Abstract: This article focuses on the wear problem of the disengagement slider of the clutch of the triple hydraulic pump of the DC-32 compaction vehicle. By installing an adjustable limit device, the problem was finally solved, extending the service life of the clutch of the triple hydraulic pump and ensuring that the equipment operates in good condition.
Keywords: DC-32 compaction vehicle; Hydraulic system; Triple pump; Detachment device; clutch; Wear and tear; Adjustable limit
1. Preface
The DC-32 compactor (as shown in Figure 1) has been widely used in railway line repair, speed up line renovation, and new line construction nationwide, and is the main model for railway line maintenance in China. The DC-32 compaction vehicle is a double sleeper compaction vehicle, which operates in a step-by-step manner and can perform tasks such as track lifting, track alignment, leveling, compaction of ballast under the sleepers on both sides of the steel rail, and compaction of ballast at the ends of the sleepers. The vehicle's operating system adopts an open hydraulic transmission. Hydraulic transmission has the advantages of simple structure, compact layout, large output energy, small volume, sensitive response, stepless speed regulation, easy automatic control and overload protection, smooth transmission, safety and reliability, light weight, long service life, and easy replacement.
The hydraulic system of the DC-32 compactor consists of three hydraulic pumps, including one T2SDCB triple blade pump and two T6D double blade pumps. These three hydraulic pumps are installed on the power take-off port of the power shift gearbox, driven by the diesel engine, and provide pressure oil to each hydraulic circuit. The three hydraulic pumps provide power for the oil pump and vibration oil motor, the lifting and clamping of the tamping device and tamping pick, the lateral movement of the tamping device and the lifting of the tamping racket, the lifting and shifting device and the operation walking oil motor, as well as the braking and support oil cylinder.
Figure 1 DC-32 compaction truck
The DC-32 compaction truck triple pump needs to be manually disengaged during the operation and operation conversion process. Long term operation will gradually move the position of the uncoupling lever handle outward, causing wear on the uncoupling slider and ultimately leading to difficulty in uncoupling the triple pump, affecting operation. The effectiveness of the uncoupling device of the triple hydraulic pump is the determining factor for the normal operation of the DC-32 compactor. At present, there are several DC-32 compactors in my department that were manufactured in 2006. After investigation, it was found that the DC-32 compactors were only equipped with disengagement limits for two double pumps when they were manufactured. Therefore, in recent years, the clutch assembly of the triple hydraulic pump needs to be replaced every year during use; Otherwise, the clutch disengagement slider of the triple hydraulic pump of the DC-32 compaction vehicle will wear out, seriously affecting the normal operation of the equipment and the construction of compaction, track lifting, and other operations. This article extends the service life of the clutch and ensures the good condition of the equipment by installing an adjustable limit device.
2. Wear analysis and solutions in the application of triple hydraulic pump clutch
During the operation and operation transition of the DC-32 compaction truck triple hydraulic pump, manual disengagement is required. After prolonged operation, the position of the release rod handle will slowly move outward, causing wear and tear on the release slider, ultimately leading to difficulties in disengaging the triple hydraulic pump, affecting normal operation and construction. Our company needs to replace this clutch every year because the value of the triple hydraulic pump is over 300000 RMB. Solving this problem is time-consuming, labor-intensive, and increases the cost of vehicle maintenance. Additionally, there are significant safety hazards during the operation conversion process.
The actual situation of the triple hydraulic pump uncoupling device and the wear of the clutch uncoupling slider when the DC-32 tamping truck leaves the factory are shown in Figures 2 and 3.
Figure 2 External Off hook
Figure 3 Internal detachment slider
The hydraulic pump is the power source for the hydraulic system of the DC-32 compactor. The detachment slider of the DC-32 compaction vehicle is an important component of the hydraulic pump clutch, and the wear of the slider directly determines whether the power of the hydraulic pump can be transmitted to the working hydraulic system; So reducing the wear of the slider and extending the service life of the clutch are the top priorities of equipment maintenance work. After careful analysis and repeated on-site testing, we have made the following improvements to the slider of the pressure pump clutch based on usage.
2.1 Improvement Plan 1
According to the principles of "simple and convenient renovation" and "visual monitoring and control", spray "detach" and "hang" marks on the handle of the DC-32 compactor before on-site operation; And mark the corresponding detachment positions on the detachment rod of the triple hydraulic pump with different colored paint pens.
The red mark represents the pump disengagement position, and the yellow mark represents the pump hanging position, which is easier to observe during the disengagement process. Being able to monitor whether the triple hydraulic pump is properly disengaged through labeling makes manual operation easier to grasp. The spraying position is shown in Figure 4.
Figure 4 Marking effect at the uncoupling handle
After one year of use, it was found during inspection that the improvement of the triple hydraulic pump uncoupling rod in the DC-32 compaction vehicle effectively solved the wear of the slider for vehicles with newly replaced clutch assemblies; However, due to different operators, it is necessary to constantly observe whether the disconnection has reached the corresponding mark, which has a certain impact on the conversion of equipment operations and shortens the pure operation time. This improvement plan has relatively high requirements for personnel, affects pure operation time, and cannot adapt to actual on-site application.
2.2 Improvement Plan 2
Install an adjustable limit device on the detachment mechanism of the DC-32 compaction vehicle.
In order to increase the on-site operation time of the compaction vehicle, reduce the duration of the detachment process, minimize the impact of human factors, expand the adaptability of the adjustable limit device, and ensure the transformation effect, two DC-32 compaction vehicles are selected to install adjustable limit devices.
The above two DC-32 compactors are vehicles with a disengagement clutch that has been in use for 6 months and vehicles with a newly replaced disengagement clutch.
At the end joint bearing of the uncoupling rod in the triple hydraulic pump? Install adjustable limit devices, use mechanical positioning, and secure with self-locking nuts. The limit device of the triple pump plays a role in fixing the position after the detachment is in place. The installation plan is shown in Figure 5.
Figure 5: Installing an adjustable limit device on the detachment mechanism of the DC-32 compaction vehicle
After one year of use, it was found that the installation of an adjustable limit device on the triple hydraulic pump disengagement mechanism of the DC-32 compaction vehicle effectively solved the wear of the slider for vehicles with newly replaced clutch assemblies. By using mechanical positioning, the requirements for operators in the detachment process have been reduced. Adopting adjustable limit devices to adapt to the current situation of vehicles at different times on site, extending the service life of clutch assemblies, reducing operational power, eliminating hidden dangers, and ensuring on-site assembly line operations.
Analysis and summary of the wear problem of the clutch disengagement slider of the 2.3DC-32 tamping car triple hydraulic pump
(1) Equipment design defects. The DC-32 compaction vehicle (D08-32 automatic leveling compaction vehicle) is a large-scale road maintenance machinery produced domestically by introducing technology from the Austrian company Palsser&THurer. This machine is a double pillow compactor, with a walking mode for operation. Capable of carrying out tasks such as track lifting, track alignment, leveling, compacting ballast under the sleepers on both sides of the steel rail, and compacting ballast at the ends of the sleepers. The driving force behind the performance of the above tasks is the hydraulic system, and the uncoupling pump process is an important link in the transition between operation and tasks. When the equipment leaves the factory, only limit devices are installed on the decoupling devices of two double pumps. The lack of status monitoring and limit devices for the uncoupling of triple pumps can easily cause wear and tear on the uncoupling paddles, resulting in hydraulic system abnormalities that cannot meet operational requirements.
(2) Differences in the quality of homework drivers. The personnel of the homework vehicle team have frequent updates and changes, and there is insufficient awareness of the importance of the DC-32 tamping vehicle detachment pump process. The newly hired personnel simply believe that the uncoupling pump is just a mechanical action without any precautions. In fact, mechanical component wear is a major factor in the failure of large-scale road maintenance machinery. It is urgent to improve the quality and awareness of homework personnel.
(3) The "Maintenance Rules for DC-32k Compaction Vehicle" (Tie Zong Yun [2014] No. 167) does not specify the inspection items and standards for the hydraulic system repair items in daily inspection and maintenance, regular inspection and maintenance, annual maintenance, and comprehensive maintenance of the DC-32 compaction vehicle triple pump disengagement clutch.
Therefore, the fundamental reason for the wear of the clutch disengagement slider of the DC-32 tamping truck triple hydraulic pump is that the disengagement device of the triple pump is not equipped with a limiter.
3. Solution
(1) Add regular inspection and maintenance items: Check the wear of the clutch disengagement slider of the triple hydraulic pump of the DC-32 tamping car every 2 years.
(2) Install an adjustable limit device at the joint bearing at the end of the detachment rod of the DC-32 compaction truck triple pump, and use mechanical positioning to limit the detachment device.
4. Conclusion
Through the analysis of wear and solution of the clutch of the triple hydraulic pump in the DC-32 tamping car, it can be seen that the wear of the clutch during use is due to design defects. Now, adjustable limit devices have been installed on the uncoupling devices of the triple pumps of our four DC-32 compactors. After a period of on-site operation verification, this improvement plan effectively solves the wear of the clutch uncoupling slider of the triple hydraulic pump of the DC-32 compactor, ensuring normal operation and construction on site.
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2025-09-20