Railcar Bogie Assembly Using Wheelbase Fixing Jig
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Solution Overview
Problem
The existing bogie assembly method is complex due to the lack of a fixed plate spring to the bogie frame and axle boxes, requiring manual measurement with a tape measure to maintain a designed wheelbase between wheelsets.
Innovation Solution
A wheelbase fixing jig is used to position and lock the axle box devices, ensuring the wheelbase is set to a predetermined value by extending in the car longitudinal direction and including locking portions at both ends to secure the axle box devices, facilitating the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual measurement with a tape measure is used to maintain wheelbase, then the bogie assembly can be completed without additional equipment, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The wheelbase fixing jig is designed with pre-set dimensions that correspond to the designed wheelbase value. The jig performs the positioning action in advance, eliminating the need for manual measurement and adjustment during assembly. The locking portions are pre-configured to engage with the axle box devices at the correct spacing, so when the jig is installed, the wheelbase is automatically set to the designed value without requiring workers to measure and adjust manually.
2Manufacturing precision
If no wheelbase fixing device is used, then the bogie structure remains simple, but the wheelbase cannot be accurately maintained at the designed value
Solution Approach 1:
The wheelbase fixing jig serves as an intermediary tool that temporarily bridges the gap between the simple bogie structure and the requirement for precise wheelbase control. The jig includes locking portions that engage with the axle box devices, acting as a mediator to transfer and maintain the correct spacing. This intermediary device provides the necessary precision during assembly without permanently complicating the bogie structure, as the jig is removed after positioning is complete.
3Adaptability or versatility
If the plate spring is not fixed to the bogie frame and axle boxes, then the bogie structure becomes simpler and more flexible, but the wheelbase cannot be automatically maintained during assembly
Solution Approach 1:
The wheelbase fixing jig enables the assembly process to be self-servicing by automatically establishing the correct wheelbase dimension through its pre-configured structure. When the jig is locked to the axle box devices, it self-adjusts their positions to maintain the designed wheelbase value without requiring external measurement tools or manual calculation. The jig's geometry inherently provides the correct spacing, making the system self-sufficient for precise positioning.
Data Source
AI summary
A method of assembling a railcar bogie includes: a positioning step of locking a wheelbase fixing jig to a pair of axle box devices to position the pair of axle box devices such that a wheelbase between a pair of wheelsets supported by the respective axle box devices becomes a predetermined designed value, the pair of axle box devices being arranged away from each other in a car longitudinal direction, the wheelbase fixing jig extending in the car longitudinal direction; a plate spring arranging step of making the pair of axle box devices support a plate spring extending in the car longitudinal direction; and a bogie frame arranging step of making a longitudinal direction middle portion of the plate spring support a bogie frame and coupling the bogie frame to the pair of axle box devices.