Large Casting Steel Track Power System Gearbox for Railway

Under the high-speed train carriage traveling at 350 kilometers per hour, a group of silver-gray precision devices are operating silently at a speed of thousands of revolutions per minute. This gear box, known as the “heart of the track power system”, is a masterpiece of modern mechanical engineering in terms of its material selection and functional design.

I. The Pinnacle Creation of Materials Science for Modern Railway Gearbox

The manufacturing of modern gearboxes has transcended the limitations of traditional steel, forming a multi-layer composite material system. The core transmission gears are made of 18CrNiMo7-6 carburized alloy steel. After vacuum low-pressure carburizing treatment, a 2mm-deep hardened layer forms on the surface, with a Rockwell hardness of HRC62-64, while the core part still maintains a toughness of HRC30-35. This “outer hardness and inner flexibility” characteristic enables it to withstand a 20,000N·m instantaneous impact torque and possess the ability to resist fatigue fracture. The latest PVD titanium aluminum nitrogen coating developed by German Voith Company has further reduced the friction coefficient of the gear surface to below 0.03, equivalent to forming a continuous lubricating “solid oil film” on the contact surface.

The material of the box body is trending towards lightweight innovation. The aluminum-silicon alloy box body developed by CRRC has an ultimate tensile strength of over 380 MPa after T6 heat treatment. Compared with the traditional cast iron, it reduces the weight by 40% while improving the heat dissipation efficiency by 25%. The carbon fiber reinforced composite material box body developed by Kawasaki Heavy Industries of Japan has achieved a 35% weight reduction on the Tokaido Shinkansen. Its unique vibration damping characteristic also reduces the running noise by 8 decibels.

II. Function Matrix of Precise Collaboration for Modern Railway Gearbox

This metallic life form has an internal construction of a precise dynamic balance system. The three-stage reduction gear set is like a precise mechanical symphony orchestra: the first-stage helical gear enters at a 15° helical angle, reducing the motor’s 6000 rpm speed to 2000 rpm, and at the same time, through the involute tooth profile design, the transmission error is controlled within 3 arc seconds; the secondary planetary gear system realizes load diversion through 6 equalizing pins, ensuring that the stress distribution uniformity of a single gear reaches 98%; the final cylindrical gear adopts the drum-shaped fillet technology, compensating for the elastic deformation during high-speed operation, and ensuring that the contact area of the meshing always maintains above 85%.

The integrated intelligent lubrication system is like the circulatory system of a device. Under the drive of the centrifugal oil pump, the fully synthetic PAO lubricating oil forms a stable oil pressure of 3.5 bar. The 10 μm-level filter screen embedded in the oil circuit can capture 99.97% of metal debris. Combined with the three-stage temperature control module of the oil cooler, the working oil temperature is precisely controlled within the golden range of 75 ± 2℃. The magnetic chip removal device applied in Beijing Metro Line 19 has achieved a breakthrough of lubricating oil replacement-free for 20,000 hours.

Company Profile

Luoyang Fenyo Heavy Industries Co., Ltd. was founded in 1998, covers an area of 72,600㎡, with more than 300 employees, 32 technicians, including 5 senior engineers, 11 assistant engineers, and 16 technicians. It has been rated as Luoyang Engineering Technology Center, Luoyang Technology R&D Center, and National High-tech Enterprise for many times.

Our production capacity is 30,000 tons per year. Currently, we mainly produce cast steel, cast iron (gray iron, ductile iron, etc.), processing of finished product and component assembly. The company mainly produces parts and railcar gearbox component assemblies for high-speed rail, railcars, locomotives, passenger cars, subways, mines, coal machines, petroleum machinery, wind power, water conservancy, ceramics, engineering machinery and other equipment. At the same time, the products have been exported to Russia, the United States, Germany, Argentina, Japan, France, South Africa, Italy and other countries.

FAQS

Q1: Are you a manufacturer or trading company?
A:Yes,our company was founded in 1998, with nearly 30 years in casting industry, a total area of 72,600㎡, with a factory building area of 51,000㎡.
Q2. What are your main products?
A: We primarily focus on steel casting, iron casting, finished product machining, and component assembly production.
Q3: How precision can you produce casting parts?
A: We have the capability of producing casting parts with different casting processes. The production is strictly comply with ISO 9001, ISO 14001 and ISO45001,EN15085, IRIS.
Q4. Can you produce according to the samples?
 Yes, we can produce by your samples or technical drawings. We can build drawings for you after we get your samples too.
Q5: How do you do Quality Control before delivery?
A: Quality inspection is a very important factor to guarantee the quality of steel casting parts. We follow 3 times of inspection during the whole production process. And we will provide material testing report, dimensional testing report, and mechanical properties testing report to our clients before delivery.

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