洛阳凯迈电涡流缓速器培训资料(中英文)

洛阳凯迈电涡流缓速器培训资料CAMAElectromagneticretarderTrainingMaterial凯迈（洛阳）机电有限公司CAMA（luoyang）ElectromechanicEquipmentCo.,LtdDHB系列缓速器培训资料凯迈（阳机）机电有限公司1目录DIRECTORY电涡流缓速器原理…………………………2Electromagneticretarderprinciple主机总成及安装……………………………5Theretarderassemblypart电器总成及安装……………………………11TheElectricSystem维护与保养…………………………………33Maintenance故障与排除…………………………………38TroubleshootingDHB系列缓速器培训资料凯迈（阳机）机电有限公司2电涡流缓速器原理Electromagneticretarderprinciple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.DHB系列缓速器培训资料凯迈（阳机）机电有限公司3定子固定安装在汽车底盘大梁上线圈装在定子上DHB系列缓速器培训资料凯迈（阳机）机电有限公司4DHB系列缓速器培训资料凯迈（阳机）机电有限公司5主机总成部分Theretarderassemblypart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.UptonowNanfengcompanycanprovidetheelectromagneticretarderswhicharematchedwith电磁场在转子产生电涡流转子叶片通过风冷散发制动能量DHB系列缓速器培训资料凯迈（阳机）机电有限公司6imterminaledZFS5-80/S6-90,QiJiangS6-90/S6-85/S5-80,TieMa,DaTong,FAWseries,DongFengseriesofgearboxesandetc.Inordertointroduceoperatortotheretarderinstallation,theprocessofmountingtheDHB20AretardertotherearpartofQiJiangS6-90gearboxistakenasanexample.(Exceptforthestatorbrackets,theinstallingprocessesoftheothercomponentswhichareattachedtogearboxesaresimilartotheDHB20A)●安装示意图：SchemeofInstallation:456789101112321图（1）Diagram(1)●零组件汇总表PARTLISTDHB系列缓速器培训资料凯迈（阳机）机电有限公司7序号ITEM名称DESCRIPTION数量QTY1六角螺母M12、弹簧垫圈12NutM12,SpringWasher1242后转子RearRotor13六角螺栓M12×90、双头螺柱M12×80、螺母M12、弹簧垫圈12、平垫12HexagonBoltM12x90,SpringWasher1284定子总成StatorAssembly15双头螺柱M16×1.5，螺母M16×1.5、弹簧垫圈16StudBoltM16x1.5,NutM16x1.5,SpringWasher1686传动轴法兰DrivingShaftFlange17六角螺栓M16×1.5×30、轻型弹簧垫圈16HexagonBoltM16x1.5x30,SpringWasher1688前转子总成FrontRotorAssembly19六角螺栓M22×1.5×55、弹簧垫圈22HexagonBoltM22x1.5x55,SpringWasher22410M形调整垫片M-shapeSpacerSpool按需aset11支架Bracket112变速箱端盖和输出法兰Thespecialrearunitofgearboxandoutputflange1★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:ItmustbeensuredthattheforeandrearDHB系列缓速器培训资料凯迈（阳机）机电有限公司8wheelsofthevehiclearenotmovedbeforeinstallingtheretarder,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M22×1.5×50、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InstallationofRetarderAssemblyDHB系列缓速器培训资料凯迈（阳机）机电有限公司9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-shapespacerspoolmustbehalfofthetotalDHB系列缓速器培训资料凯迈（阳机）机电有限公司10clearancewhichhasbeenadjustedbeforeretarderissold.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)shouldbemountedtothefrontro