A workbench system for assembling and torquing railway car brake valve assemblies

Abstract

The utility model relates to railway freight car overhauling technical field provides a kind of workbench system of railway freight car brake valve assembly torque fastening, including workbench body, vertical plate is fixedly arranged above the workbench body, characterized by, the vertical plate is respectively equipped with electronic torque wrench, code scanning gun, card reader, router, alarm lamp and display, the electronic torque wrench is electrically connected with the display, the electronic torque wrench is electrically connected with alarm lamp, electronic torque wrench is electrically connected with router, code scanning gun is electrically connected with the display, the precision problem caused by manual operation is solved.

Description

Technical Field

[0001] This utility model relates to the field of railway freight car maintenance technology, specifically to a workbench system for torque tightening of railway freight car brake valve assembly. Background Technology

[0002] The 120 valve in railway freight cars is a core control component of the vehicle's braking system, and its assembly quality directly affects the braking performance and operational safety of the entire vehicle. During the assembly of the 120 valve, extremely strict requirements are placed on the tightening torque of key connecting components such as bolts. Torque deviations not only affect the sealing effect but may also cause structural deformation, thread damage, and even pressure leakage and braking failure.

[0003] The following technical problems were encountered by the staff when operating the existing 120 valve of the railway freight car: (1) Insufficient accuracy in manually controlled torque can easily lead to either excessive looseness or excessive tightness, resulting in decreased sealing performance of the 120 valve, accelerated wear of components, and even serious quality hazards such as brake failure. Specifically, manual operation cannot accurately control the applied torque, and the phenomenon of excessively loose or excessively tight torque is common. Insufficient torque can easily lead to loose connections and leakage at the sealing surface, causing the valve body to degrade in a vibrating environment; excessive torque may cause thread stripping, bolt breakage, or component damage, significantly increasing the failure rate and maintenance costs. (2) Low operational efficiency, making it difficult to meet the needs of mass production. Relying entirely on manual operation is not only labor-intensive but also has limited operating speed, which has become a bottleneck in the production line cycle time. At the same time, manual recording of fastening data, such as torque values, sequence, and operators, is prone to errors, omissions, and even retroactive filling, which seriously affects the authenticity and traceability of the data. Utility Model Content

[0004] To achieve the above objectives, this utility model proposes a workbench system for torque tightening of railway freight car brake valve assembly, comprising a workbench body, with a vertical plate fixedly installed on top of the workbench body. The vertical plate is characterized by being equipped with an electronic torque wrench, a barcode scanner, a card reader, a router, an alarm light, and a display. The electronic torque wrench is electrically connected to the display, the alarm light, and the router, and the barcode scanner is electrically connected to the display.

[0005] A further configuration includes a work surface above the workbench body, on which an anti-reaction plate is fixedly installed. The work surface provides a flat, stable, and dedicated operating area, which optimizes ergonomics and enables the operator to perform assembly operations comfortably and efficiently.

[0006] Further configured, the anti-reaction fixing plate includes a plate body fixed to the workbench by bolts, and a first valve body fixing hole, a third valve body fixing hole and a fourth valve body fixing hole are provided on one side along the length direction of the plate body, realizing a rigid connection between the fixing plate and the workbench, ensuring the stability of the entire support system, and also facilitating later maintenance or replacement.

[0007] Further configured, the first valve body fixing hole includes a first rectangular hole extending to the bottom of the plate body, and a first semi-circular hole is provided at the top of the first rectangular hole. The fixing hole can adapt to valve bodies or installation interfaces of different sizes and structures.

[0008] Further configured, the second valve body fixing hole includes a second rectangular hole extending to the bottom of the plate body, a second semi-circular hole is provided at the top of the second rectangular hole, the width of the first rectangular hole is greater than the width of the second rectangular hole, and the diameter of the first semi-circular hole is greater than the diameter of the second semi-circular hole.

[0009] Further configured, the third valve body fixing hole includes a third rectangular hole extending to the bottom of the plate body, and a circular hole is provided at the center of the third rectangular hole. The circular hole is added at the center of the rectangular hole to allow passage of protruding conduits, connectors or long bolts on the valve body, providing clearance space for these non-standard or protruding components.

[0010] Further, several material boxes are fixedly installed at the bottom of the upright plate, enabling centralized, classified, and fixed-position management of commonly used tools, fasteners (such as bolts and washers of different specifications) or small parts.

[0011] A further feature is that the material box is fixedly installed on the side wall of the upright plate by bolts. The use of bolt fixing instead of simple hanging or placement ensures the stability and reliability of the material box when frequently taking and putting in items.

[0012] A further feature is that storage cabinets are spaced apart on the front side of the workbench body, providing a larger enclosed storage space for storing infrequently used large tools, spare parts, drawings, documents, or personal items.

[0013] The device is further configured such that a keyboard is mounted on the workbench, a mouse is mounted on one side of the keyboard, the keyboard is electrically connected to the monitor, and the mouse is electrically connected to the monitor, providing operators or administrators with convenient input and control means for performing operations such as system settings, program selection, data query, and manual input of information (e.g., when scanning fails).

[0014] The beneficial effects of one or more of the above technical solutions: (1) Through the automatic control of the mechanical electronic wrench, the torque error is controlled within ±3%, which solves the problem of insufficient precision caused by manual operation and avoids the failure of 120 valve caused by improper tightening.

[0015] (2) By working together with card readers, barcode scanners and routers, operator information, material information, torque data and operation time are recorded to form a complete traceability chain, which facilitates the rapid location and analysis of quality problems. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.

[0017] Figure 1 This is a schematic diagram of the structure of this utility model.

[0018] Figure 2 This is a schematic diagram of the system framework of this utility model.

[0019] Figure 3 This is a schematic diagram of the structure of this utility model.

[0020] In the diagram, 1. Workbench body; 11. Vertical plate; 12. Work surface; 2. Barcode scanner; 3. Card reader; 4. Router; 5. Alarm light; 6. Monitor; 7. Electronic torque wrench; 8. Keyboard; 9. Mouse; 10. Locker; 11. Material box; 12. First valve body fixing hole; 13. First rectangular hole; 14. First semi-circular hole; 15. Second valve body fixing hole; 16. Second rectangular hole; 17. Second semi-circular hole; 18. Third valve body fixing hole; 19. Third rectangular hole; 20. Round hole; 21. Anti-reaction fixing plate; 22. Plate body. Detailed Implementation

[0021] The specific implementation of this embodiment will now be described with reference to the accompanying drawings.

[0022] Example 1 A workbench system for torque tightening of brake valve assembly in railway freight cars, referring to Figure 1 and Figure 2The system includes a workbench body 1, with a vertical plate 11 fixedly mounted on top of the workbench body 1. The vertical plate 11 is characterized by having an electronic torque wrench 7, a barcode scanner 2, a card reader 3, a router 4, an alarm light 5, and a display 6 mounted on it. The electronic torque wrench 7 is electrically connected to the display 6, the alarm light 5, and the router 4. The barcode scanner 2 is electrically connected to the display 6. The electronic torque wrench 7, as the core actuator, automatically and accurately applies a preset torque, fundamentally eliminating the subjective errors of manual operation and the problem of torque being too loose or too tight due to physical fatigue. It controls the torque accuracy within ±3% of the process requirements, greatly improving the consistency and reliability of the 120 valve assembly.

[0023] The barcode scanner 2, card reader 3, and router 4 together form a data acquisition and transmission network. Its effect is to realize the automatic binding and real-time uploading of operator identification (through work cards), material information (through part barcodes), and torque values, creating a unique electronic "file" for each product and realizing precise traceability throughout the entire process.

[0024] The alarm light 5 and the display 6 constitute a human-machine interaction and early warning module. The display 6 can guide the operator's work in real time (such as displaying the current bolt positions that need to be tightened and the target torque value), while the alarm light 5 can immediately issue an audible and visual alarm when the torque is abnormal (such as exceeding the tolerance or not being completed). Its effect is to effectively prevent defective products from flowing into the next process and act as a quality sentinel for high quality.

[0025] The electrical connection of the entire system achieves closed-loop data flow and coordinated instructions, integrating the originally scattered and isolated operation steps into an intelligent and information-based whole, significantly improving the standardization and modernization of operations.

[0026] A worktable surface 12 is provided above the workbench body 1, and an anti-reaction force fixing plate 21 is fixedly installed on the worktable surface 12. The worktable surface 12 provides a flat, stable, and dedicated operating area, which optimizes ergonomics and allows the operator to perform assembly operations comfortably and efficiently. The anti-reaction force fixing plate 21 is a key functional component, which provides strong, stable, and reliable reaction force support during bolt tightening. This effectively prevents the valve body or worktable from shifting, vibrating, or deforming due to force, ensuring that the torque applied by the electronic torque wrench 7 is accurately transmitted to the threaded pair, rather than being consumed in the displacement of the components, thereby further guaranteeing the actual accuracy of the final tightening torque.

[0027] Reference Figure 3The anti-reaction fixing plate 21 includes a plate body 22 fixed to the workbench 12 by bolts. A first valve body fixing hole 12, a second valve body fixing hole 15, and a third valve body fixing hole 18 are provided on one side along the length of the plate body 22. The bolt fixing method achieves a rigid connection between the fixing plate and the workbench 12, ensuring the stability of the entire support system and facilitating future maintenance, replacement, or upgrades. The multiple valve body fixing holes (first 12, second 15, third 18) give the workbench system versatility and multi-functionality, enabling it to adapt to different models or specifications of railway freight car valves 120. By positioning the valve body in different fixing holes, various product assembly tasks can be completed, greatly improving equipment utilization and economy.

[0028] The first valve body fixing hole 12 includes a first rectangular hole 13 extending to the bottom of the plate body 22, and a first semi-circular hole 14 is provided at the top of the first rectangular hole 13. The combination design of "rectangular hole + top semi-circular hole" forms a structure similar to a "lock hole". This enables quick positioning and clamping of the valve body during installation. The operator can first insert the relevant parts of the valve body from the wide lower part of the first rectangular hole 13, and then push it horizontally into the upper first semi-circular hole 14, using the arc surface of the first semi-circular hole 14 for precise radial positioning and axial limiting. This design is faster and more convenient to operate than a simple round hole or threaded hole, effectively improving the efficiency of preparation work.

[0029] The second valve body fixing hole 15 includes a second rectangular hole 16 extending to the bottom of the plate body 22, and a second semi-circular hole 17 is provided at the top of the second rectangular hole 16. The width of the first rectangular hole 13 is greater than the width of the second rectangular hole 16, and the diameter of the first semi-circular hole 14 is greater than the diameter of the second semi-circular hole 17. By changing the dimensions of the rectangular hole width and the semi-circular hole diameter, the fixing hole can be adapted to valve bodies or mounting interfaces of different sizes and structures. This further enhances the versatility and flexibility of the workbench system, ensuring that connection parts of different sizes can find suitable fixing points and obtain effective support, thereby meeting the assembly needs of complex product families.

[0030] The third valve body fixing hole 18 includes a third rectangular hole 19 extending to the bottom of the plate body 22. A third semi-circular hole (not marked with a new number in the figure, but following the overall concept of the hole described in 18) is provided at the top of the third rectangular hole 19, and a circular hole 20 is provided at the center of the third rectangular hole 19. The addition of the circular hole 20 at the center of the third rectangular hole 19 allows for the passage of protruding conduits, connectors, or long bolts on the valve body, providing clearance for these non-standard or protruding components. This avoids the problem of the valve body not being able to fit snugly against the fixing plate due to local structural interference, ensuring stable and reliable clamping and fixing even for valve bodies with special structures, thus expanding the applicability of the equipment.

[0031] Several material boxes 11 are fixedly installed at the bottom of the upright plate 11. Installing the material boxes 11 enables centralized, categorized, and fixed-position management of commonly used tools, fasteners (such as bolts and washers of different specifications), or small parts. Operators can retrieve the required items without leaving their workstations, reducing wasted time and unnecessary movements in searching for and retrieving materials, making the work process smoother, improving overall assembly efficiency, and also helping to maintain the cleanliness and orderliness of the workbench 12.

[0032] The material box 11 is bolted to the side wall of the upright plate 11. Using bolts instead of simple hanging or placement ensures the stability and reliability of the material box 11 during frequent item handling, preventing accidental detachment or displacement. This robust connection also allows the material box 11 to bear a certain weight and facilitates flexible adjustment of its installation position and angle according to actual usage needs and operator habits, optimizing the site layout.

[0033] Storage cabinets 10 are spaced apart on the front side of the workbench body 1. These cabinets provide larger, enclosed storage space for storing infrequently used large tools, spare parts, drawings, or personal items. This, together with the material boxes 11 on the upright panel 11, forms a tiered storage system, ensuring both easy access to frequently used materials and maintaining a clean and safe work area. This aligns with modern on-site management requirements (such as 5S) and enhances the overall standardization of the work environment.

[0034] A keyboard 8 is installed on the workbench 12, and a mouse 9 is installed to one side of the keyboard 8. The keyboard 8 and the monitor 6 are electrically connected, and the mouse 9 is also electrically connected to the monitor 6. The keyboard 8 and mouse 9 provide operators or administrators with convenient input and control tools for system settings, program selection, data querying, and manual information input (such as when barcode scanning fails). This enhances the interactivity and flexibility of the system, making it not just an automatic actuator, but also a debuggable and manageable intelligent workstation, facilitating the adjustment and maintenance of process parameters.

[0035] The workflow of this workbench is as follows: the operator verifies their identity using a card reader → scans the QR codes of the 120 valve and materials using a barcode scanner, and the display screen confirms the match → fixes the components in the 120 valve to the anti-reaction fixing plate → the mechanical electronic wrench tightens the components to the preset torque, transmitting data to the display screen in real time → if the torque is abnormal, the alarm light is activated → after the operation is completed, the router uploads the data to the backend to achieve full traceability.

[0036] Although the specific embodiments of the present utility model have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present utility model. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solution of the present utility model are still within the scope of protection of the present utility model.

Claims

1. A workbench system for torque-fastening the assembly of brake valves for railway freight cars, comprising a workbench body, wherein a vertical plate is fixedly mounted on top of the workbench body, characterized in that, The upright plate is equipped with an electronic torque wrench, a barcode scanner, a card reader, a router, an alarm light, and a display. The electronic torque wrench is electrically connected to the display, the alarm light, and the router, and the barcode scanner is electrically connected to the display.

2. The workbench system for torque tightening of railway freight car brake valve assembly according to claim 1, characterized in that, A work surface is provided above the workbench body, and an anti-reaction fixing plate is fixedly installed on the work surface.

3. The workbench system for torque tightening of railway freight car brake valve assembly according to claim 2, characterized in that, The anti-reaction fixing plate includes a plate body fixed to the workbench by bolts, and a first valve body fixing hole, a second valve body fixing hole and a third valve body fixing hole are provided on one side along the length direction of the plate body.

4. The workbench system for torque tightening of railway freight car brake valve assembly according to claim 3, characterized in that, The first valve body fixing hole includes a first rectangular hole extending to the bottom of the plate body, and a first semi-circular hole is provided at the top of the first rectangular hole.

5. A workbench system for torque tightening of railway freight car brake valve assembly according to claim 4, characterized in that, The second valve body fixing hole includes a second rectangular hole extending to the bottom of the plate body, a second semi-circular hole provided at the top of the second rectangular hole, the width of the second rectangular hole being greater than the width of the second rectangular hole, and the diameter of the first semi-circular hole being greater than the diameter of the second semi-circular hole.

6. A workbench system for torque tightening of railway freight car brake valve assembly according to claim 3, characterized in that, The third valve body fixing hole includes a third rectangular hole extending to the bottom of the plate body, a third semi-circular hole at the top of the third rectangular hole, and a circular hole at the center of the third rectangular hole.

7. A workbench system for torque tightening of railway freight car brake valve assembly according to claim 1, characterized in that, Several material boxes are fixedly installed at the bottom of the upright plate.

8. A workbench system for torque tightening of railway freight car brake valve assembly according to claim 7, characterized in that, The material box is fixedly installed on the side wall of the upright plate by bolts.

9. A workbench system for torque tightening of railway freight car brake valve assembly according to claim 1, characterized in that, Storage cabinets are spaced apart on the front side of the workbench body.

10. A workbench system for torque tightening of railway freight car brake valve assembly according to claim 2, characterized in that, A keyboard is installed on the workbench, and a mouse is installed on one side of the keyboard. The keyboard and the monitor are electrically connected, and the mouse and the monitor are electrically connected.

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