Wheel Set Press-Mounting with Real-Time Runout Detection
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Solution Overview
Problem
Existing press-mounting and dismounting equipment for rail vehicle wheel sets easily strains the axle and fails to provide real-time accuracy in assembly, which is inadequate for the evolving demands of high-speed railway technology.
Innovation Solution
A press-mounting and dismounting machine with a frame, wheel set mounting and dismounting mechanism, and detection mechanism, featuring synchronized belt transmission, press-mounting devices, movable baffles, and a driving rotating device, allowing for precise control and real-time detection of wheel set positioning and runout, enabling accurate press-mounting and dismounting without axle rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional press-mounting equipment is used, then the structure is simple, but the axle is easily strained and assembly accuracy cannot be monitored in real time
Solution Approach 1:
The press-mounting equipment is designed with multi-functional capabilities including press-mounting, dismounting, and real-time detection functions integrated into a single system. The detection mechanism can monitor wheel position, radial runout, and end runout simultaneously during the press-mounting process, eliminating the need for separate detection equipment while providing comprehensive quality control.
Solution Approach 2:
The detection mechanism provides real-time feedback during the press-mounting process by continuously monitoring wheel position, radial runout of treads, and end runout of inner side surfaces. This feedback allows the system to adjust and maintain assembly accuracy within 0.05mm, preventing axle strain while ensuring high-quality assembly through immediate detection and correction of deviations.
2Manufacturing precision
If the equipment is updated to meet higher accuracy requirements, then the press-mounting accuracy improves, but the disassembly and maintenance become more difficult
Solution Approach 1:
The press-mounting devices are designed with movable and adjustable components that can dynamically adapt to different wheel set configurations. The detection mechanism and press-mounting devices can be repositioned along guide rails to accommodate various gauge and type requirements, making the equipment flexible rather than fixed, which simplifies maintenance and adaptation to different assembly requirements.
Solution Approach 2:
The equipment is divided into modular components including separate press-mounting devices, detection mechanisms, and movable baffle devices that can be independently adjusted or maintained. This segmentation allows individual components to be serviced without disassembling the entire system, reducing maintenance complexity while maintaining high assembly accuracy capabilities.
3Measurement precision
If real-time detection is added to monitor assembly accuracy, then the quality control improves, but the device complexity increases
Solution Approach 1:
The detection mechanism is integrated with the press-mounting devices and frame structure, sharing common support elements and control systems. The detection devices are mounted on the existing frame and move with the press-mounting devices, eliminating the need for separate detection stations and reducing overall system complexity while providing comprehensive real-time monitoring of wheel position, radial runout, and end runout.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures high accuracy and efficiency in press-mounting and dismounting multiple types of wheel sets, reducing costs and improving work efficiency by allowing automatic adjustment for different gauges without tooling changes, while ensuring the axle and disc remain stationary during the process.
Implementation Method 1
The synchronous belt transmission device is in transmission connection with the movable baffle device to drive the movable baffle device to move left and right in a horizontal direction of the base
Implementation Method 2
The press-mounting cylinder is configured to exert a forward pressure so as to drive the moving center device
Implementation Method 3
The oil cylinder drives the reducer. The reducer drives the driving wheel to rotate
Implementation Method 4
The driving wheel is in contact with the wheel disc of the wheel set and drives the wheel set to rotate
Data Source
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AI summary
A press-mounting and dismounting machine for multi-gauge and multi-type wheel sets, includes: a frame, a wheel set mounting and dismounting mechanism, and a detection mechanism. The frame includes a base, a first column, a second column and a beam. The wheel set mounting and dismounting mechanism includes a first press-mounting device, a second press-mounting device, a movable baffle device, and a synchronous belt transmission device. The first press-mounting device is arranged on the first column, and the second press-mounting device is arranged on the second column. The synchronous belt transmission device is connected with the movable baffle device to drive the movable baffle device to move in a horizontal direction of the base. The detection mechanism includes a driving rotating device and a data detection device, so as to realize accuracy test of wheel set press-mounting.