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Ensuring Reliability of Transfer Gearbox

There is a tendency in the world to create and develop intelligent vehicles. Considering that while smart vehicles have not conquered the market and potential customers are only thinking about the degree of trust in them from the point of view of the transportation process safety, the issues of ensuring the reliability of such vehicles are becoming more urgent. One of the trucks main characteristics that ensure their reliability is transmission units. The transfer gearbox of KAMAZ 6522 trucks was chosen as the object of the study. The statistics of the transfer gearbox failures for 2018-2019 were considered. Based on these statistics, the problem area of the unit and mileage the breakdown occurs were determined. The transfer gearbox main faults include the shaft bearings wear, the teeth of the included gears wear; the switching mechanism clamps wear. Bench tests have shown that the countershaft bearing is experiencing overheating due to lubricant lack, which ultimately leads to failure. In most cases, the cause of these faults is the lubrication system malfunction, as a result of which the transmission parts overheating occurs. The relevance of the work is due to the fact that it is necessary to analyze the causes of failures in the transfer gearbox that cause transmission parts overheating and establish dependencies that cause overheating. This will increase the unit reliability and propose methods for improving its operation. Based on the data obtained, it was proposed to increase the holes for the lubricant supply in the seat of the front intermediate bearing of the intermediate shaft by 1.5 mm by changing the milling parameters. At the end of the work, the transfer gearbox is again subjected to life tests. The scientific novelty lies in the establishment of the dependence of the intermediate shaft bearing heating temperature on the operating time by bench tests.