A Suspension Stiffness Optimization for Driving System in High-speed Train with the Built-in Axle Box Based on Orthogonal Test
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摘要: 驱动系统作为高速列车动力转向架的核心子系统，是高速列车安全运行的重要保障，但随着运行速度的不断提高，高速列车的可靠安全运行受到严重挑战。为了减小轴箱内置式高速动车驱动系统悬挂节点的动态载荷，降低驱动系统关键部件的振动水平，对驱动系统悬挂刚度进行了优化研究。基于多体系统动力学理论，综合考虑轨道随机不平顺激扰、牵引动力传递和齿轮啮合作用等因素的影响，建立了轴箱内置式高速动车动力学模型；利用正交试验设计方法，以减小牵引电机吊点悬挂载荷和齿轮箱车轴铰接点垂向载荷为优化目标，研究牵引电机吊点、齿轮箱吊杆吊点、电机-齿轮箱连接点的悬挂刚度对车辆关键部件振动加速度和驱动系统悬挂节点动态载荷的影响规律；并采用极差分析法对其影响规律进行分析，获得驱动系统悬挂刚度的最优匹配组合。研究结果表明：与原始设计的驱动系统悬挂刚度相比，参数优化后牵引电机吊点的纵向载荷最大值减小22.3%, 横向载荷最大值减小37.9%，垂向载荷最大值减小9.8%，齿轮箱车轴铰接点的垂向载荷最大值减小9.1%；此外，驱动系统悬挂刚度优化后的牵引电机、齿轮箱、轴箱的横向振动加速度均明显减小。Abstract: As the core subsystem of the power bogie of high-speed trains, the drive system is an important guarantee for the safe operation of high-speed trains. However, with the continuous increase in operating speed, the reliable and safe operation of high-speed trains is seriously challenged. To reduce the dynamic loads on the suspension nodes of the axle box built-in high-speed dynamic vehicle driving system and to reduce the vibration level of the key components of the driving system, this paper carries out an optimization study on the suspension stiffness of the driving system. To reduce the dynamic loads and the vibration levels of components in the driving system, an optimization analysis of the suspension stiffness is performed in this study. Based on the multi-body system dynamics theory, the axle box built-in high-speed locomotive dynamics model is established by comprehensively considering the effects of track random uneven excitation, traction power transmission and gear meshing. Using the orthogonal test design method, with the optimization objective of reducing the suspension load at the traction motor lifting point and the vertical load at the axle articulation point of the gearbox, the influence of the suspension stiffness of the traction motor lifting point, the gearbox boom lifting point, and the motor-gearbox connection point on the vibration acceleration of the key components of the vehicle and the dynamic load at the suspension nodes of the driving system are investigated. The influence law is also analyzed by using the extreme difference analysis method to obtain the optimal matching combination of the suspension stiffness of the driving system. The results show that the maximum longitudinal, lateral, and vertical suspension loads of the motor with optimized parameters are reduced by 22.3%, 37.9%, and 9.8%, respectively. Meanwhile, the vertical load between the gearbox and wheel axle is reduced by 9.1%. The lateral vibration accelerations of the motor, gearbox, and axle box are significantly reduced.
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图 2 轴箱内置式高速动车动力学模型
Figure 2. Dynamics model of the high-speed train with the built-in axle box
图 9 齿轮箱车轴铰接点垂向载荷变化规律曲线
Figure 9. Curve of regular change of the vertical load between the gearbox and the axle
表 1 驱动系统悬挂刚度径轴比及范围
Table 1. Ratio of radial to axis and range of the driving system suspension stiffness
因素 刚度径轴比 刚度范围/(MN/m) 电机-齿轮箱橡胶节点刚度A 3.7 20~35（径向） 电机吊点刚度B 0.357 45~70（轴向） 齿轮箱吊杆节点刚度C 17 29~66（径向） 
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表 2 因素水平表
Table 2. Orthogonal factors table
因素 水平序号 水平对应的刚度值/(MN/m) 电机-齿轮箱橡胶节点刚度A 1、2、3、4、5 17、22、27、32、37 电机吊点刚度B 1、2、3、4、5 40、48、56、64、72 齿轮箱吊杆节点刚度C 1、2、3、4、5 20、32、44、56、68
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表 3 驱动系统悬挂刚度正交表
Table 3. Orthogonal table of suspension stiffness of the driving system
单位: MN/m 刚度组合序号 电机-齿轮箱橡胶节点刚度A 电机吊点刚度B 齿轮箱吊杆吊点刚度C 1 17 40 20 2 17 48 32 3 17 56 44 4 17 64 56 5 17 72 68 6 22 40 32 7 22 48 44 8 22 56 56 9 22 64 68 10 22 72 20 11 27 40 44 12 27 48 56 13 27 56 68 14 27 64 20 15 27 72 32 16 32 40 56 17 32 48 68 18 32 56 20 19 32 64 32 20 32 72 44 21 37 40 68 22 37 48 20 23 37 56 32 24 37 64 44 25 37 72 56
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表 4 优化前后的驱动系统悬挂刚度
Table 4. Suspension stiffness of the driving system before and after optimization
单位: MN/m 参数名称 原始参数 优化参数 电机-齿轮箱连接橡胶点径向刚度 22 27 电机吊点轴向刚度 56 40 齿轮箱吊杆节点径向刚度 56 68
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