戈壁环境下典型的变速箱失效问题研究

于世胜; 甄伟; 闫帅; 王叶平

doi:10.7643/ issn.1672-9242.2026.02.003

PDF(3940 KB)

装备环境工程 ›› 2026, Vol. 23 ›› Issue (2) : 15-23. DOI: 10.7643/ issn.1672-9242.2026.02.003

武器装备

戈壁环境下典型的变速箱失效问题研究

于世胜, 甄伟, 闫帅, 王叶平

作者信息 +

Typical Gearbox Failures in Gobi Environment

YU Shisheng, ZHEN Wei, YAN Shuai, WANG Yeping

Author information +

文章历史 +

摘要

目的针对在戈壁环境下,多次出现因拖车救援引发的变速箱失效问题,深入开展典型变速箱失效问题研究,制定有效预防措施,防止此类问题再次发生。方法利用有限元软件仿真、油液检测分析、电镜检测等分析测试方法,多方面对失效变速箱进行故障问题分析。结果经过检测分析发现,变速箱中间轴一档齿轮断裂原因并非过载引发,而是因为长时间反复承受巨大的接触应力,齿轮的硬化层受到破坏,导致齿轮发生疲劳腐蚀,产生疲劳裂纹,进而在加载大扭矩过程中发生了疲劳断裂。结论为防止此类问题再次发生,参考飞机恒速传动装置的状态监测方法,将油液检测加入车辆的定期维护工作中,可以实现对变速箱等封闭循环系统工作状态的定量评估,对状态异常的系统进行预防性维修,防止装备使用过程中突发失效问题,影响任务的完成。

Abstract

To address the recurring gearbox failures caused by trailer recovery operations in the Gobi environment, the work aims to conduct an in-depth investigation into typical gearbox failure mechanisms and formulate effective preventive measures to prevent the recurrence of such failures. Multiple analytical and testing methods were employed to analyze the failed gearbox, including finite element software simulation, lubricant condition monitoring and analysis, and scanning electron microscopy (SEM) examination. The analysis revealed that the fracture of the first-gear wheel on the countershaft was not induced by overload. Instead, it resulted from the gear's hardened layer being damaged due to prolonged and repeated exposure to significant contact stress. This led to fatigue corrosion, initiation of fatigue cracks, and ultimately fatigue fracture during high-torque loading. To prevent the recurrence of such failures, referencing the condition monitoring methods used for aircraft Constant Speed Drives (CSDs), lubricant condition monitoring is proposed to be integrated into the vehicle's regular maintenance schedule. This enables quantitative assessment of the operational status of enclosed circulating systems like gearboxes. Systems exhibiting abnormal conditions can thus undergo preventive maintenance, preventing sudden failures during equipment operation and ensuring mission success.

导出引用

于世胜, 甄伟, 闫帅, 王叶平. 戈壁环境下典型的变速箱失效问题研究[J]. 装备环境工程. 2026, 23(2): 15-23 https://doi.org/10.7643/ issn.1672-9242.2026.02.003

YU Shisheng, ZHEN Wei, YAN Shuai, WANG Yeping. Typical Gearbox Failures in Gobi Environment[J]. Equipment Environmental Engineering. 2026, 23(2): 15-23 https://doi.org/10.7643/ issn.1672-9242.2026.02.003

中图分类号： TJ01

参考文献

[1] 吴昊阳, 赵文哲, 常颖. 装甲车辆沙漠戈壁地区环境适应性试验设计[J]. 装备环境工程, 2023, 20(12): 95-101.
WU H Y, ZHAO W Z, CHANG Y.Experimental Design of Environmental Adaptability of Armoured Vehicles in Desert Gobi Area[J]. Equipment Environmental Engineering, 2023, 20(12): 95-101.
[2] 张东光, 方静. 新疆孔雀河流域水文地质基本特征[J]. 西部探矿工程, 2024, 36(6): 103-105.
ZHANG D G, FANG J.Basic Hydrogeological Characteristics of Kongquehe River Basin in Xinjiang[J]. West- China Exploration Engineering, 2024, 36(6): 103-105.
[3] 曾海洋. 越野轮胎沙石路面行驶性能仿真分析与试验评价研究[D]. 广州: 华南理工大学, 2020.
ZENG H Y.Simulation Analysis and Experimental Evaluation on Driving Performance of Off-Road Tire Sand Pavement[D]. Guangzhou: South China University of Technology, 2020.
[4] 位君, 王义, 吴喜柱, 等. 变速器齿轮断齿失效分析[J]. 汽车零部件, 2019(1): 36-38.
WEI J, WANG Y, WU X Z, et al.Failure Analysis of Gear Tooth Fracture of a Transmission[J]. Automobile Parts, 2019(1): 36-38.
[5] 辛保娟, 曹海兰. 工程机械变速箱齿轮断齿失效分析[J]. 内燃机与配件, 2024(19): 48-50.
XIN B J, CAO H L.Failure Analysis of Gear Broken Teeth in Construction Machinery Transmission[J]. Internal Combustion Engine & Parts, 2024(19): 48-50.
[6] 高志远, 晏芙蓉. 基于ANSYS Workbench的行星齿轮减速器仿真分析[J]. 机电工程技术, 2024, 53(9): 104-107.
GAO Z Y, YAN F R.Simulation and Analysis of Planetary Gear Reducer Based on ANSYS Workbench[J]. Mechanical & Electrical Engineering Technology, 2024, 53(9): 104-107.
[7] 孙雪朋, 钱润华. 基于ANSYS的电动汽车减速器齿轮系仿真分析[J]. 内燃机与配件, 2024(10): 5-7.
SUN X P, QIAN R H.ANSYS-Based Simulation Analysis of Electric Vehicle Reducer Gear Train[J]. Internal Combustion Engine & Parts, 2024(10): 5-7.
[8] 孙剑伟, 王帅. 矿用减速器直齿轮强度动态有限元分析[J]. 煤矿机械, 2024, 45(5): 85-87.
SUN J W, WANG S.Dynamic Finite Element Analysis of Strength of Spur Gear in Mine Reducer[J]. Coal Mine Machinery, 2024, 45(5): 85-87.
[9] 顾伟红, 毛梦薇. 改进CNN在TBM变速箱磨损状态识别中的应用[J]. 隧道建设(中英文), 2023, 43(11): 1853-1861.
GU W H, MAO M W.Application of Improved Convolution Neural Network in Gearbox Wear Status Recognition of Tunnel Boring Machines[J]. Tunnel Construction, 2023, 43(11): 1853-1861.
[10] 毛梦薇. 基于卷积神经网络的TBM变速箱磨损状态识别[D]. 兰州: 兰州交通大学, 2024.
MAO M W.TBM Gearbox Wear State Recognition Based on Convolutional Neural Network[D]. Lanzhou: Lanzhou Jiatong University, 2024.
[11] 刘海亮, 黄大山, 葛开颜, 等. 基于油液监测的高原环境下特种车辆关键部件研究[J]. 设备管理与维修, 2024(20): 181-184.
LIU H L, HUANG D S, GE K Y, et al.Research on Key Components of Special Vehicles in Plateau Environment Based on Oil Monitoring[J]. Plant Maintenance Engineering, 2024(20): 181-184.
[12] 任凤华, 吴善跃, 吕跻, 等. 某船用发电柴油机油液监测案例分析[J]. 中国修船, 2022, 35(3): 20-22.
REN F H, WU S Y, LYU J, et al.A Case Study of Oil Monitoring of a Marine Generator Diesel Engine[J]. China Shiprepair, 2022, 35(3): 20-22.
[13] 张江, 崔俊杰, 郑长松, 等. 基于油液光谱数据的离合器剩余寿命随机过程预测[J]. 光谱学与光谱分析, 2022, 42(8): 2631-2636.
ZHANG J, CUI J J, ZHENG C S, et al.Stochastic Process Prediction of Clutch Remaining Life Based on Oil Spectral Data[J]. Spectroscopy and Spectral Analysis, 2022, 42(8): 2631-2636.
[14] 杨海月, 徐伟清. 一种快速判定船舶装备油液进水原因的方法研究[J]. 润滑油, 2024, 39(5): 55-58.
YANG H Y, XU W Q.Research on a Method for Rapid Identification of the Cause of Water Inflow for the Ship Equipment Oil[J]. Lubricating Oil, 2024, 39(5): 55-58.
[15] 於迪, 王冰, 钱美奇. 基于油液分析的风电齿轮油外观异常问题诊断[J]. 设备管理与维修, 2022(23): 156-158.
YU D, WANG B, QIAN M Q.Diagnosis of Abnormal Appearance of Wind Power Gear Oil Based on Oil Analysis[J]. Plant Maintenance Engineering, 2022(23): 156-158.
[16] 闫书法, 朱元宸, 陶磊, 等. 基于信息熵的机械传动油液光谱监测数据选择方法[J]. 光谱学与光谱分析, 2022, 42(8): 2637-2641.
YAN S F, ZHU Y C, TAO L, et al.Spectral Oil Condition Monitoring Data Selection Method for Mechanical Transmission Based on Information Entropy[J]. Spectroscopy and Spectral Analysis, 2022, 42(8): 2637-2641.
[17] 江宏亮, 杨红军, 刘维, 等. 装甲装备机械类故障诊断研究进展综述[J]. 机电工程技术, 2024, 53(1): 30-34.
JIANG H L, YANG H J, LIU W, et al.Review of Research Progress on Mechanical Fault Diagnosis of Armored Equipment[J]. Mechanical & Electrical Engineering Technology, 2024, 53(1): 30-34.
[18] 马佳丽. 航空发动机磨损故障多目标智能融合诊断[D]. 南京: 南京航空航天大学, 2023.
MA J L.Multi-Objective Intelligent Fusion Diagnosis of Aero-Engine Wear Fault[D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2023.
[19] 刘海霞, 王庆国, 李进, 等. 海上平台关键设备的油液监测分析及故障诊断[J]. 凿岩机械气动工具, 2024, 50(4): 51-55.
LIU H X, WANG Q G, LI J, et al.Oil Monitoring Analysis and Fault Diagnosis of Key Equipment on Offshore Platform[J]. Rock Drilling Machinery&Pneumatic Tools, 2024, 50(4): 51-55.
[20] 百度百科. Spectroil M/C油料光谱分析仪[EB/OL]. (2013-07-10)[2025-05-29]. https://baike.baidu.com/item/Spectroil%20M%2FC%E6%B2%B9%E6%96%99%E5%85%89%E8%B0%B1%E5%88%86%E6%9E%90%E4%BB%AA/
7624959.
Baidu Baike. Spectroil M/C Oil Spectrum Analyzer [EB/ OL]. (2013-07-10)[2025-05-29]. https://baike.baidu.com/item/Spectroil%20M%2FC%E6%B2%B9%E6%96%99%E5%85%89%E8%B0%B1%E5%88%86%E6%9E%90%E4%BB%AA/
7624959.
[21] 徐峰, 张倩倩, 季文龙, 等. 油液光谱数据诊断综合传动装置异常磨损定位方法[J]. 光谱学与光谱分析, 2024, 44(5): 1398-1404.
XU F, ZHANG Q Q, JI W L, et al.Study on Abnormal Wear Location of Integrated Transmission Components Based on Oil Spectral Data[J]. Spectroscopy and Spectral Analysis, 2024, 44(5): 1398-1404.
[22] 向波, 甘旭升, 韩宝安, 等. 作战舰艇柴油机磨损故障的RS-KELM诊断[J]. 火力与指挥控制, 2022, 47(7): 72-77.
XIANG B, GAN X S, HAN B A, et al.Study on RS- KELM Diagnosis of Wear Fault for Warship Diesel Engine[J]. Fire Control & Command Control, 2022, 47(7): 72-77.
[23] 闫宗庆. 基于有限元和油液分析的齿轮疲劳寿命预测研究[D]. 太原: 太原理工大学, 2021.
YAN Z Q.Research on Gear Fatigue Life Prediction Based on Finite Element and Oil Analysis[D]. Taiyuan: Taiyuan University of Technology, 2021.
[24] 史顺青, 安燕. 油液检测分析技术在机械设备状态管理的应用[J]. 设备管理与维修, 2022(21): 150-153.
SHI S Q, AN Y.Application of Oil Detection and Analysis Technology in Condition Management of Mechanical Equipment[J]. Plant Maintenance Engineering, 2022(21): 150-153.
[25] 潘卓, 郝丽春, 杨鹤, 等. 高铁齿轮箱在用油衰变状态研究[J]. 合成润滑材料, 2024, 51(2): 30-35.
PAN Z, HAO L C, YANG H, et al.Study on the Degradation State of In-Service Lubricating Oil in High-Speed Train Gearboxes[J]. Synthetic Lubricants, 2024, 51(2): 30-35.
[26] 闫宏飞. 颗粒度分析仪在风电齿轮箱油液监测中的应用[J]. 设备管理与维修, 2018(8): 185-186.
YAN H F.Application of Particle Size Analyzer in Oil Monitoring of Wind Turbine Gearbox[J]. Plant Maintenance Engineering, 2018(8): 185-186.
[27] 王敏, 王炜, 万长东, 等. 变速箱直齿轮副表面故障机理分析与试验[J]. 现代制造工程, 2021(10): 136-141.
WANG M, WANG W, WAN C D, et al.Mechanism Analysis and Test of the Surface Fault of the Spur Gear Pair in Gearbox[J]. Modern Manufacturing Engineering, 2021(10): 136-141.
[28] 陈保家, 盛洪潇, 万刚, 等. 大模数齿轮齿条副剥落故障啮合刚度分析[J]. 组合机床与自动化加工技术, 2023(12): 161-166.
CHEN B J, SHENG H X, WAN G, et al.Meshing Stiffness Analysis of Large Modulus Rack and Pinion Pair Spalling Failure[J]. Modular Machine Tool & Automatic Manufacturing Technique, 2023(12): 161-166.
[29] 任杰锶. 某轻卡变速箱的静力学仿真分析[J]. 汽车实用技术, 2021, 46(15): 108-112.
REN J S.Statics Simulation Analysis Based on a Light Truck Gearbox[J]. Automobile Technology, 2021, 46(15): 108-112.
[30] 田晓丽. 汽车变速器齿轮点蚀的仿真分析与改善研究[D]. 杭州: 浙江大学, 2023.
TIAN X L.Simulation Analysis and Improvement Research on Gear Pitting Corrosion of Automobile Transmission[D]. Hangzhou: Zhejiang University, 2023.
[31] 柳召芹, 陈俊岩, 王泽骞, 等. 重型汽车变速箱主轴抗扭强度提升分析与应用[J]. 重型汽车, 2023(3): 31-32.
LIU Z Q, CHEN J Y, WANG Z Q, et al.Analysis and Application of Improving the Torsional Strength of the Main Shaft of Heavy-Duty Truck Gearbox[J]. Heavy Truck, 2023(3): 31-32.
[32] 付卫芳, 王虎. 变速箱高档锥体断齿故障分析研究[J]. 传动技术, 2020, 34(4): 35-39.
FU W F, WANG H.Analysis and Research on the Breaking Teeth Fault of High-Speed Cone of Gearbox[J]. Drive System Technique, 2020, 34(4): 35-39.
[33] 辛相锦. 拖拉机动力换挡变速器润滑系统流动与传热仿真研究[D]. 长春: 吉林大学, 2021.
XIN X J.Simulation Research on Flow and Heat Transfer of Tractor Power Shift Transmission Lubrication System[D]. Changchun: Jilin University, 2021.
[34] 靳广虎. 正交面齿轮传动的强度与动力学特性分析研究[D]. 南京: 南京航空航天大学, 2012.
JIN G H.Research on Strength and Dynamic Characteristics of Orthogonal Face Gear Drives[D]. Nanjing: Nanjing University of Aeronautics and Astronautics, 2012.
[35] 李本军, 王东霞, 崔东伟, 等. 某变速器中间轴齿轮断齿失效分析[J]. 机械工程师, 2020(3): 147-149.
LI B J, WANG D X, CUI D W, et al.Broken Gear Failure Analysis of a Transmission Intermediate Shaft Gear[J]. Mechanical Engineer, 2020(3): 147-149.
[36] 李凯, 张国政, 邵亮, 等. 某重型载货汽车变速器齿轮失效分析[J]. 汽车工艺与材料, 2015(7): 50-52.
LI K, ZHANG G Z, SHAO L, et al.Failure Analysis of Transmission Gear of a Heavy Truck[J]. Automobile Technology & Material, 2015(7): 50-52.
[37] 曹蕾蕾, 康凡军, 郭城臣, 等. 变速箱中间轴焊接结构多轴疲劳寿命分析方法[J]. 中国机械工程, 2023, 34(13): 1605-1610.
CAO L L, KANG F J, GUO C C, et al.Multi-Axis Fatigue Life Analysis Method for Welded Structures of Transmission Intermediate Shafts[J]. China Mechanical Engineering, 2023, 34(13): 1605-1610.