对铁路动车组轮轴检修工艺及装备的探讨_图文

1、设备检修从2007年4月18日中国铁路首次在既有铁路干线上开行200km/h 以上动车组列车以来,至今已有CRH系列4种动车近200组(8辆编组上线,并陆续扩展到新建成的铁路客运专线上运行。部分动车组已运营近2年,到了3级修修程(按铁道部统一规定动车组检修实施15级修。根据测算:到2012年,我国铁路营业里程将达到11万k m,其中客专1.3万km要建成投入运营,需要运营动车组800组以上。因此,加速建设中国铁路动车组检修基地已迫在眉捷。在动车基地总平面布局、检修板块的主工艺流程基本确定情况下,如何细化,如转向架轮轴等重大部件的检修工艺流程和布局,选好关键设备(功能、技术参数、相关尺寸等尤为关

2、键。1轮轴检修总体设计思想现代化铁路动车组检修基地设计,应坚持“先进、成熟、经济、适用、可靠”的技术方针,科学合理布局,采用先进检修工艺及装备,缩短动车组在基地内停修时间,努力降低维修成本,提高运营可靠性,确保动车组具有良好运行状态。具体体现如下。(1满足检修工艺要求。纵观C R H系列4种动车组车型的性能、结构、技术参数及相关尺寸,提出轮轴解体、检修、组装检修流水线的作业工序及各工序配置设备在检修区的合理布局,实现节奏合拍,工序流、物流、信息数据流的顺畅,从而达到安全高效的目的。(2满足检修能力需求。检修线上配置的设备能力在满足检修设计工作量需要的同时,要考虑临修作业的需要,并按耗时最大工序

3、(节拍时间和每天有效工时进行计算。(3具有较高的设备兼容性。检修线各设备基本上应能兼容C R H系列动车组车型,满足轮轴检测、检修、试验的需要,但个别需要增加部分工序和辅助工装。(4工艺结构要符合人机工程学理念。从提高检修作业效率、降低作业人员强度、节约车辆运营维修成本角度,应优先选用符合人机工程学理念的先进、高效、实用的设备。2轮轴检修工艺分析参照国外车辆制造商检修工艺经验,结合我国铁路车辆检修做法,提出了以更换损坏或到期零部件与修复相结合的轮轴解体、组装检修流水线工艺方案。2.1CRH系列动车组轮轴主要技术参数及结构CRH型动车组轮轴主要技术参数见表1,C R H型动车组动、拖车轮轴外形结

4、构见图15。2.2轮轴分解流水线2.2.1作业内容轮轴分解流水线要完成C R H系列各型动车组轮对的部件拆卸、除锈、脱漆、车轴清磨、清洗、检测、齿轮箱供油、车轮踏面及制动盘端面镟修、齿轮箱排油等作业。2.2.2工艺流程根据4个动车检修基地轮轴检修(35级修工作量测算,每一基地日检修轮轴数近期约3040对,远期5065对。考虑到检修区工艺布局,以设置轮轴分解流水线23对铁路动车组轮轴检修工艺及装备的探讨邱建平摘要:对中国铁路动车组轮轴检修工艺和装备选型进行分析研究,重点介绍总体设计思想、轮轴解体流水线、组装流水线的工艺流程、平面布局、工装设备配置原则、关键设备选择等,提出了动车组检修基地轮轴车间

5、检修工艺和设备配置初步意见。关键词:动车组;轮轴;检修工艺;检修设备邱建平:中铁第四勘察设计院集团有限公司设备设计处,副总工程师,高级工程师,武汉430063表1动车组轮轴相关数据m m 名称C R H1C R H2C R H3C R H5车轮直径(括号内915(835860(790动车920(830890(810是磨耗后的极限值拖车920(860车轮宽度135135135135轮孔直径动车204.8±0.015201192拖车195.8±0.015196192轮制动盘直径640725750轮制动盘厚度135133轴制动盘直径640670640640轴制动盘厚度110978

6、0车轴内孔60603065轴颈直径130130130130轴身直径170192166166车轴总长(动车/拖车2250/22502298/23822180/21802180/2180轨距1435143514351435固定轴距2700 2 5002 5002 700图 1 CRH1动车轮对图2CRH1拖车轮对图3CRH2动车及拖车轮对条为宜。轮轴分解流水线工艺流程见图6。2.2.3平面布局按照轮轴分解线主要工序,设定在转向架轮轴检修区的合理布局,既要满足轮轴分解的检修工艺要求,又要满足上下工序之间有序衔接,保证工序流、物流、信息数据流的顺畅。轮轴检修分解线平面布局见图7。2.3轮轴组装流水线2

7、.3.1作业内容轮轴组装线要完成C R H系列各型动车组轮对组装检修作业,它包括轮对压装、电阻测试、轮对检压试验、空心轴探伤、齿轮箱清洗(预图6轮轴分解线工艺流程图安装支承轮联轴器拆卸轴箱拆卸收入检查3级修动轮是齿轮箱排油清洗否齿轮箱排油C R H2轮对是否轴端螺母拆卸轴端螺栓拆卸轴承拆卸C R H3轮对除漆清洗C R H3涂装剥离轮轴清磨是否轮对自动测量空心轴探伤3级修是否车轴磁粉探伤车轴磁粉清洗齿轮箱供油踏面摩擦面镟修3级修是否车轴油漆烘干组装线齿轮箱排油轮轴分解车轮线、车轴线-0.035-0.035图7轮轴分解线平面布局图留、齿轮箱注油、车轮踏面及制动盘端面镟修、车轮探伤、动平衡试图8轮

8、轴组装检修流水线工艺流程图图9轮轴组装检修流水线平面布局图验、轮对涂漆烘干、轴颈清洗打磨、轴颈测量、轴承存放及压装、轴端螺母组装、C R H 3型涂抹密封胶、轴箱组装、联轴节及接地装置组装、轮对回转试验、轮对与构架组装等。2.3.2工艺流程轮轴组装流水线数量同样按各基地轮轴任务量配备,一般设2条线平行布置,轮轴组装检修流水线工艺流程见图8。2.3.3平面布局轮轴组装检修流水线由控制、物流、工位、工装设备等有序组成,其中轮对组装控制系统具有数据分析处理功能,每个工位都有数据读取轴端信息,并自动显示功能,检修内容上传至数据库,为后续工位的检修提供依据。轮轴组装检修流水线平面布局见图9。检修后的车轴

9、轮轴选配系统选出的车轮轮对压装电阻测试轮对检压试验空心轴探伤齿轮箱注油1型车3级修轮对车轮、制动盘镟修车轮探伤轮对动平衡试验轮对涂漆及烘干轴颈清洗打磨轴颈测量轴承压装轴端螺母组装1、2型车轮对3型车涂抹密封轴箱组装联轴节及接地装置组装轮对回转试验通过天车将检测不合格的轮对吊到组装工位上进行分解空心轴探伤齿轮箱去油清洗踏面镟修轮轴涂装剥离信息机房配电所车轴输送小车轮对检压试验检压等待空心轴探伤齿轮箱注油车轮、制动盘镟修轮轴组装线轮对组装检修方向车轮探伤动平衡试验轴颈清洗打磨轮对3级修进入方向轮对进入方向轴承地下传输通道轮对涂漆及烘干轴承压装移动式轴承退卸机轴径测量轴端螺母组装轴箱组装联轴节组装轮

10、轴组装线轮对组装检修方向轮对回转试验轮轴组装轮对压装同温线同温线车轴检修后进入方向车轮进入方向电阻测试轮对输送车去往轮轴分解齿轮箱排油3级修去往组装线齿轮箱供油车轴磁粉清洗车轴探伤预留轮对自动检测车轴清磨轮对除锈清洗轴承拆卸轴端螺栓拆卸收入检查轴箱退卸联轴节及接地装置拆卸轮对输送车轮对组装检修方向 轴承存放3轮轴检修关键工艺装备3.1轮轴检修工艺装备配置原则(1适应车型及修程需要。全路4个动车组检修基地配置车型略有不同,初步考虑每个基地承担12个主型车型,12个兼容车型。因此,每个基地需要承担主型车全部修程(35级修,兼容车型3级修。(2在百余项工装设备中,自主开发的项目或核心部件需要引进的设

11、备,有条件时应优先选用一机多用。例如,轮轴压装机不仅要实现车轮、大齿轮、制动盘毂与车轴的冷压组装和高压油组装,同时能实现车轮、大齿轮、制动盘毂和车轴的注油分解和轮对组装后的检压测试。又如,车轮车床要选用既能加工车轮踏面,又能加工制动盘端面的设备。(3按照动车组基地检修需求,不断改进和自主开发设备,量身定做;核心部件应采用国际知名专业厂商的优质产品;对引进设备部分功能尽快国产化配套,使性能更可靠,功能更强大。(4要有完善配套设施。除主机和附属装置外,配套设施应包括设备基础,风、水、电引入节点和废汽、污水排放点等。3.2轮轴检修设备配置为了便于分析,以主修CRH2、3型动车组轮轴为例,提出设备配置

12、。轮轴分解线设备见表2。轮轴组装线设备见表3。除各工位对应的设备外,在轮轴分解和组装线上还有轮轴分解和组装线控制系统、轮对输送车、轮对转盘、扭矩测试仪、通用工具等设备。3.3关键设备选择(1轮轴分解、压装、检压设备。除C R H1型动车组轮轴组装采用热装工艺外,其余车型轮轴分解、组装均采用高压注油工艺。通过比选,初步确定选用德国生产的轮轴分解、压装检压设备,该机拥有先进成熟的液压伺服技术、精确的测量系统、先进的压力补偿功能以及可实现分解、组装、检压车轮和制动盘表2轮轴分解线设备工位名设备名称联轴节与接地装置拆卸齿轮联轴节及接地装置拆卸轴箱退卸轴箱退卸机收入检查轮对预检和建档装置齿轮箱去油清洗齿

13、轮箱排油装置齿轮箱高低速油清洗机轴端螺栓拆卸轴端螺母拆卸装置轴承拆卸轴承退卸机轮对除锈清洗轮轴除锈清洗机车轴清磨车轴清磨装置C R H3轮轴涂装剥离C R H3轮轴涂装剥离装置轮对自动检测轮对尺寸自动检测机空心轴探伤空心轴超声波探伤机车轴磁粉探伤轮对磁悬液探伤机车轴磁粉清洗磁粉清洗装置齿轮箱供油齿轮箱注油机(移动式车轮制动盘镟修车轮车床齿轮箱排油齿轮箱排油装置表3轮轴组装流水线设备工位名设备名称轮轴预组装装置轮对压装轮对压装机轮辋内侧距检测器轮位差检测工装电阻测试轮对接地电阻测量装置轮对检压试验轮对检压机空心轴超声波探伤机耦合剂容器防锈油容器空心轴探伤清除耦合剂工具涂抹防锈油工具标定轴及托架转

14、轮拨轮器工具柜齿轮箱注油齿轮箱注油机扭力矩扳手车轮、制动盘车床车轮、制动盘镟修工具柜电动砂轮机车轮探伤固定式轮辋轮辐超声波探伤机标定轮动平衡试验动平衡试验机转轮拨轮器轮对涂漆及烘干轮对涂漆烘干装置轴颈清洗打磨轴颈清洗打磨装置标记钢印轴颈测量轴颈测量装置轴承同温存放架轴承内孔测量装置轴承压装工具柜轴承压装装置轴承输送装置轴端螺母组装装置轴端螺母组装扭力矩扳手螺栓、螺母托盘电动扳机C R H3型车涂轮对举升装置抹密封胶轴箱组装机螺栓等存放架轴箱组装扭力矩扳手电动扳机轴箱、螺栓托盘联轴节及接地联轴节组装装置联轴节托盘装置组装感应加热器轮对回转试验轮对回转试验装置的功能。该设备的主要参数如下。高压油分

15、解:最高压力>200 MPa,最大推力2500kN。高压油组装:最高压力160M P a,最大推力2500kN。最大检压力为1600kN。(2轮对尺寸自动测量机(非接触高精度测量系统。引进了瑞士生产的体积精巧的线性传感器,并就不同的测量位置设置了不同的驱动程序,使专用测量元件能实现水平、垂直两方向的移动,从而全面兼容4种CRH 车型。该产品采用线性CCD 成像技术,元件自身的测量精度可达±0.01mm,整个系统的测量精度为±0.05mm。(3车轴尺寸测量机(接触高精度测量系统。该机引进了德国生产的高精度光栅长度计作为直径测量元件,从根本上保证了测量尺寸的可靠性和真实性

16、。(4空心轴超声波探伤机。2008年4月我国已研制开发出适合C R H 系列动车组空心轴超声波探伤作业的探伤机,其关键部件采用德国产品,经过西安、南昌等6个动车运用所使用,设备运行稳定。(5车轮探伤机。德国新近研制出的相控阵探头,能对车轮轮辋、轮幅及其两者过渡区进行无损检测,能调节探头的入射角及聚焦深度范围,从而使得探头数量大为减少,整个探头系统结构紧凑,操作灵活,图像完整细微,便于缺陷评估分析等,该设备特别适合带有轮装制动盘的车轮。4结论(1轮轴分解、组装采用流水作业检修方式,集控制、物流、设备、工位等一体的检修线模式。(2流水线上按工序配置的设备要确保整个系统功能可靠、能力满足要求、物流自

17、动快速、工序柔性安全、维修操作方便,其总体技术水平要达到当今国内外同类产品的领先水平。(3引进核心部件的设备,要逐步进行国产化配套,有条件时应尽快形成具有自主知识产权的产品。收稿日期2009-02-25 d =2(l2+(l -h 22(4(上接第24页有关的斜剖面图,由于传感器相对于钢轨的安装位置是固定的,而车辆运行速度已知,因此,通过几何运算,可以得到二维的车轮外形图,并可分别计算轮缘高度和轮缘厚度。3.4轮径测量钢轨外侧安装了2只激光位移传感器,其安装角度为36°,分别扫描出轮缘及踏面的端面后,在速度已知的条件下,可得到弦长l ,而两激光束高度h 可以通过激光位置传感器测量系统

18、测量得到,通过几何运算可得车轮直径d (图8。3m,而且传感器安装结构设计要保证与钢轨的电气绝缘。(2传感器防护。由于地铁环境内存在部分的粉尘,作为一种光学检测设备,激光位移传感器必须采取一定的防护措施。防护机构应安装在预留设备坑里,防护门由转角电机控制,当控制系统检测到来车时,打开防护门,实现探测,平时防护门处于关闭状态。(3设备限界要求。设备安装前应进行尺寸测算,仔细确认所涉及的安全限界,标出全部的限界尺寸,保证所有设备均不得侵入地铁车辆、设备限界,以免影响地铁列车的安全运行。(4设备防电磁干扰要求。所有设备应具有防电磁干扰的能力,且不能对地铁车辆上安装的各类设备及地铁地面上安装的各类设备

19、造成干扰。(5设备自保护要求。系统应具有自保护功能,其原始数据任何情况下均不得丢失(可实时自动转存,且任何人均无法修改。电路的设计应保证当其某一元器件发生故障时,对系统中任何其他元器件带来的间接损坏为最小,同时应保证系统的故障不扩大化。(6系统报警软件设计时,需根据实际合理设置报警条件,增加标准参数与实测参数的对比曲线,避免误报警次数太多,增加不必要的人工检查次数。收稿日期2008-12-29图8轮径测量示意图hl4注意事项(1传感器安装。所有传感器的安装必须方便可靠,不得大范围破坏现有路轨条件的基础施工(传感器安装基础施工横跨路轨范围ABSTRACTS Applying the Scient

20、ific Outlook on Development to Promote the Construction of Urban Rail Transit -C Thinking on Current Construction Development of China Urban Rail Transit Jiao Tongshan 1 The construction of China Urban Rail Transit is now staying in the important time with rapid development. The achievements we obta

21、ined are objectively summarized. At the same time, the contradiction between the current construction speed and preliminary work, the construction procedure, the phenomena of despising operation, the unified planning of traffic integration, the control of construction standards, the difference of fa

22、re in domestic urban rail transit, as well as the enhancement of government management for urban rail transit are analyzed and investigated through some phenomena in the industry. Several suggestions are also presented. Practice and Thinking of Construction for Dispatch and Command System of Urban R

23、ail Transit Network Liang Ping, Du Shimin 5 Because the rail transit of major cities in China has successively entered the stage of network operation, the construction of network dispatch and command system is put on the schedule. In this paper, by using the construction for network dispatch and com

24、mand system in Beijing Urban Rail Transit as background, the practical experiences of the construction of network dispatch and command system are summarized and the suggestion is proposed. Discussion on UPS Integration of Signal System in Urban Rail Transit Wen Renguang 8 The safe and reliable requi

25、rements of signal system to UPS are described. The potential risk after UPS integration of signal system is analyzed in detail. It indicates that although UPS integration of transit system is the trend, it is still in the research and experiment stage. The UPS integration scheme involving signal sys

26、tem should be carefully considered. Localization of Filter Element of Air Compressor in EMU of Nanjing Metro Line 1 Deng Zhigang, Sun Gang 17 The air filter element, developed on the basis of the filter principles and the air compressor structure of braking system in Nanjing Metro, has experienced t

27、he examination by professional institution and 3-month on-board comparative test. It is proven that this air filter element has qualified performance and reliable quality, and can fully substitute the import air filter element. Design and Construction of Protective Blocking Gate System Zhao Jiajian,

28、 Wu Yue 19 The protective gate system is new type metro disaster prevention equipment with dual functions of flood-proofing and civil defence. The work principles and construction of protective blocking gate system are described by analyzing the functions and constitutes of metro protective flood-bl

29、ocking gate system as well as its interfaces with signal, environment control and station control systems. Discussion on Wheel and Axle Maintenance Technology and Equipment of Railway Multiple Units Qiu Jianping 25 The wheel and axle maintenance technology and the selection of equipment of China rai

30、lway multiple units are analyzed. In the paper emphasis is laid on the introduction of overall design idea, wheel and axle disassemble and assembly line, plane layout, technics equipment collocate and key equipment selection. The suggestion is presented for the maintenance technology and equipment c

31、ollocate in wheel and axle workshop of maintenance base for multiple units. Discussion on Calculation Method of PBA Construction Method for Mining Station under Structure-Soil Interaction Zhao Wei 32 PBA construction method (Pile-Beam-Arch Mining Method has been extensively applied in the design of

32、metro stations as the restriction of surrounding environment. This paper discusses the simplified issue by calculating the model under structure-soil interaction. Construction Technology of Shallow-Buried Tri-arch Large-span Tunnel Xu Xinyan 34 Combining with the construction of shallow-buried tri-a

33、rch tunnel in the section of Xiongmao Huandao Station?Andinglu Station (including connect line of Beijing Metro Line 10, the construction scheme, technical process and operation points of shallow-buried triarch tunnel are illustrated. Static Press Construction Method with PHC Prestressed Concrete Pi

34、pe Pile Kang Litao 38 Static press construction method with PHC pipe pile is a pile driving technology that uses static press pile machine to press the prestressed concrete pipe pile (PHC pile into the ground. It has the characteristics of low noise and pollution, a little influence on the soil laye

35、r and surrounding buildings, and a little damage to pile quality. The static press construction technology is applied in the pile construction for no-platform-column canopy project of reconstruction of Tianjin Station, and achieves well social and economic benefits. Security Risk Assessment of Track

36、 Area in Metro Construction Yang Jun, Wu Yongfang, Ji Xuewei, etc. 48 Based on the security risk analysis of possibility of accidents for construction vehicles passing the track area (including part of existing lines, the risk degree of operating personnel in dangerous environment as well as the con

37、sequence of accidents in Shenzhen Metro Line 1, the risk degree of construction in the metro track area is finally evaluated. According to the characteristics of track area construction and existing line transport, the effective emergency plan is established to ensure the security of personnel and construction to