Wheelset maintenance line and maintenance method

Abstract

The present application relates to a wheel set repair line and a repair method, and relates to the technical field of freight car repair.The wheel set repair line comprises a wheel set intake area, a machining area and a wheel set disassembly area connected in sequence, the wheel set intake area is provided with an overground conveying line connected to the machining area and an underground conveying line connected to the wheel set disassembly area, and the underground conveying line passes through the machining area from underground.The two-stage repair wheel set and the three-stage repair wheel set do not need to separate the axle and the wheel, the four-stage repair wheel set needs to separate the axle and the wheel, the two-stage repair wheel set and the three-stage repair wheel set are transferred to the machining area by the overground conveying line for subsequent operation, and the four-stage repair wheel set directly reaches the wheel set disassembly area from underground by the underground conveying line through the machining area.The overground conveying line and the underground conveying line do not need to consider avoiding various equipment placed on the ground, can realize the shortest conveying path and reduce the site occupation, and can make the wheel sets of various repair stages quickly reach the subsequent operation stations, thereby improving the wheel set repair efficiency.

Description

Technical Field

[0001] This invention relates to the field of truck maintenance technology, and particularly to a wheelset maintenance line and maintenance method. Background Technology

[0002] A vehicle bogie is an independent running gear consisting of two or more wheelsets connected by a frame and other devices, capable of rotating relative to the car body, and equipped with springs and other components. It is one of the most critical components of a rail vehicle. After the wheelsets are separated from the frame, the maintenance process is divided into level two, level three, and level four repairs. Level two repairs are performed on wheelsets whose bearings are still within their service life and in good condition, thus eliminating the need for bearing removal, replacement, and pressing. Level three repairs are performed on wheelsets whose bearings have reached their service life or are faulty, requiring bearing removal and re-replacement and pressing. Level two and level three repairs are performed on wheelsets in good condition, requiring machining to restore the wheel surface to the required shape. Level four repairs may involve wheelsets with insufficient thickness that cannot be restored through machining, or internal defects found in the axle or wheel after flaw detection, requiring separation of the wheel from the axle and re-selection of wheelsets.

[0003] The existing wheelset maintenance line has maintenance equipment and transfer facilities all located on the ground. However, the maintenance items and equipment required for wheelsets of different maintenance stages are different. The installation of equipment needs to take into account the transfer path of wheelsets of different maintenance stages on the ground. Therefore, a large space is required to complete the installation of equipment, transfer and buffering of wheelsets, which is not conducive to improving maintenance efficiency. Summary of the Invention

[0004] This invention provides a wheelset maintenance line and maintenance method that can make full use of underground and aerial space to transport wheelsets, improve the transportation efficiency of wheelsets, and reduce site occupation.

[0005] On one hand, the present invention provides a wheelset maintenance line, comprising a wheelset receiving area, a machining area and a wheelset disassembly area connected in sequence. The wheelset receiving area is provided with an overhead conveyor line connected to the machining area and an underground conveyor line connected to the wheelset disassembly area. The underground conveyor line passes through the machining area underground.

[0006] In one embodiment, the wheelset receiving area is provided with a bearing removal station and a flaw detection room. The overhead conveyor line includes a first section and a second section arranged in parallel. The first section is located on one side of the bearing removal station and one side of the flaw detection room. The second section is located on the other side of the flaw detection room and extends to the machining area. Elevators are provided between the first section and the bearing removal station, between the first section and the flaw detection room, and between the second section and the flaw detection room.

[0007] In one embodiment, the underground conveyor line is parallel to the first segment and located on the side of the first segment away from the elevator.

[0008] In one embodiment, a blank storage area is provided on one side of the wheelset disassembly area, and a wheel axle processing area is provided on the side of the blank storage area opposite to the wheelset disassembly area.

[0009] In one embodiment, a temperature-controlled chamber is provided on one side of the machining area, one end of which is connected to one end of the wheel axle machining area, and a bearing press-fitting area is provided at the other end of the temperature-controlled chamber, one side of which is connected to one side of the wheelset receiving area.

[0010] On the other hand, a wheelset maintenance method is provided, including the following steps:

[0011] S1. Before the bearing is removed, the secondary wheelset is diverted and transported to the flaw detection room via an overhead conveyor line. After the bearing is removed, the tertiary and quaternary wheelset is diverted and transported to the flaw detection room via an overhead conveyor line, while the quaternary wheelset is transported to the wheelset disassembly area via an underground conveyor line.

[0012] S2. After passing the flaw detection in the flaw detection room, the secondary and tertiary wheelsets are transferred to the machining area via an overhead conveyor line for turning operations. The quaternary wheelsets are separated into usable used wheelsets and scrapped wheelsets after the wheelset disassembly area is completed.

[0013] In one embodiment, the wheelset maintenance method further includes the following steps:

[0014] S3. After the turning operation is completed, the secondary turning wheel pair is transferred to the bearing press-fitting area for the assembly of the shaft end cover accessories. After the turning operation is completed, the tertiary turning wheel pair is transferred to the same temperature room for same temperature storage.

[0015] In one embodiment, the wheelset maintenance method further includes the following steps:

[0016] S4. Transfer the usable used axles, usable used wheels, blank axles and blank wheels to the wheel and axle processing area, perform grinding on the usable used axles, turning on the blank axles, and boring on the usable used wheels and blank wheels.

[0017] In one embodiment, in step S4, two boring machines are integrated on both sides of the wheelset press machine, and the wheel hub hole of the corresponding size is processed based on the wheel axle selection method of the base shaft system.

[0018] In one embodiment, the wheelset maintenance method further includes the following steps:

[0019] After the assembly of the shaft end cap accessories of S5 and each level of the wheel set is completed, the wheel set break-in, wheel set size measurement, wheel set painting and appearance inspection are carried out in sequence in the bearing press-fitting area.

[0020] Compared with the prior art, the advantages of this invention are that, since the second-level and third-level wheelset repairs do not require the separation of the axle and wheel, while the fourth-level wheelset repairs do require the separation of the axle and wheel, in the wheelset receiving area, the second-level and third-level wheelset repairs are transported to the machining area for subsequent operations using an overhead conveyor line, while the fourth-level wheelset repairs are transported directly from the machining area to the wheelset disassembly area using an underground conveyor line. The setting of the overhead and underground conveyor lines does not need to consider avoiding various equipment placed on the ground, which can achieve the shortest possible transport path and reduce site occupation, making full use of site space, so that the wheelsets to be repaired in each repair cycle can quickly reach the subsequent work station, thereby improving the efficiency of wheelset repair. Attached Figure Description

[0021] The invention will now be described in more detail with reference to embodiments and the accompanying drawings.

[0022] Figure 1 This is a schematic diagram of the wheelset maintenance line in an embodiment of the present invention;

[0023] Figure 2 yes Figure 1 Enlarged view of point A in the middle;

[0024] Figure 3 This is a flowchart of a wheelset maintenance method in an embodiment of the present invention.

[0025] Figure label:

[0026] 1. Wheelset receiving area; 11. Aerial conveyor line; 111. First section; 112. Second section; 12. Underground conveyor line; 13. Bearing unloading station; 14. Flaw detection room; 15. Elevator; 16. First conveyor line; 17. Second conveyor line; 18. Manual re-inspection station; 2. Machining area; 21. Third conveyor line; 22. Fourth conveyor line; 3. Wheelset disassembly area; 4. Raw material storage area; 5. Wheel and axle machining area; 6. Isostatic room; 7. Bearing press-fitting and delivery area. Detailed Implementation

[0027] The invention will now be further described with reference to the accompanying drawings.

[0028] Example 1

[0029] like Figure 1 and Figure 2As shown, a wheelset maintenance line according to an embodiment of the present invention includes a wheelset receiving area 1, a machining area 2, and a wheelset disassembly area 3 connected in sequence. The wheelset receiving area 1 is provided with an overhead conveyor line 11 connected to the machining area 2 and an underground conveyor line 12 connected to the wheelset disassembly area 3. The underground conveyor line 12 passes through the machining area 2 underground.

[0030] Since level two and level three wheelset repairs do not require separating the axle and wheel, while level four wheelset repairs do require separating the axle and wheel, in wheelset receiving area 1, level two and level three wheelset repairs are transported to machining area 2 via overhead conveyor line 11 for subsequent operations, while level four wheelset repairs are transported directly from underground through machining area 2 to wheelset disassembly area 3 via underground conveyor line 12. The setup of overhead conveyor line 11 and underground conveyor line 12 does not need to consider avoiding various equipment placed on the ground, which can achieve the shortest possible transport path and reduce site occupation, making full use of site space, so that wheelsets to be repaired in each repair process can quickly reach the subsequent work station, improving wheelset repair efficiency.

[0031] like Figure 2 As shown, the wheelset receiving area 1 is equipped with a bearing removal station 13 and a flaw detection room 14. The overhead conveyor line 11 includes a first section 111 and a second section 112 arranged in parallel. The first section 111 is located on one side of the bearing removal station 13 and one side of the flaw detection room 14. The second section 112 is located on the other side of the flaw detection room 14 and extends to the machining area 2. Elevators 15 are provided between the first section 111 and the bearing removal station 13, between the first section 111 and the flaw detection room 14, and between the second section 112 and the flaw detection room 14.

[0032] The bearing removal station 13 is used for bearing removal operations on third-stage wheelsets. The third-stage wheelsets are conveyed to the bearing removal station 13 via the first conveyor line 16, then lifted by the elevator 15 onto the first section 111. From there, they are sent to the flaw detection room 14 by the elevator 15 on one side of the flaw detection room 14 for flaw detection. Wheelets that pass the flaw detection are then sent to the second section 112 by the elevator 15 on the other side of the flaw detection room 14 for subsequent processing in the machining area 2. Second-stage wheelsets do not require bearing removal, so they do not pass through the bearing removal station 13. Instead, they are directly conveyed to the elevator 15 via the second conveyor line 17 and sent to the flaw detection room 14 for flaw detection. Wheelets that pass the flaw detection are then sent to the machining area 2 by the second section 112 for subsequent processing.

[0033] In this embodiment, there are two first conveyor lines 16. The underground conveyor line 12 is parallel to the first section 111 and located on the side of the first section 111 away from the elevator 15, so that the fourth-level wheelsets can be directly transported from one of the first conveyor lines 16 to the underground conveyor line 12 to reach the wheelset disassembly area 3 for subsequent operations. The first conveyor line 16, which simultaneously undertakes the task of transporting fourth-level and third-level wheelsets, can operate flexibly according to the actual ratio of the number of fourth-level and third-level wheelsets to be repaired. When there are many fourth-level wheelsets, this first conveyor line 16 can be used entirely to transport fourth-level wheelsets. When there are few fourth-level wheelsets, this first conveyor line 16 is used for both third-level and fourth-level wheelsets.

[0034] In this embodiment, the transport routes for the secondary, tertiary, and quaternary wheelsets do not interfere with each other, enabling the wheelsets to be transported in an orderly and efficient manner, reducing the wheelset transfer time.

[0035] In this embodiment, a manual re-inspection station 18 is also provided on one side of the second segment 112. The secondary or tertiary wheelsets that are determined to be unqualified by the flaw detection room 14 will be subjected to a second flaw detection by manual means at the manual re-inspection station 18 to ensure the accuracy of the flaw detection results.

[0036] like Figure 1 As shown, a blank part storage area 4 is provided on one side of the wheelset disassembly area 3, and a wheel and axle processing area 5 is provided on the side of the blank part storage area 4 away from the wheelset disassembly area 3. The fourth-level wheelset is disassembled from the wheelset receiving area 1 through the underground conveyor line 12 into the wheelset disassembly area 3. Some of the disassembled axles and wheels can be reused. Unusable axles or wheels need to be replaced with blank wheels or blank axles from the blank part storage area 4, and then enter the wheel and axle processing area 5 for processing. Therefore, the blank part storage area 4 is set between the wheelset disassembly area 3 and the wheel and axle processing area 5 to reduce the transfer distance.

[0037] Furthermore, a temperature-controlled chamber 6 is located on one side of the machining area 2. One end of the temperature-controlled chamber 6 is connected to one end of the wheel and axle machining area 5, and the other end of the temperature-controlled chamber 6 is located at the bearing press-fitting area 7. One side of the bearing press-fitting area is connected to one side of the wheelset receiving area 1. Since the second-stage wheelset overhaul does not involve bearing removal, there is no need for journal dimension measurement or bearing selection; the axle end cap accessories can be assembled directly. The third-stage wheelset overhaul and the assembled fourth-stage wheelset overhaul require re-performing journal dimension measurement and bearing selection (journal and bearing inner diameter). Because the wheelset and bearing were previously stored in different areas, there may be a temperature difference, which can cause changes in the journal dimension or bearing inner diameter, ultimately leading to unqualified bearing press-fitting. Therefore, the wheelset and bearing need to be temperature-controlled in the same room for at least 8 hours. Since both the third-stage and fourth-stage wheelset overhauls require temperature-controlled processes, both the machining area 2 and the wheel and axle machining area 5 are adjacent to the temperature-controlled chamber 6.

[0038] The third conveyor line 21 is used to transport the third-stage wheelset from the machining area 2 to the temperature chamber 6. The fourth conveyor line 22 is used to transport the second-stage wheelset from the machining area 2 to the temperature chamber 6. Since the second-stage wheelset does not need to undergo the temperature chamber process, the fourth conveyor line 22 is located near the bearing press-fitting area 7 to facilitate the entry of the second-stage wheelset.

[0039] Example 2

[0040] like Figure 3 As shown, embodiments of the present invention also provide a wheelset maintenance method, comprising the following steps:

[0041] S1. Before the bearing is removed, the secondary wheelset is diverted and transported to the flaw detection room 14 via the overhead conveyor line 11. After the bearing is removed, the tertiary and quaternary wheelset is diverted and transported to the flaw detection room 14 via the overhead conveyor line 11. The quaternary wheelset is transported to the wheelset disassembly area 3 via the underground conveyor line 12.

[0042] S2. After passing the flaw detection in the flaw detection room 14, the secondary and tertiary wheelsets are transferred to the machining area 2 via the overhead conveyor line 11 for turning operations. The tertiary wheelsets are separated into usable used wheelsets and scrapped wheelsets after the wheelset disassembly area 3 is disassembled.

[0043] Since the second-level wheelset repair does not require bearing removal and the third-level wheelset repair does not require wheel and axle disassembly, the wheelsets for each repair process are diverted at key nodes according to the differences in the repair of each wheelset. The wheelsets are efficiently transferred using the overhead conveyor line 11 and the underground conveyor line 12, so that the repair of each wheelset is distinguished from each other, does not interfere with each other, and can be carried out simultaneously, which greatly improves the efficiency of wheelset repair.

[0044] Furthermore, the wheelset maintenance method of this embodiment also includes the following steps:

[0045] S3. After the turning operation is completed, the secondary turning wheel pair is transferred to the bearing press-fitting area 7 for the assembly of the shaft end cover accessories. After the turning operation is completed, the tertiary turning wheel pair is transferred to the temperature-controlled room 6 for temperature-controlled storage.

[0046] Since the bearings were removed during the third-stage wheelset overhaul, the wheelset needs to undergo a second round of procedures, including measuring the journal dimensions and selecting the bearings (journal and bearing inner diameters), before the bearings can be press-fitted. Because the wheelset and bearings were stored in different areas, there may be a temperature difference. This temperature difference can cause changes in the journal dimensions or bearing inner diameter, ultimately leading to unsatisfactory bearing press-fitting. Therefore, the wheelset and bearings need to be subjected to temperature homogenization within a controlled environment (temperature zone 6).

[0047] Furthermore, the wheelset maintenance method of this embodiment also includes the following steps:

[0048] S4. Transfer the usable used axles, usable used wheels, blank axles, and blank wheels to the wheel and axle processing area 5. Grind the usable used axles, turn the blank axles, and bore the usable used wheels and blank wheels. Grinding, as a finishing process in machining, only removes a very thin layer of metal from the surface of the workpiece, ultimately achieving the required machining accuracy and surface roughness, and therefore can be used to process usable used axles. Blank axles, however, can undergo more cutting, so turning is used for processing. Boring is a cutting process that uses a cutting tool to enlarge the inner diameter of holes or other circular contours, and can be used to process wheel hub holes.

[0049] In step S4, two boring machines are integrated on both sides of the wheelset pressing machine. Based on the wheel axle selection method using the basic shaft system, the wheel hub holes of the corresponding dimensions are machined. The basic shaft system is a system that specifies a fixed shaft tolerance zone and obtains different fits by selecting different hole tolerance zones. Based on the cycle efficiency of the wheel vertical boring machine and axle machining production line, two wheel boring machines are integrated on both sides of the wheelset pressing machine to complete the machining of wheel hub holes of the corresponding dimensions, and finally complete the pressing of the wheel and axle. The advantages of using the basic shaft system are:

[0050] First, the wheel and axle cards are based on the wheel set axle number, which is engraved on the axle end for easy reference by the operator.

[0051] Secondly, by finding and selecting the most suitable wheel based on the axle and wheel seat dimensions, and by choosing the economical machining allowance for the hub hole, it is beneficial to improve the utilization rate of old wheels and axles.

[0052] Third, because axles are easy to store and take up little space after processing, if axles are processed first, the assembly process can be started quickly when wheels are processed, minimizing the number of wheels on site, which is conducive to lean production management.

[0053] Furthermore, the wheelset maintenance method of this embodiment also includes the following steps:

[0054] After the axle end cap accessories of each stage of the wheelset overhaul are assembled, wheelset break-in, wheelset dimension measurement, wheelset painting, and appearance inspection are carried out sequentially in bearing press-fitting area 7. Since the above processes are required for all overhauled wheelsets, a series layout of equipment is adopted.

[0055] Although the invention has been described with reference to preferred embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, the technical features mentioned in the various embodiments can be combined in any manner as long as there is no structural conflict. The invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A wheelset maintenance line, characterized in that, It includes a wheelset receiving area, a machining area and a wheelset disassembly area connected in sequence. The wheelset receiving area is provided with an overhead conveyor line connected to the machining area and an underground conveyor line connected to the wheelset disassembly area. The underground conveyor line passes through the machining area underground. The wheelset receiving area is equipped with a bearing removal station and a flaw detection room. The overhead conveyor line includes a first section and a second section arranged in parallel. The first section is located on one side of the bearing removal station and one side of the flaw detection room. The second section is located on the other side of the flaw detection room and extends to the machining area. Elevators are provided between the first section and the bearing removal station, between the first section and the flaw detection room, and between the second section and the flaw detection room. The wheelset maintenance method of the wheelset maintenance line includes the following steps: S1. Before the bearing is removed, the secondary wheelset is diverted and transported to the flaw detection room via an overhead conveyor line. After the bearing is removed, the tertiary and quaternary wheelset is diverted and transported to the flaw detection room via an overhead conveyor line, while the quaternary wheelset is transported to the wheelset disassembly area via an underground conveyor line. S2. After passing the flaw detection in the flaw detection room, the secondary and tertiary wheelsets are transferred to the machining area via an overhead conveyor line for turning operations. The tertiary wheelsets are separated into usable used wheelsets and scrapped wheelsets after the wheelset disassembly area is disassembled. The three-stage wheelset is transported to the bearing unloading station via the first conveyor line, then lifted to the first section by the elevator, and then sent into the flaw detection room by the elevator on one side of the flaw detection room for flaw detection. The three-stage wheelset that passes the flaw detection is then sent into the second section by the elevator on the other side of the flaw detection room to enter the machining area for subsequent operations. There are two first conveyor lines. The secondary wheelset does not require bearing removal, so it does not go through the bearing removal station. Instead, it is directly transported to the elevator by the second conveyor line and enters the flaw detection room for flaw detection. After passing the flaw detection, the secondary wheelset is then sent to the machining area by the second section for subsequent operations.

2. The wheelset maintenance line according to claim 1, characterized in that, The underground transport line is parallel to the first segment and located on the side of the first segment away from the elevator.

3. The wheelset maintenance line according to claim 1, characterized in that, A blank part storage area is provided on one side of the wheelset disassembly area, and a wheel axle processing area is provided on the side of the blank part storage area away from the wheelset disassembly area.

4. The wheelset maintenance line according to claim 3, characterized in that, A temperature-controlled chamber is provided on one side of the machining area. One end of the temperature-controlled chamber is connected to one end of the wheel axle machining area. The other end of the temperature-controlled chamber is provided with a bearing press-fitting area. One side of the bearing press-fitting area is connected to one side of the wheelset receiving area.

5. The wheelset maintenance line according to claim 1, characterized in that, The wheelset maintenance method also includes the following steps: S3. After the turning operation is completed, the secondary turning wheel pair is transferred to the bearing press-fitting area for the assembly of the shaft end cover accessories. After the turning operation is completed, the tertiary turning wheel pair is transferred to the same temperature room for same temperature storage.

6. The wheelset maintenance line according to claim 1, characterized in that, The wheelset maintenance method also includes the following steps: S4. Transfer the usable used axles, usable used wheels, blank axles and blank wheels to the wheel and axle processing area, perform grinding on the usable used axles, turning on the blank axles, and boring on the usable used wheels and blank wheels.

7. The wheelset maintenance line according to claim 6, characterized in that, In step S4, two boring machines are integrated on both sides of the wheelset press machine, and the wheel hub holes of the corresponding size are processed based on the wheel axle selection method of the base shaft system.

8. The wheelset maintenance line according to claim 6, characterized in that, The wheelset maintenance method also includes the following steps: After the assembly of the shaft end cap accessories of S5 and each level of the wheel set is completed, the wheel set break-in, wheel set size measurement, wheel set painting and appearance inspection are carried out in sequence in the bearing press-fitting area.

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