Maintenance method of brake clamp assembly

Abstract

The invention provides a maintenance method of a brake clamp assembly, and aims to provide an efficient and standardized maintenance process so as to ensure the reliability and long service life of the brake clamp assembly. The method comprises the following six main steps: firstly, carrying out previous procedure handover and disassembly, and recording the states of all parts in the disassembly process; secondly, external cleaning is conducted, and thorough sand blasting cleaning is conducted on the parts; secondly, maintenance and detection are conducted, a standard tool is used for conducting accurate inspection on the parts, and the size and the surface quality are detected; performing identification management and recording, identifying all the overhauled or replaced parts, and recording overhaul data; then assembling and adjusting are conducted, and assembly is conducted strictly according to a standard drawing; and finally, testing and verifying: executing various tests of strength, leakage and sensitivity. By means of the overhauling method, the overhauling efficiency can be remarkably improved, part damage and operation errors are reduced, the service life of equipment is prolonged, and running safety of a train is guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of brake caliper assembly maintenance, in particular to a brake caliper assembly maintenance method. Background Art

[0002] In modern railway transportation, the braking system of EMUs is crucial to ensure the safety and stability of trains. As the core component of the EMU braking system, the brake caliper is responsible for contacting the brake disc with the wheelset to achieve the braking effect. The performance of the brake caliper is directly related to the braking capacity of the train and the safety of passengers. Therefore, maintaining the good working condition of the brake caliper assembly is the key to ensuring the safe operation of the train. However, during the long-term use of the brake caliper, due to the influence of high-frequency operation, temperature fluctuations, corrosion and wear factors, its components gradually suffer from varying degrees of damage and failure, such as pin wear, bushing aging, and thread damage. Traditional brake caliper maintenance methods mostly rely on manual experience, and the maintenance process is not standardized, which easily leads to incomplete maintenance or irregular operation, affecting the long-term reliability of the brake caliper. Therefore, there is an urgent need for a more efficient, accurate and standardized maintenance method to ensure the intact function of the brake caliper, extend its service life and improve the safety of railway transportation. Summary of the invention

[0003] In view of the above-mentioned technical deficiencies, an object of the present invention is to provide a method for repairing a brake caliper assembly, so as to improve the repair efficiency and ensure the high precision and long service life of the components.

[0004] To achieve the above object, the present invention adopts the following technical solution:

[0005] A method for repairing a brake caliper assembly comprises the following steps:

[0006] Handover and disassembly from previous process: Receive the brake caliper assembly to be repaired, record the appearance, identification and damage, disassemble it using appropriate tools, and record the number and source of each component;

[0007] External cleaning: Use sandblasting or fine grinding to clean the oil, rust and other impurities on the surface of parts to ensure the surface of parts is clean;

[0008] Inspection and testing: Check the size, tolerance and appearance quality of parts according to standards, and repair or replace parts that exceed the standards;

[0009] Identification management and records: Identify all repaired or replaced parts and record detailed repair data;

[0010] Assembly and adjustment: Assemble parts according to standard drawings and make adjustments to ensure the assembled brake caliper assembly works properly;

[0011] Testing and verification: Functional testing is performed on the assembled brake caliper to ensure that its performance meets the specified requirements.

[0012] Preferably, the disassembly step includes first disassembling the fixing bolts of the brake lever and the brake cylinder, ensuring that the bolts are loosened by a torque wrench, and recording the disassembly status of each component.

[0013] Preferably, in the cleaning step, for pin shaft parts, a fine grinder or polisher is used to remove the surface coating, and excessive grinding to avoid damaging the substrate.

[0014] Preferably, the inspection and testing step includes using a thread gauge to check the threads of pin-type components, and using a template to detect their key dimensions.

[0015] Preferably, in the assembly and adjustment steps, all bolts and pins are tightened using a torque wrench during installation to ensure that the torque of the bolts meets standard requirements.

[0016] Preferably, the test and verification steps include a strength test, a leakage test and a sensitivity test. The leakage of all tests must not exceed the specified standard, and the piston rod must respond in time.

[0017] Preferably, in the identification management and recording step, all repaired or replaced parts should be labeled with the manufacturer, part number, and maintenance record number information, and the label should not be easily worn.

[0018] Preferably, in the external cleaning step, compressed air and clean cloth are used for secondary cleaning during the cleaning process to ensure that no dust or impurities remain.

[0019] Preferably, in the cleaning step, the disassembled parts should be cleaned using sandblasting equipment to ensure that there are no chemical corrosion products or oil stains on the surface of the parts.

[0020] Preferably, in the test and verification steps, the test contents include strength test, low-pressure leakage test, high-pressure leakage test and manual reset test, and all test results should meet the prescribed standards to ensure the normal operation of the brake caliper unit.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] Standardized maintenance process: The present invention ensures that each operation meets the standards by formulating a unified and standard maintenance method, reduces human errors, and improves the consistency and reliability of maintenance.

[0023] Efficient parts inspection: By using special tools and testing standards, each component of the brake caliper is carefully inspected to ensure that all components meet the use standards, effectively reducing safety hazards caused by component quality problems.

[0024] Extend equipment service life: Timely repair or replacement of damaged parts avoids system failure caused by the use of aging parts, extends the overall service life of the brake caliper, and reduces maintenance costs.

[0025] Improved safety: Through precise testing and verification processes, we ensure that the brake calipers after overhaul meet the requirements of strength, leakage and sensitivity, which significantly improves the safety and reliability of railway transportation.

[0026] Traceability and record management: By marking and recording all repaired parts in detail, the traceability of the repair process is ensured, facilitating subsequent quality inspections and troubleshooting.

[0027] Strong adaptability: This method is applicable to different models of brake caliper assemblies, has strong universality, and can be widely used in the maintenance of different EMUs and railway equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a flowchart of the present invention. DETAILED DESCRIPTION

[0029] The following is combined with Figure 1 The present invention is further described.

[0030] The following is a specific implementation method of a brake caliper assembly maintenance method, which provides detailed expansion for each step to ensure the standardization and accuracy of each link to achieve efficient and safe maintenance.

[0031] Handover and disassembly of the previous process: When receiving the brake caliper assembly to be repaired, a detailed handover inspection is required first. The appearance, identification, damage and original number of all incoming parts should be recorded. Check whether there are missing or deformed parts, especially important pins and bushing parts, to confirm whether they meet the specified standards. The disassembly work should use a combination of manual and pneumatic tools to ensure that the disassembly process is efficient and does not damage the parts. When disassembling, the fixing bolts of the brake lever and the brake cylinder should be disassembled first, and the looseness of the bolts should be ensured by a torque wrench, and the disassembly of each component should be recorded. In order to avoid mixing parts from different manufacturers, all parts should be clearly separated according to their source after disassembly, and the unique identification number of the parts should be marked one by one to facilitate traceability during later maintenance.

[0032] External cleaning: The core of the cleaning process is to remove oil, rust and other impurities from the surface of the parts by physical means. During cleaning, all disassembled parts (except pin parts) should be thoroughly cleaned using sandblasting equipment. Appropriate abrasives should be used for sandblasting to ensure that no chemical corrosion or oil is left on the surface of the parts to avoid affecting subsequent inspection and repair work. When handling pin parts, care should be taken to avoid wear or change in size. Grind the pins with a fine grinder or polisher to remove the surface coating and avoid excessive grinding to damage the substrate. In addition, protective plugs should be used to protect all holes during the cleaning process of the parts to prevent unnecessary wear or damage during the sandblasting process. After all parts are cleaned, they should be cleaned again with compressed air and clean cloth to ensure that no dust or impurities are left.

[0033] Maintenance and testing: After cleaning, the parts enter the maintenance stage. The maintenance standards of each part need to formulate detailed maintenance methods based on the function and use requirements of the parts:

[0034] Inspection of pin shaft parts: For example, the pin shaft parts such as brake lever bolts and brake pad support bolts, first check whether their threads meet the standards. For thread inspection, you can use a thread gauge to test to ensure the accuracy and durability of the internal and external threads. It is particularly important to note that the surface of the thread must be smooth, free of cracks, burrs and thread slippage. If there is severe wear or cracks, it needs to be replaced. In addition, check whether the diameter, length and key dimensions of the pin shaft meet the standards, and use a special sample for testing to ensure that its dimensional accuracy does not exceed the limit.

[0035] Inspection of casting parts: For example, brake levers and suspension casting parts need to be inspected for cracks, corrosion, and deformation defects. For damaged parts, use a depth gauge and a microscope to check to ensure that the damage depth is within the standard range. If it exceeds the range, it needs to be repaired or replaced. For minor appearance defects, it can be handled by grinding or applying anti-rust oil; for more serious damage, such as cracks exceeding 30mm, replacement of parts should be considered.

[0036] Bushings and washers: Check whether their inner and outer diameters meet the standards, especially for bushings that match pins and bolts, the inner diameter dimensions must be strictly measured. For bushings with significant wear, accurate size comparisons must be made using a sample, and bushings that exceed the standards must be replaced.

[0037] Identification management and records: The present invention clearly stipulates the standards for identification management during the maintenance process. All parts that have been repaired, replaced or tested to be qualified must be re-identified. The identification content includes the manufacturer of the parts, the part number, the maintenance record number, and the date of repair or replacement to ensure the traceability of all parts. When marking, durable and non-wearable identification tools, such as laser engraving machines, must be used to ensure that the identification information is not worn during long-term use. All maintenance data should be recorded in detail in the maintenance record form, including the damage condition of the parts, the repair method, the measurement data and detailed information of the replaced parts.

[0038] Assembly and adjustment: The assembly process is a key link in maintenance. During assembly, operations should be carried out in accordance with the drawings and standards. All bolts and pins need to be installed in the specified position and tightened with appropriate torque. In order to ensure reliability after assembly, all bolts and fasteners must be checked twice after assembly, and a torque wrench should be used to ensure that the tightening torque of the nuts meets the standard requirements. For key components (such as the connecting bolts between the brake lever and the brake cylinder, and the connecting bolts between the brake pad support and the brake cylinder), an appropriate amount of grease should be applied before tightening to reduce the friction coefficient and reduce wear during long-term use. For parts that need to be adjusted, such as the adjustment of the brake lever and the clearance of the pin, they must be adjusted strictly within the specified adjustment range to ensure that the moving parts of the components can move flexibly and without jamming.

[0039] Test and verification: After assembly, the brake caliper assembly should undergo a series of rigorous functional tests to ensure that its performance indicators meet the specified requirements. The test content includes but is not limited to strength test, leakage test, and sensitivity test:

[0040] Strength test: Inflate the brake cylinder to simulate the pressure under actual working conditions and check the load-bearing capacity of each component under high pressure. The test should last for 10 seconds to ensure that the components are not damaged or permanently deformed.

[0041] Leakage test: It is divided into low-pressure and high-pressure leakage tests. In the low-pressure test, 80kPa of air is filled into the brake cylinder and the pressure is maintained for 2 minutes. The leakage shall not exceed 2kPa. In the high-pressure test, the air pressure is increased to 450kPa and the pressure is maintained for 2 minutes. The leakage shall not exceed 2kPa. During the test, a gas leakage detection instrument should be used to ensure that there is no leakage.

[0042] Sensitivity test: Inflate the brake cylinder to 45kPa, observe the reaction of the piston rod, and test the sensitivity of the brake device. Ensure that the brake device can respond in time under low pressure.

[0043] Apply anti-rust oil: After the test is passed, all parts that have not been painted should be treated with anti-rust oil. When applying anti-rust oil, ensure that all surfaces of parts that need to be applied are evenly covered with anti-rust oil. The application of anti-rust oil should include important parts such as the fixing bolts of the brake cylinder and the ends of the pins to prevent corrosion of parts due to moisture and oxidation during transportation and storage.

[0044] Summary: The brake caliper assembly maintenance method of the present invention ensures the efficient implementation of each link through standardized and precise operation procedures. From component disassembly, cleaning, maintenance, assembly to functional testing, each step is strictly operated in accordance with the standard to ensure that the repaired brake caliper can provide reliable performance guarantee in actual use. This method effectively improves maintenance efficiency, ensures high precision and long service life of components, and has broad application prospects.

Claims

1. A method for repairing a brake caliper assembly, characterized in that: The following steps are involved: Handover and disassembly from previous process: Receive the brake caliper assembly to be repaired, record the appearance, identification and damage, disassemble it using appropriate tools, and record the number and source of each component; External cleaning: Use sandblasting or fine grinding to clean the oil, rust and other impurities on the surface of parts to ensure the surface of parts is clean; Inspection and testing: Check the size, tolerance and appearance quality of parts according to standards, and repair or replace parts that exceed the standards; Identification management and records: Identify all repaired or replaced parts and record detailed repair data; Assembly and adjustment: Assemble parts according to standard drawings and make adjustments to ensure the assembled brake caliper assembly works properly; Testing and verification: Functional testing is performed on the assembled brake caliper to ensure that its performance meets the specified requirements.

2. A method for repairing a brake caliper assembly according to claim 1, characterized in that: The disassembly steps include first disassembling the fixing bolts of the brake lever and the brake cylinder, ensuring that the bolts are loosened by using a torque wrench, and recording the disassembly status of each component.

3. A method for repairing a brake caliper assembly according to claim 1, characterized in that: In the cleaning step, for pin shaft parts, a fine grinder or polisher is used to remove the surface coating, and excessive grinding to avoid damaging the substrate.

4. A method for repairing a brake caliper assembly according to claim 1, characterized in that: The inspection and testing steps include using a thread gauge to check the threads of pin shaft components and using a sample to detect their key dimensions.

5. A method for repairing a brake caliper assembly according to claim 1, characterized in that: In the assembly and adjustment steps, all bolts and pins are tightened using a torque wrench during installation to ensure that the torque of the bolts meets standard requirements.

6. A method for repairing a brake caliper assembly according to claim 1, characterized in that: The test and verification steps include strength test, leakage test and sensitivity test. The leakage volume of all tests shall not exceed the specified standard and the piston rod must respond in time.

7. A method for repairing a brake caliper assembly according to claim 1, characterized in that: In the identification management and recording steps, all repaired or replaced parts should be labeled with the manufacturer, part number, and maintenance record number information, and the label should not be easily worn.

8. A method for repairing a brake caliper assembly according to claim 1, characterized in that: In the external cleaning step, compressed air and clean cloth are used for secondary cleaning during the cleaning process to ensure that there is no residual dust or impurities.

9. A method for repairing a brake caliper assembly according to claim 1, characterized in that: In the cleaning step, the disassembled parts should be cleaned with sandblasting equipment to ensure that there are no chemical corrosion products or oil stains on the surface of the parts.

10. A method for repairing a brake caliper assembly according to claim 1, characterized in that: In the test and verification steps, the test contents include strength test, low-pressure leakage test, high-pressure leakage test and manual reset test. All test results should meet the specified standards to ensure the normal operation of the brake caliper unit.

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