行星齒輪減速器 - Ringier Events(PPT-50)

行星齒輪減速器、回轉(zhuǎn)支承在盾構(gòu)掘進(jìn)機(jī)中的應(yīng)用及維護(hù)保養(yǎng)上海市機(jī)械工程學(xué)會(huì)

趙治軍日期：10/15/2019一、盾構(gòu)掘進(jìn)機(jī)簡(jiǎn)介盾構(gòu)機(jī)始于英國(guó)，發(fā)展于日本、德國(guó)，盾構(gòu)、大直徑頂管掘進(jìn)機(jī)是專(zhuān)門(mén)用于開(kāi)挖地下隧道工程的技術(shù)密集型重大工程裝備。隨著地下空間的開(kāi)發(fā)、利用，常用的鉆爆法在掘進(jìn)速度、工程質(zhì)量、安全可靠、環(huán)境保護(hù)等方面已顯得落后，盾構(gòu)法施工隧道已經(jīng)運(yùn)用到了各國(guó)的城市建設(shè)及其它地下工程施工中，如越江跨海隧道、煤礦巷道等，因此盾構(gòu)、大直徑頂管掘進(jìn)機(jī)需求量會(huì)不斷加大。二、中國(guó)盾構(gòu)、大直徑頂管掘進(jìn)機(jī)整體概況在中國(guó)盾構(gòu)、大直徑頂管掘進(jìn)機(jī)市場(chǎng)上國(guó)外掘進(jìn)機(jī)的占有率曾經(jīng)高達(dá)95%以上，目前盾構(gòu)、大直徑頂管掘進(jìn)機(jī)中國(guó)市場(chǎng)保有量約600臺(tái)，近年來(lái)，國(guó)產(chǎn)盾構(gòu)、大直徑頂管掘進(jìn)機(jī)有了長(zhǎng)足的發(fā)展，有些品牌已經(jīng)可以與國(guó)際品牌抗衡，目前我國(guó)國(guó)產(chǎn)盾構(gòu)掘進(jìn)機(jī)市場(chǎng)（新建造部分）占有率達(dá)60%。三、盾構(gòu)掘進(jìn)機(jī)國(guó)產(chǎn)化現(xiàn)狀■■為了增強(qiáng)與國(guó)際品牌盾構(gòu)掘進(jìn)機(jī)的競(jìng)爭(zhēng)能力，中國(guó)盾構(gòu)機(jī)制造廠家必須制造出符合中國(guó)國(guó)情的產(chǎn)品，這是我國(guó)施工裝備領(lǐng)域不可回避的重要課題。目前盾構(gòu)機(jī)國(guó)產(chǎn)化接近80%，國(guó)產(chǎn)化盾構(gòu)掘進(jìn)機(jī)的核心部分：刀盤(pán)驅(qū)動(dòng)回轉(zhuǎn)支承、刀盤(pán)驅(qū)動(dòng)減速器、關(guān)鍵液壓件及電氣等元部件仍依靠進(jìn)口產(chǎn)品。四、盾構(gòu)掘進(jìn)機(jī)國(guó)內(nèi)主要生產(chǎn)廠家

目前國(guó)內(nèi)盾構(gòu)機(jī)生產(chǎn)廠家主要有：中鐵裝備（河南）、中鐵重工（湖南）、海瑞

克（廣州、大連）、上海隧道、小松中國(guó)、石川島（常熟、無(wú)錫）、三菱重工（武漢

天地）、法麥特（遼寧沈陽(yáng)北方重工）、卡特彼勒（遼寧遼陽(yáng)）、秦皇島天業(yè)通聯(lián)（日立電機(jī)）、川崎重工（杭鍋、青島）、羅賓斯（武漢）、奧村（上海力行）等大

約16家。年生產(chǎn)量約100臺(tái)，每臺(tái)盾構(gòu)掘

進(jìn)機(jī)配備行星齒輪減速器8~10臺(tái)。五、盾構(gòu)掘進(jìn)機(jī)外觀照片六、盾構(gòu)掘進(jìn)機(jī)刀盤(pán)驅(qū)動(dòng)單元六、盾構(gòu)掘進(jìn)機(jī)刀盤(pán)驅(qū)動(dòng)單元七、盾構(gòu)掘進(jìn)機(jī)刀盤(pán)驅(qū)動(dòng)單元驅(qū)動(dòng)單元組成：1、齒輪減速器+馬達(dá)（電動(dòng)機(jī)或液壓）+回轉(zhuǎn)支承；2、低速大轉(zhuǎn)矩液壓馬達(dá)+回轉(zhuǎn)支承。八、盾構(gòu)機(jī)用行星齒輪減速器的特點(diǎn)

1、行星減速器體積小、重量輕，適合于盾構(gòu)機(jī)的總體布置；2、承載能力大，效率高；

3、運(yùn)轉(zhuǎn)平穩(wěn)，噪聲低，可靠性高，使用壽命長(zhǎng)。九、刀盤(pán)驅(qū)動(dòng)減速器應(yīng)用現(xiàn)狀■■由于行星減速器具有以上優(yōu)點(diǎn)，盾構(gòu)機(jī)刀盤(pán)驅(qū)動(dòng)通常采用該類(lèi)齒輪減速器，作為盾構(gòu)掘進(jìn)機(jī)的關(guān)鍵部件之一，其性能好壞直接影響盾構(gòu)機(jī)核心部件回轉(zhuǎn)支承與切削刀盤(pán)的工作性能。該類(lèi)減速器目前以日本、德國(guó)、法國(guó)產(chǎn)為主，目前90%以上依靠進(jìn)口產(chǎn)品。隨

著我國(guó)齒輪制造與研發(fā)水平的提升，已具

備該類(lèi)減速器的研制能力，為降低整機(jī)成

本，目前“盾構(gòu)掘進(jìn)機(jī)主驅(qū)動(dòng)行星齒輪減

速器國(guó)產(chǎn)化研制”已被多家廠家提上日程。十、驅(qū)動(dòng)減速器及回轉(zhuǎn)支承研制的經(jīng)濟(jì)性■雖然目前制造業(yè)市場(chǎng)較為低迷，但盾構(gòu)掘進(jìn)機(jī)仍屬于較好行業(yè)，根據(jù)國(guó)家發(fā)改委規(guī)劃，預(yù)計(jì)該行業(yè)能持續(xù)發(fā)展到2025年，隨著市場(chǎng)競(jìng)爭(zhēng)加劇，盾構(gòu)掘進(jìn)機(jī)用行星齒輪減速器及回轉(zhuǎn)支承國(guó)產(chǎn)化是大勢(shì)所趨，國(guó)內(nèi)年市場(chǎng)需求量約120臺(tái)套，年潛市場(chǎng)約2.5億元，利潤(rùn)5000萬(wàn)元。建議專(zhuān)業(yè)廠家應(yīng)針對(duì)國(guó)內(nèi)高端客戶(hù)如：中鐵裝備、中鐵重工等進(jìn)行配套研制。十一、刀盤(pán)驅(qū)動(dòng)裝置的維護(hù)保養(yǎng)

上世紀(jì)八十年代后期上海就已引進(jìn)盾構(gòu)掘進(jìn)機(jī)，2004年以來(lái)我國(guó)更是大批量建造了（863盾構(gòu)掘進(jìn)機(jī)為首）及引進(jìn)了近600臺(tái)盾

構(gòu)掘進(jìn)機(jī)，目前大多數(shù)盾構(gòu)掘進(jìn)機(jī)進(jìn)入服役后期，部分設(shè)備帶病工作，亟需維護(hù)保養(yǎng)，該行業(yè)除了可進(jìn)行國(guó)產(chǎn)化研制外，年總需求維護(hù)行星減速器量約1000臺(tái)左右，回轉(zhuǎn)支承維護(hù)保

養(yǎng)約100套，潛在的市場(chǎng)同樣比較客觀。優(yōu)化設(shè)備壽命周期成本■■■■更長(zhǎng)的服務(wù)壽命縮短交貨周期比新驅(qū)動(dòng)更便宜的價(jià)格客戶(hù)定制產(chǎn)品節(jié)約能源，減少消耗節(jié)能環(huán)保節(jié)能&節(jié)約材料對(duì)環(huán)境和可持續(xù)的貢獻(xiàn)為什么要維護(hù)保養(yǎng)、修復(fù)驅(qū)動(dòng)裝置?盾構(gòu)掘進(jìn)機(jī)驅(qū)動(dòng)裝置進(jìn)入服役后期盾構(gòu)驅(qū)動(dòng)裝置維護(hù)保養(yǎng)及修復(fù)在今天已成為客戶(hù)亟需的服務(wù)誰(shuí)是一站式服務(wù)的合作伙伴？齒輪減速器維護(hù)保養(yǎng)及修復(fù)內(nèi)容1、檢查所有齒輪及傳動(dòng)零部件；2、更換所有密封件及接近預(yù)期壽命軸承；3、損壞齒輪及軸更換。4、空載試驗(yàn)后進(jìn)行加載試驗(yàn)；5、空載及加載試驗(yàn)達(dá)到出廠要求后進(jìn)行外觀處理。行星齒輪減速器維護(hù)保養(yǎng)實(shí)例保養(yǎng)前保養(yǎng)后行星齒輪減速器維護(hù)保養(yǎng)實(shí)例保養(yǎng)前行星齒輪減速器維護(hù)保養(yǎng)實(shí)例保養(yǎng)前保養(yǎng)后部分行星齒輪減速器損壞實(shí)例部分行星齒輪減速器損壞實(shí)例驅(qū)動(dòng)減速器維保后加載試驗(yàn)Section

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presentation.軸承修復(fù)基本理論

經(jīng)過(guò)一定轉(zhuǎn)數(shù)運(yùn)轉(zhuǎn)以后其中一個(gè)軸承圈剛剛出現(xiàn)表下層疲勞而導(dǎo)

致的剝落時(shí)軸承已經(jīng)運(yùn)行的時(shí)間。僅有10%的軸承能達(dá)到理論壽 命L1090%的軸承由于各種各樣的原 因而導(dǎo)致的表面損壞而失效。軸承疲勞機(jī)理交變應(yīng)力導(dǎo)致疲勞軸承表面切應(yīng)力較低表面一定深度下切應(yīng)力較高軸承修復(fù)之根本

通過(guò)各種方式去表面疲勞層或各原因造成的表面陷最佳修復(fù)時(shí)機(jī)潤(rùn)滑油分析SKF狀態(tài)監(jiān)測(cè)傳統(tǒng)的低頻振動(dòng)監(jiān)測(cè)Time預(yù)警時(shí)間軸承失效損壞開(kāi)始耳聽(tīng)手摸振動(dòng)強(qiáng)度Section

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presentation.軸承主要失效模式ISO對(duì)失效的分類(lèi)腐蝕潤(rùn)滑不良導(dǎo)致表面損傷改正措施:?增加油膜厚度使用帶有EP或AW添加劑的潤(rùn)滑劑?檢查含水量

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simply

copy

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(以SL3級(jí)修復(fù)為例）組裝保持架?chē)娚安考逑床考z查最終檢查清清洗防銹，包裝.裝箱游隙測(cè)量解體測(cè)量，分析軸承圈拋光滾動(dòng)體拋光回轉(zhuǎn)支承軸承修復(fù)實(shí)例修復(fù)前回轉(zhuǎn)支承軸承修復(fù)實(shí)例修復(fù)后回轉(zhuǎn)支承軸承修復(fù)實(shí)例回轉(zhuǎn)支承軸承(RKS

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