至 2014 年 8 月，我国汽车保有量已居世界第二。随着汽车报废数量的上升，废旧 车辆的合理利用是一个亟待解决的问题。多年来，各种品牌与型号轿车已大量配置了 CVT，较大一部分已进入报废与维修期，因此，开展废旧 CVT 的回收与再制造具有其 必要性与紧迫性。 本文重点对废旧 CVT 绿色清洗技术与再制造可行性评估进行了研究。主要研究内 容与成果如下， 1) 在查阅国内外文献的基础上，分析了废旧汽车变速箱再制造的技术、经济与环 境可行性，综述了再制造变速箱的剩余寿命理论与清洗技术研究现状。 2) 进行了“绿色”清洗技术研究与“绿色”清洗剂开发。以变速箱内部残留油污 初步清洗为研究内容，提出了一种以无患子果皮为原料的“绿色”清洗技术，通过果皮 萃取物溶液质量浓度与试验温度为变量的正交试验，获取清洗剂的最佳使用条件，为再 制造工程所需的“绿色”清洗剂开发提供了一种新的思路与方法。 3) 进行了废旧 CVT 剩余寿命的研究与评估。并将研究重点聚焦于利用铁谱技术评 估废旧 CVT 零部件摩擦副的运行状态与磨损情况，将铁谱分析的结果作为参考依据， 结合车辆行驶里程数与使用时间等轿车运行状态原始数据，评估再制造 CVT 的剩余使 用寿命。 4) 研究与制订了典型废旧 CVT 再制造工艺规程。以 RE0F10A 型 CVT 为例，着重 对传动系统零件进行分选归类，分别进行清洗、修复与更换等再制造工艺流程，最后重 新装配并进行台架试验。通过分选归类统计，主从动轴总成旧件重复利用率高达 87%， 具有良好的再制造环境可行性，为废旧 CVT 再制造工程提供了一个典型范例。 关键词，变速箱，再制造可行性，CVT，剩余寿命，铁谱分析，“绿色”清洗，工 艺规程II RESEARCH ON GREEN CLEANING TECHNOLOGY AND REMANUFACTURABILITY OF USED CAR TRANSMISSION BOX ABSTRACT The vehicle population of China has occupied second place in the world until August 2014. As the number of end-of-life vehicle (ELV) rising, the used car processing problems has been highlighted. Continuously variable transmission (CVT) has been increasingly applied to vehicles of various models for years. Most of these vehicles have been identified as ELV. In order to deal with these problems properly, the out-of-service CVT must be remanufactured as soon as possible. This thesis focuses on the environmental-friendly cleaning and the feasibility of remanufacturing various kinds of the used CVT, as the followings: 1) The technology feasibility, economic feasibility and environmental benefits of the used CVT remanufacturing have been analyzed on the foundation of reviewing the previous literature. The research of the remaining service life and environmental-friendly cleaner are summarized . 2) The feasibility of cleaning oil fouling by extracting sapindus mukorossis is researched in this thesis, which proposes a novel solution for developing an environmental-friendly cleaning technology. The best prescription of sapindus mukorossi solution is researched through the orthogonal experiment approach with prescription quality concentration and temperature as variables. 3) The remaining service life of the remanufactured CVT is researched in this thesis. The wear pattern and operation state of out-of-service CVT friction pairs is assessed by the ferrography technology. Then remaining service life of the remanufactured CVT parts is assessed using a combination of service life, service miles e.g. with the results from the ferrographie analysis, which provides a new approach of remaining service life assessment for the remanufactured CVT. 4) The remanufacturing processes of CVT is researched and formulated in this thesis. In the case of the out-of-service RE0F10A CVT, the parts of transmission are classified and analyzed in detail. The remanufactured CVT is assessed based on rig test after all remanufacturing procedures finished. The result shows that utilization rate of used parts is as high as 87%, which provides a typical example for out-of-service CVT remanufacturing. Key words: transmission, remanufacturability, CVT, remaining service life, the ferrography technology, environmental-friendly cleaner, process procedureIII 目 录 摘要.............................................................................................................................................I ABSTRACT............................................................................................................................III 第 1 章 绪论.............................................................................................................................1 1.1 研究目的及意义........................................................................................................1 1.2 再制造工程概念与国内外现状................................................................................2 1.2.1 再制造工程的相关概念.................................................................................2 1.2.2 国内外再制造工程研究现状.........................................................................3 1.3 废旧汽车零部件再制造可行性研究现状................................................................5 1.4 再制造清洗技术的研究现状....................................................................................6 1.5 剩余寿命评估的研究现状........................................................................................7 1.6 本文的主要研究内容................................................................................................8 第 2 章 废旧汽车变速箱再制造可行性分析.......................................................................11 2.1 废旧汽车变速箱再制造可行性分析概述..............................................................11 2.2 再制造技术可行性分析..........................................................................................12 2.3 再制造经济可行性分析..........................................................................................13 2.4 再制造环境可行性分析..........................................................................................13 2.5 CVT 结构对再制造可行性的影响.........................................................................14 2.6 本章小结..................................................................................................................15 第 3 章 再制造零部件绿色清洗技术研究与开发.............................................................. 17 3.1 再制造清洗技术概述..............................................................................................17 3.1.1 再制造清洗概述...........................................................................................17 3.1.2 常用油污清洗方法分类...............................................................................17 3.1.3 废旧产品油污的特点...................................................................................18 3.1.4 环境友好型植物萃取清洗剂去污原理.......................................................18 3.2 无患子植物介绍......................................................................................................20 3.2.1 无患子植物简介...........................................................................................20 3.2.2 无患子皂苷结构及其性质...........................................................................20 3.2.3 无患子萃取物溶液清洗试验流程...............................................................21 3.3 无患子皂苷萃取实验研究......................................................................................22 3.3.1 试验材料与方法...........................................................................................22 3.3.2 无患子果皮中皂苷含量测定.......................................................................23 3.3.3 无患子皂苷溶液表面张力测定...................................................................25 3.4 无患子皂苷清洗能力验证试验方案设定..............................................................26 3.4.1 试验目的与材料...........................................................................................26 3.4.2 试验方法与过程...........................................................................................27 3.4.3 试验结果与讨论...........................................................................................27IV 3.5 试验油污用量的研究.............................................