1 Scope
This document specifies the technical requirements, test methods, inspection rules, marks, packaging and storage of low-speed vehicle drive axle (including chain drive axle, transmission integrated drive axle and shaft drive axle).
This document is applicable to the design, manufacturing and inspection of low-speed vehicle drive axle.
2 Normative References
The contents in the following documents, through normative references, constitute indispensable provisions of this document. Where, for dated references, only the version corresponding to that date applies to this document; For undated references, the latest version (including all amendments) is applicable to this document.
GB/T 191 Packaging Pictorial Marks for Storage and Transportation
GB 1922-2006 Solvent Oil for Paint and Cleaning
GB/T 2828.1 Sampling Procedures for Inspection by Attributes - Part 1: Sampling Plan for Lot by Lot Inspection Indexed by Acceptance Quality Limit (AQL)
GB/T 23924 Dry friction production bath for tricycles and low-speed trucks
JB/T 5673-2015 Technical Requirements for Painting of Agricultural and Forestry Tractors and Tools
3 Terms and definitions
There are no terms and definitions to be defined in this document.
4 Technical Requirements
4.1 General requirements
4.1.1 The products shall comply with the provisions of this document and be manufactured according to the product drawings and technical documents approved by the manufacturer's specified procedures.
4.1.2 All parts and components shall meet the requirements of corresponding parts and components standards. Purchased parts shall have qualification certificates and can be assembled only after passing the inspection.
4.1.3 The appearance quality shall meet the following requirements.
a) The cast drive axle housing shall be flat and free of cracks, inclusions, air holes and other defects affecting the quality. The axle housing weld of the welded drive axle shall be uniform, firm, reliable, neat and beautiful, and shall be free of welding defects such as missing welding, burn through, false welding, cracks, etc.
b) The metal coating and oxidation treatment layer on the surface of parts shall not be peeled and rusted.
c) Exposed fasteners shall be galvanized, passivated or treated with other rust prevention measures.
d) The paint coating on the non matching external surface of the drive axle shall comply with TQ-1-2-DM in JB/T 5673-2015.
4.2 Assembly
4.2.1 Parts shall be cleaned before assembly; There shall be no metal chips, rust and other sundries that affect the cleanliness of the assembly. During assembly, check whether the marks of the mating parts are consistent.
4.2.2 The assembly shall be connected reliably without looseness, and the tightening torque of fasteners shall meet the requirements of the instruction manual or drawings.
4.2.3 All moving parts of the drive axle shall move flexibly without jamming, shifting, impact and abnormal sound.
4.2.4 All parts of the drive axle shall be filled with lubricating grease or oil according to the instructions or drawings. There shall be no oil leakage and seepage at the oil seals and joint surfaces of the drive axle.
4.2.5 The transmission part of the transmission integrated drive axle shall be equipped with oil quantity check or liquid level limit device.
4.2.6 Under the working condition of the transmission integrated drive axle transmission control mechanism, the gear shifting operation shall be light, smooth, flexible, accurate and reliable, and there shall be no phenomenon of failing to shift or shifting out of gear.
4.2.7 After the assembly of the drive axle is completed, put it into the leakage test solution under the test pressure of 0.025 MPa~0.030 MPa for air tightness test. Keep the pressure for 3 min, and no bubbles shall appear in each part of the drive axle.
4.2.8 After passing the air tightness test, the drive axle shall be subject to no-load running in test. The drive axle shall operate at an input speed of about 1000 r/min for 30 minutes. During the running in test, the drive axle shall be free of abnormal noise, and the steering shall be flexible. The temperature rise of all bearing devices shall not exceed 25 ℃
4.2.9 The clutch of drive axle shall be completely and thoroughly separated, and the combination shall be stable and reliable.
4.3 Performance
4.3.1 Static torsional strength
The backup coefficient of static torsional strength of chain drive axle or transmission conjoined drive axle assembly shall not be less than 2. The backup coefficient of static torsional strength of other drive axle assemblies shall not be less than 1.8,
4.3.2 Vertical bending rigidity
When the drive axle housing (frame) is loaded with 3 times of the rated load, the maximum deformation per meter of wheel track shall not exceed 1.5 mm. 4.3.3 Heavy straight bending static strength
The backup coefficient of vertical bending (fracture or severe plastic deformation) of chain drive axle or transmission integrated drive axle shall not be less than 4.5; The backup factor for vertical bending (fracture or severe deformation) of other drive axle housings shall not be less than 6.
4.3.4 Vertical bending fatigue life
The test data shall be distributed according to the logarithmic normal distribution (or Weibull distribution), and the life shall not be less than 80 × 10 times, and the minimum life of test samples shall not be less than 50 × 10 times.
4.3.5 Fatigue life of assembly
4.3.5.1 Fatigue life of chain drive axle or transmission integrated drive axle assembly rotating system
The chain drive axle reaches 50 × After 10 'test cycles, the main parts of the drive axle shall not be damaged, and the passive sprocket shall not have gear tooth fracture, tooth surface crushing or serious wear and other failures after reaching the specified cycle times.
4.3.5.2 Fatigue life of other drive axle assembly gears
The test data shall be distributed according to the logarithmic normal distribution (or Weibull distribution), and the life shall not be less than 50 × 10 'times, the minimum life of the test sample shall not be less than 30 × 10 'times,
Judgment standard of gear failure; Tooth fracture, tooth surface crushing, tooth surface serious peeling and tooth surface serious pitting (the total area of tooth surface fatigue peeling and pitting accounts for more than or equal to 1% of all tooth surfaces; for peeling on a single tooth surface, the pitting area is more than or equal to 4% of the tooth surface).
4.3.6 Clutch performance
The drive axle clutch shall meet the requirements of GB/T 23924.
4.3.7 Cleanliness
The cleanliness limit of the drive axle is measured by the volume of the rated filling volume of the working medium, and the cleanliness index of the drive axle shall not be greater than 5o mg/L The maximum particle size shall not exceed 80 pm
4.3.8 Noise
Drive axle noise shall not exceed 8o dB (A)
4.3.9 Transmission efficiency
The transmission efficiency of the drive axle shall not be less than 90% when the gear is in the highest gear.
5 Test method
5.1 Appearance quality
The appearance quality shall be inspected by visual inspection, and the painting quality shall be inspected according to JB/T 5673-2015.
5.2 Measurement of size, shape and position
The dimensional tolerance and geometric tolerance of each part shall be inspected with measuring tools of corresponding accuracy level.
5.3 Clutch test
Clutch test of drive axle shall be carried out according to GB/T 23924.
6 Inspection Rules
6.1 Delivery inspection
6.1.1 Each drive axle shall be inspected by the inspection department of the manufacturer before leaving the factory, and the product shall be attached with a certificate of conformity.
6.1.2 See Table 4 for delivery inspection items. The certificate can be issued only after all items of each drive axle are qualified.
6.2 Type inspection
6.2.1 Type inspection shall be carried out under any of the following circumstances:,
a) Identification of trial production and finalization of new products or old products transferred to other factories
b) After formal production, there are major changes in structure, material and process, which may affect product performance
c) Regular (generally 2 years) spot check and inspection during mass production
D. Production is resumed after 1 year of production suspension;
e) The factory inspection results are significantly different from the previous type inspection results; f The national quality supervision authority puts forward the requirements for type inspection.
6.2.2 See Table 4 for the inspection items and classification of non conformities in the type inspection. All inspection items that do not conform to the provisions of Chapter 4 are non conformities. The non conformities are divided into three categories: A, B and C according to the importance of the inspection items,
7 Label, packaging and storage
7.1 Signage
The drive axle shall be provided with a label, which shall be legible, installed correctly and firmly, and shall indicate the following contents:
a) Manufacturer name or registered trademark
b) Product name
c) Product model; D Factory number; e) Executive standard number; f Manufacturing date (year, month). 7.2 Packaging
7.2.1 The following documents shall be attached when the drive axle is packed:
a) Product certificate;
b) Installation and operation manual of drive axle.
7.2.2 When packaging, the specified accessories, spare parts, etc. shall be put into the box together with the drive axle, and the packing list shall be attached.
7.2.3 During packaging, all exposed threaded parts shall be protected, and dust-proof and moisture-proof measures shall be taken in the packaging box. The packaging materials shall be moisture-proof, and the packaging shall be reliable to avoid damage to the drive axle during transportation.
7.2.4 The following contents shall be marked on the outside of the packing box, and the pictorial marks shall comply with the provisions of GB/T 191:
7.3 Storage
7.3.1 The product shall be stored in a ventilated, dry and rainproof place with sun protection and free from acid and alkali gas erosion. It shall not be stored in the same warehouse with inflammable goods, chemical corrosives and other harmful goods. The drive axle shall be placed in such a way as to avoid deformation and bumps.
7.3.2 Under normal storage, the product shall have a valid rust prevention period of 12 months. Those exceeding 12 months shall be re inspected according to 6.1.
1 Scope
2 Normative References
3 Terms and definitions
4 Technical Requirements
5 Test method
6 Inspection Rules
7 Label, packaging and storage
