1 System Introduction :
The PHS200-B1M of HS. DESENVOLVIMENTO INDUSTRIA E COMERCIO DE EQUIPMENTO LTDA, BRAZIL is a system designed for the assembly/disassembly of the wheels sets for the railway cars, locomotive it is fully automated, computerized, and labor saving system. With the system to centralizer the axle about the mobile car and a Laser to measure the gauge between wheels. All assembling data are dispalyed in the monitor and recorded in computer, operator is able to know immediately if there is a misfit and supervisor can check in the data base for any assembly record.
With this system, the human error can be reduced to lowest level, the wheel sets assembled are in their best position to perform reality, attain a low wear, low noise and less friction loss.
2 System Specifications : P/N PHS200-B1M
- Wheel diameter range : from 28 in. to 42 in.(about 711mm to about 1066 mm)
- Shaft(Axle) length : 6.14.3 ft.(about 1870 mm ( large length is possible under inquiry )
- Assembly time per one wheel set : about 30 seconds ( 60 seconds to assemble complete)
- Centralized Axle : (Used screw sphere drive ac motor to center axle in table base)
- Capacity of the press: 200 tons ( 300-400 TON owe your necessity )
- Laser measured gauge between wheels to stop assemble:( allowance accuracy + or – 0,5mm in FS)
- Data output, displacement vs. pressure(see annex 1 any sample diagram)
- System dimension : L=15 ft, W = 6 ft, H=9 ft ( to gauge rail from 1000mm)
- System total weight : 30,000lb (without wheels and axle)
- System can be installed in wide gauge rails and narrow gauge rail from to 1000mm
2.1 P/N PH200-B1.6M 200 ton GAUGE 1600mm
2.2 P/N PHS300-B1M 300 ton GAUGE 1000mm
2.3 P/N PHS300-B1.6M 300 ton GAUGE 1600mm
2.4 PN PHS400-B1M 400 ton GAUGE 1000mm
2.5 P/N PHS400-B1.6M 400 ton GAUGE 1600mm
3. Operation procedures:
a. wheel sets assembly
The wheels are placed on two gloves that are placed in the tips of the axle. Now the axle with the wheels is placed on the mobile car of the press to initiate the assembly is given start-up in the button start, the centralizer initiates making pressure in the two extremities of the axle leading it stops being centered in the car to mobile. After the centered axle this if it initiates the procedure of assembly of the first wheel, hydraulic cylinder is set in motion and starts to push the axle for inside of the hole of the wheel.
A system of Laser is used to control the assembly of the wheels in the axle, determined how much the axle goes to penetrate in the wheel, This goes to make with that we have defined the gauge between wheels. The placed laser this in the center of the mobile car and continuously measures the distance of the center of the axle until the internal face of the wheel, and when this distance will be exactly same the one that was programmed for the gauge of assembly it disconnect the actuate of the hydraulic cylinder of force.
All procedure of assembly will be executed automatically, first a wheel , later the second wheel and when it finishes the assembly them two wheels the axle with a two wheels assembly is removed from above of the press and dispatch of back the press up the rail.
To assemble two wheels in one axel is necessary only one minute
b. wheel sets disassembly
To disassemble the wheels of the axle, first it is necessary to prepare the press.
1-Remove the mobile car for front of the press
2-To place the central castle to up top and to arrest it in the connecting rods.
3-To place the axle with the wheels on the press, it must be hung in the rolling bridge of sustentation.
4- O dismount (disassembly) procedure is made manual, not automatize.
5- First is set in motion the hydraulic cylinder of a side that pressure the axle to force it and having wheel being
supported in the castle until it to leave the cube of wheel
6- repeats the procedure for the second wheel
To disassemble two wheels of the axle is necessary only one minute
c. existing wheel set between wheels gauge measuring (Optional)
System HS SYSTEM PG to measure gauge between wheels and verify parallelism between wheels.
The H.S. desenvolvimento to make system HS SYSTEM PG that he is used for verification of parallelism and the measure between wheels after the assembly. The system uses two sensor ultrasonic that they are mounted in a structure in which the axle after to be mounted is placed on it to be analyzer. This structure has a support for the axle in a side and in the other extremity of the axle it has a support with an motor-drive to turn it 360 degrees so that the measure of parallelism is made in all the circumference of the inside wheel.
The system is controlled for a PLC that inside registers the data of the measures informing if this within of the established or off . O PLC allows your to enter with the data that will be reference with the tolerance demanded, thus it analyzes if this inside or not and informs in a report through of a printer.
d. existing wheel set axle center measuring
Not necessary if to make the measurement and marking of the center of the axle to become the assembly of the wheels in the axle, the centralizer makes this automatically, is so to place the axle with the wheels in the tip on the press and it the assembly procedure all is made automatically
The maintenance of the press is very simple,e is not necessary great stops of functioning to execute the maintenance.
a) Check up level of oil hydraulic of the unit of power.
b) Cleanse dust in the lenses of the sensors ultrasonic and Laser
c) Check up if exists leak of hydraulic oil in the gasket cylinder
d) Cleanse cylinders dust in ruler digital, in the electronic components as computer and electric cabinet.
e) Used one calibrator for verification of the force of presser in each 6 months.
f) The calibrator is made with cell of load and supplied for the H.S.Desenvolvimento as optional.
5. Benefits and comparison
1-The new car with centralizer eliminates the necessity of if marking the middle in the axle and allows a faster operation and accuracy the measure of the gauge between wheels.
2-The centralizer fixed the axle for the top extremities, making with that the same if it dislocates together with the car, eliminated any possibility of error in the control of the penetration of the axle in the wheel, thus guaranteeing a measure between wheels, trustworthy and inside of the tolerance demanded.
3-The sensor ultrasonic with laser without physical contact allows a precision of up to 0,5 mm between wheels, what it is not possible with the current system through the template.
4-The time of assemble of the two wheels can arrive the 60 seconds after the axle have been located on the car.
5- Increase of the production of assemble with more trustworthiness and not rebuilding necessary, time less esteem of assemble in 60 seconds.
6- The press with two cylinders of force allows a considerable increase in the production since it is not necessary loss of time to turn the axle for assemble and disassemble of the second wheel.
8- Eliminate the mechanism of turn of the mobile car what it drastically reduces complexity of automation and maintenance.
9-After the wheels to have been assemble the withdrawal of the axle from above of the press are made automatically not needing bridge rolling .Os rail under the press if they is elevate to up through a hydraulic cylinder raising the axle and making to roll it for to back of the press in the stock park
10-Compared with other presses, our press is total automatize , depending on the operator only to place axle in top of it and to press the start button. We have one considerable reduction of the workmanship hand and operators and reduction in the assembly time, without counting on high quality of the assemble since the system of centralization and the sensor ultrasonic make all complex part and of precision without depending on the operator who always has its imperfections.
Automated Wheel Press Recorder
The Automated Wheel Press Recorder (HSRW) is a computerized system for recording pressure while mounting train wheels. All of our press recorders generate mounting diagrams like those produced by the H.S.Desenvolvimento. Because the mounting diagrams are computer generated, storage and retrieval operations are greatly simplified. This makes reporting, inspections and supervisory functions much easier. The press recorders produces many reports or you can use your desktop database to produce your own customized charts and graphs. It is operated by touch screen, mouse or keyboard
All of the press recorders consist of a personal computer, a pressure transducer, a linear displacement sensor and two barcode scanners (optional). The personal computer runs custom software to log pressure versus distance and displays a mounting diagram on the screen as each wheel is mounted. This allows you to know immediately if wheels are misfits and if they have been demounted. The information is saved to a local hard disk and to a backup hard disk immediately after the second wheel is mounted. Scanning the wheel serial numbers with the barcode scanners eliminates the need to write them down or type them.
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