Locomotive wheelset hollow bushing overhaul and repair methods and systems

Abstract

This invention discloses a method and system for overhauling hollow bushings for locomotive wheelsets, comprising the following steps: performing flaw detection on the hollow bushing to detect the presence and location of cracks; welding repair at the crack location and grinding the weld repair area smooth; obtaining ultrasonic stress relief parameters and using an ultrasonic stress relief device to perform impact treatment on the weld repair area; obtaining the ultrasonic stress relief parameters includes: retrieving ultrasonic stress relief parameters from an ultrasonic stress relief database based on crack parameters, hollow bushing specification parameters at the crack location, and welding parameters, and controlling the ultrasonic stress relief device to perform stress relief treatment on the weld repair area. This invention significantly shortens the time required for hollow bushing overhaul, reduces residual stress after treatment, avoids the influence of welding residual stress on the weld repair area, and improves the repair quality of hollow bushings.

Description

Technical Field

[0001] This invention belongs to the field of locomotive wheelset maintenance technology, specifically relating to a method and system for the maintenance and treatment of hollow axle sleeves of locomotive wheelsets. Background Technology

[0002] When reworking a certain type of locomotive wheelset, it is necessary to inspect the condition of the hollow bushing. When cracks are found in the hollow bushing, the usual method is to repair the cracks by welding. After welding repair, the hollow bushing needs to be left to release welding stress for a long time, resulting in a long rework cycle for the locomotive wheelset, which is difficult to meet the needs of actual production. Summary of the Invention

[0003] The purpose of this invention is to provide a method for overhauling and processing hollow bushings of locomotive wheelsets, so as to solve the problems of long repair cycles and difficulty in ensuring repair quality of locomotive wheelsets.

[0004] Another objective of this invention is to provide a system for overhauling and repairing hollow axle sleeves for locomotive wheelsets.

[0005] This invention is achieved through the following technical solution: The maintenance and repair method for hollow bushings of locomotive wheelsets includes the following steps: S01. Perform flaw detection on the hollow bushing to check for cracks and determine the location of cracks; S02. Repair the cracked area by welding and grind the repaired area smooth. S03. Obtain ultrasonic stress relief parameters and use ultrasonic stress relief equipment to perform impact treatment on the weld repair area. The parameters for obtaining ultrasonic stress relief treatment include: Obtain the crack parameters on the hollow bushing; Obtain the specifications of the hollow bushing at the location of the crack; Obtain the welding parameters for the weld repair; Based on the crack parameters, the specifications of the hollow bushing at the crack location, and the welding parameters, ultrasonic stress relief parameters are obtained from the ultrasonic stress relief database, and the ultrasonic stress relief equipment is controlled to perform stress relief treatment on the weld repair area.

[0006] In some embodiments, the method further includes the step of establishing an ultrasonic stress relief treatment database, the step of establishing an ultrasonic stress relief treatment database including: K01. Pre-create cracks at the designated positions on the hollow bushing sample and obtain crack size parameters; K02. Repair the crack by welding and obtain the welding parameters for the repair. K03. The stress at the weld repair location is detected to obtain the initial internal stress; K03. Set the ultrasonic stress relief treatment parameters and use ultrasonic stress relief equipment to perform stress relief treatment on the weld repair area. K04. The stress at the weld repair location is detected to obtain the residual internal stress; K05. Based on the initial internal stress and the residual internal stress, calculate the residual rate of the welding internal stress after treatment. K06. Establish the relationship between crack size parameters, welding parameters, ultrasonic stress relief parameters and welding internal stress residual rate at a set position on the hollow bushing. K07. Obtain the relationship between crack size parameters, welding parameters, ultrasonic stress relief parameters and welding internal stress residual rate at various locations on the hollow bushing, and establish an ultrasonic stress relief database.

[0007] In some embodiments, when repairing a hollow bushing, the location of the crack, the crack size parameters, and the welding parameters are obtained. Based on the ultrasonic stress relief database, the corresponding ultrasonic stress relief parameters are automatically obtained, and stress relief treatment is performed on the weld repair area.

[0008] In some embodiments, when overhauling a hollow bushing, the initial internal stress of the weld repair area before stress relief treatment and the residual internal stress after stress relief treatment are obtained. Based on the crack location, crack size parameters, welding parameters, ultrasonic stress relief parameters, and residual internal stress rate corresponding to the hollow bushing, the relationship at the corresponding location on the hollow bushing in the ultrasonic stress relief database is updated.

[0009] In some embodiments, based on the locomotive wheelset repair situation, the location data of cracks appearing on the hollow bushing are statistically analyzed to obtain the core area on the hollow bushing that is prone to cracking. The size parameters of the cracks on the hollow bushing are statistically analyzed to obtain the range of crack size parameters on the hollow bushing. Based on the range of crack size parameters, the crack size parameters are divided into multiple range segments, and the range segment with the most cracks is the core crack range segment.

[0010] In some embodiments, the welding parameters, ultrasonic stress relief parameters, and corresponding residual welding internal stress rate are obtained in the core region and the core crack range. Based on the welding parameters, ultrasonic stress relief parameters, and residual internal stress rate of the weld, the corresponding formulas for the core region and core crack range in the ultrasonic stress relief database are modified.

[0011] In some embodiments, the ultrasonic stress relief parameters include ultrasonic frequency, processing power, and processing time.

[0012] On the other hand, the present invention also provides a locomotive wheelset hollow bushing maintenance and processing system, comprising: Ultrasonic generator; A control system for controlling an ultrasonic generator; the control system includes: A data acquisition unit is used to acquire crack location parameters, crack size parameters, and welding parameters. The data processing unit obtains the corresponding ultrasonic stress relief parameters based on the data acquired by the data acquisition unit and the ultrasonic stress relief database. The control unit controls the ultrasonic generator according to the ultrasonic stress relief treatment parameters to perform stress relief treatment on the weld repair area.

[0013] Compared with the prior art, the present invention has the following advantages and beneficial effects: Based on the characteristics of hollow bushings, this invention employs ultrasonic stress-relieving equipment to relieve stress on the welded parts after welding, which greatly shortens the time required for hollow bushing maintenance. At the same time, by optimizing the ultrasonic stress-relieving operation, residual stress after treatment can be reduced, avoiding the influence of welding residual stress on the welded parts and improving the repair quality of hollow bushings. Attached Figure Description

[0014] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the operation of the maintenance and treatment system of the present invention.

[0016] in: 1. Ultrasonic generator, 2. Ultrasonic impact gun, 3. Hollow bushing. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments.

[0018] During the repair process of hollow bushings, after welding repairs are performed on the cracked areas, the hollow bushings need to be annealed to release the welding stress in the repaired areas. However, due to the size and structure of the hollow bushings, it is currently not possible to directly anneal them. Instead, natural aging treatment can be performed by placing them in the bushings to release the internal stress, resulting in a long repair cycle for hollow bushings.

[0019] In this invention, after welding the welded parts of the hollow bushing, an ultrasonic stress relief device is used to subject the welded parts to high-frequency impact to eliminate the internal stress in the welded parts, thereby reducing the time required for rework of the hollow bushing.

[0020] Specifically, in one embodiment, the method for overhauling and processing the hollow bushing of locomotive wheelsets includes the following steps: S01. Perform flaw detection on the hollow bushing to check for cracks and determine the location of cracks; S02. Repair the cracked area by welding and grind the repaired area smooth. S03. Obtain ultrasonic stress relief parameters, and use ultrasonic stress relief equipment to perform impact treatment on the weld repair area; refer to Figure 1 The ultrasonic stress relief equipment includes an ultrasonic generator 1 and an ultrasonic impact gun 2. When performing ultrasonic stress relief treatment, the control parameters of the ultrasonic stress relief equipment are set to control the ultrasonic impact gun 2 to perform stress relief treatment on the weld repair position of the hollow bushing 3.

[0021] To achieve better stress relief and minimize welding stress, the method used in this embodiment for obtaining ultrasonic stress relief parameters is as follows: Obtain the crack parameters on the hollow bushing; these crack parameters include crack size parameters, crack type, etc., where crack size parameters include crack length, crack depth, etc. Obtain the specifications of the hollow bushing at the location of the crack. For the same model of locomotive wheelset, the specifications of the hollow bushing correspond to the location of the crack. We believe that because the structure of the hollow bushing is relatively complex, the difference in the location of the crack on the hollow bushing will have a certain impact on the actual effect of ultrasonic stress relief.

[0022] Obtaining welding parameters for weld repair is mainly because different welding parameters may have a certain impact on the generated internal stress.

[0023] Based on the crack parameters, the specifications of the hollow bushing at the crack location, and the welding parameters, ultrasonic stress relief parameters are obtained from the ultrasonic stress relief database. The ultrasonic stress relief equipment is then used to perform stress relief treatment on the weld repair area to improve the effect and quality of the stress relief treatment.

[0024] In one embodiment, the method further includes the step of establishing an ultrasonic stress relief treatment database, which includes: K01. Pre-create cracks at the designated positions on the hollow bushing sample and obtain crack size parameters; K02. Repair the crack by welding and obtain the welding parameters for the repair. K03. The stress at the weld repair location is detected to obtain the initial internal stress; K03. Set the ultrasonic stress relief treatment parameters and use ultrasonic stress relief equipment to perform stress relief treatment on the weld repair area. K04. The stress at the weld repair location is detected to obtain the residual internal stress; K05. Based on the initial internal stress and the residual internal stress, calculate the residual rate of the weld internal stress after treatment; here, the residual rate of the weld internal stress is the ratio between the residual internal stress and the initial internal stress. K06. Establish the relationship between crack size parameters, welding parameters, ultrasonic stress relief parameters and welding internal stress residual rate at a set position on the hollow bushing. K07. Obtain the relationship between crack size parameters, welding parameters, ultrasonic stress relief parameters and welding internal stress residual rate at various locations on the hollow bushing, and establish an ultrasonic stress relief database.

[0025] This paper presents a method for establishing an ultrasonic stress relief treatment database. In this method, based on the structural characteristics of hollow bushings, the maintenance process of hollow bushings is simulated on hollow bushing samples, and relevant parameters in the process are obtained. Based on the relevant parameters, the relationship between treatment parameters such as crack size parameters and welding internal stress residual rate is established. This relationship can be established by creating a table of relationships between various parameters, or by using a fitting method to obtain the functional expressions or models between the parameters, thus forming an ultrasonic stress relief treatment database.

[0026] In one embodiment, when repairing a hollow bushing, the location of the crack, the crack size parameters, and the welding parameters are obtained. Based on the ultrasonic stress relief database, the corresponding ultrasonic stress relief parameters are automatically obtained, and stress relief treatment is performed on the weld repair area.

[0027] Based on the established ultrasonic stress relief database, after obtaining the crack location, crack size parameters, and welding parameters on the hollow bushing, the ultrasonic stress relief parameters corresponding to the best stress relief effect are obtained by querying the established relational table or based on function expressions or models. The ultrasonic stress relief equipment is then controlled based on these ultrasonic stress relief parameters to perform the stress relief operation.

[0028] In one embodiment, when repairing a hollow bushing, the initial internal stress of the weld repair area before stress relief treatment and the residual internal stress after stress relief treatment are obtained. Based on the crack location, crack size parameters, welding parameters, ultrasonic stress relief parameters, and residual internal stress rate corresponding to the hollow bushing, the relationship at the corresponding location on the hollow bushing in the ultrasonic stress relief database is updated to further improve the stress relief effect.

[0029] In one embodiment, based on the rework status of locomotive wheelsets, the location data of cracks appearing on the hollow bushing are statistically analyzed to obtain the core area on the hollow bushing that is prone to cracking. The size parameters of the cracks on the hollow bushing are statistically analyzed to obtain the range of crack size parameters on the hollow bushing. Based on the range of crack size parameters, the crack size parameters are divided into multiple range segments, and the range segment with the most cracks is the core crack range segment.

[0030] In one embodiment, the welding parameters, ultrasonic stress relief parameters, and corresponding residual welding internal stress rate are obtained in the core region and the core crack range. Based on the welding parameters, ultrasonic stress relief parameters, and residual internal stress rate of the weld, the corresponding formulas for the core region and core crack range in the ultrasonic stress relief database are modified.

[0031] By analyzing the core area and crack range of hollow bushings prone to cracking, experimental data under corresponding crack parameters are increased to obtain more accurate ultrasonic stress relief treatment parameter relationships, thereby improving the stress relief treatment effect. Parameters from the aforementioned areas during hollow bushing rework are used to update and correct the relationships in the database to improve the stress relief treatment effect in these areas.

[0032] In one embodiment, the ultrasonic stress relief parameters include ultrasonic frequency, processing power, and processing time. Optimizing the ultrasonic stress relief parameters based on the actual situation during the hollow bushing rework process can effectively ensure the stress relief effect and reduce the impact of welding internal stress.

[0033] like Figure 1 As shown, the hollow bushing was repaired using the above method. After stress relief treatment, the residual internal stress at the weld repair site was reduced to less than 20% of the original value. Continuous testing of the hollow bushing revealed that no defects such as cracks occurred at the weld repair site.

[0034] On the other hand, the present invention also provides a locomotive wheelset hollow bushing maintenance and processing system, comprising: Ultrasonic generator; The control system is used to control the ultrasonic generator. The control system includes: The data acquisition unit is used to acquire crack location parameters, crack size parameters, and welding parameters. The data processing unit obtains the corresponding ultrasonic stress relief parameters based on the data acquired by the data acquisition unit and the ultrasonic stress relief database. The control unit controls the ultrasonic generator according to the ultrasonic stress relief parameters to perform stress relief treatment on the weld repair area.

[0035] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., used to indicate the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship that the product of this invention is usually placed in during use. They are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0036] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this invention does not imply that the components are required to be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0037] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0038] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A method for overhauling and repairing hollow axle sleeves of locomotive wheelsets, characterized in that, Includes the following steps: S01. Perform flaw detection on the hollow bushing to check for cracks and determine the location of cracks; S02. Repair the cracked area by welding and grind the repaired area smooth. S03. Obtain ultrasonic stress relief parameters and use ultrasonic stress relief equipment to perform impact treatment on the weld repair area. The parameters for obtaining ultrasonic stress relief treatment include: Obtain the crack parameters on the hollow bushing; Obtain the specifications of the hollow bushing at the location of the crack; Obtain the welding parameters for the weld repair; Based on the crack parameters, the specifications of the hollow bushing at the crack location, and the welding parameters, the ultrasonic stress relief parameters are obtained from the ultrasonic stress relief database, and the ultrasonic stress relief equipment is controlled to perform stress relief treatment on the weld repair area. It also includes the step of establishing an ultrasonic stress relief treatment database, which includes the following steps: K01. Pre-create cracks at the designated positions on the hollow bushing sample and obtain crack size parameters; K02. Repair the crack by welding and obtain the welding parameters for the repair. K03. The stress at the weld repair location is detected to obtain the initial internal stress; K03. Set the ultrasonic stress relief treatment parameters and use ultrasonic stress relief equipment to perform stress relief treatment on the weld repair area. K04. The stress at the weld repair location is detected to obtain the residual internal stress; K05. Based on the initial internal stress and the residual internal stress, calculate the residual rate of the welding internal stress after treatment. K06. Establish the relationship between crack size parameters, welding parameters, ultrasonic stress relief parameters and welding internal stress residual rate at a set position on the hollow bushing. K07. Obtain the relationship between crack size parameters, welding parameters, ultrasonic stress relief parameters and welding internal stress residual rate at various locations on the hollow bushing, and establish an ultrasonic stress relief database.

2. The method for overhauling and processing hollow axle sleeves of locomotive wheelsets according to claim 1, characterized in that, When repairing hollow bushings, the location, size, and welding parameters of cracks are obtained. Based on the ultrasonic stress relief database, the corresponding ultrasonic stress relief parameters are automatically obtained, and stress relief treatment is performed on the welded parts.

3. The method for overhauling and processing hollow axle sleeves of locomotive wheelsets according to claim 2, characterized in that, When overhauling hollow bushings, obtain the initial internal stress of the weld repair area before stress relief treatment and the residual internal stress after stress relief treatment. Based on the crack location, crack size parameters, welding parameters, ultrasonic stress relief parameters, and residual internal stress rate corresponding to the hollow bushing, the relationship at the corresponding location on the hollow bushing in the ultrasonic stress relief database is updated.

4. The method for overhauling and processing hollow axle sleeves of locomotive wheelsets according to claim 2, characterized in that, Based on the locomotive wheelset repair situation, collect data on the location of cracks on the hollow bushing to identify the core areas on the hollow bushing that are prone to cracking. The size parameters of the cracks on the hollow bushing are statistically analyzed to obtain the range of crack size parameters on the hollow bushing. Based on the range of crack size parameters, the crack size parameters are divided into multiple range segments, and the range segment with the most cracks is the core crack range segment.

5. The method for overhauling and processing hollow axle sleeves of locomotive wheelsets according to claim 4, characterized in that, Obtain the welding parameters, ultrasonic stress relief parameters, and corresponding residual welding internal stress rate in the core area and the core crack range. Based on the welding parameters, ultrasonic stress relief parameters, and residual internal stress rate of the weld, the corresponding formulas for the core region and core crack range in the ultrasonic stress relief database are modified.

6. The method for overhauling and processing hollow axle sleeves of locomotive wheelsets according to claim 1, characterized in that, The ultrasonic stress relief parameters include ultrasonic frequency, processing power, and processing time.

7. A locomotive wheelset hollow axle sleeve repair and maintenance system, characterized in that, The maintenance process using the locomotive wheelset hollow bushing maintenance method according to any one of claims 1-6 includes: Ultrasonic generator; A control system for controlling an ultrasonic generator; the control system includes: A data acquisition unit is used to acquire crack location parameters, crack size parameters, and welding parameters. The data processing unit obtains the corresponding ultrasonic stress relief parameters based on the data acquired by the data acquisition unit and the ultrasonic stress relief database. The control unit controls the ultrasonic generator according to the ultrasonic stress relief treatment parameters to perform stress relief treatment on the weld repair area.

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