Railway vehicle bogie cleaning method

Abstract

The invention provides a railway vehicle bogie cleaning method, which belongs to the technical field of vehicle maintenance, and comprises the following steps: dividing a bogie into a steel area, an aluminum area and a rubber area according to component materials; s2, dirt information of all areas of the bogie is obtained; s3, according to the dirt information, personalized cleaning parameters are matched for all the areas of the bogie; s4, low-frequency ultrasonic pretreatment is conducted on the steel area and the aluminum area of the bogie, and then regional spraying is conducted on all the areas according to the cleaning parameters; and S5, the cleaned bogie is subjected to hot air drying, residual dirt is detected through an image recognition module after drying, and if the residual coverage degree is larger than or equal to 5%, the steps S4-S5 are repeated. According to the railway vehicle bogie cleaning method provided by the invention, after the bogie is partitioned according to the material, the cleaning scheme is customized for each partition, so that the cleaning quality and the maintenance safety of the bogie are comprehensively improved.

Description

Technical Field

[0001] This invention belongs to the field of vehicle maintenance technology, and more specifically, relates to a method for cleaning railway vehicle bogies. Background Technology

[0002] As a core component supporting the car body, transmitting traction and braking forces, and ensuring driving stability, the bogie of railway vehicles directly affects the safety and reliability of railway transportation. According to industry maintenance standards, railway vehicles require a comprehensive disassembly and overhaul of the bogies every certain mileage (e.g., 1.2 million kilometers for EMUs and 800,000 kilometers for freight cars). Thorough cleaning before overhaul is a crucial preliminary step to ensure maintenance quality. During long-term operation, the surface of the bogie accumulates a large amount of oil, dust, rust, brake residue, and other contaminants. These contaminants not only interfere with maintenance personnel's judgment of component defects but also accelerate corrosion and aging, shorten the bogie's service life, and may even lead to safety accidents.

[0003] However, current bogie cleaning technologies used in the railway industry still face many technical bottlenecks that urgently need to be addressed. For example, the invention patent with authorization announcement number CN102275569B discloses a method for cleaning railway vehicle bogies, which mainly uses a fixed-parameter spraying method without considering the differences in the materials of the bogie components. Bogies are composed of components made of various materials such as steel, aluminum, and rubber, and the temperature resistance, pressure resistance, and corrosion resistance of different materials vary significantly. During the cleaning process, if high-temperature and high-pressure parameters are set according to the requirements of steel components, it will lead to oxidation and corrosion of aluminum components and accelerated aging of rubber components; if gentle parameters are used, stubborn dirt on steel components will be difficult to remove completely, creating a dilemma of inadequate cleaning and component damage.

[0004] Furthermore, the characteristics of bogie fouling differ significantly among different types of railway vehicles. High-speed train bogies are primarily composed of leaking oil from gearboxes and dust, while freight car bogies are mainly affected by coal dust, ore particles, and brake residue. Passenger car bogies, on the other hand, are primarily covered by oil and mud. Current technologies employ fixed-component cleaning solutions and a single cleaning mode, failing to dynamically adjust according to the type of fouling. This results in low cleaning efficiency, either extending cleaning time due to insufficient solution concentration or causing resource waste and residual corrosion due to excessive concentration.

[0005] Furthermore, bogies may develop potential defects such as microcracks during operation. In the existing high-pressure spraying process, the impact force of the water flow may cause microcracks to propagate, exacerbating safety risks. At the same time, the lack of real-time damage monitoring during the cleaning process, relying solely on manual inspection after cleaning, makes it easy to miss defects due to dirt residue or blind spots, creating potential safety hazards for subsequent operation. Summary of the Invention

[0006] The purpose of this invention is to provide a method for cleaning railway vehicle bogies, which aims to solve the problems existing in the prior art mentioned in the background section and improve the cleaning quality and maintenance safety of bogies.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is: to provide a method for cleaning railway vehicle bogies, comprising the following steps: S1. The bogies are divided into steel, aluminum, and rubber sections according to the material of their components. S2. Obtain dirt information for each area of ​​the bogie; S3. Based on the dirt information, match personalized cleaning parameters for each area of ​​the bogie; S4. First, perform low-frequency ultrasonic pretreatment on the steel and aluminum areas of the bogie, and then spray each area separately according to the cleaning parameters. S5. Dry the cleaned bogie with hot air. After drying, detect residual dirt using an image recognition module. If the residual coverage is ≥5%, repeat steps S4-S5.

[0008] In one possible implementation, the dirt information includes the coverage and thickness of the dirt.

[0009] In one possible implementation, the cleaning parameters include the cleaning fluid composition and spraying parameters, wherein the spraying parameters include spraying temperature, spraying pressure, spraying angle, and spraying time.

[0010] In one possible implementation, in step S3, matching the cleaning fluid composition for each area of ​​the bogie specifically involves: The cleaning fluid for steel areas consists of: 4%-5% neutral cleaning agent, 1.0%-1.2% surfactant, and the remainder is water; The cleaning solution for aluminum areas consists of: 3%-4% neutral cleaning agent, 0.8%-1.0% surfactant, 0.3%-0.5% aluminum corrosion inhibitor, and the remainder is water; The cleaning solution for rubber areas consists of: 2%-3% neutral detergent, 0.5%-0.8% low-foaming surfactant, and the remainder is water.

[0011] In one possible implementation, in step S3, matching the spray parameters for each region of the bogie specifically involves: The spraying parameters for the steel area include: spraying temperature 55℃-60℃, and spraying pressure 18kg / cm². 2 -20kg / cm 2 Spray angle 25°-35°, spray time 22min-28min; The spraying parameters for the aluminum area include: spraying temperature 45℃-50℃, and spraying pressure 12kg / cm². 2 -15kg / cm2 Spray angle 40°-50°, spray time 18min-22min; The spraying parameters for the rubber area include: spraying temperature 40℃-45℃, and spraying pressure 8kg / cm². 2 -12kg / cm 2 Spray angle 55°-65°, spray time 12min-18min.

[0012] In one possible implementation, in step S4, the bogie status is monitored in real time by an ultrasonic damage monitoring module and an infrared temperature monitoring module during the spraying process. If the sprayed area of ​​the bogie is detected to be in a damaged state, the spraying parameters are downgraded.

[0013] In one possible implementation, when the ultrasonic damage monitoring module detects a microcrack length ≥0.2mm in the spray area, or the infrared temperature monitoring module detects a temperature ≥65℃ in the spray area, the spray area is determined to be in a damaged state. The downgrading of the spray parameters includes reducing the spray pressure by 20%-30% and increasing the spray angle by 5°-15°.

[0014] In one possible implementation, in step S4, the frequency of the low-frequency ultrasonic preprocessing is 20kHz-30kHz, the power is 500W-800W, the action time is 5min-10min, and the distance between the ultrasonic transducer and the bogie component is 50mm-80mm.

[0015] In one possible implementation, in step S5, the hot air temperature for hot air drying is 60℃-70℃, the wind speed is 2m / s-3m / s, and the drying time is 12min-18min.

[0016] In one possible implementation, in step S5, a rust inhibitor is sprayed onto the bogie during the drying process to form a protective film.

[0017] The beneficial effects of the railway vehicle bogie cleaning method provided by this invention are as follows: Compared with the prior art, the railway vehicle bogie cleaning method of this invention first divides the bogie into steel, aluminum, and rubber areas according to material, and uses a rotatable anti-slip cleaning table to avoid damage to different temperature and pressure resistant materials by a single parameter, while ensuring that the spraying is thorough; then, high-definition cameras and optical sensors are used to accurately obtain the type, coverage, and thickness of dirt in each area, providing data support for subsequent personalized parameters, solving the problem that existing fixed cleaning fluids and modes are difficult to adapt to the different dirt characteristics of EMU, freight car, and passenger car bogies; subsequently, differentiated cleaning parameters are matched for different areas, with high-concentration surface cleaning fluids used for the steel area. Surfactants and high-temperature, high-pressure parameters enhance the removal of stubborn dirt. Corrosion inhibitors are added to aluminum areas, and medium temperature and pressure are used to prevent oxidation and corrosion. Low-foaming surfactants and low temperature and low pressure are used to prevent aging in rubber areas. Combined with low-frequency ultrasonic pretreatment to loosen oil stains, this ensures both cleaning effectiveness and component protection. During the spraying process, ultrasonic damage monitoring (detecting micro-cracks) and infrared temperature monitoring are integrated, which can promptly trigger the downgrading of cleaning parameters, reducing the safety risk of high-pressure water flow expanding micro-cracks and filling the blind spot of existing methods that rely solely on manual inspection after cleaning. Finally, hot air drying combined with rust inhibitors forms a protective film to prevent post-cleaning corrosion, and residual dirt detection ensures cleaning quality. This comprehensive approach improves both the cleaning quality and maintenance safety of bogies. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a process flow diagram of a railway vehicle bogie cleaning method provided in an embodiment of the present invention. Detailed Implementation

[0020] To make the technical problems, solutions, and beneficial effects of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] Please see Figure 1 The present invention will now describe a method for cleaning railway vehicle bogies. The method for cleaning railway vehicle bogies includes the following steps: S1. The bogie is divided into steel, aluminum, and rubber sections based on component materials. In practice, the steel section of the bogie includes temperature- and pressure-resistant components such as brake beams, axles, and wheelset supports, which are mainly covered with oil and brake residue. The aluminum section includes easily corroded components such as aluminum alloy shock absorbers and lightweight frames, which are mainly covered with dust and light oil. The rubber section includes components with poor heat resistance such as rubber seals, elastic bushings, and air spring interfaces, which are mainly covered with a small amount of dust.

[0022] In this step, after determining the various sections of the bogie, the bogie is hoisted onto a rotatable cleaning platform. The cleaning platform has a diameter of 3-4m and a load-bearing capacity of ≥5t. The four corners of the bogie are fixed with anti-slip positioning clamps. In specific applications, the contact surface between the positioning clamps and the bogie is provided with a polyurethane layer to avoid scratching the surface of the bogie components. The cleaning platform used in this embodiment can rotate around a vertical axis at a speed of 5r / min-10r / min to ensure that the bogie can be sprayed without dead angles during subsequent cleaning.

[0023] This step lays the foundation for subsequent differentiated parameter design by dividing the area according to the material, avoiding damage to multi-material components by a single parameter; by using a rotatable cleaning table combined with anti-slip clamps, it ensures uniform spray coverage and avoids bogie displacement caused by spray impact, thus improving operational safety.

[0024] S2. Obtain dirt information for each area of ​​the bogie.

[0025] In this step, the dirt information includes the type, coverage, and thickness of the dirt. In practice, high-definition image acquisition modules are used to acquire surface images of various areas of the bogie. These modules utilize industrial-grade high-definition cameras, such as the Hikvision MV-CA050-10GM, with 5 megapixels, a resolution of 2560×1920, an IP67 protection rating, and adaptability to high humidity cleaning environments. Specifically, 4-6 industrial-grade high-definition cameras are positioned at the bottom and sides of the cleaning chamber to collect image data of various areas of the bogie. The image data is transmitted to an edge computing unit, where a deep learning model identifies the type of dirt (oil, dust, rust, brake residue) and its coverage.

[0026] In this step, the thickness of the dirt is detected using an optical dirt thickness sensor. In practice, spray arms are arranged on the top and sides of the cleaning chamber, with spray heads mounted on them. The optical dirt thickness sensor is integrated into the spray arm and staggered with the spray heads to prevent water flow from obstructing the laser. The detection direction of the optical dirt thickness sensor is consistent with the water outlet direction of the spray heads. In application, the movement trajectory of the spray arm completely overlaps with the field of view of the high-definition camera, ensuring a one-to-one correspondence between the detection points of the optical dirt thickness sensor and the image acquisition area. The optical dirt thickness sensor detects dirt thickness based on the principle of laser reflection.

[0027] S3. Based on the dirt information, match personalized cleaning parameters for each area of ​​the bogie; In this step, the dirt information obtained in step S2 is transmitted to the control module, which is a PLC control system, with Siemens S7-1500 being an optional model. The control module matches the cleaning fluid composition and spray parameters for the three main areas according to the dirt information.

[0028] In practice, the specific composition of the cleaning fluid for each area of ​​the bogie is as follows: The cleaning fluid for steel areas comprises: 4%-5% neutral cleaning agent, 1.0%-1.2% surfactant, and the remainder is water; the surfactant is fatty alcohol polyoxyethylene ether.

[0029] The cleaning solution for aluminum areas comprises: 3%-4% neutral cleaning agent, 0.8%-1.0% surfactant, 0.3%-0.5% aluminum corrosion inhibitor, and the remainder is water; the aluminum corrosion inhibitor is a sodium silicate-based corrosion inhibitor or an organic acid ester-based corrosion inhibitor.

[0030] The cleaning solution for the rubber area comprises: 2%-3% neutral detergent, 0.5%-0.8% low-foaming surfactant, and the remainder is water; the low-foaming surfactant is an alkyl glycoside.

[0031] The neutral cleaning agent in the cleaning solution for each of the above zones has a pH value of 6.8-7.5, and a non-ionic environmentally friendly cleaning agent is selected.

[0032] The spraying parameters include spraying temperature, spraying pressure, spraying angle, and spraying time. The spraying angle refers to the angle between the water outlet direction of the spray head and the perpendicular line to the surface of the corresponding bogie component. When the spraying angle is 0°, the spray head directly hits the component surface. In this step, the spraying parameters for each area of ​​the bogie are specifically matched as follows: The spraying parameters for the steel area include: spraying temperature 55℃-60℃, and spraying pressure 18kg / cm². 2 -20kg / cm 2 Spray angle 25°-35°, spray time 22min-28min; The spraying parameters for the aluminum area include: spraying temperature 45℃-50℃, and spraying pressure 12kg / cm². 2 -15kg / cm 2 Spray angle 40°-50°, spray time 18min-22min; The spraying parameters for the rubber area include: spraying temperature 40℃-45℃, and spraying pressure 8kg / cm². 2 -12kg / cm 2 Spray angle 55°-65°, spray time 12min-18min.

[0033] In practice, for steel areas, a cleaning solution with a high concentration of surfactants was selected to enhance the solubility of oil stains. A higher spray temperature, higher spray pressure, and a smaller spray angle were also chosen to improve the removal efficiency of stubborn dirt (such as brake residue). For aluminum areas, a cleaning solution with a low concentration of surfactants and corrosion inhibitors was selected to reduce the risk of corrosion to aluminum parts. A medium spray temperature, medium spray pressure, and a relatively large spray angle were chosen to avoid excessive impact of the spray water on aluminum parts, which could damage the oxide film on the surface of the aluminum parts. For rubber areas, a cleaning solution with low-foaming surfactants was selected to prevent foam residue from clogging rubber seals. A lower spray temperature, lower spray pressure, and a relatively large spray angle were chosen to avoid excessive impact of the spray water on rubber parts and prevent aging of the rubber parts.

[0034] S4. First, perform low-frequency ultrasonic pretreatment on the steel and aluminum areas of the bogie, and then spray each area separately according to the cleaning parameters.

[0035] In this step, during low-frequency ultrasonic pretreatment of the steel and aluminum areas of the bogie, the ultrasonic waves generate microbubbles in the steel and aluminum areas through cavitation. The bursting of these bubbles produces localized impact force, which loosens stubborn oil stains adhering to the steel and aluminum areas. In practice, 4-6 ultrasonic transducers are arranged around the cleaning station. The operating frequency of the transducers is 20kHz-30kHz, and the power is 500W-800W. The distance between the ultrasonic transducers and the bogie components is 50mm-80mm, and the treatment time for the steel and aluminum areas is 5-10 minutes.

[0036] After completing the low-frequency ultrasonic pretreatment, the control module controls the spray head to spray and clean each zone according to the predetermined spray parameters.

[0037] During the spraying process, the bogie status is monitored in real time by an ultrasonic damage monitoring module and an infrared temperature monitoring module. If the sprayed area of ​​the bogie is detected to be damaged, the spraying parameters are downgraded.

[0038] Specifically, two focused ultrasonic probes (Olympus V314-RM optional) are integrated on the spray arm to scan key components (brake beam, axle, shock absorber) in the steel and aluminum areas in real time, detecting defects such as microcracks and surface wear. An infrared thermal imager (FLIR T1040 optional) is installed at the top of the cleaning chamber to monitor the surface temperature of each area, preventing localized overheating and oxidation. During implementation, when the ultrasonic damage monitoring module detects a microcrack length ≥0.2mm in the spray area, or the infrared temperature monitoring module detects a temperature ≥65℃ in the spray area, the spray area is determined to be damaged. The downgrading of spray parameters includes reducing the spray pressure by 20%-30% and increasing the spray angle by 5°-15° to reduce the impact of the spray water on the spray area and minimize high-pressure impact damage to the components.

[0039] S5. Dry the cleaned bogie with hot air. After drying, detect residual dirt using an image recognition module. If the residual coverage is ≥5%, repeat steps S4-S5.

[0040] In this step, after the bogie is cleaned, the cleaning chamber is switched to drying mode, and the hot air generators on the top and sides are turned on to output hot air at a temperature of 60℃-70℃ and a wind speed of 2m / s-3m / s. At the same time, the rotatable cleaning table is rotated at 5r / min to ensure that all areas of the bogie are heated evenly. The drying time is 12min-18min.

[0041] During the drying process, rust inhibitor atomizing nozzles are installed at the outlet of the hot air generator. A phosphate ester-based environmentally friendly rust inhibitor (model optional, BASF Irgaform TMR-45) is atomized at a concentration of 0.2%-0.4% and mixed into the hot air. The hot air carries the rust inhibitor droplets, which adhere to the bogie surface, forming a transparent rust-preventive film with a thickness of 0.5μm-1μm. This step, combining hot air drying with rust prevention treatment, thoroughly solves the problem of post-cleaning rust.

[0042] After drying, the high-definition camera from step S2 is used to capture images of the bogie surface again, and the image recognition module detects the coverage of residual dirt. If the residual coverage is less than 5%, the cleaning is deemed satisfactory and the bogie can be transferred to the maintenance process. If the residual coverage is ≥5% (e.g., a small amount of oil residue remains in the gaps of the brake beam), the control module will automatically trigger a local secondary cleaning: only for the residual area, follow steps S4-S6.

[0043] This invention provides a method for cleaning railway vehicle bogies. Compared with existing technologies, it first divides the bogie into steel, aluminum, and rubber areas based on material, and uses a rotatable, non-slip cleaning table to fundamentally avoid damage to different temperature and pressure resistant materials caused by a single parameter, while ensuring no blind spots in the spraying. Then, a high-definition camera and optical sensors are used to accurately acquire the type, coverage, and thickness of dirt in each area, providing data support for subsequent personalized parameters. This solves the problem that existing fixed cleaning solutions and modes are difficult to adapt to the different dirt characteristics of bogies in EMUs, freight cars, and passenger cars. Subsequently, differentiated cleaning parameters are matched for different areas, with high-concentration surfactants and high-temperature, high-pressure parameters used to enhance the cleaning of the steel area. For stubborn dirt removal, corrosion inhibitors are added to aluminum areas and medium temperature and pressure are used to prevent oxidation and corrosion. Low-foaming surfactants and low temperature and pressure are used to prevent aging in rubber areas. Low-frequency ultrasonic pretreatment is used to loosen oil stains, ensuring both cleaning effectiveness and component protection. During the spraying process, ultrasonic damage monitoring (detecting micro-cracks) and infrared temperature monitoring are integrated, which can trigger the downgrading of cleaning parameters in a timely manner, reducing the safety risk of high-pressure water flow expanding micro-cracks and making up for the blind spots of the existing reliance on manual inspection after cleaning. Finally, hot air drying combined with rust inhibitors forms a protective film to prevent post-cleaning corrosion, and residual dirt detection ensures cleaning quality. This comprehensively improves the cleaning quality and maintenance safety of bogies.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for cleaning railway vehicle bogies, characterized in that, Includes the following steps: S1. The bogies are divided into steel, aluminum, and rubber sections according to the material of their components. S2. Obtain dirt information for each area of ​​the bogie; S3. Based on the dirt information, match personalized cleaning parameters for each area of ​​the bogie; S4. First, perform low-frequency ultrasonic pretreatment on the steel and aluminum areas of the bogie, and then spray each area separately according to the cleaning parameters. S5. Dry the cleaned bogie with hot air. After drying, detect residual dirt using an image recognition module. If the residual coverage is ≥5%, repeat steps S4-S5.

2. The method for cleaning railway vehicle bogies as described in claim 1, characterized in that, The dirt information includes the coverage and thickness of the dirt.

3. The method for cleaning railway vehicle bogies as described in claim 1, characterized in that, The cleaning parameters include the cleaning fluid composition and spraying parameters, including spraying temperature, spraying pressure, spraying angle, and spraying time.

4. The method for cleaning railway vehicle bogies as described in claim 3, characterized in that, In step S3, the specific composition of the cleaning fluid for each area of ​​the bogie is as follows: The cleaning fluid for steel areas consists of: 4%-5% neutral cleaning agent, 1.0%-1.2% surfactant, and the remainder is water; The cleaning solution for aluminum areas consists of: 3%-4% neutral cleaning agent, 0.8%-1.0% surfactant, 0.3%-0.5% aluminum corrosion inhibitor, and the remainder is water; The cleaning solution for rubber areas consists of: 2%-3% neutral detergent, 0.5%-0.8% low-foaming surfactant, and the remainder is water.

5. A method for cleaning railway vehicle bogies as described in claim 3, characterized in that, In step S3, the spray parameters for matching each area of ​​the bogie are specifically as follows: The spraying parameters for the steel area include: spraying temperature 55℃-60℃, and spraying pressure 18kg / cm². 2 -20kg / cm 2 Spray angle 25°-35°, spray time 22min-28min; The spraying parameters for the aluminum area include: spraying temperature 45℃-50℃, and spraying pressure 12kg / cm². 2 -15kg / cm 2 Spray angle 40°-50°, spray time 18min-22min; The spraying parameters for the rubber area include: spraying temperature 40℃-45℃, and spraying pressure 8kg / cm². 2 -12kg / cm 2 Spray angle 55°-65°, spray time 12min-18min.

6. A method for cleaning railway vehicle bogies as described in claim 3, characterized in that, In step S4, the bogie status is monitored in real time by the ultrasonic damage monitoring module and the infrared temperature monitoring module during the spraying process. If the spraying area of ​​the bogie is detected to be in a damaged state, the spraying parameters are downgraded.

7. A method for cleaning railway vehicle bogies as described in claim 6, characterized in that, When the ultrasonic damage monitoring module detects a microcrack length ≥0.2mm in the spray area, or the infrared temperature monitoring module detects a temperature ≥65℃ in the spray area, the spray area is determined to be in a damaged state. The downgrading of the spray parameters includes reducing the spray pressure by 20%-30% and increasing the spray angle by 5°-15°.

8. A method for cleaning railway vehicle bogies as described in claim 1, characterized in that, In step S4, the low-frequency ultrasonic preprocessing has a frequency of 20kHz-30kHz, a power of 500W-800W, an action time of 5min-10min, and a distance of 50mm-80mm between the ultrasonic transducer and the bogie component.

9. A method for cleaning railway vehicle bogies as described in claim 1, characterized in that, In step S5, the hot air temperature for hot air drying is 60℃-70℃, the wind speed is 2m / s-3m / s, and the drying time is 12min-18min.

10. A method for cleaning railway vehicle bogies as described in claim 1, characterized in that, In step S5, a rust inhibitor is sprayed onto the bogie during the drying process to form a protective film.

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