EP2192017A2 - Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung - Google Patents

Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung Download PDF

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Publication number
EP2192017A2
EP2192017A2 EP09177242A EP09177242A EP2192017A2 EP 2192017 A2 EP2192017 A2 EP 2192017A2 EP 09177242 A EP09177242 A EP 09177242A EP 09177242 A EP09177242 A EP 09177242A EP 2192017 A2 EP2192017 A2 EP 2192017A2
Authority
EP
European Patent Office
Prior art keywords
inductor
frame
metal
heating
straightening
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP09177242A
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English (en)
French (fr)
Other versions
EP2192017B1 (de
EP2192017A3 (de
Inventor
Paolo Buonanno
Gualtiero Gailli
Beniamino Mazzone
Raffaele Scognamiglio
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Ansaldobreda SpA
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Ansaldobreda SpA
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Publication date
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Priority to EP20090177242 priority Critical patent/EP2192017B1/de
Publication of EP2192017A2 publication Critical patent/EP2192017A2/de
Publication of EP2192017A3 publication Critical patent/EP2192017A3/de
Application granted granted Critical
Publication of EP2192017B1 publication Critical patent/EP2192017B1/de
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61F—RAIL VEHICLE SUSPENSIONS, e.g. UNDERFRAMES, BOGIES OR ARRANGEMENTS OF WHEEL AXLES; RAIL VEHICLES FOR USE ON TRACKS OF DIFFERENT WIDTH; PREVENTING DERAILING OF RAIL VEHICLES; WHEEL GUARDS, OBSTRUCTION REMOVERS OR THE LIKE FOR RAIL VEHICLES
    • B61F5/00—Constructional details of bogies; Connections between bogies and vehicle underframes; Arrangements or devices for adjusting or allowing self-adjustment of wheel axles or bogies when rounding curves
    • B61F5/50—Other details
    • B61F5/52—Bogie frames
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D1/00—Straightening, restoring form or removing local distortions of sheet metal or specific articles made therefrom; Stretching sheet metal combined with rolling
    • B21D1/14—Straightening frame structures
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/10—Induction heating apparatus, other than furnaces, for specific applications
    • H05B6/101—Induction heating apparatus, other than furnaces, for specific applications for local heating of metal pieces
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/02—Induction heating
    • H05B6/36—Coil arrangements
    • H05B6/40—Establishing desired heat distribution, e.g. to heat particular parts of workpieces

Definitions

  • the present invention relates to a method of straightening and calibrating a railway bogie frame by means of induction heating.
  • railway bogie frames are made by reciprocally connecting, by means of electric welding, metal portions shaped by means of previous production cycles; during the electric welding operations, the metal material (typically Fe 510 D1) undergoes a thermal cycle from ambient temperature to melting temperature and from melting temperature to ambient temperature in a relatively short time.
  • the metal material typically Fe 510 D1
  • the above-mentioned rapid thermal cycle creates residual strains in the metal material of melted zones and thermally altered zones, indeed introduced by rapidly heating/cooling the metal.
  • the residual strains are also introduced by the use of fasteners which are arranged on the metal portions to be welded to prevent the structure from being excessively deformed during the welding operations.
  • the railway bogie frames undergo a strain-relieving process by arranging the whole bogie in a electric furnace having a controlled temperature.
  • a straightening and calibrating procedure is carried out by using specific calibration tools (e.g. screw jacks) adapted to generate loads on the frame itself, and by heating some zones of the frame in a localized manner.
  • specific calibration tools e.g. screw jacks
  • the heating operations should be carried out at a temperature of 650° C in order to maximize its effects.
  • the heating operation is carried out by using an oxy-acetylene blowpipe, the flame of which reaches very high temperatures (2500-3000° C) which are much higher than the optimal heating temperatures (650° C).
  • the fundamental parameters for the success of the straightening and calibrating process are: the distance of the flame from the zone subjected to heating and the movement speed of the flame.
  • Such parameters are manually and empirically controlled by an operator, who indeed carries out the heating process on the basis of his/her experience.
  • the method consists in applying induction heating technology, which is based on the generation of a medium frequency, variable intensity magnetic field, in a specific device, commonly named inductor.
  • Induced currents are generated when a metal conducting body is placed within the magnetic field, which currents cause the heating of the piece by Joule effect.
  • the present invention relates to a method of straightening and calibrating a railway bogie frame wherein said frame is made by reciprocally connecting, by means of electric welding operations, metal portions shaped by means of previous production cycles; during the electric welding operations, the metal material undergoes a thermal cycle which produces melted zones and thermally altered zones in which residual strains introduced by rapidly heating/cooling the metal are present, said frame being subjected to a step of heating in a furnace which does not completely eliminate the distortions in the frame because some parts thereof may not be aligned with respect to the nominal shape; said straightening and calibrating method by heating comprising the step of applying loads to said frame and punctually heating at least one portion of the frame, characterized in that said step of heating comprises the steps of: arranging an inductor facing said portion and feeding an alternating current to the inductor so as to generate induced currents in the metal portion facing the inductor; such induced currents close in the metal portion which is heated in a concentrated, punctual manner by Joule effect
  • numeral 1 shows as a whole a railway bogie frame made according to a known process.
  • the frame 1 was made by reciprocally connecting, by means of electric welding, metal portions shaped by means of previous production cycles; during the electric welding operations, the metal material (typically Fe 510 D1) underwent a thermal cycle which took it from ambient temperature to melting temperature and from melting temperature to ambient temperature in a relatively short time.
  • the metal material typically Fe 510 D1
  • frame 1 further comprises two side-members 3, connected to each other by means of a pair of rectilinear cross-members 4.
  • Each side-member 3 comprises two vertical walls 8 (only one of these delimiting one side facing outwards is visible in figure 1 ) and two upper/lower flange plates 10,11 and a predetermined number of internal ribs (not shown).
  • the rectilinear cross-members 4 have a structure similar to that of the side-members 3.
  • Each side-member 3 comprises a rectilinear central portion 3_a and a pair of raised end portions 3_b which extend integrally upwards from opposite ends of the rectilinear central portion 3_a.
  • the flat wall 8 is connected by welding S to the upper flange plate 10, which delimits an upper side of the side-member 3 and to a lower flange plate 11 which delimits a lower side of the side-member 3.
  • the frame 1 further underwent a thermal treatment in a furnace (not shown) under controlled temperature.
  • a local heating of a zone Z of the frame 1 is obtained by arranging an inductor 20 facing a metal portion of the frame 1 and feeding a medium frequency, alternating current (10-30 KHz) to the inductor 20, so as to generate induced currents in the metal portion facing the inductor 20; such induced currents close in the metal portion which is heated in a concentrated, punctual manner by Joule effect, thus introducing geometric deformations in the zone Z, which contribute, along with the action of specific calibration tools of the known type which act on the frame 1 (e.g. screw jacks, not shown), to straighten and calibrate the frame.
  • a medium frequency, alternating current (10-30 KHz) to the inductor 20
  • induced currents close in the metal portion which is heated in a concentrated, punctual manner by Joule effect
  • a straightening and calibrating process is thus carried out, consisting in locally heating a zone Z of the frame in which an optimal temperature (approximately 650° C) is reached, which does not damage the frame itself and does not modify the features of the metal.
  • the process is implemented without requiring the use of flames and without producing harmful gases.
  • the provided thermal contribution may be easily controlled by adjusting the features of the current fed to the inductor 20.
  • the inductor 20 may be fed by the feeder (frequency converter) known under the trademark MINAC® 50/80 from EFD INDUCTION and adapted to provide an output power in the range of 50-80 KW and a variable frequency between 10 and 40 KHz.
  • the feeder frequency converter
  • MINAC® 50/80 from EFD INDUCTION
  • the feeder may be provided with a feedback temperature control in the heated zone Z in order to ensure the repeatability of the straightening and calibrating strain-relieving process.
  • the inductor 20 consisting of a tubular copper element having a rectangular section - made according to a first variant
  • the inductor 20 is arranged with the rectilinear elements 25a, 25b facing each other and coplanar to the flat wall 8 and with the U-shaped bridge elements 26a,26b and 28a,28b, respectively, accommodating the edges 10_a, 11_a of the flange plates 10 and 11.
  • the inductor 20 has shaped turns so as to make a profile which mimics the profile of a section of the portion subjected to heating by forming an air gap having a constant value (typically of 3-5 mm).
  • the inductor 20 - made according to a second variant - comprises a plurality of turns formed by:
  • the inductor 20 is arranged with the rectilinear elements 35a, 35b and 40 facing each other and coplanar to a flat wall 42 of the frame 1 and with the U-shaped bridge elements 36a,36b accommodating the edges 42_a of the wall 42.
  • an air gap having a constant value (typically of 3-5 mm) is formed.
  • the inductor 20 - made according to a third variant - is shaped so that it may be used with a cylindrical tubular portion 44 of the frame 1 and comprises a plurality of turns formed by:
  • a channel 60 is made, which extends through the turns and the terminals belonging to the inductor 20 (in such a case, the turns may be formed by a rectangular-section tube); such a channel 60 has a feeding opening in which cooling water from a feeding circuit (not shown) is introduced, and a discharge opening.
  • the forced flow of water from the feeder e.g. the frequency converter MINAC® 50/80 is adapted to generate a cooling water flow
  • an inductor 50 comprises first and second terminals 51 and 52, connected to a system of turns made by means of the same rectangular-section, tubular conductor used for the inductor 20.
  • the system of turns comprises an inlet segment 53 connected to the terminal 51, an outlet segment 54 connected to the terminal 52, a fixed branch 55 connected to the inlet segment 53 and an oscillating branch 56 connected between the fixed branch 55 and the outlet segment 54.
  • an inductor 50 has more than 1 branch, according to the geometry of the cross section on which the straightening and calibrating interventions should be carried out.
  • the oscillating branch 56 is advantageously connected by means of a pair of hinges 57, 58 to the inlet segment 53 and the fixed branch 55, respectively.
  • Each hinge 57, 58 is configured to ensure the diffusion continuity of electric current and cooling fluid from terminals 51, 52, segments 53, 54, and branches 55, 56.
  • each branch comprises both a fluidic circuit and an electric circuit, and such circuits are connected in series to each other.
  • each hinge 57, 58 comprises first and second elements 59, 60, each of which has a through pipe for the cooling fluid.
  • the fluidic connection between the first and second elements 59, 60 is preferably carried out by means of a flexible pipe 61 connected between the through pipes (dashed line in the figure).
  • the path of electric current and cooling fluid from the terminal 51 is as follows: outlet segment 53, hinge 57, oscillating branch 56, hinge 58, fixed branch 55 and outlet segment 54.
  • a single inductor may be mounted by means of hinges 57, 58 on each portion to be straightened, and thus the assembly/disassembly operation may be simplified.
  • an inductor 50 having a complex geometry which at least partially reproduces the cross section of the bogie portions to be straightened and calibrated such a cross section is processed in the best possible manner, thus ensuring the high quality of the straightening and calibrating process.
  • the inductor 50 is mounted as described for the inductor 20, i.e. so as to have a substantially constant gap with respect to the cross section of the bogie portion to the treated.

Landscapes

  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Induction Heating (AREA)
  • Heat Treatment Of Articles (AREA)
EP20090177242 2008-11-26 2009-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung Active EP2192017B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20090177242 EP2192017B1 (de) 2008-11-26 2009-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP08425762A EP2192016A1 (de) 2008-11-26 2008-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung
EP20090177242 EP2192017B1 (de) 2008-11-26 2009-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung

Publications (3)

Publication Number Publication Date
EP2192017A2 true EP2192017A2 (de) 2010-06-02
EP2192017A3 EP2192017A3 (de) 2012-01-25
EP2192017B1 EP2192017B1 (de) 2013-05-15

Family

ID=40559725

Family Applications (2)

Application Number Title Priority Date Filing Date
EP08425762A Withdrawn EP2192016A1 (de) 2008-11-26 2008-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung
EP20090177242 Active EP2192017B1 (de) 2008-11-26 2009-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP08425762A Withdrawn EP2192016A1 (de) 2008-11-26 2008-11-26 Verfahren zum Geradebiegen und Kalibrieren eines Eisenbahndrehgestells mithilfe von magnetischer Induktionsheizung

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017218645A1 (de) * 2017-10-19 2019-04-25 Zf Friedrichshafen Ag Induktor und Verfahren zum induktiven Erwärmen eines Gelenks für ein Fahrzeug
CN114618906A (zh) * 2022-02-16 2022-06-14 江苏科技大学 一种具有恒间隙加热装置的感应加热矫平系统及其方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5650464B2 (ja) * 2010-08-26 2015-01-07 東日本旅客鉄道株式会社 鉄道車両用台車の製造方法

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2428825A (en) * 1941-02-27 1947-10-14 Linde Air Prod Co Method of controlling distortion, straightening distorted objects, and/or altering the shape of metal objects
FR1602058A (de) * 1968-12-20 1970-10-05
US4668850A (en) * 1984-01-12 1987-05-26 Akebono Brake Industry Co. Ltd. High frequency induction heating device for brake shoe lining
DE19738976A1 (de) * 1997-05-14 1998-11-19 Horn Klaus Vorrichtung zum thermischen Richten eines Bauteils aus Metall
DE29804574U1 (de) * 1998-03-16 1999-01-28 KUKA Schweissanlagen GmbH, 86165 Augsburg Induktor für eine induktive Heizeinrichtung

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102017218645A1 (de) * 2017-10-19 2019-04-25 Zf Friedrichshafen Ag Induktor und Verfahren zum induktiven Erwärmen eines Gelenks für ein Fahrzeug
CN114618906A (zh) * 2022-02-16 2022-06-14 江苏科技大学 一种具有恒间隙加热装置的感应加热矫平系统及其方法

Also Published As

Publication number Publication date
EP2192016A1 (de) 2010-06-02
EP2192017B1 (de) 2013-05-15
EP2192017A3 (de) 2012-01-25

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