A wheel lapping optimization method, system, storage medium and device

Abstract

The present disclosure provides a wheel turning optimization method, system, storage medium and device, obtains the rim thickness and wheel diameter value of all wheels of a whole vehicle wheel set; sets the initialization parameters; according to the relationship between the initialization parameters and the obtained values, the rim thickness prediction value and the wheel diameter prediction value of the two sides of a single wheel set after turning are calculated; the wheel diameter prediction values of the two sides of a single wheel set are processed to the minimum value of the two; the whole vehicle wheel turning prediction result is obtained by cyclic calculation; according to the whole vehicle wheel turning prediction result, the wheel set matching result and its turning prediction result are determined. The present disclosure globally considers the wheel diameter and rim thickness state before turning of the whole train wheel, automatically calculates and gives the optimal turning amount suggestion, reduces the labor intensity of manual calculation, and at the same time reduces the loss caused by turning processing of the wheel diameter.

Description

Technical Field

[0001] This disclosure belongs to the field of vehicle wheel turning technology, specifically relating to an optimized wheel turning method, system, storage medium, and device. Background Technology

[0002] The statements in this section are merely background information relating to this disclosure and do not necessarily constitute prior art.

[0003] Wheel turning is a maintenance method that restores wheel flange thickness at the cost of sacrificing tread diameter. During advanced maintenance of high-speed trains, wheel turning is required to ensure that the wheel profile meets maintenance requirements after machining.

[0004] According to the "Provisional Technical Conditions for Thin-Flanged Tread Profile of EMU Wheels," the technical requirements for thin-flange tread types of EMU LMA (Low-Flanged Motion Assembly) wheels are clearly defined. The profiles are specified as follows: 28, 28.5, 29, 29.5, 30, 30.5, 31, 31.5, 32, 32.5, based on a 0.5mm reduction in flange thickness from 32.5mm. After wheelset resurfacing, the wheel tread profile must meet these requirements, and the flange thickness must not be less than 28.5mm. Simultaneously, the maintenance procedures stipulate that resurfacing wheels must meet the wheel diameter difference matching requirements (wheel diameter difference ≤ 0.5mm for the same wheelset, ≤ 3mm for the same bogie, and ≤ 3mm for the same train). In addition to meeting the thin-flange tread profile requirements, wheelset resurfacing must also meet the EMU wheel diameter difference matching requirements.

[0005] According to the inventor, the current advanced wheel tread resurfacing strategy for high-speed trains is unreasonable. The commonly used wheel resurfacing strategy calculates the amount of wheel resurfacing work for a single train (taking eight wheels as an example) based on the wheel flange thickness and diameter, ensuring that the wheel diameters of the same wheelset, bogie, and car meet requirements. This strategy relies on the operator's experience and, while simple to calculate, only considers the wheel flange thickness and diameter of a single car for resurfacing decisions, which has limitations. This results in excessive loss of wheel diameter value for the entire train's wheels due to resurfacing, increasing maintenance costs. According to statistical analysis of the wheel size data of the EMU trains undergoing repair, the wheel sets with wheel diameters of 800-820mm before repair generally had insufficient flange thickness (less than 28.5mm, and some less than the service limit of 26mm). Due to the current technical requirements for new thin flanges and the requirements for wheel turning on a per-vehicle basis, the small wheel diameter and insufficient flange thickness in some individual trains increased the amount of wheel turning work required for those trains. As a result, the wheel diameter of some trains after turning was less than 800mm, and they had to be scrapped. Summary of the Invention

[0006] To address the aforementioned problems, this disclosure proposes an optimized wheel turning method, system, storage medium, and device. This disclosure comprehensively considers the wheel diameter and flange thickness of the entire train before turning, automatically calculates and provides the optimal turning amount suggestion, reducing the labor intensity of manual calculation, and minimizing wheel diameter loss due to turning.

[0007] According to some embodiments, the present disclosure adopts the following technical solutions:

[0008] An optimized method for wheel turning includes the following steps:

[0009] Obtain the flange thickness and wheel diameter values ​​for all wheels of the entire wheel pair;

[0010] Set initialization parameters;

[0011] Based on the relationship between the initialization parameters and the acquired values, the predicted values ​​of the flange thickness and wheel diameter after the turning of the wheels on both sides of a single wheelset are calculated under different conditions.

[0012] The predicted wheel diameters of both wheels on a single wheelset are processed to the minimum of the two values.

[0013] The prediction results for the wheel turning of the entire vehicle are obtained by iterative calculation;

[0014] Based on the prediction results of the wheel turning of the whole vehicle, the wheelset matching results and its turning prediction results are determined.

[0015] As an alternative implementation method, the specific process of setting initialization parameters includes setting the turning ratio coefficient and the pre-processing target value of the rim thickness.

[0016] As an alternative implementation method, the specific process for calculating the predicted flange thickness and wheel diameter of both wheels of a single wheelset after turning and repairing, depending on the circumstances, includes:

[0017] When the obtained flange thickness Sd is less than the set flange thickness pre-processing target value Sdg, the predicted flange diameter value D' = Dk * (Sdg - Sd) is calculated by the turning ratio coefficient k. The predicted flange thickness value is equal to the flange thickness pre-processing target value Sdg, where D is the obtained flange diameter value.

[0018] As an alternative implementation method, the specific process for calculating the predicted flange thickness and wheel diameter of both wheels of a single wheelset after turning and repairing, depending on the circumstances, includes:

[0019] When the obtained flange thickness Sd is not less than the set flange thickness pre-processing target value Sdg, the flange thickness Sd is found to be the closest turning flange thickness grade Sd'={29,29.5,30,30.5,31,31.5,32,32.5} according to the principle of minimizing the loss of the flange diameter value. The predicted flange diameter value D'=Dk*(Sdg-Sd), where k is the set turning ratio coefficient.

[0020] As an alternative implementation, the two wheels are designated as sides A and B.

[0021] As an alternative implementation method, the specific process of cyclically calculating the prediction result of the whole vehicle wheel turning includes repeatedly executing the steps of calculating the predicted value of the flange thickness and the predicted value of the wheel diameter after turning of the wheels on both sides of a single wheelset according to the relationship between the initialization parameters and the acquired values, and making the predicted value of the wheel diameter on both sides of the single wheelset processed to the minimum value of the two, thereby calculating the prediction result of the whole vehicle wheel turning.

[0022] As an alternative implementation method, the specific process of reordering based on the whole vehicle wheel turning prediction results includes reordering the wheel diameter predictions from smallest to largest according to the calculated turning prediction results to obtain new turning prediction results.

[0023] As an alternative implementation, the specific process of determining the wheelset matching result and its turning prediction result includes comparing the prediction result values ​​of each set number of wheelsets starting from the first wheelset based on the newly sorted turning prediction results. The difference between the maximum and minimum values ​​must not exceed the wheel diameter difference matching requirement of the same vehicle. Otherwise, the maximum value of the wheel diameter prediction value of each set number of wheelsets is adjusted to the wheel diameter prediction value that meets the requirements, and the wheelset matching result is output.

[0024] A wheel turning optimization system, comprising:

[0025] The parameter acquisition module is configured to acquire the flange thickness and wheel diameter values ​​of all wheels in the entire wheel pair;

[0026] The settings module is configured to set initialization parameters;

[0027] The prediction module is configured to calculate the predicted values ​​of the flange thickness and wheel diameter after the wheels on both sides of a single wheelset are turned, based on the relationship between the initialization parameters and the acquired values, depending on the specific circumstances.

[0028] The setting module is configured to process the predicted wheel diameter values ​​of both wheels on both sides of a single wheelset to the minimum of the two values;

[0029] The loop calculation module is configured to perform loop calculations to obtain the prediction results of the wheel turning repair of the entire vehicle.

[0030] The optimization module is configured to reorder the wheelset matching results and their re-maintenance prediction results based on the whole vehicle wheel turning prediction results.

[0031] A computer-readable storage medium storing a plurality of instructions adapted for loading by a processor of a terminal device and executing steps in the method.

[0032] A terminal device includes a processor and a computer-readable storage medium, the processor being configured to implement instructions; the computer-readable storage medium being configured to store a plurality of instructions adapted to be loaded by the processor and executed in accordance with the steps of the method.

[0033] Compared with the prior art, the beneficial effects of this disclosure are as follows:

[0034] This disclosure ensures that the flange thickness of all wheels after turning and machining is not less than the minimum limit, and that the machined wheels meet the requirements for matching wheel diameter difference.

[0035] This disclosure allows for the setting of boundary parameter values, which has a certain guiding nature and can be flexibly adjusted according to vehicle and operational requirements, etc.

[0036] This disclosure can quickly calculate the recommended value of the turning amount and the wheel matching result;

[0037] This disclosure calculates the amount of wheel turning based on the wheel flange thickness and wheel diameter of the entire train. Compared with considering the wheel condition of a single car, the results are better. According to the application effect, the amount of wheel turning per train is reduced by about 32%, which reduces the maintenance cost throughout the entire life cycle.

[0038] To make the above-mentioned objects, features and advantages of this disclosure more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0039] The accompanying drawings, which form part of this disclosure, are used to provide a further understanding of this disclosure. The illustrative embodiments of this disclosure and their descriptions are used to explain this disclosure and do not constitute an undue limitation of this disclosure.

[0040] Figure 1 This is a schematic diagram of the lathe repair process;

[0041] Figure 2 This is a flowchart illustrating one embodiment of the present disclosure;

[0042] Figure 3 This is a schematic diagram showing the result of one embodiment of the present disclosure; Detailed implementation method:

[0043] The present disclosure will be further described below with reference to the accompanying drawings and embodiments.

[0044] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0045] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this disclosure. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms “comprising” and / or “including” are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0046] Example 1

[0047] An optimization method for wheel turning of a whole train, with the wheel diameter and flange thickness after turning as decision variables, aims to minimize the turning amount of wheels of the whole train, while satisfying: (1) the flange thickness of all wheels after turning shall not be less than the minimum limit; (2) the wheels after turning meet the wheel diameter difference requirements of the matching set (for example, the wheel diameter difference of the same wheelset ≤ 0.5mm, the wheel diameter difference of the same bogie ≤ 3mm, and the wheel diameter difference of the same car ≤ 3mm).

[0048] The above can be achieved through the following steps: Figure 2 As shown:

[0049] Step (1): Obtain the flange thickness Sd and wheel diameter D of all wheels in the entire wheelset using an automatic wheelset measuring machine;

[0050] Step (2): Set the strategy initialization parameters:

[0051] ① Turning ratio coefficient k: This coefficient refers to the ratio of the wheel diameter difference ΔD before and after machining to the rim thickness difference ΔSd. This value is generally set based on on-site turning experience. According to on-site data statistics, in this embodiment, while ensuring the standard shape of the wheel, for every 1mm restoration of the rim thickness, approximately 5.8mm needs to be turned off in the diameter direction of the wheel tread.

[0052] ② Target value for pre-machining of rim thickness Sdg. Taking into account factors such as machining errors, in this embodiment, Sdg is set to 28.5mm.

[0053] Step (3): Calculate the predicted wheel diameter D' and predicted flange thickness Sd' after the wheels on both sides A and B of a single wheelset are turned. This is divided into the following two cases:

[0054] (1) When the rim thickness Sd is less than Sdg, the predicted wheel diameter D' = Dk * (Sdg - Sd) is calculated by the turning ratio coefficient k, and the predicted rim thickness Sd' = Sdg is calculated.

[0055] (2) When the flange thickness Sd is not less than Sdg, according to the principle of minimizing the loss of the flange diameter, find the flange thickness grade Sd'={29,29.5,30,30.5,31,31.5,32,32.5} that is closest to Sd and D'=Dk*(Sdg-Sd).

[0056] Step (4): Based on the calculation results of step (3), in order to meet the wheel diameter difference requirement of a single wheelset, the predicted wheel diameter D' of the wheels on both sides of wheelset A and B is processed to the minimum value of the two.

[0057] Step (5): Repeat steps (3) and (4) to automatically calculate the predicted wheel diameter D' and predicted flange thickness Sd' for all wheelsets in the entire wheelset.

[0058] Step (6): Based on the turning prediction results calculated in step (5), reorder the wheel diameter prediction values ​​D' from smallest to largest to obtain new turning prediction results.

[0059] Step (7): Based on the prediction results of step (6), compare the prediction results of every 4 wheelsets starting from the first wheelset. The difference between the maximum and minimum values ​​must not exceed the wheel diameter difference matching requirements of the same vehicle. Otherwise, adjust the maximum value of the wheel diameter prediction values ​​of every 4 wheelsets to the wheel diameter prediction value that meets the requirements, and output the wheelset matching results.

[0060] Step (8): Output the wheel turning and repair suggestions and matching results for the whole train to assist the turning and repair personnel in carrying out the processing work according to the decision results.

[0061] It should be noted that the above embodiments are merely examples, and the setting range or setting value of the above parameters can be adjusted according to specific circumstances, and are not limited to the values ​​given above. Any adjustment / setting of the above values ​​is easily conceived by those skilled in the art and should fall within the protection scope of this disclosure.

[0062] Example 2

[0063] A wheel turning optimization system, comprising:

[0064] The parameter acquisition module is configured to acquire the flange thickness and wheel diameter values ​​of all wheels in the entire wheel pair;

[0065] The settings module is configured to set initialization parameters;

[0066] The prediction module is configured to calculate the predicted values ​​of the flange thickness and wheel diameter after the wheels on both sides of a single wheelset are turned, based on the relationship between the initialization parameters and the acquired values, depending on the specific circumstances.

[0067] The setting module is configured to process the predicted wheel diameter values ​​of both wheels on both sides of a single wheelset to the minimum of the two values;

[0068] The loop calculation module is configured to perform loop calculations to obtain the prediction results of the wheel turning repair of the entire vehicle.

[0069] The optimization module is configured to reorder the wheelset matching results and their re-maintenance prediction results based on the whole vehicle wheel turning prediction results.

[0070] The present invention also provides the following product examples:

[0071] A computer-readable storage medium storing a plurality of instructions adapted for loading by a processor of a terminal device and executing the steps of the method in Embodiment 1.

[0072] A terminal device includes a processor and a computer-readable storage medium, the processor being configured to implement various instructions; the computer-readable storage medium being configured to store a plurality of instructions adapted to be loaded by the processor and executed in the method of Embodiment 1.

[0073] The above embodiments comprehensively consider the wheel diameter and flange thickness of the entire train before wheel turning, automatically calculating and providing optimized turning requirements, reducing the labor intensity of manual calculations, and minimizing wheel diameter loss due to turning. Based on application results, approximately 32% of the turning work is saved per train, reducing overall life-cycle maintenance costs.

[0074] While the specific embodiments of this disclosure have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of this disclosure. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of this disclosure are still within the scope of protection of this disclosure.

Claims

1. An optimized method for wheel turning, characterized in that, Includes the following steps: Obtain the flange thickness and wheel diameter values ​​for all wheels of the entire wheel pair; Set initialization parameters; Based on the relationship between the initialization parameters and the acquired values, the predicted values ​​of the flange thickness and wheel diameter after the turning of the wheels on both sides of a single wheelset are calculated under different conditions. The predicted wheel diameters of both wheels on each side of a single wheelset are machined to the minimum of the two values; The prediction results for the wheel turning of the entire vehicle are obtained by iterative calculation; Based on the prediction results of the wheel turning of the whole vehicle, the wheelset matching results and its turning prediction results are reordered. The specific process of reordering based on the whole vehicle wheel turning prediction results includes reordering the wheel diameter prediction results from smallest to largest according to the calculated turning prediction results to obtain new turning prediction results; The specific process for determining the wheelset matching results and its turning prediction results includes comparing the prediction results of each set number of wheelsets starting from the first wheelset based on the newly sorted turning prediction results. The difference between the maximum and minimum values ​​must not exceed the wheel diameter difference matching requirement of the same vehicle. Otherwise, the maximum value of the wheel diameter prediction values ​​of each set number of wheelsets is adjusted to the wheel diameter prediction value that meets the requirements, and the wheelset matching results are output.

2. The wheel turning optimization method as described in claim 1, characterized in that, The specific process of setting initialization parameters includes setting the turning ratio coefficient and the pre-machining target value for the rim thickness.

3. The wheel turning optimization method as described in claim 1, characterized in that, The specific process for calculating the predicted flange thickness and wheel diameter of both sides of a single wheelset after turning and repairing, depending on the specific circumstances, includes: When the obtained flange thickness Sd is less than the set flange thickness pre-processing target value Sdg, the predicted flange diameter after processing D'=Dk*(Sdg-Sd) is calculated by the turning ratio coefficient k. The predicted flange thickness after processing is equal to the flange thickness pre-processing target value Sdg, where D is the obtained flange diameter value.

4. The wheel turning optimization method as described in claim 1 or 3, characterized in that, The specific process for calculating the predicted flange thickness and wheel diameter of both sides of a single wheelset after turning and repairing, depending on the specific circumstances, includes: When the obtained flange thickness Sd is not less than the set flange thickness pre-processing target value Sdg, the flange thickness Sd is found to be the closest turning flange thickness grade Sd'={29,29.5,30,30.5,31,31.5,32,32.5} according to the principle of minimizing the loss of the flange diameter value. The predicted flange diameter value D'=Dk*(Sdg-Sd), where k is the set turning ratio coefficient.

5. The wheel turning optimization method as described in claim 1, characterized in that, The specific process of obtaining the prediction result of the whole vehicle wheel turning includes repeatedly executing the steps of calculating the predicted value of the flange thickness and the predicted value of the wheel diameter after turning of the wheels on both sides of a single wheelset according to the relationship between the initialization parameters and the acquired values, and making the predicted value of the wheel diameter on both sides of a single wheelset process to the minimum value of the two, so as to obtain the prediction result of the whole vehicle wheel turning.

6. A wheel turning and repair optimization system, employing the wheel turning and repair optimization method as described in any one of claims 1-5, characterized in that, include: The parameter acquisition module is configured to acquire the flange thickness and wheel diameter values ​​of all wheels in the entire wheel pair; The settings module is configured to set initialization parameters; The prediction module is configured to calculate the predicted values ​​of the flange thickness and wheel diameter after the wheels on both sides of a single wheelset are turned, based on the relationship between the initialization parameters and the acquired values, depending on the specific circumstances. The setting module is configured to process the predicted wheel diameter values ​​of both wheels on either side of a single wheelset to the minimum of the two values; The loop calculation module is configured to perform loop calculations to obtain the prediction results of the wheel turning repair of the entire vehicle. The optimization module is configured to reorder the wheelset matching results and their re-maintenance prediction results based on the whole vehicle wheel turning prediction results.

7. A computer-readable storage medium storing a plurality of instructions adapted to be loaded by a processor of a terminal device and to execute the steps of the method of any one of claims 1-5.

8. A terminal device comprising a processor and a computer-readable storage medium, the processor being configured to implement instructions; the computer-readable storage medium being configured to store a plurality of instructions adapted to be loaded by the processor and to execute the steps of the method of any one of claims 1-5.

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