ZD9系列电动转辙机 维护及检修技术要求

毕业设计（论文）

题目：ZD(J)9系列电动转辙机的维护与检修

专 业： 铁道通信信号 班 级： 通号3141 学 号： 06304140139 姓 名： 党程峰 指导老师： 马丽 起止日期： 2016.11.27－2017.1.12

诚 信 承 诺

本毕业设计（论文）是本人独立完成，没有任何抄袭行为，如有不实，一经查出，本人自愿承担一切后果。

承诺人：

2016年11月28日

陕西铁路工程职业技术学院

毕业设计（论文）总成绩评定表

班 级 通号3141 姓 名 党程峰 学 号 06304140139 设计（论文）题目 ZD(J)9系列电动转辙机的维护与检修 指导教师评分 答辩评分 总成绩 成绩指导教师评语： 指导教师签名： 年 月 日 注：1.根据专业具体实际情况，如未安排答辩环节，答辩评分及答辩小组评语可不填写。

系毕业设计（论文）答辩小组评语： 答辩小组组长签名： 年 月 日

摘 要

ZD9系列电动转辙机是目前用量最大的转辙机之一，它的用途是改变道岔的开通方向，锁闭道岔，反映道岔的位置状态。ZD9系列转辙机行车速度大于120KM/h的线路上的道岔采用外锁闭装置应具备内锁闭功能；低于120KM/h线路上的道岔可采用内锁闭功能的转辙机。它可以单机牵引道岔，也可以通过系列中不同型号转辙机的相互匹配实现双机牵引道岔，从而满足不同的道岔需求。

在这片设计中，主要针对ZD9系列转辙机的类型及组成及各部分作用，技术指标及传动原理，调试和日常维护工作，安装及技术要求，维护常见故障及解决方案。

关键字：ZD9系列电动转辙机 维护及检修技术要求

I

目 录

绪 论 ··························································································· 1 第一章 转辙机 ················································································· 2 1.1转辙机的作用 ·············································································· 2 1.2转辙机的技术要求 ········································································ 2 1.3转辙机的分类 ·············································································· 4 1.3.1按动作能源和传动方式分类 ······················································· 4 1.3.2按供电电源种类 ······································································ 4 1.3.3按锁闭道岔的方式 ··································································· 4 1.3.4按动作速度分类 ······································································ 4 1.3.5按是否可挤 ············································································ 4 1.4转辙机的组成 ·············································································· 4 1.5转辙机主要部件作用 ····································································· 4 1.5.1电动机 ·················································································· 5

1.5.1.1直流电动机的正装和反装 ····························································· 5 1.5.1.2电气参数 ························································································· 5

1.5.2减速器 ·················································································· 5 1.5.3传动装置 ··············································································· 5

1.5.3.1启动片 ····························································································· 5 1.5.3.2主轴 ································································································· 5

1.5.4转换锁闭装置 ········································································· 5 1.5.5自动开闭器 ············································································ 5 1.5.6表示杆 ·················································································· 6

1.5.6.1表示杆的组成 ················································································· 6 1.5.6.2缺口调整 ························································································· 6

1.5.7摩擦联结器 ············································································ 6

II

1.5.8挤切装置 ··············································································· 6 1.6转辙机动作过程 ··········································································· 6 1.6.1齿条块及自动开闭器动作过程（定位向反位传动过程） ·················· 6 1.6.1启动片、速动片、速动爪、自动开闭器的动作过程 ························ 7 1.7转辙机电气特性 ··········································································· 7 1.8转辙机的安装 ·············································································· 7 1.8.1安装装置 ··············································································· 7 1.8.2安装方式 ··············································································· 7 1.8.3道岔的锁闭方式 ······································································ 7

1.8.3.1内锁闭 ····························································································· 7 1.8.3.2分动外锁闭 ····················································································· 8

图1.1 ···························································································· 9 1.8.4道岔转换过程 ········································································· 9 图1.2 心轨钩式外锁闭装置实物图（与左侧翼轨密贴） ··························· 9 1.8.5道岔锁闭过程 ········································································· 9 第二章 ZD（J）9系列转辙机使用及维护 ············································· 11 2.1概述·························································································· 11 2.1.1 型号组成及表示意义 ······························································ 11 2.1.2 ZD（J）9型电动转辙机的特点 ················································ 11 2.2 ZD(9)系列电动转辙机的结构 ························································· 11 2.2.1电动机 ················································································· 12 2.2.2减速器 ················································································· 12 2.2.3滚珠丝杠 ·············································································· 12 2.2.4摩擦连接器 ··········································································· 12 2.2.5自动开闭器 ··········································································· 12 22.6安全接点 ··············································································· 12 2.2.7接线端子 ·············································································· 12

III

2.3 使用环境及适用范围 ··································································· 13 2.3.1 使用环境 ············································································ 13 2.3.2 适用范围 ············································································· 13 2.3.3 ZD9系列电动转辙机可用来转换各种铁路道岔的尖轨、心轨和道岔的外锁闭装置。 ························································································· 13

2.3.3.1 ZD9系列电动转辙机能满足以下要求 ······································· 13

2.3.3.2产品结构和动作原理 ···························································· 14 2.4 ZD9电动转辙机的接点组 ······························································ 15 2.5转辙机的安装 ············································································· 15 2.6表示缺口的调整 ·········································································· 16 2.7转辙机摩擦联接器的调整 ······························································ 16 2.8 ZD(J)9型电动转辙机系列 ····························································· 16 第三章 ZD（J）9转辙机电路分析及电路故障 ······································· 18 3.1常见的表示电路故障数据 ······························································ 19 3.2五线制道岔各线的作用 ································································· 20 3.3五线制道岔各线的路径 ································································· 20 3.4启动电路故障处理 ······································································· 21 3.5 ZDJ9道岔动作电路示意图 ····························································· 21 3.5.1动作电路原理 ········································································ 21 3.5.2动作电路分析 ········································································ 22 3.6 道岔表示电路 ············································································· 22 3.6.1表示电路特点 ········································································ 22 3.6.2表示电路原理 ········································································ 23 3.6.3 表示电路元件分析 ································································· 23 3.6.3.1 R1的作用 ·········································································· 23 3.6.3.2 R2的作用 ·········································································· 23

IV

3.6.3.3 2DQJ接点的作用 ········································································· 23

第四章 ZD(J)9型转辙机的安装与调试 ················································ 25 4.1 产品技术参数 ············································································· 25 4.1.1 交流系列电动转辙机 ······························································ 25 4.1.2直流系列电动转辙机 ······························································· 26 4.2 接点组和控制电路 ······································································ 28 4.2.1 接点组 ················································································ 28 4.2.2 控制电路 ············································································· 28 4.3 转辙机的安装 ············································································· 29 连接动作杆、表示杆、锁闭杆 ··························································· 29 安装ZD(J)9型电动转辙机 ······························································· 29 调整密贴锁闭及表示缺口 ································································· 29 施工完毕 ······················································································ 29 电气特性测试 ················································································ 29 室外电缆配线导通 ·········································································· 29 送电试验 ······················································································ 29 室内模拟试验 ················································································ 29 检测电动转辙机 ············································································· 29 电动转辙机内部配线、清扫 ······························································ 29 角钢安装 ······················································································ 29 道岔方正调整、道岔整治 ································································· 29 4.4 转辙机的调试 ············································································· 31 第五章 ZD9电动转辙机故障处理与日常维护 ········································· 33 5.1 ZD9系列电动转辙机概述 ······························································ 33 5.1.1 主要技术参数 ······································································· 33 5.2整机结构及传动原理 ···································································· 33

V

5.2.1 ZD9系列电动转辙机结构 ························································· 33 ZD(J)9系列电动转辙机，由电动机、减速器、自动开闭器、主轴、动作杆、表示杆、底壳、机盖、移位接触器等组成。（厂家不带配线，E型机无移位接触器） ········································································································ 33

5.2.2 ZD9系列电动转辙机传动原理 ··················································· 33 5.2.3转辙机主要部分的技术特点 ······················································ 33 5.3 ZD(J)9系列电动转辙机主要部件的作用 ·········································· 34 5.3.1电动机是电动转辙机的动力装置 ················································ 34 5.3.2减速器 ················································································· 34 5.3.3摩擦联接器 ··········································································· 35 5.3.4 转换锁闭装置 ······································································· 35 5.3.5接点转换装置 ········································································ 35 5.3.6挤岔保护装置 ········································································ 36 5.3.7移位接触器的作用 ·································································· 36 5.3.8转辙机配线的作用 ·································································· 36 5.3.9机壳和机盖 ··········································································· 36 5.4 ZD(J)9系列转辙机常见故障分析与处理 ·········································· 36 5.4.1机盖开启不灵活是何原因 ························································· 36 5.4.2机盖不落锁是何原因 ······························································· 36 5.4.3安全接点在插入手擦把时自动切断电路，非经人工恢复为何又接通电路 ········································································································ 37

5.4.4安全电门动力接点环打入静接点片接触深度不到4MM是何原因 ········ 37 5.4.5机壳内进水进尘是何原因 ························································· 37 5.5 ZD9系列电动转辙机日常维护 ························································ 37 5.5.1 在用手摇动作道岔时的注意事项 ··············································· 38 5.5.2 维护工作 ············································································· 38 5.5.3 维修工作 ············································································· 38 5.5.4 保养工作的技术说明 ······························································ 38

VI

5.5.4.1检查转辙机的内部状态 ························································· 38 5.5.4.2检查配线线束的状态 ···························································· 38 5.5.4.3检查零件是否受损 ······························································· 39 5.5.4.4手摇把连板及手动开关的功能检查 ········································· 39 5.5.4.5检查转辙机的固定 ······························································· 39 5.5.4.6动作杆涂润滑脂（TR-1） ······················································ 39 5.5.4.7滚珠丝杠涂润滑脂（TR-1） ··················································· 39 5.5.4.8丝杠母注润滑脂（TR-1） ······················································ 39 5.5.4.9齿轮涂润滑脂（TR-1） ························································· 39 5.5.4.10表示杆（锁闭杆）涂润滑脂（TR-1）及注润滑油 ······················ 39 5.5.4.11锁块及锁闭铁涂润滑脂 ······················································· 39 5.5.4.12动作板注润滑油 ································································ 40 5.5.4.13推板套两滑动面涂润滑脂 ···················································· 40 5.5.4.14锁闭杆缺口状态检查 ·························································· 40 5.5.4.15阻尼构涂润滑脂 ································································ 40 5.6 维护工作的技术说明 ··································································· 40 5.6.1 电动机的拆卸 ······································································· 40 5.6.2表示杆（锁闭杆）及其方孔套的拆卸 ········································· 40 5.6.3端盖的析卸 ··········································································· 40 5.6.4滚珠丝杠的折卸 ····································································· 41 5.6.5摩擦联接器的拆卸 ·································································· 41 5.6.6滚珠丝杠轴承的拆卸 ······························································· 41 5.6.7动作杆的折卸 ········································································ 41 5.6.8锁块的折卸 ··········································································· 41 5.6.9接点组的拆卸 ········································································ 42 5.6.10 手动开关的拆卸 ··································································· 42 5.6.11 挤脱器挤脱后的恢复（挤脱后现场可以自行恢复） ····················· 42 5.6.12阻尼机构的拆卸 ··································································· 42 第六章 ZD9型电动转辙机摩擦电流的调整 ············································ 43

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第七章 电动转辙机检修 ··································································· 44 7.1联系登记 ··················································································· 44 7.2转辙机外观检查 ·········································································· 44 7.3动作试验目视检查 ······································································· 44 7.4暗锁及遮断器 ············································································· 44 7.5内部清扫及配线检查 ···································································· 44 7.6电动机 ······················································································ 44 7.7减速器及摩擦连结器 ···································································· 44 7.8自动开闭器 ················································································ 45 7.9表示示杆 ··················································································· 45 7.10动作杆及移位接触器 ··································································· 45 7.11电缆盒 ····················································································· 45 7.12安装装置 ·················································································· 45 7.13试验、记录 ··············································································· 45 7.14加锁、消记 ··············································································· 45 7.15联系登记 ·················································································· 46 致 谢 ····························································································· 47 参考文献 ························································································· 48

VIII

绪论

绪 论

随着计算机技术的发展，我国于上世纪八十年代初开始研制和开发应用于铁路车站的计算机实时控制系统。二十多年过去了，经过许许多多科技人员的不懈努力，我国在这一领域的研究取得了突飞猛进的发展，转辙机得到广泛应用，开创了中国铁路发展史上一个新的里程碑。

ZD（J）9型电动转辙机是为我国铁路提速的需要研制的。借鉴了国内外成熟的先进技术，结合我国铁路线路和道岔的实际情况进行了优化设计，并根据道岔的不同转换动程和转换力以及交流、直流不同供电方式开发的系列产品。具有转换力大、效率高等特点。既使用多点牵引分动外锁闭道岔的转换，也可用于尖轨联动的内锁闭道岔转换。最近，对ZD（9）型转辙机进行改进，使之成为适用于客运专线适用的转辙机。

ZD（J）9型系列电动转辙机（以下简称转辙机）是一种能适应交、直流电源的新型转辙机。它有着安全可靠的机内锁闭功能，因此既可适用于联动内锁道岔，又可适用于分动外锁道岔，既适用于单点牵引，又适用于多点牵引，安装时，既能角钢安装，又能托板安装。

ZD(J)9型电动转辙机可用来转换各种铁路道岔的尖轨、心轨和道岔的外锁闭装置，可以替代现有的各类转辙机，该转辙机能满足以下要求：

有速动开关检测尖轨或心轨的终端位置，转换道岔，有保持尖轨和心轨在密贴位置的锁闭装置，道岔在挤岔后有切断表示的功能。

转辙机采用滚珠丝杠减速，既有高效率特点。电机采用三相交流380V电源，因此电缆单芯控制距离长，交流电机比直流电机故障少。接点系统采用铍青铜静接点组和铜钨合金动接点环。伸出杆件用镀铬防锈，伸出处用聚乙烯堵孔圈和油毛毡防尘圈支承和防尘。转动和滑动面均用SF2复合材料衬套和衬垫，因此转辙机的维护工作量小。停电或维护中需要手动转换时，可以转动手动开关轴，切断安全开关的接点后插入手摇把，就可以手动转换转辙机。 1

陕西铁路工程职业技术学院毕业设计（论文） 第一章 转辙机 道岔的转换与锁闭，是直接关系行车安全的关键设备。道岔的操纵分为手动、电动两种方式。手动式作业人员通过道岔握柄在现场直接操纵道岔的转换与锁闭，这种凡是效率低，劳动强度大，不能适应铁路现代化的要求。手动方式真随着非集中连锁的被改造而逐渐减少。电动方式，是由各类转换机转换和锁闭道岔，易于集中操纵，实现自动化。转辙机是重要的信号基础设备，它对于保证行车安全，提高运行效率，改善行车人员的劳动强度，起着非常重要的作用。 1.1转辙机的作用 （1）转换道岔的位置，根据需要转换至定位或反位。 （2）道岔转换到所需的位置并密贴后，实现锁闭，防止外力转换道岔。 （3）正确反映道岔的实际位置，道岔尖轨密贴于基本轨后，给出相应的表示。 （4）道岔被挤或因故处于“四开”位置时，及时给出报警和表示。 1.2转辙机的技术要求 （1）转辙机的安装应与道岔成方正，转辙机外壳纵侧面的两端与基本轨或中分线垂直距离的偏差，不大于10 mm(外锁闭道岔，不大于5 mm) （2）列车运行速度大于120 km／h的道岔应采用外锁闭装置。 （3）多点(含两点及以上)牵引道岔应采用多机牵引方式。 （4）发生挤岔时，转换设备应可靠切断道岔表示。 （5）列车运行速度大于120 km／h的线路，道岔应采用三相380 V电源电压的交流电动、电液转辙机牵引。其他线路可采用额定电压160 V直流电动、电液转辙机牵引。 （6）驼峰调车场道岔应采用额定电压180-220V直流快速电动、电液、电空转辙机牵引；还可采用额定电压20V的直流快速电空转辙机牵引。 （7）多机牵引道岔使用的不同动程的转辙机，应满足道岔同步转换的要求。 （8）尖轨、心轨的第一牵引点转辙机，应采用动作杆和锁闭杆同时锁闭的方式。 （9）道岔密贴检查：

2

陕西铁路工程职业技术学院毕业设计（论文） 列车运行速度120 km／h及以下区段的道岔密贴检查应满足以下要求 1单点牵引道岔牵引点中心线处有4 ○mm及其以上间隙时，密贴尖轨和心轨不得锁闭和接通道岔表示。 2驼峰调车场使用的快速转辙机可不设表示杆检查表示。如设表示杆时，在道岔○牵引点中心线处有7mm及其以上间隙时，密贴尖轨不得接通道岔表示。 3两点及三点牵引道岔第一牵引点中心线处有4 ○mm及其以上间隙时，密贴尖轨和心轨不得锁闭和接通道岔表示，其余牵引点检查6 mm。尖轨的密贴段，在牵引点间有10 mm及以上缝隙时不得接通道岔表示。 列车运行速度大于120 km／h小于160 km／h区段的道岔密贴 1单点牵引道岔牵引点中心线处有4 ○mm及其以上间隙时，密贴尖轨和心轨不得锁闭和接通道岔表示。 2两点及三点牵引道岔第一牵引点中心线处有4 ○mm及其以上间隙时，密贴尖轨和心轨不得锁闭和接通道岔表示，其余牵引点检查6 mm。尖轨的密贴段，在牵引点间有10 mm及以上缝隙时不得接通道岔表示。 列车运行速度大于160 km／h区段的道岔密贴检查应满足以下要求 1牵引点中心线处尖轨与基本轨、心轨与翼轨间有4 ○mm及以上间隙时，锁闭机构不得锁闭和接通道岔表示。 2尖轨、心轨的密贴段，在牵引点间有5 mm及以上缝隙时不得接通道岔表示。 ○3多点牵引道岔在尖轨与基本轨和心轨与翼轨不密贴段的牵引点可不设表示杆，○也不进行密贴检查，其他牵引点应设置表示杆。 （10）道岔表示冗余系统 1在第一牵引点中心线处尖轨或心轨密贴时有4 ○mm及以上间隙时，锁闭机构不得锁闭或接通道岔表示。 2当尖轨或心轨从密贴位斥离至5 mm及以上缝隙时，应断开道岔表示。 ○（11）道岔表示电路中的电压 1反向电压不小于500V，正向电流不小于300 mA的整流元件。 ○ 2三相交流转辙机表示电路中应采用反向电压不小于500 V，正向电流不小于1A○的整流元件。 (12)各种类型的转辙机及密贴检查装置应符合下列技术要求

1能可靠了转换道岔。在尖轨与基本轨密贴后，将道岔锁闭在规定位置，并给出○

3

陕西铁路工程职业技术学院毕业设计（论文） 道岔位置的表示。 2正常转换道岔时，挤切销或保持联结装置应保证不发生挤切或挤脱。当道岔被○挤时，同一组道岔上的转辙机或转换锁闭器、密贴检查装置的表示接点必须断开。 1.3转辙机的分类 1.3.1按动作能源和传动方式分类 转辙机可分为电动转辙机、电动液压转辙机和电空转辙机。 电动转辙机：ZD6系列转辙机和S700K型电动转辙机。 电液转辙机：由电动机提供动力，采用液力传动的方式。如ZY（J）系列转辙机。 电空转辙机：由压缩空气作为动力，由电磁换向阀控制。如ZK系列转辙机。 1.3.2按供电电源种类 转辙机可分为直流转辙机和交流转辙机 直流转辙机：如ZD6系列电动转辙机、电控转辙机。直流电动机的缺点是，由于存在换向器和电刷，易损坏，故障率较高。 交流转辙机：如S700K型电动转辙机和ZYJ7型电液转辙机。 1.3.3按锁闭道岔的方式 转辙机可分为内锁闭转辙机和外锁闭转辙机 内锁闭转辙机：ZD6系列电动转辙机 外锁闭转辙机：S700K型电动转辙机和ZYJ7型电液转辙机。 1.3.4按动作速度分类 转辙机分为：普通动作转辙机（3.8 s以上）和快动转辙机(0.8s以下)。 1.3.5按是否可挤 转辙机分为可挤型和不可挤型。 1.4转辙机的组成 转辙机由电机、减速器、自动开闭器、移位接触器、摩擦联结器、主轴、动作杆、表示杆、外壳。 1.5转辙机主要部件作用

4

陕西铁路工程职业技术学院毕业设计（论文） 1.5.1电动机 电动机是转辙机的动力源，采用直流串激电动机。 1.5.1.1直流电动机的正装和反装 直流电动机的正转和反转可通过改变激磁绕组(定子绕组)中或电枢(转子绕组)中的电流方向来实现。 1.5.1.2电气参数 基本参数：额定电压160V；额定电流2．0A；摩擦电流2．3～2．9A；短时工作输出功率≥220VA；单定子工作电阻 (2.85±0.1 4)×2?：刷间总电阻4.9?±0.245 ?。 1.5.2减速器 将转速降下来，使转辙机能够输出较大转矩的力。 1.5.3传动装置 1.5.3.1启动片 （1）启动片是介于减速器和主轴间的传动媒介。 （2）启动片除了起连接主轴的作用外，还对自动开闭器起控制作用。 1.5.3.2主轴 （1）主要由主轴、主轴套、轴承、止挡栓等组装而成。 （2）主轴带动锁闭齿轮，通过与齿条块配合完成转换和锁闭道岔。 1.5.4转换锁闭装置 转换锁闭装置由锁闭齿轮和齿条块、动作杆组成。用来把旋转运动改变为直线运动以带动道岔尖轨位移，并最后完成内部锁闭。电动转辙机每转换一次，锁闭齿轮与齿条块要完成解锁、转换、锁闭三个过程。 1.5.5自动开闭器 自动开闭器用来及时、正确反映道岔尖轨的位置，并完成控制电动机和挤岔表示的功能。在解锁过程中，由自动开闭器接点断开原表示电路，接通准备反转的动作电路；锁闭后，由自动开闭器接点自动断开电动机动作电路，接通表示电路。自动开闭

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陕西铁路工程职业技术学院毕业设计（论文） 器由4排静接点、2排动接点、2个速动爪、2个检查柱及速动片等组成。静接点、动接点、速动爪、检查柱对称地分别装于主轴的两侧，但又是一个整体。 1.5.6表示杆 1.5.6.1表示杆的组成 电动转辙机的表示杆与道岔的表示连接杆相连随道岔动作，用来检查尖轨是否密贴，以及在定位还是在反位。表示杆由前表示杆、后表示杆及两个检查块组成。 1.5.6.2缺口调整 应在道岔密贴调整好以后进行。先在动作杆伸出位置，调整表示连接杆螺母，使前表示杆上的标记，与窗口标记重合，这时检查柱应落入表示杆缺口并保持每侧有1．5 mm的间隙。然后在动作杆拉入位置，道岔密贴后，松开并紧螺栓，调整后表示杆的螺母，使检查柱落入后表示杆的缺口且保持每侧有1． 5 mm的间隙。再经几次定、反位动作试验，设备工作正常，上紧并紧螺栓，调整工作即告完毕。 1.5.7摩擦联结器 保护电动机和吸收转动惯量的联结装置。摩擦联结器的摩擦力要调整适当，过紧会失去摩擦联结作用，损坏电动机和机件；过松不能正常带动道岔转换。摩擦联结器的松紧用调整螺母调整弹簧压力来实现。调整的标准是，额定摩擦电流应为额定动作电流的1.3-1.5倍。 1.5.8挤切装置 挤切装置包括挤切销和移位接触器，用来进行挤岔保护，并给出挤岔表示。两个挤切销(主销和副销)把动作杆与齿条块连成一体。 1.6转辙机动作过程 1.6.1齿条块及自动开闭器动作过程（定位向反位传动过程） 当电动机通入规定方向的道岔控制电流，电动机轴按逆时针方向旋转。电动机通过齿轮带动减速器，这时输入轴按顺时针方向旋转，输出轴按逆时针方向旋转。输出轴通过启动片带动主轴，按逆时针方向旋转。锁闭齿轮随主轴逆时针方向旋转，锁闭

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陕西铁路工程职业技术学院毕业设计（论文） 齿轮在旋转中完成解锁、转换、锁闭三个过程，拨动齿条块，使动作杆带动道岔尖轨向右移动，密帖于右侧尖轨并锁闭。同时通过启动片、速动爪、速动片带动自动开闭器的动接点动作，与表示杆配合，断开第1、3排接点，接通第2、4排接点。完成电动机转换、锁闭及给出道岔表示的任务。 1.6.1启动片、速动片、速动爪、自动开闭器的动作过程 1.7转辙机电气特性 额定工作电压为直流160V。摩擦电流：正反向摩擦电流相差应小于0.3A,ZD6-A、D、F、G、H、K型转辙机单机使用时，摩擦电流为2.3-2.9A，ZD6-E型和ZD6-J型转辙机双机配套使用时，单机摩擦电流为2.0-2.5A。 1.8转辙机的安装 1.8.1安装装置 安装装置有基础角钢、尖端杆、密贴调整杆、连接杆。 1.8.2安装方式 转辙机的安装分为正装和反装 站在电动机侧看，动作杆向右伸，即为正装；动作杆向左伸，即为反装。按定位分为四种情况：正装拉入定位、正装伸出定位、反装拉入定位、反装伸出定位。正装拉入和反装伸出为定位时，自动开闭器第1、3排接点接通。正装伸出和反装拉入定位时，自动开闭器第2、4排接点接通，判断正反装。 1.8.3道岔的锁闭方式 道岔的锁闭是把尖轨或可动心轨等可动部分固定在某个开通位置，当列车通过时不受外力作用而改变。 道岔按其锁闭方式可分为内锁闭和外锁闭。 1.8.3.1内锁闭 转辙机内部进行锁闭，由动作杆经外部杆件对道岔实现位置固定。 ZD6型转辙机就是由其内部的锁闭齿轮的圆弧面和齿条块的削尖齿实现锁闭的。 实质上，内锁闭方式锁闭道岔是对道岔可动部分进行间接锁闭。

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陕西铁路工程职业技术学院毕业设计（论文） 内锁闭的缺点： （1）外部杆件受到外力冲击时，易造成尖轨与基本轨不密贴，威胁行车安全。 （2）列车冲击力直接作用于转辙机内部，使转辙机部件易受损，不适应提速需要。 1.8.3.2分动外锁闭 当道岔由转辙机带动转换到某个特定位置后，通过本身所依附的锁闭装置，直接把尖轨与基本轨或心轨与翼轨密贴夹紧并固定，称为道岔的外锁闭。即道岔的锁闭主要不是依靠转辙机内部的锁闭装置，而是依靠转辙机外部的锁闭装置实现的。 由于外锁闭道岔的两根尖轨之间没有连接杆，在道岔转换过程中，两根尖轨是分别动作的，所以又称分动外锁闭道岔。 分动外锁闭道岔转换设备的特点： （1）改变了传统的框架式结构，使尖轨的整体刚性大幅度下降。 （2）尖轨分动后，转换启动力小，而且一根尖轨的变形不影响另一根尖轨，由此造成的反弹、抗劲等转换阻力均减小很多。 （3）两根分动尖轨在外锁闭装置作用下，无论是在启动解锁，还是密贴锁闭过程中，所需的转换力均较小，避开了两根尖轨最大反弹力的叠加时刻。 （4）同时承担两根尖轨弹性力的过程是在密贴尖轨解锁以后到斥离尖轨锁闭以前这一较短的时间内，而此时正是电动机功率输出的最佳时刻，使电气特性和机械特性得到良好的匹配。 （5）外锁闭装置一旦进入锁闭状态，车辆过岔时，轮对对尖轨和心轨产生的侧向 冲击力基本上不传到转辙机上，即具有隔力作用，有利于延长转辙机及各类转换部件的使用寿命。 （6）由于两尖轨间无连接杆，所以密贴尖轨很难在外力作用下与基本轨分离，可靠地保证了行车安全。 （7）由于密贴尖轨与基本轨之间由外锁闭装置固定，克服了内锁闭道岔靠杆件推力或拉力使尖轨与基本轨密贴易造成4 mm失效的较大缺陷。 （8）分动尖轨用钩型外锁闭装置 1组成：锁闭杆、锁闭框、锁闭铁、锁钩、锁轴、尖轨连接铁 。 ○2通过锁钩与锁闭铁作用，直接将尖轨与基本轨锁闭在一起。 ○

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陕西铁路工程职业技术学院毕业设计（论文） 图1.1 1.8.4道岔转换过程 锁闭杆继续运动，带动两侧锁钩运动，从而带动两根尖轨继续活动，（如图1-1所示）。当锁闭杆动作160mm时，锁闭杆凸块与右侧锁钩的缺口脱离，并抬起锁钩的燕尾部，使其沿锁闭铁的斜面上升，该锁钩后部锁闭（如图1-2所示）。 图1.2 心轨钩式外锁闭装置实物图（与左侧翼轨密贴） 1.8.5道岔锁闭过程

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陕西铁路工程职业技术学院毕业设计（论文） 虽然右侧尖轨已密贴，但锁闭杆继续运动，带动左侧锁钩及左侧尖轨继续移动。当锁闭杆动作220mm时，右侧尖轨由于锁钩及锁闭框的作用，使该锁钩固定在不变的位置，有足够的锁闭量，实现了锁闭。这时左侧锁钩的缺口与锁闭杆的凸块相咬合，由于转辙机具有内锁作用，使锁钩处于不动位置，有足够有开程，对斥离轨也实现了锁闭。 10

陕西铁路工程职业技术学院毕业设计（论文） 第二章 ZD（J）9系列转辙机使用及维护 ZD（J）9型电动转辙机是为我国铁路提速的需要研制的。借鉴了国内外成熟的先进技术，结合我国铁路线路和道岔的实际情况进行了优化设计，并根据道岔的不同转换动程和转换力以及交流、直流不同供电方式开发的系列产品。具有转换力大、效率高等特点。既使用多点牵引分动外锁闭道岔的转换，也可用于尖轨联动的内锁闭道岔转换。最近，对ZD（9）型转辙机进行改进，使之成为适用于客运专线适用的转辙机。 ZD（J）9型系列电动转辙机（以下简称转辙机）是一种能适应交、直流电源的新型转辙机。它有着安全可靠的机内锁闭功能，因此既可适用于联动内锁道岔，又可适用于分动外锁道岔，既适用于单点牵引，又适用于多点牵引，安装时，既能角钢安装，又能托板安装。 2.1概述 2.1.1 型号组成及表示意义 ZD(J)9——?-?/?型电动转辙机,其中Z表示转辙机，D表示电动，J表示交流不标表示直流，第一个?表示派生类型，第二个?表示动作杆动程，第三个?表示额定转换力。 2.1.2 ZD（J）9型电动转辙机的特点 （1）采用滚珠丝杠减速，效率较高。 （2）交流系列采用三相380V交流电动机，故障少，电缆单芯控制距离长。根据需要可配置直流系列转辙机。 （3）接点系统采用铍青铜静接点组和铜钨合金动接点环。 （4）伸出杆件用镀铬防锈，伸出处用聚乙烯堵和油毛毡防尘圈支撑和防尘。 （5）转动和滑动面用SF-2复合材料衬套和衬垫，维护工作量小。 （6）停电或维修时需手动转换的情况下，课转动手动开关轴，断开安全接点插入手摇把，予以手动转换转辙机。 2.2 ZD(9)系列电动转辙机的结构 ZD(9)型转辙机结构如下图。由底壳、盖、电动机、减速器、摩擦连接器、滚珠丝 杠、动作杆、左右锁闭杆、接点组、安全开关组、挤脱器、接线端子等组成（如图2-1）。

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陕西铁路工程职业技术学院毕业设计（论文） 2.2.1电动机 （1）交流电动机 为ZDJ802-4型专用交流电动机，额定输出功率0.4kW，当电源电压为三相380V、单相电阻为54Ω时，额定转矩为2N˙m，转速大于或等于1330r/min。 （2）直流电动机 额定电压为160V，额定转矩2N˙m，转速大于或等于980r/min。 2.2.2减速器 为两级减速，在改变转换力或转换时间时，可以变动减速比。ZD(J)9-A型第一级速比为38/26，第二级速比为46/18，总速比为3.74。ZD(J)9-B型第一级速比为44/20，第二级速比亦为46/18，总速比5.63.这是由于双机牵引的道岔要求第二牵引点先动，使得宏观上达到同步。 2.2.3滚珠丝杠 选用国产磨削丝杠，直径Φ32mm，导程10mm。由于导程大，滚珠也大，故可靠性高。 2.2.4摩擦连接器 采用干摩擦，主动片是4片外摩擦片，用钢带加工，被动片为3片内摩擦片，用12个弹簧加压。 2.2.5自动开闭器 自动开闭器接点组与ZD6型相同，只是将动接点支架改进成为有两处压嵌连接的结构，因此左右调板设在同侧，缩小了接点组尺寸，减少了零件品种。 22.6安全接点 采用沙尔特堡开关。 2.2.7接线端子 采用德国产笼式弹簧的2线接线端子，由于接线部分没有螺纹连接，使用中无需检查或重新拧紧，能抗振动和冲击，是一种免维护的接线端子。 12

陕西铁路工程职业技术学院毕业设计（论文） 2.3 使用环境及适用范围 2.3.1 使用环境 转辙机能在下列条件下可靠地工作： 环 境 大 气 压 力 周围空气温度 空气相对湿度 条 件 不低于70 kPa（海拔高度不超过3000m） -40 ～ +70°C 不大于90%（25°C） 周围无引起爆炸危险，并且无足以腐蚀金属以及破坏绝缘的有害气体或导电尘埃。 2.3.2 适用范围 转辙机有交流和直流两种类型，可适用不同的供电种类。另外，还能满足转换不同类型道岔的要求，比如单机牵引、双机牵引、多点牵引等，既可适用于普通道岔转换，又可适用于提速道岔建设中的客运专线道岔转换的使用要求。 转辙机还可根据所安装的牵引点不同分为可挤型与不可挤型。 2.3.3 ZD9系列电动转辙机可用来转换各种铁路道岔的尖轨、心轨和道岔的外锁闭装置。 2.3.3.1 ZD9系列电动转辙机能满足以下要求 （1）有速动开关检测尖轨或心轨的终端位置； （2）转换道岔； （3）有保持道岔尖轨和心轨在密贴位置的锁闭装置； （4）道岔在挤岔后有切断表示的功能。 转辙机采用滚珠丝杠减速，具有高效率特点。电机采用三相交流380V电源，因此 电缆单芯控制距离长，交流电机比直流电机故障少。接点系统采用我厂最新研制的静接点组和动接点组。伸出杆件用镀铬防锈，伸出处用聚乙烯堵孔圈和油毛毡防尘圈支承和防尘。转动和滑动面均用SF2复合材料衬套和衬垫，因此转辙机的维护工作量小。停电或维护中需要手动转换时，可以转动手动开关轴，切断安全开关的接点手插入手

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陕西铁路工程职业技术学院毕业设计（论文） 摇把，就可以手动转换辙机。为了满足用户在大修改造中节省投资，派生有ZD9型直流系列电动转辙机。 2.3.3.2产品结构和动作原理 转辙机由底壳、热涂锌的盖、电机减速器、摩擦连接器、滚珠丝杠副、动作杆、左右锁闭杆（表示杆）、接点组、安全开关组、挤脱器和接线端子等组成。 转辙机的动作原理。电机上装有减速器，电机的驱动力矩经减速器减速后传动摩擦连接器，摩擦连接器内两面烧结有铜基摩擦材料的内摩擦片通过花键传动滚珠丝杠副的滚珠丝杠，将旋转运动转换成为滚珠丝杠母的直线运动。在滚珠丝杠母外套有推板套，推动动作杆上的锁块，在锁闭铁的作用下，形成了转辙机的解锁、转换和锁闭动程。ZD（J）9 和ZD（J）9-B、D型的锁闭铁是通过挤脱器固定在底壳上，挤脱力为28KN±2KN。ZD（J）9-A、C型的锁闭铁则直接固定在底壳上。 ZD（J）9-A和B型机是用于两点牵引尖轨分动外锁闭装置的道岔。ZD（J）9-C和D型机是用于两点牵引尖轨联动的道岔。在推板套上固定有动作板，动作板与动接点轴、起动片、速动片和弹簧的相互动作关系。 ZD（J）9-A和B型机左右锁闭杆分别与两根尖轨相连，当一根锁闭杆通过锁闭柱将尖轨锁在机内时，在斥离尖轨上固定的另一根锁闭杆则成为挤岔表示杆。当挤岔时，通过斥离离尖轨动作作为挤岔表示杆的锁闭杆上有斜面的缺口，推动检查柱断开表示接点，给出挤岔表示。而在锁闭位置的锁闭柱不动作，同时由于两根尖轨用拉杆连接在一起而同时转换，动作杆在超过挤脱力后就解锁，而处于锁闭位置的锁闭杆，由于安装装置的连接杆，当挤岔时应因变形而损坏。一根锁闭杆上的锁闭用的直缺口和挤岔表示用的斜缺口的距离与尖轨动程有关，只能适用于相应的尖轨动程，当超过此动程范围需另配该动程范围的锁闭杆。挤岔时，当挤脱器中的锁闭铁在动作杆上锁块作用下，脱开挤脱柱，在锁闭铁上的凹槽推动水平顶杆，水平顶杆推动竖顶杆，竖顶杆推动动接点支架，从而切断表示，非经人工恢复锁闭铁，不可能再接通表示。 在推板套与动作杆间有弹簧制动机构，转辙机在进入锁闭动程切断电机电源后，动作杆的侧斜面通过摩擦块压缩弹簧，从而将传动系统的惯性动作制动住。 ZD（J）9-A和C型为两点牵引道岔第一牵引点用的不可挤型转辙机，故没有挤脱器，有动作杆的锁块锁闭和与密贴尖轨相连的锁闭杆锁闭。道岔的挤岔表示由ZD（J）-B、D型转辙机给出。

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