This standard specifies the reliability test methods for drive axles on site and in the laboratory and their characteristic quantity observation values. This standard applies to drive axles for wheeled vehicles such as loaders, cranes, and excavators. JB/T 5929-1991 Reliability test methods for drive axles of construction machinery JB/T5929-1991 Standard download decompression password: www.bzxz.net

Mechanical Industry Standard of the People's Republic of China
JB/T5929-91
Engineering Machinery Drive Axle
Published on December 17, 1991
Reliability Test Method
Implemented on July 1, 1992
Published by the Ministry of Machinery and Electronics Industry of the People's Republic of China
Mechanical Industry Standard of the People's Republic of China
Engineering Machinery Drive Axle
Subject Content and Scope of Application
Reliability Test Method
JB/T5929—91
This standard specifies the field reliability test method and laboratory reliability test method of the drive axle and its characteristic quantity observation value. This standard applies to the drive axle (excluding brakes) for wheeled vehicles such as loaders, cranes, and excavators. 2
Reference standards
GB10675
GB3300
JB/T5928
3Failure modes
Reliability test method for hydraulic excavator
Complete machine test method for counterbalanced forklift
Test specification for truck crane and tire crane Driving reliability test
Type test method for tire loader
Engineering machinery drive axle
Bench test method
According to the nature and degree of harm of the fault, the faults are divided into 3 categories. See Table 1. Table 1 Failure mode classification
Fatal failure
Serious failure
General failureWww.bzxZ.net
Parts name
Axle housing, carrier planet carrier, differential, wheel hub, etc.
Differential housing, main reducer housing and planet carrier shaft
Differential gear lining, axle gear village and planetary gear lining
Main reducer and wheel reducer
Approved by the Ministry of Machinery and Electronics Industry on December 17, 1991Failure mode
Drive axle scrapped due to fracture
Cracks in the housing, cracks or peeling of accessory welds. Plastic deformation is greater than 1.5mm per meter
Local fracture, severe wear or severe scratch damage
Serious wear or burns
Broken teeth, crushed tooth surface, Key corrosion or peeling due to wear and tear
Oil leakage due to failure
Oil temperature is too high due to tight bearing clearance or insufficient oil
Remove within 1 hour
1992-07-01Implementation
Minor fault
Oil plug
Parts name
Parts joint surface
Main reducer and wheel reducer
Drive axle field reliability test method
JB/T5929-91
Continued Table 1
Failure mode
Oil leakage caused by loose oil plug
Oil leakage caused by loose screw
Slight abnormal noise
Drive axle field reliability test is carried out together with its host field reliability test. It is a non-destructive test. 4.1 Test Purpose
In the on-site reliability test, the reliability characteristic quantity of the drive axle is measured to identify the quality of batch products and verify the reliability of new products. 4.2 Test Method
4.2.1 Test Sample
Exclude
Mean Time Between Failures MTBF and Effectiveness K. Use no less than 30 drive axles (for dual-axle drive models, half each for the front and rear axles, and for models equipped with through-axles, half each for the middle and rear axles) that meet the design requirements provided by the entrusting unit, sample two (one for each different variety), install them on one (dual-axle or multi-axle drive models) or two (single-axle drive models) sampling hosts, and conduct centralized assessment tests with the hosts. 4.2.2 On-site reliability test of loader drive axle 4.2.2.1 Technical preparation before test
The technical preparation of the whole machine shall be in accordance with Article 1.4.1.5 of JB3688.3; the necessary design and process data of the drive axle shall be attached; a point thermometer shall be equipped to measure the oil temperature of the drive axle, the range of the point thermometer is 0～+110℃, and the accuracy is ±1%. 4.2.2.2
Test time
The reliability test time of the loader drive axle is 1000h, which is also applicable to other models. The continuous operation time per day shall not be less than 6 operating conditions in accordance with Article 3.3 of JB3688.3. The reliability test of the excavator drive axle shall be in accordance with Articles 4.5, 6.1, and 6.3 of GB10675. 4.2.3#
The reliability test of the drive axle of the truck crane and the tire crane shall be in accordance with Chapters 1 and 2 of JB4032.2. 4.2.4
4.2.5 The reliability test of the forklift drive axle shall be carried out in accordance with the requirements specified in Articles 14.2, 14.4.1 and 14.4.5 of JB3300. 4.2.6 The pre-test preparations, test conditions, test time (or total mileage) and operating methods of other models shall be carried out in accordance with the whole machine reliability test methods of each host or with reference to the corresponding provisions of the above-mentioned models (when the host has no reliability test standards). 4.3 Collection of reliability test data
All test data of the drive axle during the test, including operating conditions, maintenance time, work area transfer, number of failures, number of test participants, etc., shall be recorded in Table 7.
No serious failures are allowed during the test. The number of failures recorded in Table 7 refers to the general failures specified in Chapter 3 of this standard. 4.4 Test results
4.4.1 Disassembly inspection
After the test, disassemble the drive axle and inspect it according to the instructions and drawings. Observe whether the parts are damaged, deformed or abnormally worn, and precisely measure the wear of the main parts to determine their wear amount. 4.4.2 Observed values ​​of quantities to be measured
The mean trouble-free working time is calculated according to formula (1): a.3
JB/T5929-91
Where: MTBF mean trouble-free working time, h/time; T. Total working time of the root sample, h;
m--Number of failures in the whole test, times; number of samples.
b. Effectiveness is calculated according to formula (2):
T. ×100
K ~ T.++T,%
Where: K,--effectiveness (i.e. technical utilization coefficient),%;T-normal maintenance and repair time,h;
Tfailure downtime (abnormal maintenance and repair time),h. 5 Laboratory reliability test method
The laboratory reliability test is a fatigue life test on the four main components of the main reducer bevel gear pair, wheel side reducer gear pair, half shaft and axle housing on the bench, which is a destructive test. The purpose of this test is to confirm whether the service life of the four main components of the main reducer bevel gear pair, wheel side reducer gear pair, half shaft and axle housing can reach or exceed the service life of the drive axle assembly (i.e. the first overhaul life). 5.1 The vertical bending fatigue test of the drive axle housing is carried out according to JB/T5928
5.2 Fatigue life test of the main reducer bevel gear pair5.2.1 Test purpose
Determine the bending and contact fatigue life of the main reducer bevel gear pair. Only one test is allowed according to the need. 5.2.2 Test samples and technical preparation
5.2.2.1 Test samples
The entrusted unit shall provide no less than 30 sets of finished products that meet the design requirements and match the specific host, and 3 sets shall be sampled. 5.2.2.2 Necessary technical information
Information such as drive axle design, process and operating instructions: The total life of the drive axle required by the host (first overhaul life angle 1): Typical use specifications or program load spectrum of the actual working conditions of the host. 5.2.3 Test equipment
The test equipment can be a closed test bench or an open test bench, and equipped with a torque meter, a tachometer, a counter and a thermometer. a.
Test bench accuracy: within 20h of continuous operation, the error for a given torque value is 5%, and the error for a given speed is +10r/min;
Torque meter accuracy: ±0.50%;
Tachometer accuracy: ±1%;
Eight-digit counter accuracy: ±0.1%;
Oil temperature measurement of the bridge: range 0+110℃, accuracy ±1%. 5.2.4 Test conditions
5.2.4.1 Test torque
Maximum torque T of bending fatigue test
Select the maximum working torque T of the active bevel gear (hereinafter referred to as the maximum torque) as the maximum torque T of the bending fatigue test: 3
Maximum torque of contact fatigue test
JB/T5929-91
TH= (0.7~0.8)TF
Where: T Maximum torque of contact fatigue test, N·m; TpF Maximum torque of bending fatigue test, N·m. 5.2.4.2 Maximum torque T of the active bevel gear The maximum torque T is selected according to the smaller of the following two conditions. Determined according to the maximum torque of the engine.
For mechanical transmission system:
Toax = Tenri,-mK,
In the formula, T...
--the maximum output torque of the engine, N·m; i\——the low gear ratio of the gearbox (or through the transfer case); 7m the total efficiency from the engine to the active bevel gear; K. Torque distribution coefficient.
For hydromechanical transmission system:
Tmax = T'Tmaxig7,K.
In the formula: TT--the maximum output torque of the engine and the torque converter working together, N·m: 7.——the total efficiency from the output end of the torque converter to the active bevel gear. Torque distribution coefficient K. The value should comply with the provisions of Table 2. Table 2
According to static strength
According to fatigue strength
Torque distribution coefficient K.
Single-axle drive
Mechanical
Determined by the drive axle adhesion torque, calculated according to formula (6). mGon
Where: G-drive axle load at full load, N; 9——adhesion coefficient, according to the design value of the main engine; i-total transmission ratio of the drive axle;
了---total transmission efficiency of the drive axle, according to the design value of the main engine: wheel rolling radius, m.
5.2.4.3 Test speed
Machinery driven by multiple axles
Non-through axle
Select the maximum speed under the actual working conditions corresponding to the test torque as the test speed n. Through axle
·（3）
·（4）
·（5）
（6）
In order to speed up the test speed, the enhanced test method of increasing the test speed can be adopted, but the increased speed shall not exceed 0.5 times the maximum working speed (i.e. npmx<1.5n).
5.2.4.4 Test oil temperature
JB/T5929-91
Add lubricating oil according to the instructions of the operating manual of the moving bridge (or main engine). During the test, the oil temperature of the gear is controlled between +60~+80℃, and it is allowed to reach +90℃ for a short time; the oil temperature of the hyperbolic gear oil is controlled between +70～+90℃, and it is allowed to reach +100℃ for a short time. The above oil temperature is measured at the oil level hole.
It is allowed to use air cooling or water cooling to control the oil temperature of the test bridge during the test. 5.2.5 Test procedure
5.2.5.1 Contact spot test
Check the contact spot according to the loading procedure of 0, 0.25TpF, 0.5T, 0.75TpF, 1T. a.
If the contact spot does not meet the requirements of the drawing, it should be readjusted and calibrated, and then executed according to a of this article until it is qualified. b.
5.2.5.2 Loading method
Test run
Run for 1 hour at a speed of 1.5 to 2 times the test speed n. and at a test torque of 3% and 15% respectively. b. Formal test
Load according to the loading procedure in Table 3 or Table 4. During the test, record the torque, speed and oil temperature in the bridge every 1 hour and fill in Table 9. Other fatigue test methods can also be used. Termination of the test
When doing bending fatigue test, the breaking of the gear teeth (at this time there is a loud noise and vibration) is the termination state. When doing contact fatigue test, the termination state is a sharp increase in load and abnormal noise. At this time, the pitting area exceeds 25% of the working area of ​​the tooth (that is, the pitting area rate exceeds 25%).
Table 3 Loading program table
Corresponding to the test torque
7,%
Corresponding to the test torque
T,%
Test results
Test time
Until damage
Table 4 Fast test loading program table
Test time
Until damage| |tt||Record arrangement: The data in Table 9 are statistically arranged according to Table 5. Test speed
≥n,
Test speed
≥ngant
Test torque T
Test speed
Typical use specifications of the main engine are statistically arranged according to Table 6.
JB/T592991
Table 5 Test record arrangement
Cumulative time!
Table 6 Typical use specifications of the main engine
Typical working conditions
Observed value of characteristic quantity
The percentage of given working conditions in the total life
%
Equivalent to the equivalent life cycle number N of actual work. Calculated according to formula (7). Nep N'ep
In the formula, K is the bending strength K=6; contact strength K=3; q--strengthening coefficient, take q=2~2.3;
N\.--equivalent number of cycles of the test, times; T\. Equivalent torque of the test, N·m;
Ti\When testing, any level of torque is substituted by T, T,\; the actual
number of revolutions corresponding to torque T rpm
N. The number of cycles of any level of test torque is substituted by N, N,.. respectively. The cumulative number of cycles of the test is N,=N,+N+.+N,i6
N number of cycles,
N number of load cycles
（10）
JB/T592991
T, any working condition torque is substituted by T,,T,.T respectively; N. - Cycle basis of infinite life Number, bending fatigue N. =3×10°, contact fatigue N. =5X10\; N,--the number of cycles of torque under any working condition, respectively substituted with N., N,..…N; Tep-equivalent torque of actual work, N·m. d. Data processing
Gear fatigue life follows the log-normal distribution (or Weibull distribution) and takes the median fatigue life. e. Result processing
Write a test report based on the sorted test data, contact spots, metallographic analysis results of broken teeth or pitting state analysis results. 5.3 Fatigue test of wheel-end reducer gear
5.3.1 Test purpose
Determine the bending and contact fatigue life of the wheel-end reducer gear pair. Only one type is allowed according to the needs. 5.3.2 Test sample and technical preparation
According to the provisions of Article 5.2.2.
5.3.3 Test device
According to the provisions of Article 5.2.3.
5.3.4 Test conditions
5.3.4.1 Test torque T is calculated according to formula (11): Thp = 0. GiT,
wherein. i. Main reducer transmission ratio;
T, same as Article 5.2.4.1 of this standard.
5.3.4.2 Test speed n
According to the provisions of Article 5.2.4.3.
5.3.4.3 Test oil temperature
According to the provisions of Article 5.2.4.4.
5.3.5 Test procedure
According to Article 5.2.5.
5.3.6 Test results
According to the provisions of Article 5.2.6.
5.4 Overall test of main reducer and wheel reducer gear pair 5.4.1 Test purpose
Same as Article 5.2.1 and Article 5.3.1.
5.4.2 Test samples and technical preparation
5.4.2.1 Test samples
The entrusted unit shall provide no less than 30 drive axles that meet the design requirements, and 3 are sampled. 5.4.2.2 Necessary technical data
According to the provisions of Article 5.2.2.2.
5.4.3 Test equipment, test conditions and test procedures shall be in accordance with the provisions of Articles 5.2.3, 5.2.4 and 5.2.5. 5.4.4 Test results
3. If one of the gear pairs is damaged first during the test, the gear test will be terminated, and a new gear pair will be replaced to continue the test until the other gear pair is damaged. The two tests of the last damaged gear pair should be accumulated. bt
The test results shall be carried out in accordance with Article 5.2.6.
5.5 Half-shaft torsional fatigue test
5.5.1 Test purpose
Determine the half-shaft torsional fatigue life.
5.5.2 Test samples
JB/T5929-91
The client shall provide no less than 30 half-shaft finished products that meet the design requirements, and take 3 samples. Attach necessary design and process data. 5.5.3 Test device
A vibration type (mechanical vibration, electro-hydraulic servo) or crank-connecting rod type torsional fatigue testing machine can be used, and equipped with a torque meter. The test bench accuracy is the same as that specified in Article 5.2.3.
5.5.4 Test torque Tbp
The test torque adopts the symmetrical cyclic stress method. The test torque is calculated according to formula (12): Th 0.6i.TF
Where: i. -
- Main reducer transmission ratio;
-Same as Article 5.2.4.1 of this standard.
5.5.5 Test procedure
Shaft fracture;
Mount the half shaft horizontally on the testing machine;
Load according to symmetrical cyclic load, the cycle period is 45. Positive load 1$, no load 15; load 1$, no load 1s and so on, until half an hour. Record the test parameters (such as load, torsion angle) every half an hour to monitor the operation of the testing machine and the initiation and expansion of fatigue cracks. The number of fatigue crack occurrence cycles and crack expansion cycles should be recorded separately in the test; stop the machine, record the downtime, and accumulate the number of cycles; f.
Data and result processing.
The test data is statistically processed according to the symmetrical normal distribution or Weibull law, and the PN curve is drawn to calculate the safe life. Analyze the test data and the damage of parts and write a test report. 5.6 Test report
According to the provisions of Chapter 5 of JB/T5928.
Table? Drive axle on-site reliability test record Drive axle model
Supervisor
Test participants:
Test date
Test site
Operation conditions
Operation time
Oil temperature in the axle
Downtime due to reasons
Failure mode
Drive axle model
Factory number
Test participants:
Damaged parts
Name of parts
Recording time
Additional instructions:||tt| |JB/T5929-91
Table.8 Statistics of damage to components during reliability test Test date
Test site
Components at the time of damage
Damage characteristics
Working time
Supervisor
Measures taken after damage
Cause of damage
Drive axle life test record
Cumulative time
Tested axle
Tested axle
This standard was proposed and managed by Tianjin Engineering Machinery Research Institute of the Ministry of Machinery and Electronics Industry. This standard was drafted by Tianjin Engineering Machinery Research Institute of the Ministry of Machinery and Electronics Industry. The main drafters of this standard are Chen Fenglan and Hou Xinlan. Technical measures
Motor current
The effect of technical measures
Recorder
People's Republic of China
Mechanical industry standard
Reliability test method
Engineering machinery drive axle
JB/T5929-91
Publishing and Distribution Department of Mechanical Standardization Research Institute of Ministry of Machinery and Electronics Industry 100081)
(Beijing 8144 Mailbox
No reproduction
Copyright reserved
Printed by Qinghe County Printing Factory, Hebei Province
Format 880×1230
First edition in December 1991
Printing sheet 7/8
Number of words 18000
First printing in December 1991
Print number 00.001~500
Price 1.40 yuan
No. 0492
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