洛阳凯迈电涡流缓速器培训教程文档格式.docx
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缓速器基本原理是电磁感应现象
1855年,法国物理学家LeonFOUCAULT先生发现了电磁感应现象.
Theworkingprincipleofelectromagneticretarderiselectromagnetisminduction,whichisfoundbyphysicalscientistLeonFOUCAULTin1855.
电源断开时铁锤急速下降
Hammerdroppedquicklywhenpowerisoff.
电源接通时铁锤缓速下降
Hammerdroppedslowlywhenpowerison.
定子固定安装在汽车底盘大梁上
线圈装在定子上
主机总成部分
目前我公司能提供与进口ZFS5-80/S6-90变速箱、綦江S6-90、QJ1506、S5-80变速箱、铁马变速箱、大同变速箱、一汽解放系列变速箱和陕齿富勒系列变速箱等相匹配的电涡流缓速器。
下面以DHB20A缓速器在綦江S6-90变速箱后端盖上安装为例,介绍缓速器的安装过程。
(在其它变速箱上的安装,除了定子支架稍有不同之外,其他过程基本相同)
Anelectromagneticretarderwhichisafrictionlessbrakingsystemusedinvehiclecanbeattachedtotherearpartofthegearbox,thereardriveaxle,orinbetweenthedrivingshafts.UptonowNanfengcompanycanprovidetheelectromagneticretarderswhicharematchedwithimterminaledZFS5-80/S6-90,QiJiangS6-90/S6-85/S5-80,TieMa,DaTong,FAWseries,DongFengseriesofgearboxesandetc.Inordertointroduceoperatortotheretarderinstallation,theprocessofmountingtheDHB20AretardertotherearpartofQiJiangS6-90gearboxistakenasanexample.(Exceptforthestatorbrackets,theinstallingprocessesoftheothercomponentswhichareattachedtogearboxesaresimilartotheDHB20A)
●安装示意图:
SchemeofInstallation:
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图
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Diagram
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●零组件汇总表PARTLIST
序号ITEM
名称
DESCRIPTION
数量QTY
六角螺母M12、弹簧垫圈12NutM12,SpringWasher12
4
后转子RearRotor
六角螺栓M12×
90、双头螺柱M12×
80、螺母M12、弹簧垫圈12、平垫12
HexagonBoltM12x90,SpringWasher12
8
定子总成StatorAssembly
5
双头螺柱M16×
1.5,螺母M16×
1.5、弹簧垫圈16
StudBoltM16x1.5,NutM16x1.5,SpringWasher16
6
传动轴法兰DrivingShaftFlange
7
六角螺栓M16×
1.5×
30、轻型弹簧垫圈16
HexagonBoltM16x1.5x30,SpringWasher16
前转子总成FrontRotorAssembly
9
六角螺栓M22×
55、弹簧垫圈22HexagonBoltM22x1.5x55,SpringWasher22
10
M形调整垫片M-shapeSpacerSpool
按需
aset
11
支架Bracket
12
变速箱端盖和输出法兰
Thespecialrearunitofgearboxandoutputflange
★注意:
在缓速器安装前应确保车前后轮不能移动,断开原车电源,并用高度尺测量变速箱箱体端面与变速箱输出法兰端面之间的距离,应为193mm;
用百分表测量变速箱输出法兰的轴向窜动量应小于0.3mm;
径向和轴向跳动量均应小于0.05mm;
变速箱输出法兰端面的平面度应小于0.1mm。
如不符合则换装符合要求的变速箱。
●IMTERMINALANTNOTICE:
Itmustbeensuredthattheforeandrearwheelsofthevehiclearenotmovedbeforeinstallingtheretarder,andthemainswitchofbatteryisoff。
thedistancebetweentheendsurfaceandoutputflangeofgearboxhousing,measuredbyheightgauge,shouldbe193.5mm。
theaxialplayofthegearboxoutputflangemeasuredbydialindicatorshouldbelessthan0.3mm。
theradialplayshouldbelessthan0.05mm。
theplanenessoftheoutputflangeendsurfaceofthegearboxshouldbelessthan0.1mm.Iftheconditionsmentionedabovecannotbemet,substitutewiththequalifiedgearbox.
★电涡流缓速器安装步骤
Assemblyofelectromagneticretarder:
注意!
!
缓速器上的所有螺栓、螺母、螺杆处必须涂抹乐泰270或相同强度螺纹锁固剂!
IMTERMINALANTNOTICE:
Itmustbeensuredthatallbolts,nutsandthreadedrodsaredaubedwithLETAI270orthesamestepthreadlocker!
1.安装支架(序号11):
InstallationofBracket(Item11)
用4个六角螺栓M22×
50、弹簧垫圈22、(序号10),将支架(序号11)固定在变速箱后端盖(序号12)上,螺栓紧固力矩为230~250Nm。
(注意:
操作时不能损坏原车体)
Thebracket(Item11)shouldbefixedtotherearunitofgearbox(Item12)by4hexagonboltsM22x1.5x55,springWashers22withfasteningmomentof230N.m~250N.m.(Note:
Thevehiclebodycannotbedamagedwhileoperating)
2.安装缓速器主机总成InstallationofRetarderAssembly
安装缓速器之前应将S6-90变速箱置于空挡。
把缓速器主机总成整体吊起,注意应使用定子总成上φ12通孔作为起吊受力点,切不可使接线盒或线圈承受机械外力!
用8个六角螺栓M16×
1.5、弹簧垫圈16(序号7)将缓速器主机总成固定在变速箱输出法兰(序号12)上,紧固力矩220~240Nm。
TheS6-90gearboxshouldbesettoneutralpositionbeforemountingtheretarder.Hoisttheretarderassemblybyφ12throughholesatthestatorpart,thejunctionboxandcoilcannotstandanyexternalmechanicalforce!
Theretarderassemblyshouldbefixedtotheoutputflange(Item12)by8hexagonboltsM16x1.5,springWashers16(Item7)withfasteningmomentof220N.m~240N.m.
3.初选支架四支角M形调整垫片厚度,为1mm。
TheinitiallyselectedthicknessofM-shapespacespool(Item10)fixedtothe4outsolesofthebracketshouldbe1mm.
4.固定定子总成(序号4)InstallationofStatorassembly(Item4):
首先拆掉转子总成上4个L形定位片及薄螺母。
缓速器定子总成(序号4)的接线盒的方向朝上,对准支架(序号11)上的安装螺纹孔,用8个六角螺栓M12X90(紧固扭矩为90Nm)、弹簧垫圈12和平垫12(序号3)、M形调整垫片(序号10)将定子总成固定在支架(序号11)上。
通过增减M形调整垫片数量和厚度调整转子内侧与定子端面之间的间隙为总气隙的1/2。
(总气隙在出厂时已调好)
Thestatorpartoftheretarder(Item4)whosejunctionboxfaceupsideshouldbeconnectedtobracket(Item11)by8hexagonboltsM12,springWashers12(Item3)andM-shapespacerspool(Item10)whichispositionedbetweentheoutsolesofthebracketandthebackupblockofthestatorwithfasteningmomentof90N.m,theclearancebetweentherotorandthestatorwhichisadjustedthroughincreasingordecreasingthenumberofthedifferentM-shapespacerspoolmustbehalfofthetotalclearancewhichhasbeenadjustedbeforeretarderissold.
5.安装传动轴前半轴(序号6)Installationofforesemi-axleofdrivingshaft(Item6):
用双头螺柱M16×
1.5、螺母M16×
1.5、弹簧垫圈16(序号5)将传动轴前半轴(序号6)和前转子总成(序号8)连接,预紧力矩220~240Nm。
Theforesemi-axleofdrivingshaft(Item6)shouldbemountedtothefrontrotor(Item8)viastudboltsM16x1.5,springwasher16(Item5)andnutsM16x1.5fastenedwith220N.m~240N.mmoment.
6.安装后转子(序号2)Installationofrearrotor(Item2)
将后转子(序号2)用4个螺母M12、弹簧垫圈12(序号1)固定在前转子总成(序号8)上,紧固力矩为120Nm,并保证后转子内侧与定子总成端面间隙为总气隙的1/2。
Therearrotor(Item2)shouldbeattachedtothefrontrotor(Item8)via4nutsM12andspringwasher12(Item1)withfasteningmomentof120Nm。
Itmustbeensuredthatthegapbetweentherotorinsideandtheendsurfaceofthestatorisbehalfofthetotalclearancewhichhasbeenadjustedbeforeretarderissold..
7.安装传动轴后半轴Installationofrearsemiaxleofdrivingshaft:
对准传动轴标记,将传动轴后半轴插入前半轴,再将传动轴后半轴安装到后桥输出法兰上,并按厂家规定扭矩紧固螺母。
Aftertargetingthealignmentmarkofthedrivingshaft,inserttherearsemiaxleintotheforesemiaxle(Item6)andthenmounttherearsemiaxleofthedrivingshafttotheoutputflangeoftherearaxlebyfasteningthenutswithspecifiedmoment.
8.辅助吊架(或托架)的安装Installationofauxiliaryhangingbracket
缓速器主机安装在变速箱之后,用辅助吊架(或托架)将缓速器吊起来(或托起来),辅助吊架(或托架)固定到大梁上(辅助吊架或托架一般由用户自备。
)
Afterattachingtheretardertothegearboxandthenhoisting(orpropping)theretarderwithauxiliaryhangingbracket(orpoppet),mounttheauxiliaryhangingbracket(orpoppet)tothevehiclechassis(theauxiliaryhangingbracketshouldbeprovidedbyclients).
电气总成部分TheElectricSystem
一.安装条件Installationcondition
安装前请详细阅读本说明书、车辆安装条件、安装前注意事项。
如不符合车辆安装条件,可能会造成缓速器工作不正常,或原车其他设备工作不正常,引发其他故障。
Theinstallationmanual,vehicleinstallationconditionandimportantnoticesshouldalwaysbereadthroughcarefullybeforeinstallation.Ifthevehicleinstallationconditioncannotbemet,mayleadtoabnormaloperationofretarderorothervehicleequipments.
如不遵守安装前注意事项,可能会造成人车安全事故!
Iftheimportantnoticesisnotobserved,mayinvolvedangertolifeandlimbandtheriskofdamagetovehicle.
●车辆安装条件:
1.蓄电池:
24V≥150AH
Battery:
2.发电机(选装):
28V≥150A
Generator:
●安装前注意事项Importantnotice
1.安装前断开安装车辆总电源,确保车内所有电设备断开电源。
Beforecarryingoutworkingontheunit,themainswitchofbatteryshouldbeoffinordertoensureallelectricequipmentsinthevehicleshutdown.
2.确保驻车安全,车轮用枕木塞固牢靠。
Thevehiclewheelsmustbelockedbywoodensleepertoensurethesafetyofhaltingthevehicle.
●安装前准备Preparationbeforeinstallation:
请准备以下工具:
螺丝刀、剥线钳、电钻、活动扳手、开口扳手、梅花扳手、照明灯具、电焊机等。
Requiredtools:
screwdriver,cablestripper,electricdrill,adjustablespanner,openendwrench,plumblossom-shapewrench,lightingfixtures,electricalwelderandetc.
警告WARNING:
安装缓速器电气系统或车辆维修时,如进行焊接,必须关闭整车电源,拆除总电源正负极连线。
如带电源安装或进行焊接可能会损坏电气部件。
Iftheweldingisnecessarywhileinstallingtheelectricalsystemoftheretarderormaintainingthevehicle,thesystemmustbedisconnectedfromtheelectricalpowersupplyofthevehicleanddismantletheconnectinglinebetweenthecathodeandanodeofthebattery.Theelectricalcomponentsmaybedamagedincaseofinstallingorweldingwhileelectrifying.
二.安装流程图Installationflowsheet
注:
用户可以根据实际情况,
~
的安装顺序可以做相应的调整,
的安装顺序必须严格遵守本流程。
Note:
Theinstallingsequenceoftheprocedure1~5canbeadjustedinaccordancewiththeactualconditionbycustomer,butthesequenceoftheprocedure6~9mustbeobservedstrictly.
三.缓速器接线原理图Eletricconnectiondiagram
ConnectorPlugDJ7061-6.3-21andDJ7011-6.3-21mustbeconnectedtosignalofvehicle.Definitionisasbelow.
①如果ABS作用时输出低有效信号,(如:
0V),则接ABSL,缓速器将停止工作,;
反之,如果输出高有效信号,则接ABSH。
若车辆无ABS系统,可将ABSL和ABSH悬空。
IfABSoutputsloweffectivesignal,connectitwithABSL(pin7).Inotherwords,ifpin7receivedlowsignal,pin4hasnooutput24V。
onthecontraryconnectitwithABSH(pin8)ifABSoutputshigheffectivesignal.
IfthereisnoABSsystemonthevehicle,keepABSLandABSHimpending.
②打开点火钥匙,NF标志灯亮;
当车速达到5Km/h以上,绿色圆型灯点亮;
当手柄分别拨至1、2、3、4档,红色梯形灯逐个点亮;
当超温报警器检测到缓速器主机温度超过110℃,绿色圆型灯闪烁,此时请关断缓速器检查。
Startupengineandignitionswitch,the“NF”lampofworking
indicatorlightisilluminated。
Whenthespeedofvehicleisabove5Km/h,theround
lamp(greenlight)isilluminated。
pushthehand-leverswitchtostep1,2,3,4respectivelyandthe
scalariformlampisilluminatedonebyone。
Ifthetemperatureannunciatorofretardertestt