WO2020245761A1 - Tour à roues à portique - Google Patents

Tour à roues à portique Download PDF

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Publication number
WO2020245761A1
WO2020245761A1 PCT/IB2020/055272 IB2020055272W WO2020245761A1 WO 2020245761 A1 WO2020245761 A1 WO 2020245761A1 IB 2020055272 W IB2020055272 W IB 2020055272W WO 2020245761 A1 WO2020245761 A1 WO 2020245761A1
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WO
WIPO (PCT)
Prior art keywords
portal
wheel
wheel lathe
machining
wheels
Prior art date
Application number
PCT/IB2020/055272
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English (en)
Inventor
Bhojraj Hemraj Teli
Original Assignee
Bhojraj Hemraj Teli
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Bhojraj Hemraj Teli filed Critical Bhojraj Hemraj Teli
Publication of WO2020245761A1 publication Critical patent/WO2020245761A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B5/00—Turning-machines or devices specially adapted for particular work; Accessories specially adapted therefor
    • B23B5/28—Turning-machines or devices specially adapted for particular work; Accessories specially adapted therefor for turning wheels or wheel sets or cranks thereon, i.e. wheel lathes

Definitions

  • the present disclosure relates to the field of lathes.
  • a primary object of the present disclosure is to provide a portal wheel lathe.
  • Another object of the present disclosure is to provide a portal wheel lathe for re-profiling of worn-out and re-disced railway wheel sets.
  • Yet another object of the present disclosure is to provide a portal wheel lathe, which enables hot simultaneous machining of both wheels and machining of a single wheel of the wheel set.
  • Still another object of the present disclosure is to provide a portal wheel lathe, which allows machining of inner and outer faces of the wheel.
  • the present disclosure envisages a portal wheel lathe for machining of railway wheels.
  • the portal wheel lathe comprises a pair of headstocks, a spindle assembly, a tread profile machining system, a hydraulic distributor, a portal frame, a drive mechanism and a control unit.
  • the pair of headstocks is configured to clamp the wheels for machining and to undergo sliding movement along a wheel holding axis of the portal wheel lathe.
  • the spindle assembly which is supported on the respective headstock, comprises a spindle having a face chuck for clamping a wheel.
  • the spindle is configured to provide rotation of the wheels about the wheel holding axis.
  • the tread profile machining system has two separate tool posts for simultaneous machining of the two wheels.
  • the hydraulic distributor facilitates supply of hydraulic pressure for the spindle assembly, the headstocks and the tool holders.
  • the portal frame is configured to be rigidly fixed to the ground and to support the headstocks, the spindle assembly, the tread profile machining system and the hydraulic distribution system.
  • the portal frame is provided with a portal for insertion and removal of the wheels.
  • the drive mechanism comprises a drive motor that is configured to facilitate angular displacement of the spindle of the spindle assembly and thereby facilitate rotation of the wheels to be machined and sliding of the headstocks.
  • the control unit controls operation of the drive mechanism, the tread profile machining system and the hydraulic distributor.
  • the headstocks are configured to be powered and controlled independently of each other.
  • synchronization of actuation of both face chucks is enabled by the control unit through electronic coupling.
  • the face chuck of each headstock comprises a plurality of axial clamping elements mounted on the face chuck, a plurality of projections mounted on the face chuck at equal angles to the axial clamping elements and a plurality of proximity switches, each of the proximity switches being configured to sense position of its corresponding projection and generate a corresponding sensed signal.
  • the stopping position of the clamping elements of the face chuck is controlled by the control unit using the sensed signals.
  • each of the tool posts is provided with a pair of tool holders.
  • the tool holders are configured to facilitate holding of tools for machining of outer and inner faces of the wheels.
  • the tool holders include a duplex tool holder for enabling machining of inner faces of the wheels.
  • the portal frame includes guide ways for mounting and sliding of the tool posts.
  • the tread profile machining system comprises a cross slide configured to slide in the operative longitudinal direction and also to be displaced in the operative forward- reverse direction.
  • the portal frame includes guideways for the headstocks, wherein the headstocks being configured to traverse along the guideways.
  • the portal wheel lathe a headstock sliding assembly configured to facilitate sliding of the headstock.
  • the headstock sliding assembly comprises a box nut supported the portal frame, a lead screw engaged with the box nut and connected with the headstock, a brake motor and a V-belt pulley mechanism coupling the brake motor and the lead screw.
  • the spindle is coupled to the drive motor through a gear mechanism.
  • the portal wheel lathe includes a lifting and lowering system, said lifting and lowering system comprises a cross member, a hydraulic piston-cylinder mechanism and wheel guide plates.
  • the cross member has two track rollers on either side for supporting the wheels to be machined.
  • the hydraulic piston-cylinder mechanism has a piston and a cylinder, wherein the piston supports the cross member.
  • the wheel guide plates provide for the lateral location of the set of the wheels to be machined.
  • the portal wheel lathe includes a centering system.
  • the centering system comprises a hydraulically operated main arm with two feeler arms. The first feeler arm is fixed relative to the main arm and the second feeler arm is configured to swivel at a diameter and height equal to the diameter and height of the wheel to be machined.
  • the portal wheel lathe includes a cutting depth determination system.
  • the cutting depth determination system comprises a probing head attached to a probing head shaft.
  • the probing head having a profiled roller and a sensing transducer or a limit switch connected to the control unit.
  • the portal wheel lathe includes a brake disc machining arrangement.
  • the brake disc machining arrangement comprises a sliding ram with the cutting tool provided for the brake disc turning tools.
  • the portal wheel lathe includes an automatic conveyor chip disposal system.
  • the portal wheel lathe includes a refrigeration type oil chiller equipment for cooling of the hydraulic oil of the hydraulic distributor.
  • the portal wheel lathe includes a chip crusher arrangement.
  • the portal wheel lathe includes an electrostatic oil filtration equipment.
  • the drive mechanism is configured to be driven by electrical power.
  • the portal wheel lathe is provided with a cover having a portal for insertion and removal of the wheels.
  • the present disclosure also envisages a method of synchronizing actuation of face chucks of a portal wheel lathe.
  • the envisaged method comprises the steps of: i. receiving a command for clamping of axial clamping elements of the face chucks of the spindles; ii. initiating a‘slow-down’ mode of the drive motors of the face chucks and hence slowly moving the axial clamping elements of the face chucks; iii. reading signal coming from proximity switches sensing the position of the axial clamping elements; and iv. on sensing presence of an obstruction, stopping the movement of the respective spindle.
  • the method includes stopping the drive motors of the spindles if the face chucks are detected to be at different relative angular positions and synchronizing the face chucks by inching the face chucks individually.
  • Figure 1 illustrates as isometric view of the portal wheel lathe of the present disclosure with an enclosure
  • Figure la illustrates of portal wheel lathe of Figure 1 without the enclosure
  • Figure lb illustrates an isometric view of a portal frame of the portal wheel lathe of the present disclosure
  • Figure 2 illustrates an isometric view of a headstock assembly of the present disclosure
  • Figure 3a illustrates an isometric view of a spindle assembly of Figure 2;
  • Figure 3b illustrates a side view of the spindle assembly of Figure 3
  • Figure 4 illustrates a sectional view of a hydraulic distributor for headstock of the portal wheel lathe of the present disclosure
  • Figure 5 illustrates an isometric view of a headstock sliding assembly of the portal wheel lathe of the present disclosure
  • Figures 6a, 6b, 6c, 6d illustrate various views of a wheel set clamping arrangement of the portal wheel lathe of the present disclosure
  • Figure 7 illustrates a front view of an arrangement for synchronization of both face chucks of the portal wheel lathe of the present disclosure
  • Figures 8a, 8b, 8c illustrate various view of a lifting jack of the portal wheel lathe of the present disclosure
  • Figure 9 illustrates a side view of a wheel set catching and ejecting device of the portal wheel lathe of the present disclosure
  • Figure 10 illustrates an isometric view of a centring device of the portal wheel lathe of the present disclosure
  • Figure 11 illustrates schematic details of CNC control profiling system of the portal wheel lathe of the present disclosure
  • Figure 12 illustrates a tool layout for wheel turning of the portal wheel lathe of the present disclosure
  • Figure 13 illustrates schematic details of profile checking of the present disclosure
  • Figure 14 illustrates wheel measurement details of the portal wheel lathe of the present disclosure
  • Figure 15a, 15b illustrate details of a probing head for the portal wheel lathe of the present disclosure
  • Figure 16 illustrates an isometric view of a CNC controlled tool post for the portal wheel lathe of the present disclosure
  • FIGS 17a and 17b illustrate brake disc turning using the portal wheel lathe of the present disclosure
  • Figure 18 illustrates side view of a chip conveyor for the portal wheel lathe of the present disclosure
  • Figure 19a illustrates a turning sequence of the portal wheel lathe of the present disclosure
  • Figure 19b illustrates a turning cycle of the portal wheel lathe of the present disclosure.
  • Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
  • first, second, third, etc. should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
  • the present disclosure envisages a portal wheel lathe, as illustrated through Figures 1 to 20.
  • the CNC portal wheel lathe of the present disclosure is an extremely rigid machine suitable for re -profiling of worn-out and re-disced wheel sets. It is capable of: i. Re-profiling worn out and re-disced railway wheel sets with work hardened spots of up to 450 BHN: The tensile strength of the wheel material under normal condition can be up to 125 kg/mm2. ii. Simultaneous machining of either the wheels or single wheel of wheel set: The machine is very rigid, precision and CNC controlled as described in following paragraphs. iii.
  • a duplex tool is incorporated which enables machining of inner face of the wheels.
  • a separate tool holder is incorporated which enables machining of outer face of wheels.
  • Machine is having very high rigidity and is built in a very precision way as described in the following paragraphs. This enables undertaking cuts of depth up to 8 mm, i.e., a reduction of 16mm on diameter, without undue vibrations. It is free from undue chattering and vibrations while one or both the wheels of a wheel set are being re -profiled. iv. of brake discs mounted on the wheel sets. Details are described later on.
  • the portal wheel lathe of the present disclosure is an extremely rigid machine. It consists of a portal frame (bed) (shown in Figure 1) and a head stock (shown in Figure 2).
  • the head stock assembly comprises a heavy-duty spindle assembly, hydraulic distributor (shown in Figure 4), drive mechanism for the spindle and thus the wheel rotation, headstock sliding arrangement (shown in Figures 5).
  • the portal wheel lathe of the present disclosure also comprises an arrangement for synchronisation of both face chucks (as shown in Figure 7), a wheel set lifting and lowering system (shown in Figure 8), centering system (shown in Figure 10), a tread profile machining system (CNC tool post (shown in Figure 16)), a cutting depth determination (wheel measuring) system (shown in Figure 13, Figures 14 and 15), a brake disc machining arrangement (shown in Figures 17a, 17b), an automatic conveyor chip disposal system (shown in Figure 18)and a refrigeration type oil chiller equipment, optionally a chip crusher arrangement and an electrostatic oil filtration equipment.
  • the hydraulics, lubrication, tooling and electrostatic oil filtration systems, the machining cycle and the controls shall also be described in detail in the following paragraphs.
  • the portal frame / bed is of rigid structure with very high static and dynamic rigidity and is made from Cl casting (e.g., to grade FG-260 as per IS-210).
  • the machine frame(bed) can also be made in fabricated construction.
  • the machine frame (bed) is of slant version and hardened and ground wear resistant guide ways / linear motion guideways are provided on either end of bed where headstock is sliding on the bed.
  • near uniform wall thickness is adopted all over except for the resting pads.
  • Generous ribbing structure is adopted. Ribs are properly merged with each other and the end walls with appropriate filleting. This gives uniform cooling of the casting which results in minimum internal stresses during the casting process. Thermal stress relieving is done after casting to remove the stresses during the casting.
  • Entire design and the procedure adopted ensure the extremely rigid structure to absorb the weight of various machine elements and the cutting forces developed during the wheel turning operation.
  • the portal frame / bed is accurately machined to close tolerances for mounting of headstock and CNC tool post guideways.
  • Guideways are also provided for mounting and sliding of the CNC tool post.
  • the portal frame (bed) is provided with adequate no. of foundation bolts for anchoring to shop floor foundation.
  • Each foundation bolt is accompanied by levelling bolt for initial and subsequent alignment and levelling.
  • headstocks are rigid structures, individually powered, each traversable on hardened guide ways / linear motion guideways, on each side of bed to enable obstruction free roll through operation of wheel set. Both headstocks move through individual electric motors connected to sturdy lead screws. Automatic locking is provided when gauge length distance is reached.
  • headstock is basically a very rigid structure made out of cast iron (e.g., of grade FG: 260 as per IS-210), with dense ribbing and near uniform wall thickness except for the mounting pad areas. This gives very sound casting with minimum stresses. Thermal stress relieving is adopted to relieve the stresses.
  • Head stock is very precisely machined and hand scraped to control the accuracies given in the detailed drawings.
  • Hardened and ground OHNS guide ways / linear motion guideways are incorporated on the resting faces of the headstock mating with bed. This gives precision alignment and smooth sliding of the heads tocks on the bed guideways.
  • cables connecting the headstock to the machine control panel are routed through the cable drag chain.
  • the hoses connecting the headstock to the hydraulic power pack are also routed through cable drag chain for additional safety.
  • Head stock supports heavy duty spindle assembly, hydraulic distributor, drive for the spindle and thus the wheel rotation, headstock sliding arrangement. All these are explained in the following paragraphs.
  • the main spindle is precision-machined incorporating adjustable, double-row, high precision anti-friction bearings for its mounting.
  • the axial thrust is absorbed by pre-loaded anti-friction thrust bearings.
  • the main spindles are made from forged steel and are precision machined. All the bearing seats of these spindles are precision ground within very precision tolerance. Similarly, the bore of the main spindle in which the centering sleeve/centre barrel slides is provided with wear-resistant bronze bushes. As shown in Figures 3a, 3b, each spindle is supported on the adjustable double row high precision anti-friction bearings at front end and cylindrical roller bearing at the rear end. The axial thrust is absorbed by the cylindrical roller thrust bearing of a very large size. Ball thrust bearing is provided at the rear end for preloading this cylindrical roller thrust bearing. Very rigid and precision assembly is incorporated which is very essential for heavy duty wheel turning operation.
  • main sleeve, 303 made out of alloy steel is incorporated.
  • the sleeve is precisely ground to close tolerances.
  • Front end has a taper bore to accommodate the dead centre.
  • This sleeve with dead centre can slide to and fro to hold the wheel set between centres.
  • Hydraulic cylinder, 314 is incorporated inside the spindle sleeve itself for the movement of spindle sleeve. Hence, the clamping of wheel set between centres is under hydraulic pressure.
  • Inside bore diameter of sleeve is precisely honed to close tolerances and surface finish.
  • a piston, part 37 is sliding with its seals. Very reliable imported seals from reputed manufacturer are incorporated to give very long trouble-free service.
  • a piston is mounted on the piston rod, 312, which is firmly held in the spindle. It has through hole for supply of oil. Oil is fed by the hydraulic distributor through this piston rod.
  • clamping element 313 is provided. Due to typical construction of the ring, once it is pressed on faces, it tries to increase the outer diameter and reduce the inner diameter. Since it is firmly held in the spindle, outer diameter cannot increase but the inner diameter will reduce depending upon the wear developed on sleeve. Cylinder 314 is incorporated behind this clamping element, which is activated by the pressurized oil, thus, creating axial force on the clamping element.
  • a seat is provided for mounting the face chuck. Through holes are drilled in the spindle to supply oil from hydraulic distributor for the gripper’s axial and radial movements on the face chuck 39.
  • Main spindle receives drive for rotation from very rigid helical gear 35.
  • This gear is in mesh with a gear mounted on the output shaft of the gearing arrangement. Due to direct mesh and connected to the face chuck directly a very rigid drive is available for driving the wheel set while turning.
  • the oil supply for the movement of the barrels and the jaws is through an oil distributor, i.e., a hydraulic distributor, which is not having any seals so that breakdowns due to seal failures do not occur.
  • an oil distributor i.e., a hydraulic distributor, which is not having any seals so that breakdowns due to seal failures do not occur.
  • It basically consists of a shaft made out of alloy steel in hardened, tempered and nitrided condition. This shaft is mounted on the rear face of the spindle directly. Cast iron / alloy steel sleeve is mounted on this shaft which is a non-rotating element. Shaft is accurately ground and lapped. Bore of the sleeve is accurately honed for precision rotary motion. Controlled radial clearance is kept to ensure that the spindle works proper .
  • a rotary encoder is incorporated on one of these distributors for spindle speed feedback.
  • the main drive for rotating the wheel set is through AC motor with stepless speed control over the range of speed.
  • Stepless drive for the spindle rotation is realised by an AC motor connected to VVVF drive.
  • Each spindle and thus, the face plate/chuck is driven by an individual motor which is accurately synchronized by microprocessor based electronic coupling.
  • These motors are connected to spindle through reduction gear box 22.
  • Both the drives are electronically coupled through a microprocessor-based interface.
  • the system is operating in master-slave operating mode working on a load sharing principle.
  • the entire speed regulation is less than 1%. This ensures perfect synchronization of the two-face plate drives, hence, there is no heat built up.
  • a reduction gear box is incorporated to connect the drive motor to the main spindle with the required reduction of speed.
  • a hardened and profile-ground pinion is incorporated on the output shaft of the gearbox. This pinion is in mesh with a rigid gear which is mounted on the face chuck. As explained above, this face chuck is mounted on the spindle of the machine. Face chuck carries the wheel set clamping arrangement as explained at below. In this way, the drive is established from the drive motor to the wheel set to be machined.
  • Headstock sliding assembly basically consists of a sturdy lead screw and box nut arrangement.
  • a Box nut 66 is mounted in a rigid bracket 69. This bracket is firmly bolted to the machine bed. Box nut is stationary and non-rotating and lead screw is rotating.
  • the lead screw is made from alloy steel in hardened and tempered condition. It is supported on extremely rigid bearing assembly incorporated in bearing housing.
  • A‘V’ belt pulley is incorporated on the end of this lead screw.
  • a brake motor 62 is rigidly mounted on the headstock with a provision of belt tensioning arrangement.
  • ‘V’ belt pulley 63 is fixed on the motor shaft. Both these pulleys are interconnected by the‘V’ belts.
  • Metallic linear scale arrangement or limit switches are incorporated for giving feedback of headstock movement and position to the CNC controls of the machine. The arrangement is explained as per Figure 5. Hence, the position of the headstock is known in the CNC controls.
  • the headstock sliding motor can be rotated in clockwise or counter-clockwise direction for sliding the headstock in forward or reverse direction. Rotation of the motor will rotate the lead screw, which will result in sliding motion of the headstock.
  • the motor is equipped with electromagnetic failsafe brake to ensure instantaneous stopping of headstock. Head stock positioning is controlled by the limit switches arrangement.
  • each spindle is having location seat provided for mounting of face plate/chuck.
  • This assembly basically consists of a rigid face chuck.
  • the face chuck is rigid S.G. iron casting. It has a precision machined location for mounting on the spindle. Heavy duty bolts are provided for rigid mounting with the spindle. Front side of the face chuck is accurately machined and hand-scraped for mounting of hardened and ground guide ways.
  • FIGS. 6a-6d Please refer Figures 6a-6d.
  • four nos. axial grippers are mounted on the face chuck.
  • three axial or radial grippers can also be used.
  • Hardened and ground guide ways 817 are mounted on the precision machined and hand-scraped seats available on the face chuck.
  • the guide ways are firmly bolted on the face chuck.
  • gripper body 82 is mounted and is sliding with precision location arrangement.
  • the gripper body is a rigid steel casting.
  • a linear bush 813 is mounted within this gripper body.
  • a gripper shaft 88 is sliding on this linear bush.
  • a hydraulic cylinder is incorporated within this gripper assembly for axial movement of the gripper shaft.
  • a gripper shaft is made from alloy steel in hardened and tempered condition. Precision machining, including grinding and bore honing is done for durable performance of the hydraulic seals. Reputed make seals and ⁇ ’ rings is incorporated. Replaceable jaw 810 is incorporated on this gripper shaft. Specially designed gripper jaws are mounted on the front end of this gripper shaft.
  • lead screw 86 is provided for each gripper assembly.
  • the lead screw is made from alloy steel in hardened and tempered condition.
  • the lead screw is supported on the combination thrust and radial bearings. Bearings are mounted in the bearing housings which are firmly bolted to the face chuck.
  • Helical rack, 819 is mounted on each gripper assembly. This helical rack is in mesh with the lead screw.
  • a bevel pinion 84 is mounted at inward end of lead screw.
  • the bevel pinion is in mesh with the central bevel gear 83 which is mounted in the bore provided in the face chuck with a special radial ball bearing.
  • a spur gear is incorporated on the central bevel gear.
  • the spur gear is in mesh with the output pinion of gripper sliding arrangement.
  • a hydraulic motor is provided. This hydraulic motor is connected to the hydraulic system through necessary piping and the hydraulic distributor. Series of gears are provided which connects the hydraulic motor to the spur gear provided on the central bevel gear. Hence, when the hydraulic motor is actuated by the direction control valve, gears rotate resulting in rotation of the central bevel gear. Rotation of central bevel causes the rotation of bevel pinion and thus, the lead screw. Due to this radial sliding motion of the gripper takes place. Direction of sliding motion is selected from the control pendant. Hence, it can be seen that, radial movement of clamping devices i.e. the grippers is push button controlled and will enable quick adjustment for wheel sets with variable diameter. The grippers will have adequate radially infinitely adjustable arrangement for accommodating wheel sets of varying diameters as per requirements.
  • axial clamping elements 94 are mounted on the face chuck Part no. 2.
  • projected metallic pieces i.e., metallic projections 95 are mounted on the face chuck at approximately 45° to the axial clamping elements as shown in the drawing.
  • Four projections are incorporated 90° to each other. Any one of the nearest projections is sensed by the proximity switch.
  • Proximity switch 91 is mounted on the headstock as shown. Stopping position of the face chuck is controlled by the metallic projection 95 and the proximity switch. Similar arrangement is incorporated on both side headstocks. Whenever stopping command is given, drive will get into slow down mode and look for a signal from the proximity switch. As soon as signal from the proximity switch is received sensing the nearest obstruction, the spindle will stop instantaneously.
  • both the face chucks will always stop at the same angular position.
  • This angular position is such that axial clamping devices (axial grippers) are at approximately 45° as shown in the drawing. In this position unobstructed loading and unloading of wheel set with axle boxes is possible.
  • the face chucks stop at different angular position due to any malfunctioning it will not be possible to start the main drive again unless both the face chucks are synchronized in the same angular position using the individual inching command. In this way, most appropriate synchronization arrangement is incorporated.
  • a hydraulically operated lifting and lowering arrangement is provided for lifting and lowering of the wheel set. This enables easy and quick loading and unloading of wheel set.
  • the arrangement is explained as per Figures 8a, 8b, 8c.
  • This basically consists of a cross member 105 and hydraulic cylinder 102.
  • Cross member is a rigid fabricated element with adequate ribbing structure to withstand the weight of the wheel set. It has two track rollers 1010 on either side for supporting the wheel set on flanges. Wheel guide plates 1017 will also be incorporated for the lateral location of the wheel set.
  • This cross member is mounted on the piston of hydraulic cylinder 102.
  • Hydraulic cylinder basically consists of rigid cylinder tube accurately honed and will have provision for mounting on the machine bed.
  • Piston rod is hard chrome plated and ground.
  • Guide bush 1016 is incorporated for precision sliding of piston rod. Seals of reputed manufacturers are used. This enables very rigid cylinder for the jack.
  • Additional guide bar 104 is provided for additional guide and to prevent rotational movement of cross member.
  • lifting jack cross member is equipped with a spring- loaded centre bullet for detecting the wheel set during the unloading cycle. On completion of machining cycle, once the jack is raised to receive the wheel set, this centre bullet gets pressed by the inside face of wheel which actuates the limit switch giving confirmation of wheel set receipt on the jack. On this confirmation, wheel set is released from the centres and axial clamping devices and the headstock traverses back.
  • a hydraulically operated wheel set catching and ejecting device is incorporated for roll in and roll out of the wheel set. It basically consists of a rigid arm which is connected to the hydraulic cylinder 104. When the wheel set is rolled in, the arm is in receiving condition. As soon as the wheel set is rolled in, the arm is tilted to avoid roll out of wheel set. After turning, wheel set is lowered by the jack. Roll out arm is actuated by the hydraulic cylinder to roll out the wheel set.
  • Centering device assembly is mounted on one of the headstocks. It basically consists of hydraulically operated main arm with two feeler arms. A first feeler arm is fixed and a second feeler arm is swivelling with the diameter and height of wheel. Once the centering height is achieved a sensing arm actuates the limit switch, which stops the lifting motion of jack. Centering position is 2-3 mm below the centre height.
  • centering device swings in and both the feeler arms touch the wheel flanges.
  • Wheel set is lifted by the jack.
  • the second feeler arm will activate the limit switch and lifting motion of the jack is stopped.
  • jack is raised. Receipt of the wheel set is sensed by centre bullet 1012 which activates the limit switch 1013 as per Figure 8c. This will terminate the lifting motion of the jack.
  • centre sleeves, grippers and headstocks are retracted and the wheel set is lowered on the machine rails.
  • Roll out arm are actuated by the hydraulic cylinder to roll out the wheel set.
  • a tread profile machining system is a very important feature of the CNC Portal Wheel Lathe of the present disclosure.
  • Two separate CNC tool posts are provided for si ultaneous machining of the two wheels. Details of one of the CNC tool post is described in the following paragraphs with reference to Figure 16.
  • Extremely rigid and precise slide assembly is incorporated for the portal wheel lathe. It will basically consist of a rigid longitudinal slide. This is made from cast iron (e.g., of grade FG260 as per IS-210). This slide will have adequate ribbing structure for extreme rigidity and stability. It is thermally stress relieved. This slide will be moving on the hardened and ground guideways / linear motion guideways provided on the bed in longitudinal direction. Precision and rigid ball screw and nut is incorporated for the sliding movement of this slide on the bed. A ball screw is rigidly supported on the portal frame with the help of bearings. It is connected to a servomotor with a reduction gearbox. Ball screw nut is fixed to this longitudinal slide.
  • the longitudinal slide moves in forward or reverse direction depending upon the direction of the rotation of the servomotor shaft.
  • a precise and controlled motion of longitudinal slide is established which is treated as‘Z’ axis for the CNC system.
  • hardened and ground guide ways / linear motion guideways are provided for the cross slide.
  • Extremely rigid cross slide is incorporated on this slide. This is made from cast iron (e.g., of grade FG260 as per IS-210). It is having adequate ribbing structure for extreme rigidity and stability.
  • This slide moves on the hardened and ground guide ways / linear motion guideways incorporated on the longitudinal slide.
  • Precision and rigid ball screw and nut is incorporated for the sliding movement of cross slide on the base slide.
  • the ball screw is rigidly supported on the base slide with the help of bearings. It is connected to the servomotor with the gearbox. Ball screw nut is fixed to the cross slide.
  • the cross slide moves in forward or reverse direction depending upon the direction of the rotation of the servomotor shaft.
  • cross slide is established which is treated as‘X’ axis for the CNC system.
  • wheel profiling and facing tools are provided on the cross slide. Wheel profiling and facing tools are rigidly held on this slide.
  • a sliding ram with the cutting tool is provided for the brake disc turning tools. This ram remains in withdrawn / parked condition whenever not being used. For brake disc turning, this ram is extended out with tools for the machining operation. This is suitable for wheel mounted or axle mounted brake discs. Similarly, this can also be used for the outside wheel facing operation.
  • Machine is equipped with two tool slide assemblies.
  • the axes are treated as XI, X2, Z1 and Z2 in the machine. Two axes on each side are sufficient to generate the wheel profile and to perform pre and post measuring operation.
  • the CNC system is a fully closed loop system. Schematic details of CNC system are given in the Figure 11. As can be seen, servomotors part 135 are driven by servo drives which are directly controlled by the CNC system. Feedback from the axis is available, which is connected to the CNC system directly. This enables position and velocity feedback to the CNC system to control the position and speed of the axis. This ensures controlled movement of the axis. Based on the data from pre-measurement, the CNC system will ensure automatic positioning of tools during machining operation. Similarly, electrical energy is stored in the capacitors of the CNC system. In the event of power failure, the cross slide is moved away automatically by utilizing the energy stored in capacitor.
  • Occasional outside facing of wheels can be done by the brake disc turning tool or a separate tool holding arrangement. Whenever required, this tool can be extended out to the cutting position and whenever not required it is kept in parked position.
  • CUTTING DEPTH DETERMINATION WHEEL MEASURING
  • the machine is equipped with CNC based system to determine minimum metal removal necessary to achieve the required profile for the wheel sets in normal worn out condition.
  • the system performs the measurement at various locations for both the wheels of wheel set for deciding the precise diameter along with minimal material removal required for turning.
  • the display system indicates the diameter before and after turning along with depth of cut and suggested wheel profile. Based on these suggestions, the operator is able to take corrective actions if required. Based on the corrective actions taken by the operator, the CNC system calculates the distribution of cuts in order to process the profiling in single/multiple cuts. System is explained in detail with drawings in the following paragraphs.
  • a sliding type of cutting depth determination system is incorporated on the tool slide.
  • Precision linear motion guide ways are provided for the sliding movement of measuring head.
  • a hydraulic cylinder is incorporated for this sliding motion.
  • the probing head basically consist of a special profiled roller.
  • the profile of the roller is designed to take all the measurement readings as indicated in Figure 13 and figure 14.
  • the sensing arrangement is suitably connected to the probing head shaft.
  • a digital transducer or a precision limit switch is incorporated. This transducer / limit switch accurately senses the movement of the probing head when roller is pressed against the wheel profile.
  • a spring is incorporated for the pre- loading of the roller against the wheel profile. In this, the roller is used as a probe for the measurement of wheel profile at required locations. After completing the measurement activity, the probing head is retracted to a safe home position and the safety flap is closed. This enables movement of the probing head away from the chip generating area. Internal details of probing arrangement are given in Figure 15a, 15b.
  • a roller is incorporated for profile sensing.
  • the roller is mounted on the roller bracket which is firmly held on a support shaft 13 as shown in this Figure 15a, 15b.
  • the support shaft 13 is rigidly held on the supports, viz. part no. 10 and 16 with the help of pre-loaded linear bearings. These bearings enable transmission of the roller shaft movement without any losses which is normally associated with conventional bearing supports.
  • an axial clamping arrangement 17 is incorporated.
  • a hydraulic cylinder 18 is incorporated for axial clamping.
  • a spring 9 is incorporated to ensure adequate pre-tension on the rollers during measurement.
  • a hinge bracket 6 is mounted on the support shaft. It is firmly held on the support shaft.
  • a ball holder 7 is held on this hinge bracket at the other end.
  • a sensing pin 4 is accurately held on Supports 1 and 2 through preloaded linear motion bearings. This pin is held against ball holder through the ball 5 and spring 2.
  • a probe 19 is suitably held on the probing head. The probe will sense the movement of sensing pin. Hence, the movement of the sensing pin will cause the movement of sensor which is recorded in the CNC system. It can be seen that one sensor is required on each probing head.
  • Figure 13 shows the position of the probing head during flange top gauging at point no. 5.
  • Figure 13 shows the position of the probing head during inside face gauging at point no. 0.
  • Figure 13 shows the position of the probing head during tread point 2 gauging at point no. 1.
  • Figure 13 shows the position of the probing head during tread point 1 gauging at point no. 6.
  • Figure 13 shows the position of the probing head during flange point 1 gauging at point no. 2.
  • Figure 13 shows the position of the probing head during flange point 2 gauging at point no. 3.
  • Figure 13 shows the position of the probing head during flange point 3 gauging at point no. 4.
  • FIG. 13 gives the details of locations of the measuring points during the pre and post inspection of wheel. These points are selected considering the typical wear pattern encountered in railway wheel sets.
  • ⁇ ’ point represents the inside face. Measurement is done by rotating the wheel set thus, enabling measurement of face runout. When two wheels of wheel set are measured, wheel gauge is derived. Measurements at three points can be taken by indexing the wheel by approximately one-third revolution. Measurement can also be carried out continuously by rotating the wheel set and allowing the probe roller to travel along the profile. Point No.l represents measurement at tread circle. Tread diameter is established by this measurement. Measurement is done by rotating the wheel set thus, enabling measurement of radial runout. Similarly, points No.6 is behind the tread circle where skid marks are encountered.
  • Point nos. 2, 3 and 4 represent the same. Correct flange thickness is established by point no.3. Additional measurements are taken at point No.3 and 4 which is necessary to establish the root wear and thus the optimum wheel profile. Point No.5 represents flange top. This measurement establishes the flange height.
  • FIG 14 which represents above measurements with the help of probing roller. Co-relation of the two drawings is also shown in this drawing. Due to typical wheel profile, profiled roller is used for scanning various locations as shown. This roller is supported on sealed bearings. As shown in the drawing, flange top is sensed by the straight outside diameter of roller. All other points are sensed by the angular profile of roller. Entire scan cycle is automatic and is done one by one without any operation assistance. Complete measuring cycle as mentioned for pre-inspection can be used for the post inspection. However, CNC profiling is a totally closed loop activity and a variation in profile beyond 0.2mm is very-very rare. Hence, only diameter measurement can be performed during the post inspection.
  • Measurement arm slides out to safe parking position.
  • Cross slide advanced so that straight OD of roller hits the wheel flange top.
  • Flange top i.e., measurement of Pt. No.‘5’ as per Figure 13 is recorded.
  • Cross slide withdrawn and inside face measurement i.e. measurement of Pt. No. ⁇ ’ as per Figure 13 is recorded by the angular edge of roller. Measurement is done by rotating the wheel set thus, enabling measurement of face runout.
  • Both the slides are positioned and measurement of point no.‘1’ as per Figure 13 is recorded. Measurement is done by rotating the wheel set thus, enabling measurement of radial runout.
  • CNC system will advise the optimum depth of cut. As shown in the drawing, blue coloured profile represents the worn-out profile of the wheel. Based on the data collected, CNC will advise 25mm flange thickness and 1 mm depth cut. If operator opts for 29 mm flange thickness, system will display 8mm depth of cut and adjust the machining settings accordingly. Based on selection data of pre - inspection is transferred in the Data Base of the system. In this way, most appropriate and most suitable wheel inspection arrangement is incorporated. Non-contact laser measurement can also be for wheel profile and diameter measurement as detailed above.
  • Brake disc turning arrangement is explained as per Figures 17a, 17b.
  • additional rigid, alloy steel ram is incorporated on the basic tool post of the machine. It is case carburized and hardened to min. 55 HRC.
  • Mating slide ways is lined with SKC material.
  • Standard available tool holder and inserts are used for the brake disc turning operation.
  • This ram with tool holder is kept in retracted condition during normal wheel turning operation.
  • Ram retraction and extending out is actuated by the hydraulic cylinder operated from the CNC control pendant.
  • tool is positioned by the longitudinal slide.
  • Ram is extended out by the hydraulic cylinder.
  • Cross feed is initiated by cross slide for the machining operation.
  • the basic machine and the tool post remain the same. Only the brake disc turning arrangement is added on the basic tool post.
  • chip conveyor is installed in a pit below the machine for effective collection of chips. Chips discharge end is at a suitable height above normal ground level. Chips is collected in a chip bin / trolley parked on the ground level.
  • the conveyor is basically heavy-duty steel belt conveyor. It basically consists of hinged links in formed loop construction made out of CRCA steel. This forms the basic chain belt construction. Rollers are provided on either end for supporting purpose. Side wings are provided on chain belt inside the rollers. Additional steel links are provided outside the rollers. This basically forms endless chain belt construction. Sprockets are provided at either side on the bottom and top end for continuous movement of the chain belt conveyor.
  • Top end sprockets are connected to the drive motor through chain sprocket, ball type safety clutch and reduction gear box.
  • Ball type safety clutch is operated immediately in the event of jam or overload, and the conveyor motion is stopped.
  • Roller switch ensures feed back to the electrical system switching off the drive motor, giving audio and visual indication.
  • Hoppers are incorporated on either side on chip collection area to ensure chips are directed on the moving hinge belt conveyor. Just before start of inclination, bell-mouth construction is incorporated to ensure gradual compression of accumulated chips.
  • Top covering plate is incorporated on the inclined portion to avoid roll back of the chips when being conveyed upwards. Chips are delivered at the required height and location. Entire conveyor is supported on rigid fabricated structure.
  • Conveyor will get switched ON’ automatically once the machining cycle start command is given through CNC. Similarly, ON’ and OFF’ push buttons are incorporated on control desk for its operation in manual mode.
  • Hinged belt conveyor keeps on moving continuously. Chips fallen on the conveyor belt is conveyed continuously till the exit point. Side hoppers will direct the stray chips on the conveyor. Similarly, side wings of the chain belt will ensure falling of chips on the hinged belt. As the chips are conveyed through bell-mouth, they are compressed if required and conveyed on the inclined portion through covered top plate. This ensures conveying of chips to the exit point and delivery into the chip trolley. In this way, the most reliable automatic conveyor type chip disposal system is proposed.
  • Hydraulic system of the machine basically consists of a tank with its accessories like, oil level gauge, temperature gauge, thermostat, float switch, oil filler breather etc. Drain plug is also incorporated at lowest portion of the tank for draining out the oil. Pumps and filters are also mounted on this tank. Various valves like direction control valves, flow control valves, pressure relief valve, pressure reducing valves, check valves, pilot operated check valves etc., are incorporated based on the functional requirement of the actuator. Pilot operated check valves are incorporated for grippers, centre sleeve, headstock clamps, lifting jack, centering device cylinder to avoid undesirable motion in the event of power failure. All the filters are with electrical clog indication.
  • Chiller type heat exchanger is incorporated for the effective cooling of hydraulic oil in local ambient conditions.
  • Hydraulic system is procured from reputed manufacturer. Machine elements like hydraulic cylinder, hydraulic motor etc. are connected by the rigid seamless pipes which are amply supported on the brackets. Hydraulic hoses of reputed make are used as required. LUBRICATION
  • a separate lubrication system is incorporated for headstock spindle bearings, and gearing arrangement.
  • Each headstock has individual lubrication system. It basically consists of lubrication tank.
  • Lubrication pump forces the lubrication oil to various lubrication points through cartridges/progressive blocks, to ensure metered quantity of oil reaches to all the required points.
  • Flow switch and float switch is incorporated to ensure proper working of lubrication system. In case of drop of lubrication oil level, float switch will give feedback to controls. Similarly, in case of no flow of lubrication oil, flow switch will give the signal to the controls. Machine is stopped if any signal is received with alarm message.
  • a separate lubrication system is incorporated for the slide lubrication. All the guide ways and ball screws are lubricated. Intermittent, pressurized, metered quantity of lubrication oil / grease is supplied to all the lubrication point. Level switch and pressure switch is incorporated to ensure protection against lubrication failure. Signals from float switch and pressure switch is connected to controls.
  • Hydraulic system consisting of pumps, various valves, manifold blocks, hydraulic cylinders etc.
  • clean oil is absolutely essential.
  • Hydraulic system is having the filters incorporated for the regular cleaning of hydraulic oil.
  • these filters are of 10-micron capacity. Due to this, particles of less than ten-micron capacity which are very high in quantity cannot be filtered by these regular filters. Continuous accumulation of these particles results in deterioration of oil quality which results in mal functioning of hydraulic valves, pump and failure of cylinder seals. This results in breakdown of the machine.
  • electrostatic oil filtration system is used. This system works continuously as long as hydraulic system is working.
  • This system removes, metallic, non-metallic, organic and in-organic particles from oil, ensuring very good quality of oil and continuous trouble-free working of the hydraulic system and, thus, the machine.
  • Machine is provided with centralized ergonomically designed control console. It consists of operator panel with colour display and various soft keys. Operator friendly HMI screens are provided for ease of operation. Machine can be easily operated using these screens and the soft keys.
  • the CNC control panel is air conditioned to ensure satisfactory working in the local ambient conditions. As shown in the drawings all the equipment is properly mounted to ensure trouble-free performance.
  • the foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
  • the present disclosure described herein above has several technical advantages including, but not limited to, the realization of a portal wheel lathe, which: • enables both simultaneous machining of both wheels and machining of a single wheel of the wheel set;
  • One of the object of the Patent Law is to provide protection to new technologies in all fields and domain of technologies.
  • the new technologies shall or may contribute in the country economy growth by way of involvement of new efficient and quality method or product manufacturing in India.
  • To provide the protection of new technologies by patenting the product or process will contribute significant for innovation development in the country. Further by granting patent the patentee can contribute in manufacturing the new product or new process of manufacturing by himself or by technology collaboration or through the licensing.
  • the Applicant submits that the present disclosure will contribute in country economy, which is one of the purposes to enact the Patents Act, 1970.
  • the product in accordance with present invention will be in great demand in country and worldwide due to novel technical features of a present invention is a technical advancement in portal wheel lathes for railway wheels.
  • the technology in accordance with present disclosure will provide product cheaper, saving in time of total process of machining. The saving in machining time will improve the productivity, and cost cutting of the process, which will directly contribute to economy of the country.
  • the product will contribute a new concept in machining, wherein patented process/product will be used.
  • the product is developed in the national interest and will contribute to country economy.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turning (AREA)

Abstract

La présente invention concerne un tour à roues à portique pour l'usinage de roues ferroviaires. Le tour à roues à portique comprend une paire de traverses d'attelage comportant un ensemble broche chacun, un système d'usinage de profil de bande de roulement, un distributeur hydraulique, un bâti à portique, un mécanisme d'entraînement et une unité de commande. La paire de traverses d'attelage (24) serre les roues pour l'usinage et subit un mouvement coulissant le long d'un axe de support de roues. Le système d'usinage de profil de bande de roulement comporte deux porte-outils séparés (18) pour l'usinage simultané des deux roues. Le bâti à portique est pourvu d'un portique pour l'insertion et le retrait des roues. L'unité de commande commande le fonctionnement du mécanisme d'entraînement, du système d'usinage de profil de bande de roulement et du distributeur hydraulique (31). Le tour à roues à portique a l'avantage de permettre l'usinage simultané des deux roues ainsi que l'usinage des faces interne et externe de la roue.
PCT/IB2020/055272 2019-06-04 2020-06-04 Tour à roues à portique WO2020245761A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201921022185 2019-06-04
IN201921022185 2019-06-04

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Publication Number Publication Date
WO2020245761A1 true WO2020245761A1 (fr) 2020-12-10

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WO (1) WO2020245761A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114247905A (zh) * 2022-02-09 2022-03-29 浙江华壹钢业有限公司 合金钢法兰自动定位车削装置
RU2794650C1 (ru) * 2022-09-16 2023-04-24 Общество с ограниченной ответственностью проектно-конструкторское бюро "Горизонт" Станок для обточки колёсной пары

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0598181B1 (fr) * 1992-11-17 1996-09-18 HEGENSCHEIDT-MFD GmbH Méthode pour l'usinage d'une paire de roues et dispositif utilisant cette méthode
WO2008061937A2 (fr) * 2006-11-23 2008-05-29 Hegenscheidt-Mfd Gmbh & Co. Kg Tour à essieux montés à portique

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0598181B1 (fr) * 1992-11-17 1996-09-18 HEGENSCHEIDT-MFD GmbH Méthode pour l'usinage d'une paire de roues et dispositif utilisant cette méthode
WO2008061937A2 (fr) * 2006-11-23 2008-05-29 Hegenscheidt-Mfd Gmbh & Co. Kg Tour à essieux montés à portique

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114247905A (zh) * 2022-02-09 2022-03-29 浙江华壹钢业有限公司 合金钢法兰自动定位车削装置
CN114247905B (zh) * 2022-02-09 2023-05-26 浙江华壹钢业有限公司 合金钢法兰自动定位车削装置
RU2794650C1 (ru) * 2022-09-16 2023-04-24 Общество с ограниченной ответственностью проектно-конструкторское бюро "Горизонт" Станок для обточки колёсной пары
RU221168U1 (ru) * 2023-08-10 2023-10-24 Общество с ограниченной ответственностью "Инженерная компания Комплекс-Центр" Колесотокарный станок

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