货车轮轴基础工艺线设计及轮轴信息化管理
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摘要
为满足铁路高速、重载提出的新要求,近年来在轮轴设计方面围绕提高强度、降低噪声、减轻重量、增加安全性、便于检修等,许多国家做了不少有价值的工作。同时制造和工艺方面也有很大改进,轮轴的制造水平显著提高。轮轴运用管理对提高运输效率、保障运输安全是十分重要的,计算机和信息技术的广泛应用将成为今后轮轴运用与检修中的趋势。
根据济南机车车辆厂轮轴工艺线建设项目,本文提出了“货车轮轴基础工艺线设计及轮轴信息化管理”研究课题,并主要进行了以下几方面工作:
通过对目前国内外轮轴加工组装的新技术新工艺进行研究,结合工厂轮轴生产现状,对货车轮轴生产线进行了工艺方案设计。车轴、车轮加工及组装工艺线和无轴箱滚动轴承组装工艺线的应用,使工厂轮轴生产达到加工数控化、检测及组装自动化、过程管理信息化。
从轮轴制造工艺流程出发,阐述了工艺线设计中采用的加工组装新技术。选用进口车轴数控成型磨床及数控外圆磨床,其磨削质量稳定,磨削过程具备跟踪测量检测功能,实现磨削尺寸和过程的自动控制;轴径和防尘板座直径实现静态或动态检测、储存和传输,在线测量。采用车轴全自动测量机可自动完成车轴部分参数的自动测量,取代传统的人工测量方法,保证数据的可靠性;测量数据可与HMIS系统共享。采用进口车轮车床及镗床,设备利用微机控制,能实现自动定心夹紧,封闭式切削,完成轮孔直径半精车、精车及圆弧R5和R3的精加工。采用全自动轮对压装机能使轮轴一次组装完成,自动控制内侧距和轮位差等组装尺寸,利用计算机控制系统,能自动记录压装曲线,并按标准自动判断曲线是否合格,自动打印曲线图及输出数据。
利用成熟的铁路货车技术管理信息系统(HMIS)工厂级应用系统、HMIS车辆工厂轮轴工位系统,实现车辆信息系统和微控、工控智能设备数据的共享,使车辆信息系统能够快捷、方便地采集数据,并制定了数据接口协议。货车轮轴管理系统在轮轴加工组装过程中的应用,实现了车轴、车轮、轴承新制的在线数量管理、状态管理和质量信息管理要求。
In recent years, for satisfying the new request of railway high speed, heavy loading, many country have done worthy works in wheel and axle design to raise strength, lower noise, decrease weight, increase safety and easy checking and fixing. At the same time, great improvements have been obtained in manufacture and technology, and the manufacturing level of the axle raised obviously. The usage and management of wheel and axle are very important for improving transportation efficiency and guarantee transportation safety. The widely application of computer and information technology will be the trend in the usage and maintaining of wheel and axle.
According to the wheel-axle production line project of Ji' nan locomotive and rolling stock plant, this dissertation put forward "Designing of wheel-axle foundation production line and management of wheel-axle information" and mainly carried on following several aspect works:
According to current new technique of the domestic and international wheel-axle assembling is researched, and combining present produce condition, we have designed the machining and assembling product line of axle and wheel and non axle box rolling bearing assembling product line. That made produce obtained machining by numerical control, automation inspecting and assembling, information-based process management.
This paper expatiates some new machining and assembling technique which are used in the design. Numerical control forming grinder and cylindrical grinder are used , and the quality is fine. They have tracking function in grinding process, and are able to autocontrol the dimension and process. They can measure, store and transmit static or dynamically for axle journal and dustproof seat information. Automatic measuring machine is adopted to inspect some dimension of the axle, instead traditional manual measuring and it is more credible. The measuring data can be share with HMIS system. Wheel lathe and boring machine are used, which are controlled by microcomputer. They can centering and clamp automatically, and cut close. They can accomplish wheel hole semi-precision cutting, precision cutting and precision finishing of arc R3 and R5. Wheel set mounting press is used to assemble wheel and axle one-off. The dimensions, such as wheels inner distance etc. are set up automatically. Computer control system is adopted to note the curve of mounting and judge if the curve is eligibility, then print graph and output data.
Using adult factory grade HMIS system for wheel-axle, share the data of rolling stock information system and microcomputer control equipments, joint agreement is established, and the collection of data is more convenient and quicker. The amount management, state management and quality information management of axle, wheel and bearing in produce progress are achieved.
根据济南机车车辆厂轮轴工艺线建设项目,本文提出了“货车轮轴基础工艺线设计及轮轴信息化管理”研究课题,并主要进行了以下几方面工作:
通过对目前国内外轮轴加工组装的新技术新工艺进行研究,结合工厂轮轴生产现状,对货车轮轴生产线进行了工艺方案设计。车轴、车轮加工及组装工艺线和无轴箱滚动轴承组装工艺线的应用,使工厂轮轴生产达到加工数控化、检测及组装自动化、过程管理信息化。
从轮轴制造工艺流程出发,阐述了工艺线设计中采用的加工组装新技术。选用进口车轴数控成型磨床及数控外圆磨床,其磨削质量稳定,磨削过程具备跟踪测量检测功能,实现磨削尺寸和过程的自动控制;轴径和防尘板座直径实现静态或动态检测、储存和传输,在线测量。采用车轴全自动测量机可自动完成车轴部分参数的自动测量,取代传统的人工测量方法,保证数据的可靠性;测量数据可与HMIS系统共享。采用进口车轮车床及镗床,设备利用微机控制,能实现自动定心夹紧,封闭式切削,完成轮孔直径半精车、精车及圆弧R5和R3的精加工。采用全自动轮对压装机能使轮轴一次组装完成,自动控制内侧距和轮位差等组装尺寸,利用计算机控制系统,能自动记录压装曲线,并按标准自动判断曲线是否合格,自动打印曲线图及输出数据。
利用成熟的铁路货车技术管理信息系统(HMIS)工厂级应用系统、HMIS车辆工厂轮轴工位系统,实现车辆信息系统和微控、工控智能设备数据的共享,使车辆信息系统能够快捷、方便地采集数据,并制定了数据接口协议。货车轮轴管理系统在轮轴加工组装过程中的应用,实现了车轴、车轮、轴承新制的在线数量管理、状态管理和质量信息管理要求。
In recent years, for satisfying the new request of railway high speed, heavy loading, many country have done worthy works in wheel and axle design to raise strength, lower noise, decrease weight, increase safety and easy checking and fixing. At the same time, great improvements have been obtained in manufacture and technology, and the manufacturing level of the axle raised obviously. The usage and management of wheel and axle are very important for improving transportation efficiency and guarantee transportation safety. The widely application of computer and information technology will be the trend in the usage and maintaining of wheel and axle.
According to the wheel-axle production line project of Ji' nan locomotive and rolling stock plant, this dissertation put forward "Designing of wheel-axle foundation production line and management of wheel-axle information" and mainly carried on following several aspect works:
According to current new technique of the domestic and international wheel-axle assembling is researched, and combining present produce condition, we have designed the machining and assembling product line of axle and wheel and non axle box rolling bearing assembling product line. That made produce obtained machining by numerical control, automation inspecting and assembling, information-based process management.
This paper expatiates some new machining and assembling technique which are used in the design. Numerical control forming grinder and cylindrical grinder are used , and the quality is fine. They have tracking function in grinding process, and are able to autocontrol the dimension and process. They can measure, store and transmit static or dynamically for axle journal and dustproof seat information. Automatic measuring machine is adopted to inspect some dimension of the axle, instead traditional manual measuring and it is more credible. The measuring data can be share with HMIS system. Wheel lathe and boring machine are used, which are controlled by microcomputer. They can centering and clamp automatically, and cut close. They can accomplish wheel hole semi-precision cutting, precision cutting and precision finishing of arc R3 and R5. Wheel set mounting press is used to assemble wheel and axle one-off. The dimensions, such as wheels inner distance etc. are set up automatically. Computer control system is adopted to note the curve of mounting and judge if the curve is eligibility, then print graph and output data.
Using adult factory grade HMIS system for wheel-axle, share the data of rolling stock information system and microcomputer control equipments, joint agreement is established, and the collection of data is more convenient and quicker. The amount management, state management and quality information management of axle, wheel and bearing in produce progress are achieved.
引文
[1]严隽耄主编.车辆工程.北京:中国铁道出版社,2003
[2]徐国明.轮轴精加工及组装生产线的研制.铁道车辆.1998年第9期
[3]周翊民.面向21世纪的中国铁路轮轴技术.铁道车辆.1998年第12期
[4]谈大同.中国铁路车辆轮轴的现状与展望.铁道车辆.1998年第12期
[5]杨燮林.美国机车车辆轮轴加工技术简介.机车车辆工艺.1988,(6)
[6]车轴生产自动线.国外机车车辆工艺.1976,(5)
[7]郑伟生.国外轮轴技术发展综述(一).国外铁道车辆.1998年第4期
[8]郑伟生.国外轮轴技术发展综述(二).国外铁道车辆.1998年第5期
[9]刁克军.我国重载铁路货车车轴及轴承的技术发展.铁道车辆.2006年第6期
[10]郭玉玺.中国第二条辗钢整体车轮生产线及其工艺技术水平分析.铁道车辆.1998年第9期
[11]车轮、车轴机械机加工无人化系统的研制.国外机车车辆工艺.1977,(7)
[12]新型车轮车床.国外机车车辆工艺,1978,(1)
[13]车轴的程序超声波探伤和自动记录.国外机车车辆工艺.1978,(6)
[14]王彦豪.客车轮对压装问题探讨.铁道机车车辆工人.1996,(08)
[15]陈辉刚.轮对压装实现互换的可行性分析(一).铁道机车车辆工人.1997,(10)
[16]徐国明.影响轮对压装质量的因素.机车车辆工艺.1984,(02)
[17]郑东.铁路货车轮对压装曲线记录仪的研制.西南交通大学,2003
[18]王明新.铁道车辆车轴可靠性与安全性分析系统.西南交通大学,2005
[19]江先志.轨道车轮轴自动拆装机及其控制系统的研究.武汉理工大学,2004
[20]#12
[21]高向东.轮对参数自动检测新装置.机车电传动.2005,(01)
[22]吴学军.轮对自动检测装置.铁道车辆.2003,(03)
[23]高向东.铁路车辆轮对自动检测系统的研制.机车电传动.2003,(02)
[24]高向东.铁路车辆轮对自动测量新方法.新技术新工艺.2004,(12)
[25]K Bel Knani,周贤全.新开发的轮对设计方法.国外铁道车辆.2003,(02)
[26]涂富田.全自动轮对压装机的研制.西南交通大学,2004
[27]Effect of probability of detection upon the definition of inspection intervals for railway axles.By:Carboni,M.;Beretta,S.Proceedings of the Institution of Mechanical Engineers -- Part F -- Journal of Rail & Rapid Transit,Sep2007,Vol.221 Issue 3,p409-417,9p,2 charts,4 diagrams,6 graphs;DOI:10.1243
[28]郑伟生.研讨轮轴技术促进生产发展.铁道学报.1992,(04)
[29]Failures of bearings and axles in railway freight wagons.By:Gerdun,Viktor;Cene,Bojan.Engineering Failure Analysis,Jul2007,Vol.14 Issue 5,p884-894,11p;DOI:10.1016
[30]孙振海.铁道车辆轮轴全过程管理方案研究.西南交通大学,2006
[31]第12届国际轮轴大会专栏.铁道车辆.1998,(09)
[32]杨国桢.坚持不懈地致力于轮轴技术的进步.铁道车辆.1990,(05)
[2]徐国明.轮轴精加工及组装生产线的研制.铁道车辆.1998年第9期
[3]周翊民.面向21世纪的中国铁路轮轴技术.铁道车辆.1998年第12期
[4]谈大同.中国铁路车辆轮轴的现状与展望.铁道车辆.1998年第12期
[5]杨燮林.美国机车车辆轮轴加工技术简介.机车车辆工艺.1988,(6)
[6]车轴生产自动线.国外机车车辆工艺.1976,(5)
[7]郑伟生.国外轮轴技术发展综述(一).国外铁道车辆.1998年第4期
[8]郑伟生.国外轮轴技术发展综述(二).国外铁道车辆.1998年第5期
[9]刁克军.我国重载铁路货车车轴及轴承的技术发展.铁道车辆.2006年第6期
[10]郭玉玺.中国第二条辗钢整体车轮生产线及其工艺技术水平分析.铁道车辆.1998年第9期
[11]车轮、车轴机械机加工无人化系统的研制.国外机车车辆工艺.1977,(7)
[12]新型车轮车床.国外机车车辆工艺,1978,(1)
[13]车轴的程序超声波探伤和自动记录.国外机车车辆工艺.1978,(6)
[14]王彦豪.客车轮对压装问题探讨.铁道机车车辆工人.1996,(08)
[15]陈辉刚.轮对压装实现互换的可行性分析(一).铁道机车车辆工人.1997,(10)
[16]徐国明.影响轮对压装质量的因素.机车车辆工艺.1984,(02)
[17]郑东.铁路货车轮对压装曲线记录仪的研制.西南交通大学,2003
[18]王明新.铁道车辆车轴可靠性与安全性分析系统.西南交通大学,2005
[19]江先志.轨道车轮轴自动拆装机及其控制系统的研究.武汉理工大学,2004
[20]#12
[21]高向东.轮对参数自动检测新装置.机车电传动.2005,(01)
[22]吴学军.轮对自动检测装置.铁道车辆.2003,(03)
[23]高向东.铁路车辆轮对自动检测系统的研制.机车电传动.2003,(02)
[24]高向东.铁路车辆轮对自动测量新方法.新技术新工艺.2004,(12)
[25]K Bel Knani,周贤全.新开发的轮对设计方法.国外铁道车辆.2003,(02)
[26]涂富田.全自动轮对压装机的研制.西南交通大学,2004
[27]Effect of probability of detection upon the definition of inspection intervals for railway axles.By:Carboni,M.;Beretta,S.Proceedings of the Institution of Mechanical Engineers -- Part F -- Journal of Rail & Rapid Transit,Sep2007,Vol.221 Issue 3,p409-417,9p,2 charts,4 diagrams,6 graphs;DOI:10.1243
[28]郑伟生.研讨轮轴技术促进生产发展.铁道学报.1992,(04)
[29]Failures of bearings and axles in railway freight wagons.By:Gerdun,Viktor;Cene,Bojan.Engineering Failure Analysis,Jul2007,Vol.14 Issue 5,p884-894,11p;DOI:10.1016
[30]孙振海.铁道车辆轮轴全过程管理方案研究.西南交通大学,2006
[31]第12届国际轮轴大会专栏.铁道车辆.1998,(09)
[32]杨国桢.坚持不懈地致力于轮轴技术的进步.铁道车辆.1990,(05)