Manufacturing method of roller brush in motor train unit axle pretreatment device

Abstract

The invention belongs to the technical field of nonmetal roller equipment processing, and particularly relates to a manufacturing method of a roller brush in a motor train unit axle pretreatment device, which comprises the following steps: S1, manufacturing of a dry roller brush and a wet roller brush: cutting a non-woven fabric into a strip shape, pressing and gluing; the compressed strip-shaped non-woven fabric is glued through a winding roller; the contour size of the corresponding profiling roller brush is calculated, and a corresponding tool is manufactured; turning and grinding the roller brush by using a profiling tool; and carrying out dynamic balance test on the roller brush, and packaging and warehousing after qualification. S2, a manufacturing method of the water absorption roller brush comprises the following specific steps that non-woven fabric is stamped into an annular sheet shape through a mold to be pressed and cemented; cementing and assembling with the outer layer of the roller brush; the outer contour size of the corresponding profiling roller brush is calculated, a corresponding profiling tool is manufactured, and the profiling tool is used for turning and grinding the roller brush; and carrying out dynamic balance test on the roller brush, and packaging and warehousing after qualification. According to the roller brush obtained through the method, bristles are uniform, the bristles and the roller core are firmly connected, and the precision and stability of the roller brush are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of non - metal roller equipment processing, and particularly relates to a manufacturing method of a roller brush in a pre - treatment device for a train axle of a bullet train. Background Technique

[0002] As a key component of a high - speed train, high requirements are imposed on the processing quality of the train axle. Before the painting pre - treatment stage of the train axle, it is necessary to wipe and clean solid particulate matters such as dust and magnetic powder on the axle body surface and residual liquid mixed dirt on the surface. The train axle pre - treatment device includes a dry brush assembly, a wet brush assembly, a spraying device, and a water absorption assembly. Among them, the dry brush assembly, the wet brush assembly, and the water absorption assembly all include roller brushes. The requirements for the bristles of the roller brush are high. It needs to have flexibility to avoid scratching the surface of the train axle, and also needs a certain hardness to effectively remove stubborn stains and rust.

[0003] At present, the manufacturing methods of train axle pre - treatment devices have made progress in terms of intelligence and automation, but there are still some defects in design details and functionality. For example, improper process control, uneven distribution of bristles, and insecure connection between the bristles and the roller core result in uneven cleaning or grinding of the train axle surface. The fallen bristles will adhere to the train axle surface, causing secondary pollution; poor precision of the roller brush leads to a mismatch between the roller brush and the outer surface contour of the train axle, with cleaning blind spots; poor stability of the roller brush causes vibration during high - speed operation, affecting the cleaning effect. Summary of the Invention

[0004] The purpose of the present invention is to provide a manufacturing method of a roller brush in a pre - treatment device for a train axle of a bullet train, so as to solve the problems of uneven bristles of the roller brush obtained by traditional manufacturing methods, insecure connection between the bristles and the roller core, poor precision of the roller brush, and poor stability.

[0005] A manufacturing method of a roller brush in a pre - treatment device for a train axle of a bullet train includes the following steps: S1: Manufacturing of the dry roller brush and the wet roller brush. The manufacturing methods of the two roller brushes are the same, and the specific steps are as follows: (1) Cut the non - woven fabric into strips by a cutting device, and then use a cloth pressing machine to press and bond the strip non - woven fabric to obtain a dense shape and stable performance; (2) Roll and bond the pressed strip non - woven fabric for easy bonding and assembly onto the roller core; (3) According to the contour size of the train axle of the bullet train, calculate the corresponding contour size of the profiling roller brush and make the corresponding tooling; use the profiling tooling on a grinding machine to turn and grind the roller brush until it meets the profiling roller brush contour size; (4) Conduct a dynamic balance test on the roller brush. After passing the test, it is packaged and stored in the warehouse; when the dynamic balance of the roller brush is unqualified, add dynamic balance blocks inside the roller for adjustment and conduct a dynamic balance test again. After passing the test, it is packaged and stored in the warehouse.

[0006] S2: A method for making a water-absorbing roller brush, the specific steps are as follows: (1) Punch the non-woven fabric into an annular sheet using a die through a punching machine, and then use a horizontal press to press and glue the annular sheet non-woven fabric so that the outer layer of the roller brush obtains dense performance and stable shape; (2) After the roller core is processed, it is assembled with the outer layer of the roller brush; (3) According to the outer contour dimensions of the EMU axle, calculate the corresponding outer contour dimensions of the profiling roller brush, make the corresponding profiling tooling, and use the profiling tooling to grind the roller brush to meet the contour dimensions of the profiling roller brush; (4) Perform a dynamic balance test on the roller brush, and pack and store after passing the test. If the roller brush fails to meet the dynamic balance requirement, add a dynamic balance block inside the roller for adjustment, and re-test the dynamic balance, and pack and store after passing the test.

[0007] Preferably, the non-woven fabric in step S1 (1) is made of nylon containing abrasives, which is used to remove burrs on the workpiece, and the processing results are uniform.

[0008] Preferably, the non-woven fabric in step S2 (1) is made of high-strength artificial nylon fiber and has a porous structure. During operation, the non-woven fabric can absorb and squeeze out the liquid on the surface of the workpiece and at the same time absorb dirt particles on the surface of the workpiece into the roller body, thereby cleaning the surface of the workpiece and preventing scratches.

[0009] Compared with the prior art, the present invention has the following beneficial effects: (1) Both the dry roller brush and the wet roller brush are made of non-woven fabric, which is flexible and will not scratch the axle surface. It has appropriate hardness and is a fabric that does not require spinning and weaving, and has strong cleaning ability. The belt-shaped non-woven fabric is pressed and bonded and the roller is rolled to make the material dense, the bristles are evenly distributed, and the connection between the bristles and the roller core is firm, which improves the cleaning power and durability and extends the service life of the roller brush. The water-absorbing roller brush is made of non-woven fabric, which is blanked by sheet punching, pressed and bonded, and assembled. The bristles are evenly distributed, and the connection between the bristles and the roller core is firm, forming a high-density water-absorbing layer, which quickly absorbs the residual liquid on the axle surface. The two roller brushes are used in combination to achieve "dry and wet separation" cleaning of the axle surface, which is more thorough than a single cleaning method. (2) Use cutting equipment, cloth presses, horizontal presses and other equipment to realize the unloading and bonding of strip / sheet materials, reduce manual intervention, improve product consistency and production efficiency, standardize process flow, reduce human errors, and ensure stable quality of each batch of products; (3) The high precision of the roller brush is ensured by customizing the profiling tooling. The shape of the roller brush is accurately calculated according to the outer contour of the axle, and the roller brush is processed through a turning and grinding process to perfectly match the surface of the axle to avoid cleaning blind spots; (4)Ensure the stability of the roller brush through dynamic balance adjustment, guarantee the balance of the roller brush during high-speed rotation, avoid vibration, ensure the smooth operation of the roller brush, and extend its service life. Specific embodiments

[0010] The technical solution of the present invention will be further described below in conjunction with embodiments.

[0011] Perform pre-treatment on the power shaft of the EMU DZ2. The dimensions of the power shaft of the EMU DZ2 are: Φ200×2180mm, dynamic balance: G2.5. The manufacturing methods of the dry roller brush, wet roller brush, and water-absorbing roller brush include the following: S1: Manufacturing of the dry roller brush and wet roller brush. The manufacturing methods of the two roller brushes are the same, and the specific steps are as follows: (1)Cut the non-woven fabric into strips with a cutting device, with dimensions of 90mm×1810mm, and then use a cloth pressing machine to press and bond the strip-shaped non-woven fabric to obtain a dense shape and stable performance; (2)Roll and bond the pressed strip-shaped non-woven fabric for easy bonding and assembly onto the roller core; (3)According to the contour dimensions of the EMU axle, calculate the corresponding contour dimensions of the profiling roller brush. The dimensions of the dry (wet) roller brush are Φ305×1798mm, and make the corresponding tooling; use the profiling tooling on the grinding machine to turn and grind the roller brush until it meets the profiling roller brush contour dimensions; (4)Conduct a dynamic balance test on the roller brush. Left phase angle 235º, left phase indication value 310g; right phase angle 257º, right phase indication value 268g. The dynamic balance of the roller brush is unqualified. The reason for the imbalance is that the roller core is overweight. Add dynamic balance blocks for adjustment at the corresponding phase angle positions and conduct a dynamic balance test again. Left phase angle 235º, left phase indication value 300g; right phase angle 257º, right phase indication value 260g; the dynamic balance of the roller brush is qualified, and it is packaged and stored in the warehouse.

[0012] S2: Manufacturing method of the water-absorbing roller brush. The specific steps are as follows: (1)Use a punching machine to punch the white water-absorbing non-woven fabric into a ring-shaped sheet with a mold. The outer diameter dimension is Φ310, and the inner diameter dimension is Φ200mm. Then use a horizontal press to press and bond the ring-shaped non-woven fabric to make the outer layer of the roller brush obtain dense performance and a stable shape; (2)After the roller core is processed, it is bonded and assembled with the outer layer of the roller brush; (3)According to the outer contour dimensions of the EMU axle, calculate the corresponding outer contour dimensions of the profiling roller brush: diameter Φ305mm, effective length 1800, total length 2173mm, and make the corresponding profiling tooling. Use the profiling tooling to turn and grind the roller brush to meet the profiling roller brush contour dimensions; (4)Perform dynamic balance testing on the roller brush. Left phase angle: 134º, left phase indication value: 65 g; right phase angle: 152º, right phase indication value: 84 g. The dynamic balance of the roller brush is unqualified. Reason for imbalance: The roller core is overweight. Add dynamic balance weights at the corresponding positions of the phase angle for adjustment and perform dynamic balance testing again. Left phase angle: 134º, left phase indication value: 60 g; right phase angle: 150º, right phase indication value: 70 g. The dynamic balance of the roller brush is qualified. Package and store in the warehouse.

Claims

1. A manufacturing method of a roller brush in a front treatment device for an EMU axle, characterized in that, It includes the following contents: S1: Production of dry roller brush and wet roller brush. The production methods of the two roller brushes are the same, and the specific steps are as follows: (1) Cut the non-woven fabric into strips by a cutting device, and then use a cloth pressing machine to press and bond the strip-shaped non-woven fabric to obtain a dense shape and stable performance; (2) Roll and bond the pressed strip-shaped non-woven fabric for easy bonding and assembly onto the roller core; (3) Calculate the corresponding profiling roller brush contour dimensions according to the contour dimensions of the EMU axle, and make the corresponding tooling; use the profiling tooling on the grinding machine to turn and grind the roller brush until it meets the profiling roller brush contour dimensions; (4) Conduct a dynamic balance test on the roller brush. After passing the test, it is packaged and stored in the warehouse; when the dynamic balance of the roller brush is unqualified, add dynamic balance blocks inside the roller for adjustment, and conduct a dynamic balance test again. After passing the test, it is packaged and stored in the warehouse; S2: Production method of the water-absorbing roller brush. The specific steps are as follows: (1) Punch the non-woven fabric into a ring-shaped sheet by a punching machine, and then use a horizontal press to press and bond the ring-shaped non-woven fabric to make the outer layer of the roller brush obtain dense performance and stable shape; (2) After the roller core is processed, it is bonded and assembled with the outer layer of the roller brush; (3) Calculate the corresponding profiling roller brush outer contour dimensions according to the outer contour dimensions of the EMU axle, make the corresponding profiling tooling, and use the profiling tooling to turn and grind the roller brush to meet the profiling roller brush contour dimensions; (4) Conduct a dynamic balance test on the roller brush. After passing the test, it is packaged and stored in the warehouse; when the dynamic balance of the roller brush is unqualified, add dynamic balance blocks inside the roller for adjustment, and conduct a dynamic balance test again. After passing the test, it is packaged and stored in the warehouse.

2. The manufacturing method of the roller brush in a front processing device for the axle of a multiple unit train according to claim 1, characterized in that, The non-woven fabric in step S1 (1) is a nylon material containing abrasives.

3. The manufacturing method of the roller brush in a front treatment device for the axle of a multiple unit train according to claim 1, characterized in that, The non-woven fabric in step S2 (1) is a high-strength artificial nylon fiber material with a pore structure. During the working process, it can suck dry and squeeze out the liquid on the workpiece surface, and at the same time suck the dirt particles on the workpiece surface into the roller body, playing a role in cleaning the workpiece surface and preventing scratches.