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Mechanical Industry Standard of the People's Republic of China
JB/T6127--92
Technical Conditions for Electric Flat Car
Published on June 9, 1992
Implementation of the Ministry of Machinery and Electronics Industry of the People's Republic of China on January 1, 1993
Mechanical Industry Standard of the People's Republic of China
Technical Conditions for Electric Flat Car
1 Subject Content and Scope of Application
JB/T6127-92
This standard specifies the technical requirements, test methods, inspection rules, marking, packaging, transportation, storage and quality assurance period of electric flat cars. This standard applies to low-voltage power supply, cable reel power supply, battery power supply, and slide block power supply electric flat cars (hereinafter referred to as electric flat cars) with a rated load of 5100t, with a power connection continuity rate of 25% and a working environment temperature of -20 to +40℃. Other types of electric flat cars can also be used for reference. 2 Reference standards
GB3177
GB5117
GB5676
GB8923
GB9286
GB9439
GB10095
JB2299
3 Technical requirements
3.1 Materials
Machinery oil
Technical conditions for high-quality carbon structural steel
Carbon structural steel
Weld grooves for gas welding, manual arc welding and gas shielded welding Basic types and sizes of submerged arc welding weld grooves Basic types and sizes of smooth workpiece dimensions
Carbon steel welding rods
Casting carbon steel for general engineering
Rust level and rust removal level of steel surface before painting Cross-cut test of paint and varnish film
Gray cast iron parts
Precision of involute cylindrical gears
Painting and safety signs for mining, engineering, lifting and transportation machinery products 3.1.1 The mechanical properties of the frame material shall not be lower than the properties of Q236-A or Q235-AF in GB700. The welding rod, welding wire and flux shall be compatible with the materials to be welded. The welding rod shall comply with the provisions of GB5117. 3.1.2 The mechanical properties of the reducer housing and pulley materials shall not be lower than the properties of HT200 in GB9439. 3.1.3 The mechanical properties of the axle material shall not be lower than the properties of 45 steel in GB699. 3.1.4 The mechanical properties of the wheel material shall not be lower than those of 7.G340-640 cast steel in GR5676. 3.2 Frame
The weld groove form and size of the frame welding shall comply with the provisions of GB985 and GB986. 3.2.2 The weld shall not have defects such as cracks, pores, arc pits and slag inclusions. The weld undercut depth shall not exceed 0.5mm, the continuous undercut length shall not exceed 100mm, and the total length of the weld undercut on one side shall not exceed 10% of the weld length. 3.2.3
The slag on the weld and the spatter on both sides must be removed. The straightness of the frame table within any 1m range is 4.0mm. Approved by the Ministry of Machinery and Electronics Industry on June 9, 1992, and implemented on January 1, 1993
JB/T6127-92
3.2.6. The deformation of the frame under 1.1 times the rated load shall not exceed 1/1000 (wheelbase). 3.3 Wheelset
The inner distance deviation of the wheelset is ±2.0mm. The difference in the distance between the corresponding points at the three equal divisions along the inner side of the wheelset shall not exceed 0.5mm3.3.1
3.3.2 The difference in the diameter of the two wheels on the same wheelset shall not exceed 0.5mm3.3.3 Wheel tread hardness: 525t is 179~217HB; 302~341HB for more than 30t. 3.3.4 Depth of wheel tread hardening layer: above 30t shall not be less than 4.0mm, and the hardness at 4mm shall not be less than 240HB3.4 Reducer
3.4.1 The precision grade of reducer gear pair shall comply with grade 887 in GB10095. 3.4.2 Tooth surface roughness: when the normal modulus m, is less than or equal to 8mm, the surface roughness parameter R. is 3.2um; when m, is greater than 8mm, the surface roughness parameter R. value is 6.3um. 3.4.3 Tooth surface hardness of a pair of meshing gears: the small gear shall not be less than 240HB; the large gear forging shall not be less than 187HB, and the casting shall not be less than 179HB.
3.4.4 The teeth shall not have defects and shall not be welded. 3.4.5 The assembled reducer shall rotate flexibly and without oil leakage. The reducer lubricating oil shall be L-AN15 or L-AN32 mechanical oil in GB443.
3.4.6 The noise of the reducer when running idle shall not be greater than 82dB (A) 3.4.7
The cleanliness of the reducer shall not be greater than that specified in Table 1. Table 1
Total center distance of reducer
Impurity content
3.4.8 The temperature rise of the reducer lubricating oil shall not exceed 40℃ 3.5 Cable reel
3.5.1 When installing the guide wheel device, the starting position of the split nut on the screw should be consistent with the cable position on the reel. 3.5.2 The adjustment of the brake belt spring should make the tension of the cable on the reel 150±10N. 3.5.3 The assembled reel should rotate flexibly, and the cable should be stable and reliable when retracting and releasing. 3.6 General assembly
3.6.1 The limit deviation of the wheelbase is ±2.0mm. The parallelism of the two wheels to the axis is 3.0mm (Figure 1). 3.6.2
The difference between the diagonal lines L and Lz of the two wheel pairs shall not exceed 3.0mm (Figure 1). Figure 1
3.6.4 The free ends of the bearings of the two wheel pairs shall be installed on the same side of the vehicle. 3.6.5 The clearance between the passive wheel (one of them) and the reference track surface shall not exceed 2.0mm. 3.6.6 The height deviation of the frame table: ±6.0mm for rated load 5~25t; ±8.0mm for more than 30t. 2
3.7 Electrical equipment
JB/T6127--92
3.7.1 General requirements
3.7.1.1 All electrical components shall be firmly installed on the vehicle and shall not be loose during operation. 3.7.1.2 The wiring inside the frame shall be passed through pipes, and the pipes and the frame must be fastened with pipe clamps. 3.7.1.3 The bending radius of the threading tube shall not be less than 5 times the tube diameter. There shall be no joints in the wires in the tube. The steel core rubber insulated wire shall be a multi-strand wire with a cross-section of not less than 1.5mm2 or a single-strand wire with a cross-section of not less than 2.5mm2. 3.7.1.4 Yuan
The temperature rise of the motor and other electrical components shall not exceed 80℃. 3.7.1.5
3.7.2 When the voltage at the receiving end of the cable reel power supply type and low-voltage power supply type electric flat car drops to not less than 90% of the rated voltage, the electrical equipment shall be able to work normally. 3.7.2.1
3.7.2.2 The insulation resistance of the wheel to the axle and the conductive column device to the car body shall not be less than 0.5M2. It can withstand a 50Hz, 1000V withstand voltage test and there is no breakdown or flashover within 1min.
The slider of the conductive device should be stable and flexible during operation, and there should be no jamming. 3.7.2.3
3.7.3 Battery-powered electric flat car
When the battery pack voltage is charged to the specified value, the charger should be able to automatically cut off the power supply and issue a light and sound alarm. The charging time shall not exceed 3.7.3.1
The charger should be able to flexibly realize the conversion between fast charging and conventional charging. 3.7.3.2
The charger should be able to accurately perform linear regulation of current and voltage. When the battery pack voltage drops to the specified value, there should be a light and sound alarm. The battery charging and discharging cycle shall not be less than 1200 times. The usage time in one cycle should be greater than 10h. 3.7.3.5
The battery should be well sealed and there should be no battery fluid leakage. The joint insulation should be good. 3.7.3.7 The charging circuit should ensure that there is no backflow between the charger and the battery. 3.7.4 Slide block sequentially powered electric flat car
3.7.4.1 The insulation resistance between the busbar device and the car body shall not be less than 0.5M2: The insulation resistance between the sliders and between the sliders and the ground shall not be less than 1.0M2. The insulation of each part can withstand the 50Hz, 1000V withstand voltage test within 1min without breakdown or flashover. 3.7.4.2
The electric shock protection device shall ensure flexible operation. The leakage electric shock protection expansion time shall not be less than 0.35S. 3.7.4.3 After the busbar device is assembled, the sliding line shall be flexible up and down. 3.8 Painting and rust removal
The rust removal of steel plates, profiles, castings and forgings shall reach the St2 level in GB8923. The rust removal of thin plates and pipes below 5mm shall reach the Be level in GB8923. The thickness of each layer of paint film is 25~35μm; the total thickness of the paint film is 75~140μm. The paint film adhesion should comply with the inspection requirements of level 2 in GB9286. The paint color and color samples of the product should comply with the requirements of JB2299. All exposed processed surfaces of the product should be rust-proofed before leaving the factory. 3.9 Operation noise
The operation noise value of the electric flat car shall not exceed the provisions of Table 2. Table 2
Rated load
Operation noise
3.10 The operation of the electric flat car under the rated voltage shall be stable. 5~50
Under the specified conditions of use, the first overhaul cycle of the electric flat car shall not be less than 5 years. 3.11
3.12 Completeness
63~100
JB/T612792
In addition to the complete set of electromechanical equipment on the vehicle, the manufacturer shall also provide a ground step-down transformer for the low-voltage power supply type electric flat car; the slider-powered electric flat car shall be equipped with a ground control box and a slider. Random documents include packing list, certificate of conformity, and instruction manual. 4 Test method
4.1 Test conditions
4.1.1 The test environment temperature is -20~+40℃. 4.1.2 The test load is a uniform load, and the load is a standard weight block or a weighed weight. 4.1.3 The test should be carried out on a straight track. The length is more than 30m, and the slope should be less than 2/1000. 4.1.4 Select a section within the length of the test track as the reference track, so that the height difference of the track surface at the point of contact with the four wheels should be less than 0.5mma
4.1.5 The accuracy of the test instruments, meters, and measuring tools should comply with the provisions of GB3177 and be within the validity period of the calibration. 4.1.6 The paint and rust layer that affect the conductivity must be removed from the plane of the low-voltage power supply track and the upper surface of the slider of the low-voltage power supply. The resistance value between the two track busbars shall not be less than 102
4.1.7 The lubricating oil specified in Article 3.4.5 is injected into the reducer. There should be enough lubricating oil (grease) in each lubrication part. 4.2 Speed reducer test
4.2.1 Sealing test: After running the reducer at rated speed without load for 1 hour each in both forward and reverse directions, observe whether the casing has oil leakage. No oil drops on the casing indicate no oil leakage.
4.2.2 Noise test: Run at rated speed without load, without other external sound interference, measure the noise at four points on the contour line of the shell section surface, 1m away from the front, back, left and right of the speed reducer, and take the highest value. 4.2.3 Cleanliness test: After the sealing and noise tests, filter the impurities cleaned out of the speed reducer with a 120-mesh net. Dry at a temperature of 120-135℃ for 1 hour, weigh after cooling, Www.bzxZ.net
4.2.4 Temperature rise test: Use a thermometer to measure the temperature difference of the lubricating oil of the speed reducer before the no-load test and after the overload test, which is the temperature rise of the speed reducer lubricating oil.
4.3 Electrical system test
4.3.1 Before the test, all wiring should be carefully checked, and the temperature rise of electrical components such as motors should be measured during the test. If there are severely burned components such as contacts, they should be replaced.
4.3.2 The current, voltage and other indicating instruments should react flexibly during the test, and the indicated values should be correct. Each button switch should be flexible and reliable, and there should be no looseness or jamming.
4.3.3 Low-voltage power supply electric flat car, slider power supply electric flat car 4.3.3.1 The test conditions are ambient temperature 20±5℃, relative humidity (65±5)% 4.3.3.2 The low-voltage power supply electric flat car uses a megohmmeter to test the insulation resistance value of the wheel to the axle and the conductive column device to the car body. 4.3.3.3 The slider power supply electric flat car uses a megohmmeter to test the insulation resistance value between the busbar and the car body, between the sliders, and between the slider and the ground, and uses an oscilloscope to test the leakage electric shock protection time of the electric shock protection device. 4.3.3.4 Conduct a 50Hz, 1000V withstand voltage test 4.3.4 Battery-powered electric flat car
4.3.4.1 When the voltage of a single battery cell drops to 1.75V, the light and sound alarms sound, and the battery should be charged. When the voltage of a single battery cell rises to 2V, charging stops under the indication of the light and sound alarms. Determine the charging process time. 4.3.4.2 During charging, observe whether there is a reverse flow between the charger and the battery. The current flowing from the battery to the charger is called reverse flow 4.3.4.3 After being fully charged, under the conditions of rated load and rated operating speed, the battery usage time is measured according to the power connection duration of 25%. 4.4 No-load test
4.4.1 The electrical control system should be stable and reliable, and the transmission system should be in normal working condition. 4.4.2 On the test track, at the rated voltage, the cumulative time of forward and reverse operation is 10 minutes, and the operating speed should be stable. 4.5 Load test
Use 40%, 60%, and 100% of the rated load to load evenly on the table, and the power-on duration is 25%. Start, run, and stop in forward and reverse directions. The cumulative running time is not less than 10 minutes. Each mechanism is sensitive, the running speed is stable, and each component is intact. There is no looseness in each connection. 4.6 Overload test
Based on the load test, evenly load 10% of the rated load, start, run, and stop the electric flat car, and unload after 10 minutes. Check that there are no cracks in the welds, no damage to the parts, and no looseness in each part. 4.7 Frame deformation test
Measure the deformation of the frame under 1.1 times the rated load. First, fix the dial gauge on the track base pad at the midpoint of the two axes in a natural state. The dial gauge contacts touch the bottom surface of the I-beam. Adjust the gauge to zero. When the maximum load is applied, the gauge reading is the deformation of the frame under the maximum load. This test can be carried out before unloading the overload test. 4.8 Operation noise test
In the factory or outdoors, the sound level meter is placed 1m high on the track plane and 1m away from the transmission end of the electric flat car to measure the operation noise. The actual operation noise value of the electric flat car is obtained by subtracting the background noise correction value (see Table 3) from the synthetic noise measured by the sound level meter. Table 3
Difference between synthetic noise level and background noise level Background noise correction value
4.9 Frame table straightness measurement, use a 1m steel ruler or flat ruler to contact the table steel plate. Measure the maximum gap between the two. 0.5
4.10 The internal distance measurement deviation of the wheelset shall be measured with an inside micrometer or a special measuring tool at the corresponding points of the three equal divisions along the inner circumference of the wheelset. 10
4.11 The hardness of the wheel tread shall be measured with a Brinell hardness tester. Three points of hardness shall be randomly marked on the wheel tread, and two or more points shall be qualified. 4.12 The hard layer depth of the wheel tread and the hardness at 4mm can be tested with test blocks. The test block material shall be consistent with the wheel material, and the size shall comply with the provisions of Table 4.
Wheel diameter Φ
Test block size (length × width × height)
4.13 Gear accuracy
500~600
80×130×50
700~800
105×140×65
Items that must be checked: cumulative pitch error △Fp, tooth shape error Aft. Pitch deviation Afe, tooth direction error △F. Or contact spots, if the final process is gear grinding, then add the base pitch deviation Af. Testing equipment: circumferential pitch meter, involute tester, base pitch tester (or use other testing equipment such as gear comprehensive tester, universal gear measuring instrument, etc.)
Measure the hardness of the gear tooth surface. You can arbitrarily punch three points of hardness on the tooth item or gear end face, and take the lowest value as the standard. 4.15 The tension of the cable reel spring is measured with a tension spring balance. 4.16 Wheelbase limit deviation and parallelism of two wheel pairs. Use a special gauge to insert into the center holes of the two wheels to measure. 4.17 The difference between the diagonals of two wheel pairs is measured by drilling a center positioning hole at the corresponding position on the outer surface of the bearing seat as the measurement reference. After assembly, use a special gauge to measure the L and L2 values.
4.18 The gap between a passive wheel and the reference track surface is measured by placing the electric flat car on the reference track without load. The driving wheel should be in contact with the track surface. Use a feeler gauge to detect the gap between a passive wheel and the reference track surface. 4.19 The height deviation of the frame table is detected based on the plane on the reference track. 4.20 The thickness of the paint film is measured by contacting the paint film thickness gauge with the measured surface and measuring at any ten points. The arithmetic average of the measured values is taken as the measured value.
4.21 The adhesion of the paint film is tested in accordance with the provisions of GB9286. 5 Inspection rules
5.1 Inspection classification
Electric flat cars are divided into factory inspection and type inspection, JB/T612792
5.1.1 Factory inspection
Factory inspection is carried out by the factory inspection department. Each car can be shipped only after it has passed the inspection and is accompanied by a product quality certificate. Factory inspection items:
Check the integrity of product parts and the correctness of product geometric dimensions: a.
Electrical system test;
No-load test;
Operation noise test;
For low-voltage powered electric flat cars, the insulation of the wheels to the axles and the conductive column device to the car body should be tested: for battery-powered electric flat cars, 1~2 charging and discharging tests should be carried out according to the charging and discharging requirements: for electric flat cars powered by sliders in sequence, the insulation between the busbar device and the car body, between the sliders, and between the sliders and the ground should be tested. Type inspection
Type inspection should be carried out in any of the following situations: finalization identification of new products or old products for factory production; when major changes are made to product design;
After formal production, if there are major changes in structure, materials, and processes, which may affect product performance; when the product is discontinued for more than two years and production is resumed; when there is a large difference between the factory inspection and the original performance data: products that require temporary or regular sampling inspections.
Type inspection items
All factory inspection items;
Reducer test;
Load test;
Overload test;
Frame deformation test;
Cable drum brake belt spring tension test.
Note: In the type test, the load test, overload test and frame deformation test can be carried out on the site of use for electric flat cars with a rated load of more than 30t (including 30t) when the manufacturer has no conditions for testing.
5.2 Sampling
For the prototypes for type inspection, 1 to 2 units shall be randomly selected by random sampling method, and the number of samples for batch production shall be 3% of each batch, but shall not be less than 2 units.
Marking, packaging, transportation, storage
Each electric flat car should be equipped with a load mark and product nameplate in a conspicuous position. The product nameplate should indicate: manufacturer name;
product name;
product model;
dead weight;
main technical parameters (load, motor power); manufacturing number;
year and month of production.
6.2 Electric flat cars can generally be bulked or naked (except for special requirements). Parts that need protection should be partially wrapped and have rain and moisture-proof measures. Random tools, spare parts and technical documents are packed in spare parts boxes and placed together with the whole machine. 6.3 When the electric flat car is shipped as a whole, the frame and wheels should be firmly fixed and should meet the transportation requirements of railways and roads. 6
JB/T6127-92
6.4 Electric flat cars should be kept in a moisture-proof and ventilated state during storage. They should be placed on a solid base to prevent rust and deformation. The electromechanical parts should also be maintained regularly.
7 Warranty period
If the user complies with the storage and use rules, within 6 months from the date of use but not more than 12 months from the date of delivery, if the product is affected by manufacturing defects within 12 months, the manufacturer should repair or replace parts free of charge. Additional notes:
This standard was proposed and managed by the Beijing Hoisting and Transportation Machinery Research Institute of the Ministry of Machinery and Electronics Industry. This standard was drafted by Dalian Heavy Machinery Plant, Dalian Metallurgical Machinery Plant, and Qinhuangdao Locomotive and Rolling Stock Plant. The main drafters of this standard are Wu Hanjie, Wang Yuqiao, Wang Youwen, and Liu Guizhi. People's Republic of China
Mechanical Industry Standard
Technical Conditions for Electric Flat Car
JB/T6127-92
Published by the Mechanical Standardization Research Institute of the Ministry of Machinery and Electronics Industry Printed by the Mechanical Standardization Research Institute of the Ministry of Machinery and Electronics Industry (PO Box 8144, Beijing 100081)
Copyright reserved
Reproduction prohibited
Format 880×1230
First edition in October 1992
Sheet 5/8
Word count 14000
First printing in October 1992
Print run 0.001-500
Price 1.50 yuan
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