WO2004048917A2

WO2004048917A2 - Rotating equipment testing apparatus and method

Info

Publication number: WO2004048917A2
Application number: PCT/GB2003/005135
Authority: WO
Inventors: James Forkin
Original assignee: Bombardier Transportation Gmbh
Priority date: 2002-11-26
Filing date: 2003-11-25
Publication date: 2004-06-10
Also published as: GB0227519D0; AU2003288391A1; AU2003288391A8; EP1627215A2; WO2004048917A3

Abstract

An apparatus and method for testing a rotating assembly (10) including a non-rotating component (18). The apparatus includes support means (32, 34) for supporting the rotating assembly so that the assembly may be rotated, attachment means (36) for supporting the non-rotating component so that it does not rotate, and drive means (38) for rotating the assembly while the non-rotating component remains stationary. The drive means may provide the motive force to rotate the assembly via the attachment means, and where the non-rotating component includes a gearbox or other transmission means, the attachment means may be adapted for rotating an input shaft of the gearbox or other transmission means. The assembly may be monitored by sensors. A loading means (42, 44) for applying braking force to the rotating assembly and a data processing means (60) for controlling the drive means for rotating the assembly at selected speeds may also be included.

Description

ROTATING EQUIPMENT TESTING APPARATUS AND METHOD

The invention relates generally to testing of rotating assemblies with non-rotating components and, more particularly, to an apparatus and method for testing complete wheelset assemblies including non-rotating components.

Bogies for trains typically include two or more wheelsets, each wheelset typically including two wheels mounted on an axle. A wheelset may also include equipment such as wheel- mounted or axle-mounted brake disks, bearings and bearing boxes. A power wheelset includes additional components to transfer drive power to the wheelset axle, such as a gear box, hydraulic drive, traction motor or other similar equipment. After assembly of the wheels onto the axle, the assembly is usually dynamically balanced by rotating the wheelset at high speed on a balancing machine. The brake disks, bearings and any other components that are designed to rotate with the wheels and are symmetrical about the wheelset axle may also be assembled onto the wheelset before the balancing.

The additional components of power wheelsets and other non-rotating and/or asymmetrical components such as axle boxes, gearboxes, etc. are assembled, tested and inspected separately. After mounting them onto the wheelset they are inspected visually but little or no additional testing is performed. This lack of final assembly dynamic testing is, among other reasons, because the wheelset is not symmetrical about the wheelset axle once fully assembled.

However, once assembled, a power wheelset may have problems that are only apparent under dynamic operation. Such potential problems include but are not limited to oil leaks, excessive vibration, excessive backlash, excessive rotational resistance and gear misalignment. Once the wheelset is fitted to the bogie it becomes more difficult to test due to the weight and size of the bogie and once the bogie is fitted to the train the difficulty is further increased. Furthermore, if problems are found in the wheelset it usually must be removed to make repairs, a time consuming and expensive process. Failing to identify wheelset problems prior to assembling the wheelset onto the bogie and the train can lead to problems or failure in service, with consequent risk to safety, vehicle downtime and much expense related to repairing or removing the wheelset or the faulty equipment.

The present invention seeks to solve the above problems by providing an apparatus and method for testing complete wheelset assemblies including asymmetrical components. In a preferred embodiment, the invention also tests a wheelset mounted gearbox or other transmission means, using the gearbox or other transmission means to rotate the wheelset. Optionally, the invention may also test the rotational resistance of the bearings and/or the operation of parts of the braking system.

In one aspect, the invention comprises an apparatus for testing a rotating assembly including a non-rotating component. The apparatus includes support means for supporting the rotating assembly so that it can be rotated, attachment means for supporting the non-rotating component so that it does not rotate, and drive means for rotating the rotating assembly while the non-rotating component remains stationary. The drive means may provide the motive force to rotate the rotating assembly via the attachment means, and where the non-rotating component includes a gearbox or other transmission means, the attachment means may be adapted for rotating an input shaft of the gearbox or other transmission means. Where the non-rotating component includes a traction motor, the drive means may supply power to the traction motor for rotating the rotating assembly. Braking force may also be applied to one or more appropriate parts of the rotating assembly while the rotating assembly is rotating to simulate load conditions.

Sensors may be used to monitor the rotating assembly, directly or indirectly (for example, by measuring vibrations on the drive means). Examples of relevant measurements include but are not restricted to time, input power, output power, speed of rotation of the assembly, resistive force, vibration and temperature of any part of the assembly, and stresses within any part of the assembly. These could be measured by accelerometers, temperature transducers, stress transducers and other such devices. Data processing means maybe used, among other uses, to control the rotation of the rotating assembly at selected speeds, to process the data from the sensors, to correlate such sensor data with data from other sources (such as the programme) and to produce the required outputs in appropriate formats.

Another aspect of the invention comprises a method for testing a rotating assembly including a non-rotating component. The method includes the steps of mounting the rotating assembly on supports so that the rotating assembly can be rotated, supporting the non-rotating component so that it does not rotate, and rotating the rotating assembly while the non-rotating component remains stationary. Where the non-rotating component includes a gearbox or other transmission means, the rotating assembly may be rotated by rotating an input shaft of the gearbox or other transmission means. Braking force may also be applied to the rotating assembly while the rotating assembly is rotating to simulate load conditions, and data processing means may be used to control the rotation of the rotating assembly at selected speeds.

The invention permits testing of the complete or partially complete assembled wheelset so that a greater number of faults in wheelsets can be identified and corrected prior to fitting the wheelset onto the bogie or vehicle. This results in greater reliability of the final bogie or vehicle, reduced maintenance costs, reduced failure of bogies and bogie-mounted equipment, improved safety, and reduced downtime for the vehicle using the wheelsets.

The following is a description of one embodiment of the invention, byway of example only and with reference to the following drawings, in which:

Fig. 1 is a plan view of a wheelset mounted on a wheelset testing apparatus;

Fig. 2 is an end view showing of a support means of the wheelset testing apparatus of Fig. 1; and

Fig. 3 shows a data processing means connected to wheelset testing apparatus of Fig. 1. Referring initially to Fig. 1, one embodiment of a wheelset testing apparatus 30 is shown. A wheelset 10 is shown mounted on the testing apparatus 30. The wheelset 10 comprises an axle 12 and wheels 14 and 16. Wheelset mounted equipment 18 is also attached to axle 12. The wheelset mounted equipment 18 may include for example a gearbox or other transmission means for transmitting power to the wheels, an electric traction motor, a hydraulic motor, or other components mounted directly to the wheelset axle 12. The wheelset mounted equipment 18 typically is not symmetrical about the axis of the wheelset axle 12, but usually includes weight unevenly distributed about the axis and a shape which is not symmetrical about the axis. For example, the wheelset mounted equipment 18 is shown having an asymmetrical portion 20 protruding in one direction from the axle 12.

The testing apparatus 30 includes support means 32, 34 for supporting the wheelset 10 at each end. The support means 32, 34 may be constructed as a pair of stands located at each end of the wheelset, each stand with a device for supporting the end journals 22, 24 of wheelset 10 while permitting the wheelset to rotate. Although two support means 32, 34 are shown in Fig. 1 located at the ends of the axle 12, more than two may be used and/or the support means may be located at different positions.

A preferred arrangement for the support means 32, 34 is shown in Fig. 2, which shows an end view of a stand 50 located on one side of the testing apparatus 30. Two rollers 52, 54 mounted a small distance apart on stand 50 so that the end journal 22 rests between and is supported by the rollers, while permitting the wheelset to rotate. An optional third roller 56 is mounted on an optional rectangular hinged member 58, so that the third roller 56 may be moved into a position above end journal 22 after the wheelset 10 is placed on stand 50 (and a corresponding stand at the other end of the wheelset). Hinged member 58 may then be secured in place so that third roller 56 prevents end journal 22 from lifting and jumping off the stand during operation of the testing apparatus 30. The rollers 52, 54, and 56 may be free- running or optionally one or more of the rollers may be driven in order to rotate the wheelset. In addition, one or more of the rollers may include a braking function to slow the rotating wheelset after or during a test or hold the wheelset in a fixed position between tests or apply load to the wheelset during testing. Alternatively, the wheelset is assembled with axle boxes, quill tube or other bearing configuration, and such a bearing configuration is attached to a fixed or moveable support.

Referring again to Fig. 1, an attachment means 36 is also provided to secure and support the wheelset mounted equipment 18. Attachment means 36 may conveniently attach to asymmetrical portion 20 protruding in one direction from the axle 12. Where the wheelset mounted equipment 18 is a gearbox or other transmission means, the attachment means 36 may conveniently attach to a flange plate 26 on an input shaft to the gearbox or other transmission means. The flange plate 26 is preferably the connection point to the traction motor which will be used to drive the wheelset when assembled on a train, hi this example, an attachment means 36 preferably includes a matching flange plate that can be bolted to flange plate 26 of the gearbox or other transmission means. Attachment means 36 may solely provide a means for supporting the wheelset mounted equipment 18 and holding it steady while the rest of the wheelset 10 is rotated, or attaclunent means 36 may also serve to transmit the motive force to rotate the wheelset, as shown in Fig. 1, or attachment means 36 may also provide the braking function. The attachment means 36 maybe designed to accommodate a variety of different types of wheelsets and wheelset mounted equipment and may include interchangeable parts to accommodate different wheelset designs. Attachment means 36 may include means for attaching to wheelset mounted equipment by bolting, clamping, strapping, or otherwise holding the wheelset mounted equipment 18 in place.

A motor 38 may also be provided for rotating the wheelset 10 for testing. Where the wheelset mounted equipment 18 is a gearbox or other transmission means, the motor 38 can be used to rotate the wheelset 10 by turning an input shaft of the gearbox or other transmission means and thus transmit power to the wheelset. This arrangement is shown in Fig. 1, which includes a transmission means 40 to transmit power from the motor 38 to the attachment means 36 and then to flange plate 26. This permits the motor 38 to drive the wheelset in a manner equivalent to the traction motor which will drive the wheelset when assembled on a train. The transmission means 40 may include a direct drive, hydrostatic drive, drive chain, drive belt, drive shaft, gear arrangement, or other similar arrangement, or the transmission means 40 may be omitted altogether. Thus, the attachment means 36 both supports the gearbox or other transmission means and drives the wheelset 10 through the gearbox or other transmission means to simulate the operation of the wheelset 10 and wheelset mounted equipment 18 under normal operating conditions.

Where the wheelset mounted equipment 18 is a traction motor, the attachment means 36 may be used to hold the traction motor in place while the traction motor itself may be used to rotate the wheelset 10. In this arrangement, the drive means comprises an electrical supply to power the traction motor to rotate the wheelset. The supply of electrical power to the traction motor may incorporate variable speed control of the traction motor and thus control rotation of the wheelset assembly, such as via an on-off switch or by controlling the voltage or waveform of the electrical supply, hi the preferred embodiment the speed of the motor is controlled by means of varying the input voltage.

The motor 38 may also be arranged to rotate the wheelset 10 by driving the wheelset directly. For example, the motor 38 could be coupled to one or both of the support means 32, 34 in order to grip the end journal of the wheelset and rotate the wheelset fro either or both ends of the axle 12. Similarly, the motor 38 could be coupled to the axle 12 or one or both of the wheels 14, 16 via a friction wheel or similar arrangement to rotate the wheelset. Similarly, if the wheelset is rotated by rotating one or more of the rollers 52, 54 or 56, the motor 38 may be used to drive such roller(s).

A loading means 42, 44 may also be provided for creating or simulating a load on the wheelset 10 to simulate actual operating conditions or to permit a test of the wheelset under various loading conditions. Loading means 42, 44 may include a system for applying a braking force directly to the wheels, as shown in Fig. 1, or to the axle through one or more of the rollers of one or more of the support means 32, 34, or directly to the axle, or through the wheelset mounted equipment 18. Loading means 42, 44 may include friction pads for clamping one or more of the wheels 14, 16 of the wheelset, a clutch mechanism for engaging one or more of the rollers on support means 32, 34, a friction wheel for engaging the axle 12, or any other suitable means to apply a braking force to the wheelset. Although two loading means 42, 44 are shown in Fig. 1, a single loading means may be used or more than two may be used in suitable combinations to achieve the desired results.

Fig. 3 shows a data processing means 60 which may additionally be provided for controlling the testing apparatus 30 and or for recording, displaying and/or analysing measurements taken during operation of the testing apparatus 30. The data processing means may comprise a programmable controller, microprocessor, personal computer, or other suitable computer equipment. The data processing means preferably includes storage means for storing measurements; display means for displaying the current status of the testing apparatus and measurement values; a keyboard, touch screen, dedicated switches, or other suitable input means; and a printer, screen, data port, modem, alarm system, lights or other means for outputting, displaying or otherwise showing the results of the test.

Data processing means 60 may include connections to the testing apparatus 30 and wheelset 10 to send control signals and receive measurement data. For example, data processing means 60 may send control signals 62 to the motor and control signals 64 to the loading means, and may receive measurement data 66, 68 and 70 from the support means, wheelset end journals, and wheelset mounted equipment respectively. Data received by data processing means 60 may include temperature rise, vibration, rotation speed, braking force and other measurements which may be correlated with time, wheelset speed, input power or other appropriate measures.

Data processing means 60 may be programmed to operate the motor 38 through a sequence of speeds at which the wheelset 10 is expected to operate when in service, and to apply braking force via loading means 42, 44 at selected points during the test. The data processing means 60 may print out the sequence and duration of drive speeds. This printout may be combined with a record of the tests performed and their resultant readings and results, which may include the tester's identity and the results of the test. Recorded data may include automatically recorded data and manually recorded data, for example temperature rise and vibration at various points on the wheelset at various times during the test, the existence, location and severity of any oil leaks, and any other relevant data. Thus, an embodiment of an apparatus and method for eccentric machining has been described. Although the apparatus and method have been described in relation to testing train wheelsets, the testing apparatus could be used to perform testing on any type of rotating equipment which includes components mounted asymmetrically to the axis of the equipment. The testing apparatus is particularly suited for testing any type of assembly including an axle and axle mounted gearbox or other transmission means, permitting a running test to be performed on the complete assembly including the gearbox or other transmission means prior to attachment of the assembly to a completed piece of equipment.

Optionally, the wheelset testing apparatus may incorporate a means for balancing the wheelset dynamically, i.e. identifying the location and extent of out-of-balance. This provides the advantage of balancing the entire rotating system, including the gearbox or other transmission means, traction motor, or other asymmetrical or non-rotating components assembled onto the wheelset, rather than balancing solely a number of elements of that rotating system, e.g. balancing the entire wheelset rather than just balancing the wheels-and- axle assembly.

It should be noted that the embodiments described above are susceptible to various modifications and alternative forms, and may be applied to the testing of any rotating equipment with one or more non-rotating attachments.

Claims

-9-CLAIMS

1. An apparatus for testing a rotating assembly (10) including a non-rotating component (18), the apparatus comprising: support means (32, 34) for supporting the rotating assembly so that the rotating assembly may be rotated; attachment means (36) for supporting the non-rotating component so that it does not rotate; and drive means for rotating the rotating assembly via the non-rotating component while the non-rotating component remains stationary.

2. The apparatus of claim 1, wherein the drive means (38) provides the motive force to rotate the rotating assembly (10) via the attachment means (36).

3. The apparatus of claim 1 or claim 2, wherein the non-rotating component (18) comprises a gearbox or other transmission means and wherein the attachment means (36) is adapted for rotating an input shaft of the gearbox or other transmission means.

4. The apparatus of claim 1 or claim 2, wherein the non-rotating component (18) comprises a traction motor and wherein the drive means provides power to the traction motor for rotating the rotating assembly (10).

5. The apparatus of any one of the preceding claims, further comprising a loading means (42, 44) for applying braking force to the rotating assembly (10).

6. The apparatus of any one of the preceding claims, further comprising sensors which monitor the rotating assembly.

7. The apparatus of any one of the preceding claims, further comprising data processing means (60) for controlling the drive means for rotating the rotating assembly (10) at selected speeds. -10-

8. The apparatus of any one of the preceding claims, wherein the data processing means (60) receives and processes data relating to the test of the rotating assembly.

9. The apparatus of any one of the preceding claims, wherein the support means (32, 34) comprises means for rotating the rotating assembly (10).

10. The apparatus of any one of the preceding claims, wherein the apparatus comprises means for balancing dynamically the rotating assembly (10).

11. The apparatus of any one of the preceding claims, wherein the rotating assembly is a wheelset.

12. A method for testing a rotating assembly (10) including a non-rotating component (18), the method comprising: mounting the rotating assembly on supports (32, 34) so that the rotating assembly (10) can be rotated; supporting the non-rotating component (18) so that it does not rotate; and rotating the rotating assembly (10) via the non-rotating component while the non-rotating component remains stationary.

13. The method of claim 12, wherein the non-rotating component (18) comprises a gearbox or other transmission means and wherein the rotating assembly (10) is rotated by rotating an input shaft of the gearbox or other transmission means.

14. The method of claim 12, wherein the non-rotating component (18) comprises a traction motor and wherein the rotating assembly (10) is rotated by operating the traction motor.

15. The method of any one of claims 12-14, further comprising applying a braking force to the rotating assembly (10) while the rotating assembly is rotating to simulate load conditions.

16. The method of any one of the claims 12-15 further comprising using sensors to monitor data relevant to the test of the rotating assembly. -11-

17. The method of any one of claims 12-16, further comprising using data processing means (60) to control the rotation of the rotating assembly (10) at selected speeds.

18. The method of any one of claims 12-17, further comprising using reporting means for printing or electronically displaying results of the test.

19. The method of any one of claims 12-18, wherein the rotating assembly is a wheelset.