US20120144635A1 - Methods and systems for manufacturing an axle - Google Patents
Methods and systems for manufacturing an axle Download PDFInfo
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- US20120144635A1 US20120144635A1 US13/361,756 US201213361756A US2012144635A1 US 20120144635 A1 US20120144635 A1 US 20120144635A1 US 201213361756 A US201213361756 A US 201213361756A US 2012144635 A1 US2012144635 A1 US 2012144635A1
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- United States
- Prior art keywords
- axle
- billet
- axles
- accordance
- forging
- 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.)
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
- B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J17/00—Forge furnaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
- B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/06—Making machine elements axles or shafts
- B21K1/10—Making machine elements axles or shafts of cylindrical form
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/18—Hardening; Quenching with or without subsequent tempering
- C21D1/25—Hardening, combined with annealing between 300 degrees Celsius and 600 degrees Celsius, i.e. heat refining ("Vergüten")
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/26—Methods of annealing
- C21D1/28—Normalising
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/62—Quenching devices
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/78—Combined heat-treatments not provided for above
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D7/00—Modifying the physical properties of iron or steel by deformation
- C21D7/13—Modifying the physical properties of iron or steel by deformation by hot working
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/28—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for plain shafts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27B—FURNACES, KILNS, OVENS, OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
- F27B9/00—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity
- F27B9/14—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment
- F27B9/16—Furnaces through which the charge is moved mechanically, e.g. of tunnel type; Similar furnaces in which the charge moves by gravity characterised by the path of the charge during treatment; characterised by the means by which the charge is moved during treatment the charge moving in a circular or arcuate path
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/45—Scale remover or preventor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/45—Scale remover or preventor
- Y10T29/4533—Fluid impingement
- Y10T29/4544—Liquid jet
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49764—Method of mechanical manufacture with testing or indicating
- Y10T29/49771—Quantitative measuring or gauging
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49828—Progressively advancing of work assembly station or assembled portion of work
- Y10T29/49829—Advancing work to successive stations [i.e., assembly line]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49995—Shaping one-piece blank by removing material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49998—Work holding
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/53022—Means to assemble or disassemble with means to test work or product
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/534—Multiple station assembly or disassembly apparatus
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/53539—Means to assemble or disassemble including work conveyor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/53539—Means to assemble or disassemble including work conveyor
- Y10T29/53543—Means to assemble or disassemble including work conveyor including transporting track
- Y10T29/53548—Means to assemble or disassemble including work conveyor including transporting track and work carrying vehicle
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- General Engineering & Computer Science (AREA)
- Forging (AREA)
- Heat Treatments In General, Especially Conveying And Cooling (AREA)
Abstract
A continuous system for automatically manufacturing an axle is provided. The system includes a plurality of sub-systems and an automated transport system. The plurality of sub-systems includes a furnace configured to heat a billet to a predetermined forging temperature, a forging system configured to forge an axle from a heated billet, and a machining system configured to form a machined axle from said axle. The automated transport system is configured to automatically transport a product to and from each of the plurality of sub-systems. The product includes the billet, the axle, and the machined axle.
Description
- This application is a divisional application of U.S. patent application Ser. No. 12/146,776, filed Jun. 26, 2008, entitled “METHODS AND SYSTEMS FOR MANUFACTURING AN AXLE”, the disclosure of which is hereby incorporated herein by reference in its entirety.
- The field of the invention relates generally to methods and systems for manufacturing an axle and, more particularly, to methods and systems for manufacturing an axle for a railcar using a continuous operation that includes forging, machining, heat treating, and inspecting the axle.
- The process of manufacturing an axle for a railcar generally includes several sub-processes, including heating, forging, heat treating, machining, and inspecting. At least some known axle manufacturing processes are not continuous operations. These known axle manufacturing processes are performed within different buildings and/or at different locations. In some cases, these known axle manufacturing processes are not continuous operations because the axle being produced must be given time to cool after being forged and after the heat treating process. These known processes do not include a process for continuously cooling an axle after forging while the axle moves to the next step in the manufacturing processes.
- Moreover, these known axle manufacturing processes are also typically performed in different locations in a non-continuous fashion to prevent dirt and dust formed during forging and/or heat treating from interfering with machining the axle. For example, the heat produced during forging and/or heat treating an axle may adversely affect the machines used during the machining and/or inspection processes. Accordingly, at least some known manufacturing systems perform a forging process in a first building, perform a heat treating process in a second building, and perform a machining process in a third building. At least one known manufacturing system may perform forging and heat treating in the same building, however, machining is still performed in a separate building; and often times at a separate location. None of these known processes for manufacturing an axle are a continuous process, wherein the axle continuously moves from heating, to forging, to heat treating, to machining, to final inspection. Because these known manufacturing processes are performed either within different buildings or at different locations, and not in a continuous fashion, the number of axles that these known processes are capable of producing per day is limited and the cost associated with these processes is high.
- As discussed above, the known axle manufacturing processes include a significant amount of time for cooling the axles between forging and heat treating and/or between heat treating and machining At least one known cooling method includes cooling axles under a layer of dirt for two to three days before the axles are transported to the next manufacturing process. Such cooling further reduces the number of axles per day that can be manufactured by known processes. Moreover, known manufacturing processes employ a significant number of skilled people to operate machines within the manufacturing process. Manually operating the machines depending on the type of axle being produced may further slow the manufacturing time of an axle. This lack of automation in these known processes further reduces output and increases production costs.
- In one aspect, a method for manufacturing an axle is provided. The method includes heating a billet at a heating station to a predetermined temperature, forging the heated billet at a forging station to form an axle, and machining the axle at a machining station to form a machined axle. A product is automatically transported to and from each station using a product transport system, wherein the product includes the billet, the axle and the machined axle.
- In another aspect, a method for manufacturing an axle is provided. The method includes receiving a billet at a beginning of a product transport system and entering information related to the billet into a control system at a receiving station. The information regards at least one of a heat lot, a heat code, a chemical composition, and steel mill information. The method also includes automatically cutting the billet at a cutting station to a predetermined size before heating the billet wherein the predetermined size is based on a type of axle to be manufactured from the billet, assigning a virtual tracking identifier to the billet at a marking station to automatically track the billet and any axles produced from the billet during the manufacturing process wherein the virtual tracking identifier provides the entered information regarding the billet, and heating the billet at a heating station to a predetermined temperature. The heated billet is descaled at a descaling station prior to forging the heated billet, wherein the descaling station uses a high-pressure water spray to descale the heated billet. The heated billet is forged at a forging station to form an axle, and the axle is heat treated at a heat treating station after the axle is forged at the forging station, wherein the heat treating station automatically alters a temperature of the axle to produce an axle having predetermined metallurgical properties. The axle is cooled at a post-heat treating cooling station before machining the axle to form the machined axle, wherein the axle is continuously transported through the post-heat treating cooling station by the product transport system. The method includes machining the axle at a machining station to form a machined axle, inspecting the machined axle using an inspection station, and marking the machined axle with an identification mark at an axle marking station. The identification mark provides the entered information relating to the billet and information relating to the manufacturing process used to form the machined axle. The machined axle is washed to facilitate preventing rust from forming on the machined axle, and a plurality of machined axles are automatically loaded onto at least one of a truck and a train car according to a predetermined axle shipping allocation. A product is automatically transported to and from each station using the product transport system that is controlled by the control system, wherein the product includes the billet, the axle and the machined axle.
- In yet another aspect, a continuous system for automatically manufacturing an axle is provided. The system includes a plurality of sub-systems and an automated transport system. The plurality of sub-systems includes a furnace configured to heat a billet to a predetermined forging temperature, a forging system configured to forge an axle from a heated billet, and a machining system configured to form a machined axle from the axle. The automated transport system is configured to automatically transport a product to and from each of the plurality of sub-systems, wherein the product includes the billet, the axle, and the machined axle.
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FIG. 1 is a side view of an exemplary railcar. -
FIG. 2 is a flow chart illustrating an exemplary method for manufacturing an axle. -
FIG. 3 is a schematic view of an exemplary manufacturing system for performing the method shown inFIG. 2 . -
FIG. 4 is a top view of an exemplary inbound billet system that may be used with the system shown inFIG. 3 . -
FIG. 5 is a top view of an exemplary furnace that may be used with the system shown inFIG. 3 . -
FIG. 6 is a top view of an exemplary descaler that may be used with the system shown inFIG. 3 . -
FIG. 7 is a top view of an exemplary forging system that may be used with the system shown inFIG. 3 . -
FIG. 8 is a top view of an exemplary post-forging cooling system, normalizing system, and quenching system that may be used with the system shown inFIG. 3 . -
FIG. 9 is a top view of quenching system shown inFIG. 8 and an exemplary post-normalizing cooling system, and tempering system that may be used with the system shown inFIG. 3 . -
FIG. 10 is a top view of an exemplary gantry system, axle separation system, and straightening system that may be used with the system shown inFIG. 3 . -
FIG. 11 is a top view of an exemplary cooling area that may be used with the system shown inFIG. 3 . -
FIG. 12 is a top view of an exemplary end facing system and machining system that may be used with the system shown inFIG. 3 . -
FIG. 13 is a top view of the machining system shown inFIG. 12 and an exemplary inspection system, axle marking system, and washing system that may be used with the system shown inFIG. 3 . -
FIG. 14 is a top view of an exemplary truck storage and loading area, train storage and loading area, trucking shipping area, and train shipping area that may be used with the system shown inFIG. 3 . -
FIG. 15 is a block diagram of an exemplary control system that may be used with the system shown inFIG. 3 . -
FIG. 16 is perspective view an exemplary axle formed using the method shown inFIG. 2 and the system shown inFIG. 3 . -
FIG. 1 illustrates anexemplary railcar 10. Railcar 10 includes a plurality ofaxles 12. More specifically, railcar 10 includes twoaxles 12 near a front end 14 ofrailcar 10 and two axles near arear end 16 ofrailcar 10. Eachaxle 12 includes awheel 18 coupled to each end thereof. Described herein is a method and system for manufacturing axles, such asaxles 12. -
FIG. 2 is a flow chart showing anexemplary method 100 for manufacturing an axle, such as axle 12 (shown inFIG. 1 ).Method 100 is a continuous and automated process.Method 100 can be performed at a single location and within substantially the same building.Method 100 includes receiving 102 raw materials, such as steel, from a supplier by rail and/or truck. More specifically, in the exemplary embodiment, steel billets are received 102 and stored in a raw material storage area. During receiving 102, information about each billet is read by an automated receiving system and such information is entered into a control system. More specifically, each billet includes a code, such as a barcode, attached thereto, wherein the code includes billet information, such as heat code, heat lot, chemical composition, the supplier's name, steel mill information, and/or where the billet was made. Work is scheduled 104 by entering into the control system what type of axle a billet will be formed into and when the finished axles are needed. Other information may be entered into the control system for controlling automated forging and machining processes that form the billet into at least one finished axle. - Once the work is scheduled 104, the raw material is moved 106 in the control system from a raw material status to a work-in-progress (WIP) status. The billet is
saw cut 110 automatically to a given mass for forming a particular type of axle and assigned an identification mark, such as a virtual serial number within the control system, for tracking the billet through the forging and machining processes. The raw material or billet is then conveyed 108 by an inbound billet handling system into a forging process. The identification mark allows the control system to track each billet, and later each axle, through the entire manufacturing process. More specifically, the identification mark indicates to the automated forging and machining systems what type of axle the billet is to be formed into such that the automated forging and machining systems are controlled by the control system to form the billet into the pre-selected type of axle. - The billet is automatically moved 112 from the cutting and virtual marking system to a rotary furnace. The billet is inserted 114 into a furnace by automated means, such as a robotic device. The rotary furnace heats 116 the billet to a forging temperature. The forging temperature may range from about 2100° F. to about 2200° F. In the exemplary embodiment, the forging temperature is approximately 2150° F. The heated billet is transferred 118 from the furnace by the automated means to a powered conveyor that transports the heated billet into a descaler to descale 120 the heated billet. The descaler is a high-pressure washer that removes an outer layer of slag from the heated billet, which is generated from the furnace heating. After the billet is descaled 120, a forging temperature of the billet is verified 120.
- After descaling and
verification 120, the descaled billet is automatically loaded 122 into a forge, and a double axle is forged 122 from the billet. Alternatively, a single axle is forged 122 from the billet. In the exemplary embodiment, the dimensions of the forged double axle are checked 124, and the double axle is moved 124 to post-forging (PF) cooling. The double axle is essentially two axles attached at one end of each axle wherein the two axles have substantially the same longitudinal centerline. As discussed below, each double axle will be later separated to form two axles. The double axle is then conveyed 126 through post-forge cooling tables to cool further. The double axle is further conveyed 128 from the post-forge cooling tables into a normalizing furnace in which the double axle undergoes a single normalizing process. The normalized double axle is cooled 130 at a post-normalizing cooling station, for example, a continuous walking beam. Before cooling 130 at the post-normalizing cooling station, the double axle may optionally be quenched, depending on the specifications for the double axle. - The cooled double axle is then tempered 132 in a tempering furnace. The tempered double axle is transferred 134 to a separation station and the temperature of the double axle is verified 134. In the separation station, the double axle is
saw cut 136 to separate the double axle into two single axles. In the exemplary embodiment, saw cut 136 is made at the center of the double axle and at each end of the double axle. In the next station, the straightness of the single axles is checked, and if need, an axle is automatically transferred 138 to a straightening press in which the axle is straightened 140. The straightened axle is cooled 142 in a post-tempering cooling system. The cooled, straightened axle is loaded 144 to an end facing machine, and the ends of each axle are faced 146. More specifically, the facing machine removes material from the ends of each axle and drills a center hole in each end. The axle is then automatically rough machined 148 to correspond to the specification for the type of axle that was scheduled 104. Afterrough machining 148, the axle is tested 150 using, for example, an ultrasonic inspection system, a magnetic particle imaging inspection system, and an axle property inspection system (APIS). After testing 150, the axles are automatically marked 152 with a code that includes identifying information about the axle, such as the manufacturer, the heat code, the heat lot, and/or the manufacturing month and year, based on the identification mark given to the axle when it was cut 110 from a billet. The marked axle is washed 154 and, in the control system, the status of the axle is changed 156 from WIP to finished goods. The finished axle can be automatically stored and/or automatically shipped accordingly. - The above-described method is a continuous and automated process that is performed within one building. In an alternative embodiment, the method is performed within a series of buildings. More specifically, in the exemplary embodiment, raw material (e.g., a steel billet) is continuously conveyed through the automatic processes of becoming a double axle, and then single axles, without departing from a single, continuous path. Further, the material is continuously moved throughout the process and is continuously monitored by a control system such that each product can be identified at any time. As used herein, the term “product” refers to a billet and any axle formed therefrom, such as a double axle, a single, a rough axle, and/or a machined axle.
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FIG. 3 is a schematic view of anexemplary manufacturing system 200 for performing method 100 (shown inFIG. 2 ). In the exemplary embodiment, each station, component, and/or sub-system is automated and continuous with a previous and subsequent station, component, and/or sub-system.System 200 includes, in a series connected by an automated transport system, a receivingarea 202, an inboundbillet handling system 204, a billet cutting and markingsystem 206, afurnace 208, adescaler 210, a forgingsystem 212, a post-forge (PF) coolingsystem 214, a normalizingsystem 216, anoptional quenching system 218, a post-normalizing (PN) coolingsystem 220, atempering system 222, anaxle separation system 224, astraightening system 226, acooling area 228, anend facing system 230, amachining system 232, aninspection system 234, anaxle marking system 236, awashing system 238, a truck storage andloading area 240, a train and truck storage andloading area 242, atruck shipping area 244, and a train andtruck shipping area 246. Receivingarea 202, inboundbillet handling system 204, billet cutting and markingsystem 206,furnace 208,descaler 210, forgingsystem 212,PF cooling system 214, normalizingsystem 216, quenchingsystem 218,PN cooling system 220, temperingsystem 222,axle separation system 224, straighteningsystem 226, coolingarea 228,end facing system 230,machining system 232,inspection system 234,axle marking system 236,washing system 238, truck storage andloading area 240, train and truck storage andloading area 242,truck shipping area 244, and train andtruck shipping area 246 are considered to be sub-systems ofsystem 200. - Receiving
area 202, inboundbillet handling system 204, billet cutting and markingsystem 206,furnace 208,descaler 210, forgingsystem 212,PF cooling system 214, normalizingsystem 216, quenchingsystem 218,PN cooling system 220, temperingsystem 222,axle separation system 224, straighteningsystem 226, coolingarea 228,end facing system 230,machining system 232,inspection system 234,axle marking system 236,washing system 238, truck storage andloading area 240, train and truck storage andloading area 242,truck shipping area 244, and train andtruck shipping area 246 may be referred to herein respectively as a receiving station, an inbound billet station, a billet cutting and marking station, a heating station, a descaler station, a forging station, a PF cooling station, a normalizing station, a quenching station, a PN cooling station, a tempering station, an axle separation station, a straightening station, a cooling or post-heat treating cooling station, an end facing station, a machining station, an inspection station, an axle marking station, a washing station, a truck storage and loading station, a train storage and loading station, a truck shipping station, and a train shipping station. A heat treating station, or a heat treating system, includesPF cooling system 214, normalizingsystem 216, quenchingsystem 218,PN cooling system 220, and temperingsystem 222. Within the heat treating station or system, the temperature of an axle therein is automatically altered to produce an axle having predetermined metallurgical properties, such as strength, ductility, elasticity, electrical resistivity, thermal conductivity, thermal expansion coefficient, fatigue limit, and/or hardness. Further, a “product” as referred to herein includesbillet 272 and/or axles formed frombillet 272, such asaxles -
System 200 is controlled by acontrol system 248 that is communicatively coupled with the automated transport system, receivingarea 202, inboundbillet handling system 204, billet cutting and markingsystem 206,furnace 208,descaler 210, forgingsystem 212,PF cooling system 214, normalizingsystem 216, quenchingsystem 218,PN cooling system 220, temperingsystem 222,axle separation system 224, straighteningsystem 226, coolingarea 228,end facing system 230,machining system 232,inspection system 234,axle marking system 236,washing system 238, truck storage andloading area 240, train storage andloading area 242,truck shipping area 244, and trainshipping area 246. Although,control system 248 is illustrated as being communicatively coupled to forgingsystem 212 and normalizingsystem 216, it will be understood thatcontrol system 248 is communicatively coupled with other components, sub-systems, and/or devices withinsystem 200 for receiving information and transmitting instructions.System 200 and/orcontrol system 248 are configured to manufacture a plurality of different types of axles for railcars from billets of raw material. - Further,
system 200 is housed within asingle building 250 that includes a forgingside 252 and amachining side 254, which are separated by awall 256. Building 250 includes a single roof that substantially coverssystem 200. Forgingside 252 is considered to define a first chamber of building 250, andmachining side 254 is considered to define a second chamber of building 250. Forgingside 252 includes receivingarea 202, inboundbillet handling system 204, billet cutting and markingsystem 206,furnace 208,descaler 210, forgingsystem 212,PF cooling system 214, normalizingsystem 216, quenchingsystem 218,PN cooling system 220, and temperingsystem 222.Machining side 254 includesaxle separation system 224, straighteningsystem 226, coolingarea 228,end facing system 230,machining system 232,inspection system 234,axle marking system 236,washing system 238, truck storage andloading area 240, train storage andloading area 242,truck shipping area 244, and trainshipping area 246.Wall 256separating forging side 252 andmachining side 254 is a solid wall that facilitates preventing heat from transferring from forgingside 252 to machiningside 254. More specifically,wall 256 is a solid wall that is configured to deflect heat upward and helps to create a constant air flow to exhaust heat out ofbuilding 250. As explained below in greater detail, building 250 also includes a plurality ofair fans 266 positioned on a roof of building 250, and air-intake louvers 268 positioned at various locations on the side ofbuilding 250. Theair fans 266 create a negative pressure on forgingside 252 to help discharge heat and contaminants, such as dirt and other small debris, from forgingside 252. - Automated transport system, or product transport system, includes
conveyors 258, anautomated manipulator 260,gantry 293, aline gantry 262, agantry 264, walking beam tables, and/or any other suitable automated transport system. The term “gantry,” as used herein, refers to a gantry crane. The automated transport system is communicatively coupled to controlsystem 248. In the exemplary embodiment,conveyors 258 are conveyors supplied by Güdel GmbH of Osteedrburken, Germany (“Gëdel”), automatedmanipulator 260 is an automatic manipulator manufactured by Glama Maschinenbau GmbH of Gladbeck, Germany (“Glama”), andgantries gantries system 200. Alternatively,conveyors 258,manipulator 260, and/organtries system 200 to function as described herein. In the exemplary embodiment, the automated transport system is continuous from receivingarea 202 toshipping areas control system 248 to automatically move the products throughoutsystem 200. Moreover, on forgingside 252, the automated transport system moves products at a height of about twelve feet from a floor of building 250, and on machiningside 254, the automated transport system moves products at a height of about five feet from the floor. As such, the automated transport system includes means for lowering a product from forgingside 252 to machiningside 254. Alternatively, the automated transport system may be located at any suitable height from the floor for handling products. - Further,
system 200 includes aventing system 267 for creating a negative pressure on forgingside 252 ofbuilding 250. More specifically,system 200 includes a plurality offans 266 on a roof of building 250 that draw air from forgingside 252 and discharge the air to the ambient to reduce the pressure of forgingside 252. Building 250 includeslouvers 268 defined within an exterior wall of building 250 to draw air from the ambient into building. In one embodiment, the number offans 266 in operation and/or the speed offans 266 is varied to maintain the negative pressure on forgingside 252. In an alternative embodiment, ventingsystem 267 includes any suitable components, devices, and/or processes for maintaining a negative pressure on forgingside 252 ofbuilding 250. In the exemplary embodiment, ventingsystem 267 facilitates maintaining negative pressure on forgingside 252 ofwall 256 to discharge contaminants, such as warmed, dirty air, created during a forging process from building 250. As such, the negative pressure prevents contaminants, such as dirt and/or dust, from migrating to other areas of building 250, such asmachining side 254, and confines the forging contaminants to forgingside 252. Accordingly, ventingsystem 267 facilitates maintaining the cleanliness necessary for performing a machining process within machiningside 254 ofbuilding 250. -
System 200 also includes a plurality of sensors positioned throughout building 250 and communicatively coupled to controlsystem 248 to monitor and/or controlautomated system 200. For example,system 200 includes infrared (IR)sensors 270, such as IR sensors supplied by Can-Eng Furnaces International Ltd. of Niagara Falls, N.Y. and Ontario (“Can-Eng”), positioned afterdescaler 210, in forgingsystem 212, withinPF cooling system 214, withinPN cooling system 220, andcooling area 228 to monitor and/or control cooling rates of axles within such systems.System 200 may include sensors in addition to, and/or as an alternative to,IR sensors 270. More specifically,system 200 includes any suitable sensors that enablesystem 200 to be monitored and/or controlled to function as described herein. - In the exemplary embodiment, receiving
area 202 is configured to receive shipments of raw materials. More specifically, steel billets 272 of bar stock that are, for example, about 15 feet to about 33 feet in length with various diameters, are received at and stored in receivingarea 202 until abillet 272 is used to form arough axle 306, as described herein.Billets 272 are preferably formed from vacuum degassed steel. Within receivingarea 202, a code, such as a barcode, attached to eachbillet 272 is read and the information is entered intocontrol system 248. The information for eachbillet 272 may include information, such as heat lot, heat code, chemical composition, and/or steel mill information. The billet information follows eachbillet 272 throughsystem 200 viacontrol system 248, as described herein. Received materials are transferred to inboundbillet handling system 204 for storage and/or further processing. - In the exemplary embodiment, inbound
billet handling system 204 is configured to transferbillets 272 from receivingarea 202 toconveyor 258, which transfers billets 272 to billet cutting andvirtual marking system 206. More specifically, in the exemplary embodiment,inbound handling system 204 includesracks 274 and anautomated gantry system 276 for movingbillets 272 from receivingarea 202 onto arack 274. More specifically,gantry 276 is an automated gantry system supplied by Güdel and includes an overhead conveyor and a motorized arm for movingbillets 272 according to instructions fromcontrol system 248.Racks 274 are stair-step shaped to enable the motorized arm to movebillet 272 to and fromracks 274. In one embodiment, eachrack 274 can store fivebillets 272 thereon. Alternatively,inbound handling system 204 includes any suitable automated system and/or device for transferringbillets 272 from receivingarea 202 for further processing and/or any suitable support structures for inbound materials. - In the exemplary embodiment, billet cutting and marking
system 206 includes acutting system 278 and amarking system 280. Cuttingsystem 278 is configured to automatically size abillet 272 for forming a double axle and/or a single therefrom using physical properties ofbillet 272 and a desired type of finished axle. More specifically, cuttingsystem 278 receives information fromcontrol system 248 regarding the type of axle that will be formed frombillet 272. Using the type of axle and the weight ofbillet 272,billet 272 is cut to a length that provides the mass required to form the indicated type of axle. In the exemplary embodiment, cuttingsystem 278 is a carbide saw manufactured by Advanced Machine and Engineering Co. of Rockford, Illinois (“AME”). Alternatively, cuttingsystem 278 is any suitable system and/or device that is able to automatically size a billet to correspond to a pre-determined size. - In the exemplary embodiment, marking
system 280 is configured to assign a tracking identifier to eachbillet 272 to trackbillet 272 and billet information throughsystem 200. More specifically, the tracking identifier is a virtual serial number assigned and tracked bycontrol system 248. In one embodiment, the tracking identifier is a code that is readable by a Supervisory Control And Data Acquisition (SCADA) system supplied by Can-Eng executing Wonderware software by Invensys Systems, Inc. of Lake Forest, Calif. More specifically, the code is readable by the SCADA system through input received from photo eyes located throughoutsystem 200. In the exemplary embodiment, the tracking identifier is used bycontrol system 248 and components ofsystem 200 to automatically form a particular type of axle from abillet 272.Control system 248 may include a display to allow an operator ofsystem 200 to graphically view, for example, where eachbillet 272 and/oraxle system 200 according to the assigned tracking identifier and/or temperatures within the components ofsystem 200. The tracking identifiers include the information about eachbillet 272 that was entered intocontrol system 248 at receivingarea 202. -
Conveyor 258 conveysbillet 272 from cutting and markingsystem 206 tofurnace 208.Furnace 208 is, in the exemplary embodiment, a rotary furnace, such as a rotary furnace manufactured by Can-Eng. Alternatively,furnace 208 is any suitable furnace that enablessystem 200 to function as described herein. In the exemplary embodiment,furnace 208 is configured to heatbillets 272 to about 2100° F. to about 2200° F. while having a furnace shell temperature between about 150° F. and about 200° F. Furthermore,manipulator 260 is positioned nearfurnace 208 for automatically insertingbillets 272 intofurnace 208 and automatically removingheated billets 272 fromfurnace 208. More specifically,manipulator 260 is positioned and programmed to removed abillet 272 fromconveyor 258 and insertbillet 272 intofurnace 208. Afterbillet 272 has been heated withinfurnace 208,manipulator 260 is programmed to automatically removeheated billet 272 fromfurnace 208 andplace billet 272 onconveyor 258. Further, it is determined, for example, manually, whether aheated billet 272 satisfies predetermined conditions. Ifheated billet 272 does not satisfy the conditions,manipulator 260places billet 272 within abillet rejection area 282, andcontrol system 248 changes the status of the assigned tracking identifier corresponding to the unsatisfactory billet to rejected. Rejected billets are allowed to cool and are removed fromsystem 200. Ifheated billet 272 does satisfy the conditions,manipulator 260places billet 272 onconveyor 258 as described above. Alternatively,manipulator 260 may include programs for performing any suitable processes that enablesystem 200 to function as described herein. - In the exemplary embodiment,
descaler 210 is a water descaler, such as a high-pressure water descaler supplied by Can-Eng, that is built aroundconveyor 258. Alternatively,descaler 210 is any suitable descaler that enablessystem 200 to function as described herein. In the exemplary embodiment,descaler 210sprays billet 272 with water pressurized to about 3000 psi for about 10 seconds to about 30 seconds to facilitate removing primary scale, or slag, frombillet 272. By removing scale frombillet 272 beforebillet 272 enters forgingsystem 212, the service life of forgingsystem 212 is improved. After descaling,conveyor 258 conveysbillet 272 to forgingsystem 212. - Forging
system 212 is, in the exemplary embodiment, a Radial Forging Machine, Type RF 35, manufactured by GFM GmbH of Steyr, Austria (“GFM”). Alternatively, forgingsystem 212 is any forging system capable of forming a double axle and/or a single axle from abillet 272. In the exemplary embodiment, a series of arms removes abillet 272 fromconveyor 258 and movesbillet 272 into and out of forgingsystem 212. Oncebillet 272 is in forgingsystem 212, forgingsystem 212 automatically forms an axle assembly, such as adouble axle 284, to near net shape, from abillet 272 according to the type of finished axle as indicated by the tracking identifier assigned bycontrol system 248. As used herein, “near net shape” refers to a shape that includes the approximate diameters of the finished axle, but not the specific diameter transitions, such as steps between diameters. Alternatively, forgingsystem 212 automatically forms the axle assembly as a single axle. In the exemplary embodiment, forgingsystem 212 is controlled by a computer numerical control (CNC) control system to hot builddouble axle 284 by hammeringbillet 272 with a plurality of different rams, such as four different rams, that are arranged within forgingsystem 212. Forgingsystem 212 includes at least a pair of chuck heads to guide a product through forgingsystem 212.Double axles 284 are discharged from forgingsystem 212 for transport toPF cooling system 214. Known axle forging system and/or process separate a double axle into single axles after the double axle is formed in a forge. However, in thesystem 200 described herein,double axle 284 remains as a double axle until machining begins to facilitate reducing parts in components and increasing the ease of moving axles throughsystem 200. -
System 200 includes an automated doubleaxle inspection system 286 that determines whether adouble axle 284 satisfies pre-determined conditions as transmitted toaxle inspection system 286 fromcontrol system 248. More specifically,inspection system 286 includes optical cameras programmed to measure dimensions ofdouble axle 284 and compare measured values with determined dimension values based on the type of axle indicated by the assigned tracking identifier fordouble axle 284. Ifdouble axle 284 does not satisfy the conditions,double axle 284 is placed within a doubleaxle rejection area 288, andcontrol system 248 changes the status of the assigned tracking identifier corresponding to the unsatisfactory double axle to rejected. Rejected axles are moved torejection area 288 manually and/or automatically. Rejected double axles are allowed to cool and are removed fromsystem 200. Ifdouble axle 284 does satisfy the conditions,double axle 284 is placed onconveyor 258 toPF cooling system 214. Alternatively, doubleaxle inspection system 286 may include programs for performing any suitable processes that enablesystem 200 to function as described herein. Furthermore, doubleaxle inspection system 286 may be included within forgingsystem 212. - In the exemplary embodiment,
PF cooling system 214 is configured to cooldouble axles 284 therein. More specifically,PF cooling system 214 includes cooling tables, such as continuous walking beam tables, and overhead hoods therein. The hoods draw air from the cooling tables and discharge the air to ambient. As such,double axles 284 are passively cooled withinPF cooling system 214. Further, the tables withinPF cooling system 214 are movable to conveydouble axles 284 fromaxle inspection system 286 to normalizingsystem 216 asdouble axles 284 cool. In the exemplary embodiment, a powered roller conveyor table transportsaxles 284 to normalizingsystem 216. As such,PF cooling system 214 also enables the manufacturing process to be continuous. - Normalizing
system 216 is configured to perform a single normalizing process to heat treatdouble axles 284. More specifically, normalizingsystem 216 heat treatsdouble axles 284 to achieve predetermined mechanical properties, such as strength and ductility. In one embodiment,double axles 284 are heated to between about 1100° F. and about 1650° F. Because vacuum degassed steel is used to formdouble axles 284, only a single normalizing process, as opposed to the known double normalizing process, is performed to achieve the predetermined properties. Further,axles 284 are continuously moved though normalizingsystem 216 by, for example, continuous walking beam tables. In the exemplary embodiment, normalizingsystem 216 is a normalizing furnace manufactured by Can-Eng, however, it will be understood that any suitable normalizing system that is capable of performing a single normalizing process may be used as normalizingsystem 216.Axle 284 is conveyed by, for example, a powered roller conveyor table to quenchingsystem 218. - Quenching
system 218 is configured to optionally quenchdouble axles 284 after being normalized, depending on the type of axle and/or other conditions requested by a buyer. More specifically, quenchingsystem 218 is configured to lower a temperature of double axles from a temperature of about 1600° F. to about 1800° F. to a temperature of about 200° F. to about 600° F. In the exemplary embodiment, quenchingsystem 218 includes a powered roller conveyor table and full submerging tank supplied by Can-Eng. Alternatively, quenchingsystem 218 includes any suitable components and/or devices that enablequenching system 218 to function as described herein. When quenching is not required,double axles 284 are conveyed throughquenching system 218 by the powered roller conveyor table toPN cooling system 220. -
PN cooling system 220 is configured to cooldouble axles 284 therein. More specifically,PN cooling system 220 includes cooling tables, such as continuous walking beam tables, and overhead hoods therein. The hoods draw air from the cooling tables and discharge the air to ambient. As such,double axles 284 are passively cooled withinPN cooling system 220. Further, the tables withinPN cooling system 220 are movable to conveydouble axles 284 from quenchingsystem 218 to temperingsystem 222 asdouble axles 284 cool.PN cooling system 220 is used insystem 200 to replace the known method of pile-cooling axles that includes covering the axles with dirt for an extended period of time of about 32 hours to about 48 hours. As such,PN cooling system 220 facilitates reducing cooling time after normalization, as compared to the pile-cooling method. Moreover,PN cooling system 220 also enables the manufacturing process to be continuous. -
Axle 284 is conveyed by, for example, a powered roller conveyor table, to temperingsystem 222. Temperingsystem 222 is configured to transform brittle martensite withindouble axles 284 into bainite or a combination of ferrite and cementite by heatingdouble axles 284 to between about 1000° F. and about 1350° F. In the exemplary embodiment, temperingsystem 222 is a tempering furnace manufactured by Can-Eng that includes a conveyor system, such as a continuous walking beam table, therein. Alternatively, temperingsystem 222 is any suitable tempering system that enablessystem 200 to function as described herein. In the exemplary embodiment,conveyor 258 is positioned at the end of temperingsystem 222 to removedouble axles 284 therefrom. -
Conveyor 258 includes aroundabout 290 and abuffer 292 after temperingsystem 222.Roundabout 290 automatically directsdouble axles 284 to machiningside 254 or to buffer 292 according to programming withinroundabout 290. More specifically, in the exemplary embodiment,roundabout 290 rotates and lowersdouble axle 284 to alower gantry 293 on machiningside 254.Gantry 293 passes throughaxle separation system 224 which is configured to separate adouble axle 284 into twosingle axles 294. More specifically,axle separation system 224 cuts throughdouble axle 284 at joined ends to formsingle axles 294. For example,axle separation system 224 forms four cuts indouble axle 284 such that two cuts are near the center ofdouble axle 284 and one cut is at each end ofdouble axle 284 to achieve a final length of eachsingle axle 294 based on instructions fromcontrol system 248 according to the assigned tracking identifier for thesingle axles 294. In the exemplary embodiment,axle separation system 224 is a rotary saw manufactured by AME, however,axle separation system 224 may be any suitable system, device, and/or unit for separatingdouble axle 284 intosingle axles 294 as described herein. In an alternative embodiment, when a single axle is forged in forgingsystem 212,axle separation system 224 is used to adjust the length of the single axle. In a further alternative embodiment,axle separation system 224 separates the forged axle assembly into any suitable axle configuration. - Straightening
system 226 is positioned afteraxle separation system 224 and includes averification system 296 and acorrection system 298.Verification system 296 is configured to check the straightness of eachsingle axle 294 by rotatingsingle axle 294 to check for high and low portions ofaxle 294. If anaxle 294 does not satisfy straightness requirements,correction system 298 automatically corrects the straightness ofaxle 294 by indexingaxle 294 to a high portion and pressing the high portion. More specifically, straighteningsystem 226 includes a 400-ton gap frame press manufactured by Williams, White & Co. of Moline, Ill., which is a division of Doerfer Companies (“Williams White”). Ifaxle 294 is not corrected within a predetermined number of attempts,axle 294 is rejected, andcontrol system 248 changes the status of the assigned tracking identifier corresponding to the unsatisfactory single axle to rejected. Rejected single axles are allowed to cool and are removed fromsystem 200. -
Cooling area 228 includes a plurality ofpallets 300 that are moved slowly throughout coolingarea 228 to coolsingle axles 294 thereon. More specifically, coolingarea 228 is configured to coolaxles 294 from about 1200° F. to about 200° F. in about six to ten hours while avoiding inducing warping and/or brittleness inaxles 294. Known manufacturing processes require about 32 hours to about 48 hours for cooling of axles before machining As such,cooling area 228 facilitates reducing cooling time ofaxles 294, as compared to known manufacturing processes. In the exemplary embodiment,pallets 300 are moved by a conveying system manufactured by Güdel, andcooling area 228 includes thirty-sixpallets 300 that can each hold sevenaxles 294. More specifically, coolingarea 228 includes a plurality of rows ofpallets 300 that move eachpallet 300 from ahot side 302 to acool side 304 ofcooling area 228 along each row. Asaxles 294 are moved along each row,axles 294 are passively cooled using, for example, hoods as described above. Atcool side 304,single axles 294 are removed frompallets 300 andcooling area 228 for further processing withinsystem 200. In an alternative embodiment, coolingarea 228 includes any suitable number or configuration ofpallets 300 and/or any suitable means for movingpallets 300 that enablesystem 200 to function as described herein. Alternatively, coolingarea 228 includes any suitable means for achieving the cooling of axles, as described herein. In the exemplary embodiment,overhead line gantry 262, such as Line Gantry FP-7HD manufactured by Güdel, removes anaxle 294 from coolingarea 228 formachining Line gantry 262 “handshakes” with downstream operations, such asend facing system 230,machining system 232, and/orinspection system 234, to start or stop an operation based on a “GO/NO GO” signal viacontrol system 248 fromgantry 262 to the operation or vice versa. -
End facing system 230 includes machines for facing ends ofaxle 294 by removing material from each end ofaxle 294 and drilling a center hole in each end ofaxle 294. In the exemplary embodiment,end facing system 230 includes two end facing, three-axis, CNC controlled machines manufactured by SEMA GmbH of Traunkirchen, Austria (“SEMA”), for centering and end facing.Line gantry 262 movesaxle 294 from coolingarea 228, throughend facing system 230, and tomachining system 232. In an alternative embodiment,end facing system 230 includes any suitable systems, devices, and/or machines that enablesystem 200 to function as described herein. -
Machining system 232 is located afterend facing system 230 and is configured to remove a portion of material from a wheel seat and a bearing seat of eachaxle 294 and to cut a barrel of eachaxle 294. In the exemplary embodiment,machining system 232 includes a plurality of lathes, such as lathes manufactured by Niles-Simmons Hegenscheidt Group of Chemnitz, Germany (“N-S”). More specifically,machining system 232 includes four Nile N40 roughing lathes that are four-axis CNC lathes configured to leave approximately ⅛ of an inch to approximately ¼ of an inch of excess material for finishing on a wheel seat and a bearing seat and to cut the barrel ofaxle 294. In the exemplary embodiment,line gantry 262 conveysaxles 294 through the series of lathes. More specifically, between individual machining operations,axles 294 are stored on axle buffers and are machined using a “first in-first out” approach. Alternatively,machining system 232 includes any suitable systems, devices, and/or machines that enablesystem 200 to function as described herein. In the exemplary embodiment,line gantry 262 removesrough axles 306 from machiningsystem 232 and intoinspection system 234. -
Inspection system 234 includes a plurality of inspection sub-systems, such as an ultrasonic sub-system, a magnetic particle testing sub-system, an automated visual sub-system, and/or a laser measuring sub-system, for inspecting each rough axle, or machined axle, 306. In the exemplary embodiment,inspection system 234 includes an ultrasound testing apparatus manufactured by General Electric Company of Schenectady, New York (“GE”), a magnaflux technology apparatus manufactured by K+D Flux-Technic GmbH+Co. KG of Mögglingen, Germany (“K+D”), an APIS visual inspection apparatus, and a laser measurement device manufactured by N-S. The ultrasound apparatus is a full immersion apparatus that detects voids and/or discontinuities in anaxle 306. The magnaflux technology apparatus detects scratches and/or cracks on a surface ofaxle 306, and the APIS visual inspection apparatus includes a camera to detect deep gouges and satisfy criteria that eachaxle 306 is manually viewed. The laser measurement apparatus measures a length ofaxle 306, a diameter of barrel ofaxle 306, and diameters of the wheel and bearing seats ofaxle 306. Alternatively,inspection system 234 uses any suitable technology for inspectingrough axles 306 to determine whether anaxle 306 satisfies predetermined conditions. In the exemplary embodiment,inspection system 234 automatically determines whether anaxle 306 satisfies the predetermined conditions, and automatically rejectsrough axles 306 that do not satisfy the conditions to a roughaxle rejection area 308. Ifrough axle 306 is rejected,control system 248 changes the status of the assigned tracking identifier corresponding to the unsatisfactory rough single axle to rejected. Rejected rough single axles are removed fromsystem 200. -
Line gantry 262 extends betweencooling area 228 andaxle marking system 236.Axle marking system 236 is configured to mark a final identifier onto eachrough axle 306. The final identifier is marked using any suitable process that enables the tracking identifier to withstand use ofaxle 306 with a railcar, such as railcar 10 (shown inFIG. 1 ). The final identifier may be a barcode, symbol, and/or any other suitable identifier marked on torough axle 306 at any suitable location to be read by a subsequent identifier reading device during shipping, finishing, and/or use ofaxle 306 to provide information related to eachaxle 306. In the exemplary embodiment, the final identifier is a barcode that is adhered to an end face or barrel ofrough axle 306. Further, the end face ofaxle 306 is stamped by a needle stamping station manufactured by Borries Markier-Systeme GmbH of Pliezhausen, Germany (“Borries”), and the final identifier is read using a charge coupled device (CCD) camera and a laser line. The final identifier includes information from billet barcode and the tracking identifier used during manufacturing such that the final identifier includes, for example, axle manufacturer information, heat code, heat lot, and/or steel supplier information. Alternatively, the final identifier is any suitable identifier marked by any suitable marking device to be read by any suitable identifier reading device. In the exemplary embodiment, after the final identifier is attached to anaxle 306, the tracking identifier used during manufacturing continues to be associated with eachaxle 306. -
Washing system 238, followingaxle marking system 236, is configured to wash eachrough axle 306 and apply a rust inhibitive spray to eachaxle 306.Conveyor 258 extends fromwashing system 238 to at least one of truck storage andloading area 240 and train storage andloading area 242.Gantry 264 is configured to automatically receiverough axles 306 fromconveyor 258 andplace axles 306 within truck storage andloading area 240 or train storage andloading area 242.Gantry 264 transmits a location of eachaxle 306 to controlsystem 248 using the tracking identifier to later locate anaxle 306 withinarea 240 and/or 242. Further,gantry 264 is configured to automatically moveaxles 306 between truck storage andloading area 240 and train storage andloading area 242 depending on shipping requirements and the tracking identifier assigned to eachaxle 306. In the exemplary embodiment,gantry 264 is manufactured by Güdel and includes multiple arms that can pick and place anaxle 306. Truck storage andloading area 240 and train storage andloading area 242 are each configured to storerough axles 306 therein beforeaxles 306 are shipped. More specifically,axles 306 are stored in a truck buffer and a train buffer, such as buffers manufactured by Güdel, before shipping. The buffers allow three-shift production ofaxles 306 with shipping during normal business hours.Gantry 264 is movable between the buffers for transportingaxles 306 to or from each buffer. - A
truck output conveyor 310, such as an automated conveyor and gantry manufactured by Güdel, extends between truck storage andloading area 240 andtruck shipping area 244.Truck output conveyor 310 is configured to transferaxles 306 from storage andloading area 240 to a truck withintruck shipping area 244. More specifically,truck output conveyor 310 is configured to loadaxles 306 onto the truck in either a parallel orientation or a perpendicular orientation. In one embodiment,truck output conveyor 310 is programmed to automatically load forty axles per truck. In the exemplary embodiment, output conveyor automatically locates the four corners of a truck trailer, and once a first axle is positioned and chucked on the truck trailer,output conveyor 310 automatically loads the remaining axles of the shipments on the truck trailer. - A
train output conveyor 312, such as an automated conveyor and gantry manufactured by Güdel, extends between train storage andloading area 242 and trainshipping area 246.Train output conveyor 312 is configured to transferaxles 306 from storage andloading area 242 to a train car withintrain shipping area 246. More specifically, trainoutput conveyor 312 is configured to loadaxles 306 onto the train in either a parallel orientation or a perpendicular orientation. In one embodiment, trainoutput conveyor 312 is programmed to automatically load eighty axles per train. In the exemplary embodiment,output conveyor 312 automatically locates the four corners of a train car, and once a first axle is positioned and chucked on the train car,output conveyor 312 automatically loads the remaining axles of the shipments on the train car.Train shipping area 246 may also be used to load a truck for shippingrough axles 306. - Because
system 200 includesseparate shipping areas separate output conveyors output conveyors truck shipping area 244 and/or trainshipping area 246 may include multiple bays each including anoutput conveyor truck shipping area 244 and/or trainshipping area 246 may include multiple bays, wherein oneoutput conveyor - During exemplary operation of
system 200,billets 272 are received at receivingarea 202 and are transferred toconveyor 258 via inboundbillet handling system 204. Once onconveyor 258,billets 272 are continuously and automatically moved throughsystem 200 until roughsingle axles 306 are formed and ready to be shipped. After being placed onconveyor 258 from receivingarea 202,billet 272 is cut bybillet cutting system 278 to a size suitable for forming adouble axle 284 of a predetermined type frombillet 272. Further,billet marking system 280 assigns a tracking identifier tobillet 272 incontrol system 248 for trackingbillet 272 throughoutsystem 200 and for controllingsystem 200 to form the predetermined type of axle frombillet 272.Billet 272 is then conveyed tomanipulator 260 for insertion intofurnace 208.Heated billet 272 is removed fromfurnace 208 bymanipulator 260 and positioned onconveyor 258 for transfer todescaler 210.Billets 272 may also be rejected after passing throughfurnace 208 and placed within rejectedbillet area 282. After descaling,billet 272 is transferred to forge 212 to be forged into adouble axle 284. -
Double axle 284 is either rejected or accepted. Rejecteddouble axles 284 are placed within rejecteddouble axle area 288, and accepteddouble axles 284 are conveyed toPF cooling system 214. WithinPF cooling system 214,double axles 284 are cooled by passive cooling. Cooleddouble axles 284 are transferred into normalizingsystem 216, in whichdouble axles 284 undergo a single normalizing process. After normalizing,double axles 284 are optionally quenched by water within quenchingsystem 218 such that, after quenching,double axles 284 are at a temperature of approximately 200° F. or above.Double axles 284 are transferred from quenchingsystem 218 intoPN cooling system 220 to passively cool before a tempering process. To perform the tempering process,double axles 284 are conveyed fromPN cooling system 220 to temperingsystem 222. Tempereddouble axles 222 are conveyed, viaconveyor 258 and aroundabout 290, from forgingside 252 to machiningside 254 of building 250 or to buffer 292 for storingdouble axles 284 until further processing or rejection. - During transfer to machining
side 254,double axles 284 pass throughaxle separation system 224 to be separated into twosingle axles 294.Single axles 294 are conveyed to straighteningsystem 226. Within straighteningsystem 226, the straightness of eachsingle axle 294 is determined, and anyaxles 294 that do not meet straightness requirements are straighten by straighteningsystem 226. Straightenedaxles 226 are conveyed intocooling area 228 to be cooled from approximately 1200° F. to approximately 200° F. while being continuously moved throughcooling area 228. Cooledaxles 294 are transported byline gantry 262 from coolingarea 228 toaxle marking system 236. More specifically, cooledaxles 294 are transferred from coolingarea 228 to end facingsystem 230. Withinend facing system 230, ends ofaxle 294 are faced and a hole is drilled and centered withinaxle 294.Axle 294 is then machined withinmachining system 232. More specifically, about ⅛ of an inch to about ¼ of an inch of excess material on a wheel seat and a bearing seat is left by machiningsystem 232 and a barrel ofaxle 294 is cut by machiningsystem 232. - After axle is machined to form a rough-machined
axle 306,rough axle 306 is tested withininspection system 234 to determined physical properties ofrough axle 306. More specifically,inspection system 234 detects voids and/or discontinuities, detects scratches and/or cracks on a surface ofrough axle 306, detects gouges inrough axle 306, and/or measures a length ofaxle 306, a diameter of the barrel, and diameters of the wheel and bearing seats.Rough axles 306 that are determined to not meet specifications are rejected and placed within rejectedrough axle area 308.Rough axles 306 at least meeting specifications are conveyed toaxle marking system 236 that attaches a final identifier torough axle 306. Markedrough axle 306 is washed withinwashing system 238, which also applies a rust inhibitive coating.Rough axle 306 is conveyed fromwashing system 238 to one of the storage andloading areas - More specifically, in the exemplary embodiment,
gantry 264 removesrough axle 306 fromconveyor 258 and automatically placesrough axle 306 within one of the storage andloading areas gantry 264.Rough axles 306 are retained within storage andloading areas 240 and/or 242 untilrough axle 306 is allocated to a shipment. Onceaxle 306 is allocated,axle 306 is conveyed from storage andloading area 240 to a truck withintruck shipping area 244 or from storage andloading area 242 to a train car withintrain shipping area 246. More specifically,axle 306 allocated to a truck shipment is transferred from truck storage andloading area 240 to the truck withintruck shipping area 244 bytruck output conveyor 310. Similarly,axle 306 allocated to a train shipment is transferred from train storage andloading area 242 to the train car withintrain shipping area 246 bytrain output conveyor 312. In the exemplary embodiment,system 200 can produce approximately 480 axles per day, with each sub-system ofsystem 200 having a cycle time of about 3 minutes. Accordingly, eachmachined axle 306 is manufactured from abillet 272 in about 12 hours to about 24 hours, and more particularly within about 18 hours, as compared to known manufacturing system that require at least 36 hours to manufacture an axle. -
FIGS. 4-15 are exemplary components ofsystem 200 and, as such, similar components are labeled with similar references. Further, a “product” as referred to herein includesbillet 402 and/or axles formed frombillet 402, such asaxles FIG. 4 is a top view of an exemplaryinbound billet system 400 that may be used with system 200 (shown inFIG. 3 ) as inbound billet handling system 204 (shown inFIG. 3 ). Inboundbillet handling system 400 is configured to transferbillets 402 from a receiving area to aconveyor 404, such as a conveyor supplied by Güdel, which may be used as conveyor 258 (shown inFIG. 3 ). More specifically, in the exemplary embodiment, inboundbillet handling system 400 includesracks 406 and anautomated gantry system 408 for movingbillets 402 from the receiving area onto and/or off of arack 406. More specifically,gantry 408 is an automated gantry system supplied by Güdel and includes an overhead conveyor and a motorized arm for movingbillets 402 according to instructions from a system-wide control system.Racks 406 are stair-step shaped to enable the motorized arm to movebillet 402 to and fromracks 406. In one embodiment, eachrack 406 can store fivebillets 402 thereon. Alternatively,inbound handling system 400 includes any suitable automated system and/or device for transferringbillets 402 from the receiving area for further processing and/or any suitable support structures for inbound materials. -
FIG. 5 is a top view of anexemplary furnace 500 that may be used with system 200 (shown inFIG. 3 ) as furnace 208 (shown inFIG. 3 ).Furnace 500 is a rotary furnace, such as a rotary furnace manufactured by Can-Eng. Alternatively,furnace 500 is any suitable furnace that enablessystem 200 to function as described herein. In the exemplary embodiment,furnace 500 is configured to heatbillets 402 to between about 2100° F. and about 2200° F. while having a furnace shell temperature between about 150° F. and about 300° F. Furthermore, a manipulator 502, such as an automatic manipulator manufactured by Glama, is positioned nearfurnace 500 for automatically insertingbillets 402 intofurnace 500 and automatically removingheated billets 402 fromfurnace 500. More specifically, manipulator 502 is positioned and programmed to removed abillet 402 fromconveyor 404 and insertbillet 402 intofurnace 500. Afterbillet 402 has been heated withinfurnace 500, manipulator 502 is programmed to removeheated billet 402 fromfurnace 500 andplace billet 402 onconveyor 404. Further, it is determined whether aheated billet 402 satisfies predetermined conditions. Ifheated billet 402 does not satisfy the conditions, manipulator 502places billet 402 within arejection area 504. Rejected billets are allowed to cool and are removed fromsystem 200. Ifheated billet 402 does satisfy the conditions, manipulator 502places billet 402 onconveyor 404 as described above. Alternatively, manipulator 502 may include programs for performing any suitable processes that enablesystem 200 to function as described herein. -
FIG. 6 is a top view of anexemplary descaler 600 that may be used with system 200 (shown inFIG. 3 ) as descaler 210 (shown inFIG. 3 ).Descaler 600 is a high-pressure water descaler supplied by Can-Eng, that is built aroundconveyor 404. Alternatively,descaler 600 is any suitable descaler that enablessystem 200 to function as described herein. In the exemplary embodiment,descaler 600 includes ahousing 601, a plurality ofpumps 602, and awater storage tank 604.Housing 601 includes a water spray therein, and pumps 602 andtanks 604 are configured to pump and store the water used for descaling billet 402 (shown inFIG. 4 ).Descaler 600sprays billet 402 with water pressurized to about 3000 psi for about 10 seconds to about 30 seconds to facilitate removing primary scale, or slag, frombillet 402. By removing scale frombillet 402 beforebillet 402 enters a subsequent forging system, such as forging system 700 (shown inFIG. 7 ), the service life of the subsequent forging system is facilitated to be increased. Further, as illustrated inFIG. 6 , awall 606 separates a forgingside 608, such as forging side 252 (shown inFIG. 3 ), from amachining side 610, such as machining side 254 (shown inFIG. 3 ).Wall 606 is similar to wall 256 (shown inFIG. 3 ), described herein. In the exemplary embodiment, pumps 602 andtank 604 are located on machiningside 610 ofwall 606 andhousing 601 is on forgingside 608 ofwall 606. -
FIG. 7 is a top view of an exemplary forgingsystem 700 that may be used with system 200 (shown inFIG. 3 ) as forging system 212 (shown inFIG. 3 ). Forgingsystem 700 is a Radial Forging Machine, Type RF 35, manufactured by GFM. Alternatively, forgingsystem 700 is any forging system capable of forming an axle assembly, such as double axle 801 (shown inFIG. 8 ), from a billet 402 (shown inFIG. 4 ). Alternatively, the forged axle assembly is any suitable type of axle assembly, such as a single axle. In the exemplary embodiment, a series ofarms 702 removes abillet 402 fromconveyor 404 and movesbillet 402 into and out of forgingsystem 700. Oncebillet 402 is in forgingsystem 700, forgingsystem 700 automatically forms adouble axle 801, to near net shape, from abillet 402 according to the type of finished axle as indicated by a tracking identifier assigned tobillet 402. In the exemplary embodiment, forgingsystem 700 is controlled by a CNC control system to hot builddouble axle 801 by hammeringbillet 402 with a plurality ofdifferent rams 704, such as four different rams, that are arranged within forgingsystem 700. Forgingsystem 700 includes at least a pair of chuck heads 706 to guide a product through forgingsystem 700.Double axles 801 are discharged from forgingsystem 700 for transport to a subsequent post-forge cooling system, such as post-forge cooling system 800 (shown inFIG. 8 ), byconveyor 404. - Forging
system 700 includes therein an automatedaxle inspection system 708 that determines whether adouble axle 801 satisfies pre-determined conditions. More specifically,inspection system 708 includesoptical cameras 710 programmed to measure dimensions ofdouble axle 801 and compare measured values with determined dimension values based on the type of axle indicated by the assigned tracking identifier fordouble axle 801. Ifdouble axle 801 does not satisfy the conditions,double axle 801 is placed within arejection area 712. Rejecteddouble axles 801 are allowed to cool and are removed fromsystem 200. Ifdouble axle 801 does satisfy the conditions,double axle 801 is placed onconveyor 404 to the subsequent post-forging cooling system. Alternatively,axle inspection system 708 may include programs for performing any suitable processes that enablesystem 200 to function as described herein. -
FIG. 8 is a top view of an exemplary post-forging (PF) coolingsystem 800, normalizingsystem 802, and quenchingsystem 804 that may be used with system 200 (shown inFIG. 3 ) as PF cooling system 214 (shown inFIG. 3 ), normalizing system 216 (shown inFIG. 3 ), and quenching system 218 (shown inFIG. 3 ). In the exemplary embodiment,PF cooling system 800 is configured to cooldouble axles 801 therein. More specifically,PF cooling system 800 includes cooling tables 806 and overhead hoods therein. In the exemplary embodiment, cooling tables 806 are continuous walking beam tables. The hoods draw air from cooling tables 806 and discharge the air to ambient. As such,double axles 801 are passively cooled withinPF cooling system 800. Further, tables 806 withinPF cooling system 800 are movable alongconveyors 808 to conveydouble axles 801 from an enteringconveyor 810 to an exitingconveyor 812 that transportsdouble axles 801 to normalizingsystem 802 asdouble axles 801 cool. In the exemplary embodiment,conveyors - Normalizing
system 802 is configured to perform a single normalizing process to heat treat eachdouble axle 801. More specifically, normalizingsystem 802 heat treatsdouble axles 801 to achieve predetermined mechanical properties, such as strength and ductility. When vacuum degassed steel is used to formdouble axles 801, only a single normalizing process, as opposed to the known double normalizing process, is performed to achieve the predetermined properties. Further,axles 801 are continuously moved though normalizingsystem 802 by, for example, continuous walking beam tables. In the exemplary embodiment, normalizingsystem 802 is a normalizing furnace manufactured by Can-Eng, however, it will be understood that any suitable normalizing system that is capable of performing a single normalizing process may be used as normalizingsystem 802.Axle 801 is conveyed by, for example, a powered roller conveyor table to quenchingsystem 804. - Quenching
system 804 is configured to optionally quenchdouble axles 801 after being normalized, depending on the type of axle and/or other conditions requested by a buyer. More specifically, quenchingsystem 804 is configured to lower a temperature ofdouble axles 801 from a temperature of about 1600° F. to about 1800° F. to a temperature of about 200° F. to about 600° F. In the exemplary embodiment, quenchingsystem 804 includes a powered roller conveyor table 814 supplied by Can-Eng. Alternatively, quenchingsystem 804 includes any suitable components and/or devices that enablequenching system 804 to function as described herein. When quenching is not required,double axles 801 are conveyed throughquenching system 804 by power roller conveyor table 814 to a subsequent post-normalizing cooling system, such as post-normalizing cooling system 900 (shown inFIG. 9 ). -
FIG. 9 is a top view ofquenching system 804 and an exemplary post-normalizing (PN) coolingsystem 900 and temperingsystem 902 that may be used with system 200 (shown inFIG. 3 ) as PN cooling system 220 (shown inFIG. 3 ) and tempering system 222 (shown inFIG. 3 ). -
PN cooling system 900 is configured to cooldouble axles 801 therein. More specifically,PN cooling system 900 includes cooling tables 904 and overhead hoods therein. In the exemplary embodiment, cooling tables 904 are continuous walking beam tables. The hoods draw air from cooling tables 904 and discharge the air to ambient. As such,double axles 801 are passively cooled withinPN cooling system 900. Further, tables 904 withinPN cooling system 900 are movable along aconveyor 906 to conveydouble axles 801 from quenchingsystem 804 to temperingsystem 902 asdouble axles 801 cool.PN cooling system 900 is used insystem 200 to replace the known method of pile-cooling axles under dirt. As such,PN system 900 facilitates reducing cooling time after normalization, as compared to the pile-cooling method. Aconveyor 907, such as a powered roller conveyor table, is located betweenPN cooling system 900 and temperingsystem 902 to transferaxle 801 fromPN cooling system 900 to temperingsystem 902. - Tempering
system 902 is configured to transform brittle martensite withindouble axles 801 into bainite or a combination of ferrite and cementite by heatingdouble axles 801 to about 1000° F. to about 1350° F. In the exemplary embodiment, temperingsystem 902 is a tempering furnace manufactured by Can-Eng that includes a continuous walking beam table 908 therein. Alternatively, temperingsystem 902 is any suitable tempering system that enablessystem 200 to function as described herein. In the exemplary embodiment,conveyor 404 is positioned at end of temperingsystem 902 to removedouble axles 801 therefrom. -
FIG. 10 is a top view ofconveyor 404, anexemplary gantry 1001, an exemplaryaxle separation system 1000, and anexemplary straightening system 1002 that may be used with system 200 (shown inFIG. 3 ) as gantry 293 (shown inFIG. 3 ), separation system 224 (shown inFIG. 3 ) and straightening system 226 (shown inFIG. 3 ).Conveyor 404 includes aroundabout 1004 and abuffer 1006 positioned after a tempering system, such astempering system 902.Roundabout 1004 automatically directsdouble axles 801 to machining side 254 (shown inFIG. 3 ) or to buffer 1006 according to programming withinroundabout 1004.Axles 801 withinbuffer 1006 are stored until further processing and/or rejection.Roundabout 1004 rotates and lowersdouble axle 801 togantry 1001, which transportsdouble axle 801 to aseparation system 1000 on machiningside 254.Axle separation system 1000 is configured to separate adouble axle 801 into twosingle axles 1008. - More specifically,
axle separation system 1000 cuts throughdouble axle 801 at joined ends to formsingle axles 1008. For example,axle separation system 1000 forms four cuts indouble axle 801 such that two cuts are near the center ofdouble axle 801 and one cut is at each end ofdouble axle 801 to achieve a final length of eachsingle axle 1008 based on instructions from a control system, such as control system 1500 (shown inFIG. 15 ), according to an assigned tracking identifier for thesingle axles 1008. In the exemplary embodiment,axle separation system 1000 is a rotary saw manufactured by AME, however,axle separation system 1000 may be any suitable system, device, and/or unit for separatingdouble axle 801 intosingle axles 1008 as described herein. -
Straightening system 1002 positioned afteraxle separation system 1000 is configured to check the straightness of eachsingle axle 1008 by rotatingsingle axle 1008 to check for high and low portions ofsingle axle 1008. If anaxle 1008 does not satisfy straightness requirements,straightening system 1002 automatically corrects the straightness ofaxle 1008 by indexingaxle 1008 to a high portion and pressing the high portion. More specifically,straightening system 1002 includes a 400-ton gap frame press manufactured by Williams White. Ifaxle 1008 is not corrected within a predetermined number of attempts,axle 1008 is rejected. Rejectedsingle axles 1008 are allowed to cool and are removed fromsystem 200. -
FIG. 11 is a top view of anexemplary cooling area 1100 that may be used with system 200 (shown inFIG. 3 ) as cooling area 228 (shown inFIG. 3 ).Cooling area 1100 includes a plurality ofpallets 1102 that are moved slowly throughoutcooling area 1100 to coolsingle axles 1008 thereon. More specifically,cooling area 1100 is configured to coolaxles 1008 from about 1200° F. to about 200° F. in about six to about ten hours while avoiding inducing warping and/or brittleness inaxles 1008. In the exemplary embodiment,pallets 1102 are moved by a conveyingsystem 1104 manufactured by Güdel, andcooling area 1100 includes thirty-sixpallets 1102 that can each hold sevenaxles 1008. More specifically,cooling area 1100 includes a plurality ofrows 1106 ofpallets 1102 that move eachpallet 1102 from ahot side 1108 to acool side 1110 ofcooling area 1100 along eachrow 1106. Asaxles 1008 are moved along eachrow 1106,axles 1008 are passively cooled using, for example, hoods as described herein. Atcool side 1110,single axles 1008 are removed frompallets 1102 for further processing withinsystem 200. In an alternative embodiment,cooling area 1100 includes any suitable number or configuration ofpallets 1102 and/or any suitable means for movingpallets 1102 that enablesystem 200 to function as described herein. Alternatively, coolingarea 1100 includes any suitable means for achieving the cooling of axles, as described herein. -
FIG. 12 is a top view of an exemplaryend facing system 1200 andmachining system 1202 that may be used with system 200 (shown inFIG. 3 ) as end facing system 230 (shown inFIG. 3 ) and machining system 232 (shown inFIG. 3 ). In the exemplary embodiment, anoverhead line gantry 1204, such as Line Gantry FP-7HD manufactured by Güdel, removes anaxle 1008 from coolingarea 1100 for machining More specifically,line gantry 1204 extends betweencooling area 1100 and an axle marking system 1302 (shown inFIG. 13 ). -
End facing system 1200 includes twoend facing machines 1206, with abuffer 1208 therebetween, for facing ends ofaxle 1008 by removing material from each end ofaxle 1008 and drilling a center hole in each end ofaxle 1008. In the exemplary embodiment,end facing system 1200 includes two end facing, three-axis, CNC controlledmachines 1206 manufactured by SEMA, for centering and end facing. In an alternative embodiment,end facing system 1200 includes any suitable systems, devices, and/or machines that enablesystem 200 to function as described herein. In the exemplary embodiment,line gantry 1204 movesaxle 1008 from coolingarea 1100, throughend facing system 1200, and tomachining system 1202. -
Machining system 1202 is located afterend facing system 1200 and is configured to remove a portion of material from a wheel seat and a bearing seat of eachaxle 1008 and to cut a barrel of eachaxle 1008. In the exemplary embodiment,machining system 1202 includes up to fourlathes 1210 manufactured by N-S, with abuffer 1212 between eachlathe 1210. More specifically,machining system 1202 includes four Nile N40 roughing lathes 1210 that are four-axis CNC lathes configured to leave approximately ⅛ of an inch to approximately ¼ of an inch of excess material for finishing on a wheel seat and a bearing seat and to cut the barrel ofaxle 1008. In the exemplary embodiment,line gantry 1204 conveysaxles 1008 through the series oflathes 1210. More specifically, between individual machining operations,axles 1008 are stored onaxle buffers 1212 and are machined using a “first in-first out” approach. Alternatively,machining system 1202 includes any suitable systems, devices, and/or machines that enablesystem 200 to function as described herein. In the exemplary embodiment,line gantry 1204 removes rough-machined axles 1306 (shown inFIG. 13 ) frommachining system 1202 and intoinspection system 1300. -
FIG. 13 is a top view ofmachining system 1202 and anexemplary inspection system 1300, an exemplaryaxle marking system 1302, and anexemplary washing system 1304 that may be used with system 200 (shown inFIG. 3 ) as inspection system 234 (shown inFIG. 3 ), axle marking system 236 (shown inFIG. 3 ), and washing system 238 (shown inFIG. 3 ).Line gantry 1204 transportsrough axles 1306 throughinspection system 1300 and intoaxle marking system 1302. -
Inspection system 1300 includes a plurality of inspection sub-systems, such as an ultrasonic sub-system, a magnetic particle testing sub-system, an automated visual sub-system, and/or a laser measuring sub-system, for inspecting eachrough axle 1306. In the exemplary embodiment,inspection system 1300 includes anultrasound testing apparatus 1308 manufactured by GE, amagnaflux technology apparatus 1310 manufactured by K+D, an APISvisual inspection apparatus 1312, and alaser measurement device 1314 manufactured by N-S withinvisual inspection apparatus 1312, each having abuffer 1316 therebetween.Ultrasound apparatus 1308 is a full immersion apparatus that detects voids and/or discontinuities in anaxle 1306.Magnaflux technology apparatus 1310 detects scratches and/or cracks on a surface ofaxle 1306, and APISvisual inspection apparatus 1312 includes a camera to detect deep gouges and ensure that eachaxle 1306 is manually viewed.Laser measurement apparatus 1314 measures a length ofaxle 1306, a diameter of barrel ofaxle 1306, and diameters of the wheel and bearing seats ofaxle 1306. Alternatively,inspection system 1300 uses any suitable technology for inspectingrough axles 1306 to determine whether anaxle 1306 satisfies predetermined conditions. In the exemplary embodiment,inspection system 1300 automatically determines whether anaxle 1306 satisfies the predetermined conditions, and automatically rejectsrough axles 1306 that do not satisfy the conditions. -
Line gantry 1204 extends betweeninspection system 1300 andaxle marking system 1302.Axle marking system 1302 is configured to mark a final identifier onto eachrough axle 1306. The final identifier is marked using any suitable process than enables the tracking identifier to withstand use ofaxle 1306 with a railcar, such as railcar 10 (shown inFIG. 1 ). The final identifier may be a barcode, symbol, and/or any other suitable identifier marked on torough axle 1306 at any suitable location to be read by a subsequent identifier reading device during shipping, finishing, and/or use ofaxle 1306 to provide information related to eachaxle 1306. In the exemplary embodiment, the final identifier is a barcode that is adhered to an end face or barrel ofrough axle 1306. The end face is also stamped by a needle stamping station manufactured by Borries, and the final identifier is read using a CCD camera and a laser line. The final identifier includes information from billet barcode and the tracking identifier used during manufacturing such that the final identifier includes, for example, axle manufacturer information, heat code, heat lot, and/or steel supplier information. Alternatively, the final identifier is any suitable identifier marked by any suitable marking device to be read by any suitable identifier reading device.Washing system 1304 followsaxle marking system 1302 and is configured to wash eachrough axle 1306 and apply a rust inhibitive spray to eachaxle 1306. -
FIG. 14 is a top view of an exemplary truck storage andloading area 1400, train storage andloading area 1402,trucking shipping area 1404, and trainshipping area 1406 that may be used with system 200 (shown inFIG. 3 ) as truck storage and loading area 240 (shown inFIG. 3 ), train storage and loading area 242 (shown inFIG. 3 ), trucking shipping area 244 (shown inFIG. 3 ), and train shipping area 246 (shown inFIG. 3 ). -
Conveyor 404 extends from a washing system, such as washing system 1304 (shown inFIG. 13 ), to train storage andloading area 1402. Agantry 1408 is configured to automatically receiverough axles 1306 fromconveyor 404 andplace axles 1306 within truck storage andloading area 1400 or train storage andloading area 1402. Further,gantry 1408 is configured to automatically moveaxles 1306 between truck storage andloading area 1400 and train storage andloading area 1402 depending on shipping requirements and the tracking identifier assigned to eachaxle 1306. In the exemplary embodiment,gantry 1408 is manufactured by Güdel and includes multiple arms that can pick and place anaxle 1306. Truck storage andloading area 1400 and train storage andloading area 1402 are each configured to storerough axles 1306 therein beforeaxles 1306 are shipped. More specifically,axles 1306 are stored in atruck buffer 1410 and atrain buffer 1412, such as buffers manufactured by Güdel, before shipping.Buffers 1410 and/or 1412 allow three-shift production ofaxles 1306 with shipping during normal business hours.Gantry 1408 is movable betweenbuffers axles 1306 to or from eachbuffer 1410 and/or 1412. - Truck output conveyor 310 (shown in
FIG. 3 ) is atruck output gantry 1414 that is, for example, an automated gantry manufactured by Güdel, and that extends between truck storage andloading area 1400 andtruck shipping area 1404. Alternatively,output gantry 1414 is any suitable crane, conveyor, and/or automated transport means that enablessystem 200 to function as described herein. In the exemplary embodiment,truck output gantry 1414 is configured to transferaxles 1306 from storage andloading area 1400 to a truck withintruck shipping area 1404. More specifically,truck output gantry 1414 is configured to loadaxles 1306 onto the truck in either a parallel orientation or a perpendicular orientation. In one embodiment,truck output gantry 1414 is programmed to automatically load forty axles per truck. In the exemplary embodiment,output gantry 1414 automatically locates the four corners of a truck trailer, and once a first axle is positioned and chucked on the truck trailer,output gantry 1414 automatically loads the remaining axles of the shipment on the truck trailer. - Train output conveyor 312 (shown in
FIG. 3 ) is atrain output gantry 1418 that is, for example, an automated gantry manufactured by Güdel, and that extends between train storage andloading area 1402 and trainshipping area 1406. Alternatively,output gantry 1418 is any suitable crane, conveyor, and/or automated transport means that enablessystem 200 to function as described herein. In the exemplary embodiment, trainoutput gantry 1418 is configured to transferaxles 1306 from storage andloading area 1402 to a train car withintrain shipping area 1406. More specifically, trainoutput gantry 1418 is configured to loadaxles 1306 onto the train in either a parallel orientation or a perpendicular orientation. In one embodiment, trainoutput gantry 1418 is programmed to automatically load eighty axles per train. In the exemplary embodiment,output gantry 1418 automatically locates the four corners of a train car, and once a first axle is positioned and chucked on the train car,output gantry 1418 automatically loads the remaining axles of the shipment on the train car.Train shipping area 1406 may also be used to load a truck for shipping axles. Becausesystem 200 includesseparate loading areas separate output gantries output gantries -
FIG. 15 is a block diagram of anexemplary control system 1500 that may be used with system 200 (shown inFIG. 3 ) as control system 248 (shown inFIG. 3 ).Control system 1500 includes aserver system 1502, and a plurality of client sub-systems, also referred to asclient systems server system 1502. In one embodiment,client systems server system 1502 is accessible toclient systems Client systems Client systems database server 1508 is connected to adatabase 1510 containing information on a variety of matters, for example, design specifications for a plurality of axle types, information related to the virtual tracking identifier, and/or information related to the final identifier. In one embodiment,centralized database 1510 is stored onserver system 1502 and can be accessed by potential users at one ofclient systems server system 1502 through one ofclient systems database 1510 is stored remotely fromserver system 1502 and may be non-centralized. - At least one
client system 1506 is connected toconveyor 404, the receiving area, such as receiving area 202 (shown inFIG. 3 ), inboundbillet handling system 400, a billet cutting and marking system, such as billet cutting and marking system 206 (shown inFIG. 3 ),furnace 500,descaler 600, forgingsystem 700,PF cooling system 800, normalizingsystem 802, quenchingsystem 804,PN cooling system 900, temperingsystem 902,roundabout 1004,gantry 1001,axle separation system 1000, straighteningsystem 1002, coolingarea 1100,line gantry 1204,end facing system 1200,machining system 1202,inspection system 1300,axle marking system 1302,washing system 1304,gantry 1408,truck output gantry 1414, trainoutput gantry 1418 for receiving information from and/or transmitting instructions to the above-listed components ofsystem 200, as described herein. More specifically,control system 1500 includes programming to perform method 100 (shown inFIG. 2 ) usingsystem 200 by communicating with and/or controlling the components ofsystem 200. Further,control system 1500 uses information related to the virtual tracking identifier to trackbillet 402, and axles formed frombillet 402, such asaxles method 100 and/or throughsystem 200. -
FIG. 16 is a perspective view of anexemplary axle 1600 formed using method 100 (shown inFIG. 2 ) and system 200 (shown inFIG. 3 ).Axle 1600 includes afirst wheel seat 1602, afirst bearing seat 1604, abarrel 1606, asecond bearing seat 1608, and asecond wheel seat 1610 extending in series between afirst end face 1612 and asecond end face 1614. Eachend face center hole 1616.Bearing seats wheel seats barrel 1606. Alternatively, other types of axles manufactured by usingmethod 100 and/orsystem 200 may have other relationships between diameters and/or other dimensions. In the exemplary embodiment,seats barrel 1606 are substantially cylindrical along alongitudinal axis 1618.Fillets 1620 are formed between firstbearing seat 1604 andbarrel 1606 and betweenbarrel 1606 andsecond bearing seat 1608.Steps 1622 are defined betweenfirst wheel seat 1602 andfirst bearing seat 1604 and between secondbearing seat 1608 andsecond wheel seat 1610. Alternatively,axle 1600 may include transitions other thanfillets 1620 andsteps 1622 depending on the type of axle manufactured. In the exemplary embodiment, end faces 1612 and 1614 are substantially planar and substantially parallel to each other. Center holes 1616 are defined in each faces 1612 and 1614 whereaxis 1618 intersects end faces 1612 and 1614. End faces 1612 and 1614 andcenter holes 1616 are machined by, for example, end facing system 230 (shown inFIG. 3 ), andwheel seats bearings seats barrel 1606 are machined by, for example, machining system 232 (shown inFIG. 3 ). - The above-described methods and systems for manufacturing an axle, such as an axle for a railcar, provide a continuous, automated method and system that facilitate increasing an axle output per day, as compared to known axle manufacturing systems that perform different manufacturing processes in different buildings. Increase in axle output is further facilitated by the above-described methods and systems by using continuous cool downs, rather than known cooling methods that remove the axles from the system for an extended period time before continuing the manufacturing processes. Furthermore, because the methods and systems described herein are fully automated, fewer employees are required to operate the systems and/or perform the methods such that the cost of manufacturing axles is facilitated to be decreased, as compared to manufacturing systems that are not fully automated and include manual operations. Moreover, the systems described herein are located within one building and is continuous therein because a solid wall and negative pressure on a forging side prevent heat and/or dust from migrating to a machining side, which requires cooling and cleanliness for machining processes performed therein.
- Exemplary embodiments of methods and systems for manufacturing an axle are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other manufacturing systems and methods, and are not limited to practice with only the systems and methods for manufacturing a railcar axle as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other forging and/or machining applications.
- Although specific features of various embodiments of the methods and/or systems described herein may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the methods and/or systems described herein, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
- This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (25)
1.-31. (canceled)
32. A continuous system for automatically manufacturing an axle, said system comprising a plurality of sub-systems and an automated transport system, said plurality of sub-systems comprising:
a furnace configured to heat a billet to a predetermined forging temperature;
a forging system configured to forge an axle from a heated billet; and
a machining system configured to form a machined axle from said axle, wherein said automated transport system is configured to automatically transport a product to and from each of said plurality of sub-systems, said product comprising said billet, said axle, and said machined axle.
33. A system in accordance with claim 32 , wherein said automated transport system further comprises at least one of a conveyor, a robotic manipulator, and a crane.
34. A system in accordance with claim 32 further comprising a control system configured to control said plurality of sub-systems and said automated transport system.
35. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a receiving area at a beginning of the product transport system, said receiving area configured to at least one of receive said billet and store said billet.
36. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a cutting system configured to automatically cut said billet to a predetermined size, wherein said predetermined size is based on a type of axle to be manufactured from said billet.
37. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a tracking system configured to track said billet and any axles produced from said billet during the manufacturing process.
38. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a descaler comprising a high-pressure water stray, said descaler configure to direct said high-pressure water spray at said billet to facilitate removing slag from said billet.
39. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a heat treating system configured to automatically alter a temperature of said axle to produce an axle having predetermined metallurgical properties.
40. A system in accordance with claim 39 , wherein said heat treating system comprises:
a post-forging cooling system configured to passively cool said axle;
a normalizing system configured to normalize said axle;
a post-normalizing cooling system configured to passively cool said axle; and
a tempering system configured to temper said axle, wherein said axle is continuously transported through said heat treating system by said automated transport system.
41. A system in accordance with claim 40 , wherein said heat system further comprises a quenching system between said normalizing system and said post-normalizing cooling system, said quenching system configured to quench said axle with water prior to axle.
42. A system in accordance with claim 32 , wherein said forging system is configured to forge said heated billet into a double axle, wherein said double axle includes a first axle having opposing ends and a second axle having opposing ends, wherein said first axle is coupled to said second axle at one end of each axle, wherein said plurality of sub-systems further comprise an axle separation system configured to separate said first axle from said second axle by forming at least one cut in said double axle.
43. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a straightening system configured to verify straightness of each axle before machining said axle and, if the straightness of said axle is not verified, to correct the straightness of said axle before machining said axle.
44. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a cooling area comprising a plurality of pallets and a conveyor system, said cooling area configured to passively cool said axle on said plurality of pallets before machining said axle, wherein said conveyor system continuously transports said axle through said cooling area, said automated transport system comprising said conveyor system.
45. A system in accordance with claim 44 , wherein said cooling area is configured to cool said axle from about 1200° F. to about 200° F. during a time period that is between approximately 6 hours and approximately 10 hours.
46. A system in accordance with claim 32 , wherein said machining system further comprises:
an end facing system configured to end face said axle and to define a center hole in each end face of said axle; and
a series of lathes for defining at least one of a wheel seat, a bearing seat, and a barrel of said axle, wherein said automated transport system is configured to automatically transport a product to and from said end facing system and said series of lathes.
47. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise an inspection system comprising at least one of an ultrasonic testing apparatus, a magnetic particle testing apparatus, and an automated visual inspection apparatus.
48. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a laser measuring device configured to measure dimensions of said machined axle.
49. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise an axle marking system configured to mark said machined axle with an identification mark, said identification mark providing information relating to said machined axle and said billet from which said machined axle was formed.
50. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a washing system configured to wash said machined axle to facilitate preventing rust from forming on said machined axle.
51. A system in accordance with claim 32 , wherein said plurality of sub-systems further comprise a plurality of output cranes configured to automatically load a plurality of said machined axles onto at least one of a truck and a train car according to a predetermined axle shipping allocation.
52. A system in accordance with claim 32 , wherein said system is housed within a single building.
53. A system in accordance with claim 52 , wherein said single building comprises a forging side and a machining side separated at least in part by a wall, said forging side comprises said furnace and said forging system and said machining side comprises said machining system, wherein said system further comprises a venting system for creating a negative air pressure within said forging side to facilitate preventing contaminants from migrating to said machining side.
54. A system in accordance with claim 53 , wherein said venting system comprises:
a plurality of fans located on a roof of said single building; and
a plurality of louvers located within at least one side wall of said single building.
55. A system in accordance with claim 32 , wherein said furnace and said forging system are located within a first chamber and said machining system is located within a second chamber, wherein said system further comprises a venting system for creating a negative air pressure in said first chamber for preventing contaminants from migrating to said second chamber.
Priority Applications (1)
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US13/361,756 US20120144635A1 (en) | 2008-06-26 | 2012-01-30 | Methods and systems for manufacturing an axle |
Applications Claiming Priority (2)
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US12/146,776 US8122580B2 (en) | 2008-06-26 | 2008-06-26 | Methods for manufacturing an axle |
US13/361,756 US20120144635A1 (en) | 2008-06-26 | 2012-01-30 | Methods and systems for manufacturing an axle |
Related Parent Applications (1)
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US12/146,776 Division US8122580B2 (en) | 2008-06-26 | 2008-06-26 | Methods for manufacturing an axle |
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US20120144635A1 true US20120144635A1 (en) | 2012-06-14 |
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Also Published As
Publication number | Publication date |
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MX2009007073A (en) | 2010-01-15 |
CA2670656C (en) | 2018-03-20 |
CA2670656A1 (en) | 2009-12-26 |
US8122580B2 (en) | 2012-02-28 |
US20090320263A1 (en) | 2009-12-31 |
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