Light Truck Powertrain Shell Rupture Problem Solution Research

BJ1036E2F1 Light Truck, developed by Futian Corporation, has continuously had batch cracking accidents on three shells including flywheel shell, clutch shell and gear-box shell from 1997 to 2000. The rate of the accident is about 1%. The accident ever not only made Futian Corporation certain economic loss, but also greatly affected sale of this type truck and security of customers' life and estate. To solve it, a deep, systemic and overall research program organized by me has been developed.After a period of vehicle's operation, the phenomenon of batch cracking occurs on shells of power assembly in the life-span, which shows that there are some defects in the design of power assembly. In order to solve it radically, making power assembly of BJ1036E2F1 Light Truck the research object and through dynamic simulation analysis of power assembly, this thesis obtains the distribution rules of forces of the bolts linking three shells mentioned above and the relation between forces of the bolts and rotate speed of engine. After finite element mode analysis of these three shells, inherent frequency and vibration model of shell of power assembly are gained, and thus its dynamic character is realized. Based on computer simulation analysis, experimental model of power assembly is acquired by vibration test and strength test of shell of power assembly, and the relation of forces of the shell and rotate speed of engine and imbalanced mass of rotate components is studied. Through comparing simulation analysis with experiments, the thesis systemically investigates the reasons of cracking of three shells and obtains the scheme to solve this type of problem.According to the analysis and experiments, the thesis brings forward the improved method of the system. From the investigations of vehicle's operation with improved power assembly, this type of accident occurring in BJ1036E2F1 Light Truck has almost been prevented since the late half year of 2000. In the thesis, according to the complicated assembly of vehicle, the research method of integrating dynamic simulation analysis and finite element analysis with experiment is advanced, which is utilized to solve the cracking problem of three shells effectively and in good time. It creates great economic benefit for Futian Corporation and plays a key role in production development and fault diagnose and disposal.