Determination of the real technical condition of mechanical transmissions is a key problem of diagnosing in the course of maintenance and repair of transport and technological machines in operation. The most reliable method of determining the technical condition of mechanical transmission assemblies taking into account the prospect of digitalization is thermal diagnostics based on the change in the intensity of infrared radiation of the heat source under normal conditions and under pre-failure condition. The aim of the research is practical testing of the method of thermal diagnostics based on the development of the analytical model of thermal stress and simulation of temperature loads by the method of finite-element analysis taking into account the resource bench tests on the example of the joints of drive lines. Research object -the cardan joint as per GOST R 52923-2008 (type 3 row IV, bearings 804707K4S10). The method of research includes: analytical study of cardan joint heat generation at three hierarchical levels of elementary joint "crosspin-bearing", crosspiece assembly and cardan joint assembly taking into account heat generation of adjacent parts and assemblies; simulation technique of stress-strain state taking into account thermal loading of parts on the basis of 3D-model of the joint using CAD-technology COMPAS 3D and CAE-technology APM FEM; comparative analysis of analytical and simulation technique results on the basis of data of resource bench tests on dynamics of radial play in the joint and temperature of bearing units at the level of extreme operational loading modes. As a result of the studies, the adequacy of the analytical mathematical model of the thermal stress of the cardan joint was confirmed, the method of simulation technique was verified and the operability of the complex method of thermal diagnostics for determining the real technical condition of mechanical transmission units was evaluated.
Ensuring operability of transport technological machines is connected with increase in characteristics of non-failure operation, durability and maintainability of transmission units, in particular, of drive lines. The analysis of trends of improvement of designs and technological processes of maintenance operation of drive lines shows that designs of joints with maintainable crosspieces and bearing mount assemblies are perspective. Besides, developments of technical solutions on realization of automated maintenance operation of bearing mount assemblies on the basis of control of their valid technical condition are perspective. Results of comparative assessment of operability of maintainable and serial crosspieces of asynchronous cardan joints on the example of the IV standard size on RD 37.001.665-96 are presented in the article. In the course of probes graphic 3D-models of serial and maintainable crosspieces in the computer-aided engineering system of KOMPAS-3D CAD-technologies are made. In connection with complexity of design for the purpose of increase in reliability of estimation of the crosspieces strength and stiffness, test calculations are performed on the basis of the CAE-technology by means of applied library of the final and element analysis of automated workplace of FEM for KOMPAS-3D. When evaluating the intense deformed condition of serial and maintainable crosspieces, comparative calculations of parameters at the modes of nominal operational loading are performed. The final results were estimated in sizes of equivalent normal tension, total deformations and the safety factor on fatigue strength at bend. In calculation result conclusions about the working capacity and prospects of the offered design and mode of maintenance operation of cardan joints are confirmed.
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