangletabsampleplate,couplercavityloweranti-jumpingplatformdetectiongauge,wearplatepositioninggauge,couplerknuckleexpansiondetectiongauge,couplerlugsholecouplerknucklepinholedetectiongaugeandsoon.

16、17型：鉤體尾部厚度檢測(cè)量規(guī)，鉤體鉤身長(zhǎng)度檢測(cè)量規(guī)，鉤體尾部高度檢測(cè)量規(guī)，鉤尾銷孔中部長(zhǎng)短軸檢測(cè)量規(guī)，16型鉤尾銷孔上下部長(zhǎng)軸檢測(cè)量規(guī)，17型鉤尾銷孔上下部長(zhǎng)軸檢測(cè)量規(guī)，短軸檢測(cè)量規(guī)，鉤耳孔直徑檢測(cè)量規(guī)，車鉤連鎖套頭、連鎖套口檢測(cè)量規(guī)，鉤舌鼻部磨耗檢測(cè)量規(guī)，17型鉤尾框銷孔直徑磨耗檢測(cè)量規(guī)，鉤鎖銷與鉤舌搭接量檢測(cè)量規(guī)等。16,17type:couplerbodytailthicknessdetectiongauge,couplerbodycouplerbodylengthdetectiongauge,couplerbodytailheightdetectiongauge,couplertailpinholecentrallongandshortaxisdetectiongauge,16typecouplertailpinholeupanddownthelongaxisdetectiongauge,17typecouplertailpinholeupanddownthelongaxisdetectiongauge,theshortaxisdetectiongauge,thecouplerlugdiameterdetectiongauge,couplerknuckleinterlockinghead,interlockingsocketdetectiongauge,thecouplertonguenoseweardetectiongauge,17typecouplertailframepinholediameterweardetectiongauge,couplerlockingpinandcouplertonguelapdetectiongauge,etc.Gauge,17typecouplerknucklepinholediameterweardetectiongauge,couplerlockpinandcouplertongueoverlapdetectiongauge.車鉤緩沖裝置損傷形式與檢修

Formsofdamageandmaintenanceofcouplerbuffers

鉤體的主要損傷形式有：裂紋、變形、磨耗超限等。為提高車鉤強(qiáng)度滿足提速重載的要求，13號(hào)、13A型鉤體更換時(shí)，要更換為13B型鉤體。鉤體的使用實(shí)行壽命管理。

Themainformsofdamagetothecouplerbodyare:cracks,deformation,wearandtearoverthelimit.Inordertoimprovethestrengthofthecouplertomeettherequirementsofspeedingupandheavyloading,No.13,13Atypecouplerbodyreplacement,tobereplacedwith13Btypecouplerbody.Theuseofcouplerbodyimplementslifemanagement.鉤體裂紋檢修Crackedcouplermaintenance隨著列車運(yùn)行速度的提高和牽引噸位的增加，鉤體出現(xiàn)裂紋的幾率也隨之增加。鉤體裂紋多發(fā)生在鉤耳、鉤腕、鉤頸、鉤舌尾承壁、鉤尾銷孔、下鎖腔、鉤頭上下牽引突緣的根部等部位。

Withtheincreaseoftrainspeedandtheincreaseoftractiontonnage,thechancesofcracksinthecouplerbodyalsoincrease.couplerbodycracksoccurinthecouplerear,couplerwrist,couplerneck,couplerknuckletailbearingwall,couplertailpinhole,thelowerlockingcavity,thecouplerheadandtherootoftheupperandlowertractionflangeandotherparts.造成鉤體裂紋的原因Causesofcouplercracks

一是由于貨車牽引或縱向沖擊時(shí)上述部位是拉伸載荷應(yīng)力較大的受力部位；First,becausetheaboveareaisthestressareawithhightensileloadstressduringtrucktractionorlongitudinalimpact;二是由于制造材料本身強(qiáng)度不足、疲勞；Thesecondisduetothelackofstrengthandfatigueofthemanufacturingmaterialitself;三是由于斷面突變或鑄造缺陷等引起的應(yīng)力集中等。Thirdly,stressconcentrationcausedbysuddenchangesinsectionorcastingdefects,etc.鉤體裂紋焊修CrackedCouplerWeldingRepairC級(jí)鋼、E級(jí)鋼配件裂紋焊修前應(yīng)清除缺陷、制坡口，E級(jí)鋼坡口制作只能采用冷加工的方法（如機(jī)床加工），不允許使用氧乙炔焰、碳弧氣刨等熱加工方法來清除缺陷或制備坡口。由于C級(jí)鋼、E級(jí)鋼材質(zhì)強(qiáng)度較高，容易出現(xiàn)焊后熱裂紋，因此，焊修時(shí)焊條要烘干并保溫，焊后要嚴(yán)格按照規(guī)定進(jìn)行熱處理。施焊前應(yīng)進(jìn)行預(yù)熱，預(yù)熱溫度為300～400℃，普碳鋼車鉤焊修時(shí)采用J422焊條，C級(jí)鋼采用J606焊條，E級(jí)鋼采用J857焊條。

C-gradesteel,E-gradesteelfittingscrackweldingrepairshouldberemovedbeforethedefects,thepreparationofbevels,E-gradesteelbevelproductioncanonlybeusedincoldmachiningmethods(suchasmachinetoolmachining),donotallowtheuseofoxy-acetyleneflame,carbonarcgasplanerandotherhotmachiningmethodstoremovethedefectsorpreparationofbevels.SinceC-gradesteelandE-gradesteelhavehighstrengthandarepronetopost-weldingthermalcracking,theweldingelectrodesshouldbedriedandkeptwarmduringweldingrepair,andtheheattreatmentshouldbecarriedoutinstrictaccordancewiththeregulationsafterwelding.Preheatingshouldbecarriedoutbeforewelding,andthepreheatingtemperatureis300～400℃.J422electrodeisusedforweldingandrepairingofplaincarbonsteelcouplers,J606electrodeisusedforC-gradesteel,andJ857electrodeisusedforE-gradesteel.鉤體變形檢修Couplerdeformationmaintenance鉤體變形主要有鉤身彎曲、鉤耳變形和鉤腕外脹。其原因多是由于運(yùn)行及調(diào)車作業(yè)中的過大沖擊造成的。鉤身彎曲過大時(shí)，在運(yùn)用中將會(huì)產(chǎn)生較大的彎矩，容易造成鉤舌及鉤耳的裂紋。鉤腕外漲嚴(yán)重時(shí)，即失去了控制對(duì)方鉤舌的能力，將導(dǎo)致車鉤的自動(dòng)分離。couplerbodydeformationmainlyincludescouplerbodybending,couplereardeformationandcouplerwristexpansion.Thereasonismostlyduetotheoperationandshuntingoperationscausedbyexcessiveimpact.Whenthecouplerknuckleisbenttoomuch,alargebendingmomentwillbegeneratedintheapplication,whichwilleasilycausethecrackofthecouplertongueandthecouplerear.Whenthecouplerwristisseriouslyinflated,itlosestheabilitytocontroltheothersideofthecouplerwrist,whichwillleadtotheautomaticseparationofthecouplerknuckle.鉤身彎曲調(diào)修Couplerbendingadjustment段修鉤身彎曲大于10mm時(shí)，加熱調(diào)修后探傷或更換。修調(diào)應(yīng)注意三點(diǎn)：一是將部位局部加熱至730℃～850℃后，在壓力機(jī)上進(jìn)行調(diào)直。二是調(diào)直后在室溫不低于15℃空氣中自然緩冷，不允許使用液體或水霧冷卻。三是對(duì)調(diào)修部位進(jìn)行磁粉探傷檢查。Segmentrepaircouplerbodybendinggreaterthan10mm,heatingandtuningafterprobingorreplacement.Repairandadjustmentshouldpayattentiontothreepoints:First,thepartofthelocalheatingto730℃~850℃afterstraighteninginthepress.Second,afterstraighteningintheroomtemperatureisnotlessthan15℃airnaturalslowcooling,donotallowtheuseofliquidorwaterspraycooling.Thirdly,magneticparticleflawinspectioniscarriedoutontheadjustedparts.鉤腕端部外脹變形

Deformationofthecouplerwristendbyexternaldistention13號(hào)、13A型、13B型鉤腕端部外脹變形影響閉鎖位置時(shí)，調(diào)修、堆焊或焊裝厚度為5mm～15mm、高度為60mm～70mm的梯形鋼板，鋼板要有2個(gè)φ20mm的塞焊孔，焊后磨修平整，外脹變形大于15mm時(shí)更換。16型、17型鉤腕外脹變形影響全開位置時(shí)更換。No.13,13Atype,13Btypecouplerwristendexternalexpansiondeformationaffectsthelockingposition,repair,surfacingorweldingthicknessof5mm~15mm,heightof60mm~70mmtrapezoidalsteelplate,thesteelplateshouldbe2φ20mmplugweldholes,weldgrindingandsmoothing,theexternalexpansiondeformationisgreaterthan15mmreplacement.16,17typecouplerwristexternalexpansiondeformationaffectsthefull-openpositionwhenreplacement.

鉤體磨耗檢修Couplerabrasionmaintenance鉤體磨耗是鉤體與相配合零件相對(duì)摩擦的結(jié)果。磨耗部位多發(fā)生在鉤耳孔及鉤身與托板的接觸處、16型、17型車鉤的鉤尾銷孔和鉤尾端部。其次是鉤尾側(cè)面、端面、鉤鎖腔側(cè)壁及鉤鎖腔內(nèi)防脫（跳）臺(tái)處。車鉤磨耗后，削弱了強(qiáng)度，而且影響車鉤的作用。如防脫（跳）臺(tái)磨耗后，將會(huì)使車鉤失去防脫（跳）作用。couplerbodyabrasionistheresultofrelativefrictionbetweenthecouplerandthematingparts.Abrasionoccursmostlyinthecouplerearholesandthecontactbetweenthecouplerbodyandthepallet,16-type,17-typecouplertailpinholesandtheendofthecouplertail.Followedbythesideofthetailofthecoupler,theendface,thesidewallofthecouplerlockcavityandthecouplerlockcavitytopreventdisengagement(jump)atthetable.Afterthecouplerisabraded,thestrengthisweakenedandthefunctionofthecouplerisaffected.Iftheanti-dislodgement(jumping)platformiswornout,thecouplerwillloseitsanti-dislodgement(jumping)effect.13系列防跳臺(tái)檢修

13seriesanti-jumpingtablemaintenance13號(hào)、13A型、13B型鉤腔上防跳臺(tái)原型厚度為55mm，磨耗深度超過2mm時(shí)堆焊后磨修或更換。要求鉤腔前導(dǎo)向角要恢復(fù)原型6mm凸臺(tái)原形，使凸臺(tái)根部距前壁長(zhǎng)度在48mm～50mm之間，13號(hào)、13A型、13B型下作用車鉤鉤腔下防跳臺(tái)磨耗超限時(shí)堆焊后磨修恢復(fù)原型，長(zhǎng)度方向?yàn)?6mm。No.13,13Atype,13Btypecouplercavityontheanti-jumpingplatformprototypethicknessof55mm,weardepthofmorethan2mmwhensurfacingafterweldingorreplacement.Requirementsforthefrontguidingangleofthecouplercavitytorestoretheprototype6mmtaboriginalshape,sothattherootofthetabfromthefrontwalllengthbetween48mm~50mm,No.13,13Atype,13Btypeoflowerroleofthecouplercouplercouplercavityundertheanti-jumpingtablewearexceedsthelimitofsurfacingaftergrindingandrepairingtherestorationoftheprototype,thelengthofthedirectionof16mm.

鉤舌損傷形式Formsofcouplerknuckledamage鉤舌的主要損傷形式有裂紋、磨耗、變形等。裂紋多發(fā)生在鉤舌內(nèi)側(cè)面的上、下彎角處、鉤舌銷孔、牽引突緣及沖擊突肩的根部等拉伸載荷應(yīng)力較大的受力部位，尤其是大編組列車開行以后，列車縱向沖擊加大，鉤舌裂紋比例也隨之增加。鉤舌磨耗的主要部位是內(nèi)側(cè)面，其次是鉤舌尾部側(cè)面（與鉤鎖接觸面）及鉤舌銷孔。Themainformsofdamagetothecouplerknucklearecracks,abrasion,deformationandsoon.Cracksoccurintheinnersideofthecouplerknuckle,theupperandlowercorners,couplerknucklepinhole,tractionedgeandtherootoftheimpactoftheshoulderandotherstresspartsofthetensileloadstressisgreater,especiallyafterthestartofalargegroupoftrains,thelongitudinalimpactofthetraintoincreasetheproportionofthecouplerknucklecrackshaveincreased.Themainpartofthecouplerknucklewearistheinnerside,followedbythetailsideofthecouplerknuckle(contactsurfacewiththecouplerlock)andthecouplerknucklepinhole.鉤舌損傷檢修重點(diǎn)

Highlightsofcouplerknuckleinjurymaintenance在檢修中，鉤舌變形主要是外漲，前些年比較多，自從鉤舌實(shí)行壽命管理后，以及目前鉤舌基本為C級(jí)鋼或E級(jí)鋼，外漲的現(xiàn)象已經(jīng)極少見到，包括鉤舌各部的磨耗超限的現(xiàn)象也比較少見，鉤舌故障最多的為裂紋，車鉤緩沖裝置設(shè)計(jì)理念中強(qiáng)度是從鉤舌—鉤體-鉤尾框-緩沖器-底架依次增大的，鉤舌的強(qiáng)度最小，在列車受到不正常的牽引或沖擊力時(shí)，最先受到損傷的是鉤舌，所以我們?cè)阢^舌檢修中要把防止鉤舌斷裂作為一個(gè)重點(diǎn)。Inmaintenance,thecouplertonguedeformationismainlyexternalrise,someyearsagomore,sincetheimplementationofthecouplertonguelifemanagement,aswellasthecurrentcouplertongueisbasicallyC-gradesteelorE-gradesteel,thephenomenonofexternalrisehasbeenrarelyseen,includingthecouplertongueofthevariouspartsofthewearandtearofthephenomenonofthelimitisalsorelativelyrare,thecouplertonguefailureisthemostforthecrack,thecouplerknucklecushioningdevicedesignconceptofthestrengthis