對鐵路動車組輪軸檢修工藝及裝備的探討_圖文

1、設備檢修從2007年4月18日中國鐵路首次在既有鐵路干線上開行200km/h 以上動車組列車以來,至今已有CRH系列4種動車近200組(8輛編組上線,并陸續(xù)擴展到新建成的鐵路客運專線上運行。部分動車組已運營近2年,到了3級修修程(按鐵道部統一規(guī)定動車組檢修實施15級修。根據測算:到2012年,我國鐵路營業(yè)里程將達到11萬k m,其中客專1.3萬km要建成投入運營,需要運營動車組800組以上。因此,加速建設中國鐵路動車組檢修基地已迫在眉捷。在動車基地總平面布局、檢修板塊的主工藝流程基本確定情況下,如何細化,如轉向架輪軸等重大部件的檢修工藝流程和布局,選好關鍵設備(功能、技術參數、相關尺寸等尤為關

2、鍵。1輪軸檢修總體設計思想現代化鐵路動車組檢修基地設計,應堅持“先進、成熟、經濟、適用、可靠”的技術方針,科學合理布局,采用先進檢修工藝及裝備,縮短動車組在基地內停修時間,努力降低維修成本,提高運營可靠性,確保動車組具有良好運行狀態(tài)。具體體現如下。(1滿足檢修工藝要求?？v觀C R H系列4種動車組車型的性能、結構、技術參數及相關尺寸,提出輪軸解體、檢修、組裝檢修流水線的作業(yè)工序及各工序配置設備在檢修區(qū)的合理布局,實現節(jié)奏合拍,工序流、物流、信息數據流的順暢,從而達到安全高效的目的。(2滿足檢修能力需求。檢修線上配置的設備能力在滿足檢修設計工作量需要的同時,要考慮臨修作業(yè)的需要,并按耗時最大工序

3、(節(jié)拍時間和每天有效工時進行計算。(3具有較高的設備兼容性。檢修線各設備基本上應能兼容C R H系列動車組車型,滿足輪軸檢測、檢修、試驗的需要,但個別需要增加部分工序和輔助工裝。(4工藝結構要符合人機工程學理念。從提高檢修作業(yè)效率、降低作業(yè)人員強度、節(jié)約車輛運營維修成本角度,應優(yōu)先選用符合人機工程學理念的先進、高效、實用的設備。2輪軸檢修工藝分析參照國外車輛制造商檢修工藝經驗,結合我國鐵路車輛檢修做法,提出了以更換損壞或到期零部件與修復相結合的輪軸解體、組裝檢修流水線工藝方案。2.1CRH系列動車組輪軸主要技術參數及結構CRH型動車組輪軸主要技術參數見表1,C R H型動車組動、拖車輪軸外形結

4、構見圖15。2.2輪軸分解流水線2.2.1作業(yè)內容輪軸分解流水線要完成C R H系列各型動車組輪對的部件拆卸、除銹、脫漆、車軸清磨、清洗、檢測、齒輪箱供油、車輪踏面及制動盤端面鏇修、齒輪箱排油等作業(yè)。2.2.2工藝流程根據4個動車檢修基地輪軸檢修(35級修工作量測算,每一基地日檢修輪軸數近期約3040對,遠期5065對?？紤]到檢修區(qū)工藝布局,以設置輪軸分解流水線23對鐵路動車組輪軸檢修工藝及裝備的探討邱建平摘要:對中國鐵路動車組輪軸檢修工藝和裝備選型進行分析研究,重點介紹總體設計思想、輪軸解體流水線、組裝流水線的工藝流程、平面布局、工裝設備配置原則、關鍵設備選擇等,提出了動車組檢修基地輪軸車間

5、檢修工藝和設備配置初步意見。關鍵詞:動車組;輪軸;檢修工藝;檢修設備邱建平:中鐵第四勘察設計院集團有限公司設備設計處,副總工程師,高級工程師,武漢430063表1動車組輪軸相關數據m m 名稱C R H1C R H2C R H3C R H5車輪直徑(括號內915(835860(790動車920(830890(810是磨耗后的極限值拖車920(860車輪寬度135135135135輪孔直徑動車204.8±0.015201192拖車195.8±0.015196192輪制動盤直徑640725750輪制動盤厚度135133軸制動盤直徑640670640640軸制動盤厚度110978

6、0車軸內孔60603065軸頸直徑130130130130軸身直徑170192166166車軸總長(動車/拖車2250/22502298/23822180/21802180/2180軌距1435143514351435固定軸距2700 2 5002 5002 700圖 1 CRH1動車輪對圖2CRH1拖車輪對圖3CRH2動車及拖車輪對條為宜。輪軸分解流水線工藝流程見圖6。2.2.3平面布局按照輪軸分解線主要工序,設定在轉向架輪軸檢修區(qū)的合理布局,既要滿足輪軸分解的檢修工藝要求,又要滿足上下工序之間有序銜接,保證工序流、物流、信息數據流的順暢。輪軸檢修分解線平面布局見圖7。2.3輪軸組裝流水線2

7、.3.1作業(yè)內容輪軸組裝線要完成C R H系列各型動車組輪對組裝檢修作業(yè),它包括輪對壓裝、電阻測試、輪對檢壓試驗、空心軸探傷、齒輪箱清洗(預圖6輪軸分解線工藝流程圖安裝支承輪聯軸器拆卸軸箱拆卸收入檢查3級修動輪是齒輪箱排油清洗否齒輪箱排油C R H2輪對是否軸端螺母拆卸軸端螺栓拆卸軸承拆卸C R H3輪對除漆清洗C R H3涂裝剝離輪軸清磨是否輪對自動測量空心軸探傷3級修是否車軸磁粉探傷車軸磁粉清洗齒輪箱供油踏面摩擦面鏇修3級修是否車軸油漆烘干組裝線齒輪箱排油輪軸分解車輪線、車軸線-0.035-0.035圖7輪軸分解線平面布局圖留、齒輪箱注油、車輪踏面及制動盤端面鏇修、車輪探傷、動平衡試圖8輪

8、軸組裝檢修流水線工藝流程圖圖9輪軸組裝檢修流水線平面布局圖驗、輪對涂漆烘干、軸頸清洗打磨、軸頸測量、軸承存放及壓裝、軸端螺母組裝、C R H 3型涂抹密封膠、軸箱組裝、聯軸節(jié)及接地裝置組裝、輪對回轉試驗、輪對與構架組裝等。2.3.2工藝流程輪軸組裝流水線數量同樣按各基地輪軸任務量配備,一般設2條線平行布置,輪軸組裝檢修流水線工藝流程見圖8。2.3.3平面布局輪軸組裝檢修流水線由控制、物流、工位、工裝設備等有序組成,其中輪對組裝控制系統具有數據分析處理功能,每個工位都有數據讀取軸端信息,并自動顯示功能,檢修內容上傳至數據庫,為后續(xù)工位的檢修提供依據。輪軸組裝檢修流水線平面布局見圖9。檢修后的車軸

9、輪軸選配系統選出的車輪輪對壓裝電阻測試輪對檢壓試驗空心軸探傷齒輪箱注油1型車3級修輪對車輪、制動盤鏇修車輪探傷輪對動平衡試驗輪對涂漆及烘干軸頸清洗打磨軸頸測量軸承壓裝軸端螺母組裝1、2型車輪對3型車涂抹密封軸箱組裝聯軸節(jié)及接地裝置組裝輪對回轉試驗通過天車將檢測不合格的輪對吊到組裝工位上進行分解空心軸探傷齒輪箱去油清洗踏面鏇修輪軸涂裝剝離信息機房配電所車軸輸送小車輪對檢壓試驗檢壓等待空心軸探傷齒輪箱注油車輪、制動盤鏇修輪軸組裝線輪對組裝檢修方向車輪探傷動平衡試驗軸頸清洗打磨輪對3級修進入方向輪對進入方向軸承地下傳輸通道輪對涂漆及烘干軸承壓裝移動式軸承退卸機軸徑測量軸端螺母組裝軸箱組裝聯軸節(jié)組裝輪

10、軸組裝線輪對組裝檢修方向輪對回轉試驗輪軸組裝輪對壓裝同溫線同溫線車軸檢修后進入方向車輪進入方向電阻測試輪對輸送車去往輪軸分解齒輪箱排油3級修去往組裝線齒輪箱供油車軸磁粉清洗車軸探傷預留輪對自動檢測車軸清磨輪對除銹清洗軸承拆卸軸端螺栓拆卸收入檢查軸箱退卸聯軸節(jié)及接地裝置拆卸輪對輸送車輪對組裝檢修方向 軸承存放3輪軸檢修關鍵工藝裝備3.1輪軸檢修工藝裝備配置原則(1適應車型及修程需要。全路4個動車組檢修基地配置車型略有不同,初步考慮每個基地承擔12個主型車型,12個兼容車型。因此,每個基地需要承擔主型車全部修程(35級修,兼容車型3級修。(2在百余項工裝設備中,自主開發(fā)的項目或核心部件需要引進的設

11、備,有條件時應優(yōu)先選用一機多用。例如,輪軸壓裝機不僅要實現車輪、大齒輪、制動盤轂與車軸的冷壓組裝和高壓油組裝,同時能實現車輪、大齒輪、制動盤轂和車軸的注油分解和輪對組裝后的檢壓測試。又如,車輪車床要選用既能加工車輪踏面,又能加工制動盤端面的設備。(3按照動車組基地檢修需求,不斷改進和自主開發(fā)設備,量身定做;核心部件應采用國際知名專業(yè)廠商的優(yōu)質產品;對引進設備部分功能盡快國產化配套,使性能更可靠,功能更強大。(4要有完善配套設施。除主機和附屬裝置外,配套設施應包括設備基礎,風、水、電引入節(jié)點和廢汽、污水排放點等。3.2輪軸檢修設備配置為了便于分析,以主修CRH2、3型動車組輪軸為例,提出設備配置

12、。輪軸分解線設備見表2。輪軸組裝線設備見表3。除各工位對應的設備外,在輪軸分解和組裝線上還有輪軸分解和組裝線控制系統、輪對輸送車、輪對轉盤、扭矩測試儀、通用工具等設備。3.3關鍵設備選擇(1輪軸分解、壓裝、檢壓設備。除C R H1型動車組輪軸組裝采用熱裝工藝外,其余車型輪軸分解、組裝均采用高壓注油工藝。通過比選,初步確定選用德國生產的輪軸分解、壓裝檢壓設備,該機擁有先進成熟的液壓伺服技術、精確的測量系統、先進的壓力補償功能以及可實現分解、組裝、檢壓車輪和制動盤表2輪軸分解線設備工位名設備名稱聯軸節(jié)與接地裝置拆卸齒輪聯軸節(jié)及接地裝置拆卸軸箱退卸軸箱退卸機收入檢查輪對預檢和建檔裝置齒輪箱去油清洗齒

13、輪箱排油裝置齒輪箱高低速油清洗機軸端螺栓拆卸軸端螺母拆卸裝置軸承拆卸軸承退卸機輪對除銹清洗輪軸除銹清洗機車軸清磨車軸清磨裝置C R H3輪軸涂裝剝離C R H3輪軸涂裝剝離裝置輪對自動檢測輪對尺寸自動檢測機空心軸探傷空心軸超聲波探傷機車軸磁粉探傷輪對磁懸液探傷機車軸磁粉清洗磁粉清洗裝置齒輪箱供油齒輪箱注油機(移動式車輪制動盤鏇修車輪車床齒輪箱排油齒輪箱排油裝置表3輪軸組裝流水線設備工位名設備名稱輪軸預組裝裝置輪對壓裝輪對壓裝機輪輞內側距檢測器輪位差檢測工裝電阻測試輪對接地電阻測量裝置輪對檢壓試驗輪對檢壓機空心軸超聲波探傷機耦合劑容器防銹油容器空心軸探傷清除耦合劑工具涂抹防銹油工具標定軸及托架轉

14、輪撥輪器工具柜齒輪箱注油齒輪箱注油機扭力矩扳手車輪、制動盤車床車輪、制動盤鏇修工具柜電動砂輪機車輪探傷固定式輪輞輪輻超聲波探傷機標定輪動平衡試驗動平衡試驗機轉輪撥輪器輪對涂漆及烘干輪對涂漆烘干裝置軸頸清洗打磨軸頸清洗打磨裝置標記鋼印軸頸測量軸頸測量裝置軸承同溫存放架軸承內孔測量裝置軸承壓裝工具柜軸承壓裝裝置軸承輸送裝置軸端螺母組裝裝置軸端螺母組裝扭力矩扳手螺栓、螺母托盤電動扳機C R H3型車涂輪對舉升裝置抹密封膠軸箱組裝機螺栓等存放架軸箱組裝扭力矩扳手電動扳機軸箱、螺栓托盤聯軸節(jié)及接地聯軸節(jié)組裝裝置聯軸節(jié)托盤裝置組裝感應加熱器輪對回轉試驗輪對回轉試驗裝置的功能。該設備的主要參數如下。高壓油分

15、解:最高壓力>200 MPa,最大推力2500kN。高壓油組裝:最高壓力160M P a,最大推力2500kN。最大檢壓力為1600kN。(2輪對尺寸自動測量機(非接觸高精度測量系統。引進了瑞士生產的體積精巧的線性傳感器,并就不同的測量位置設置了不同的驅動程序,使專用測量元件能實現水平、垂直兩方向的移動,從而全面兼容4種CRH 車型。該產品采用線性CCD 成像技術,元件自身的測量精度可達±0.01mm,整個系統的測量精度為±0.05mm。(3車軸尺寸測量機(接觸高精度測量系統。該機引進了德國生產的高精度光柵長度計作為直徑測量元件,從根本上保證了測量尺寸的可靠性和真實性

16、。(4空心軸超聲波探傷機。2008年4月我國已研制開發(fā)出適合C R H 系列動車組空心軸超聲波探傷作業(yè)的探傷機,其關鍵部件采用德國產品,經過西安、南昌等6個動車運用所使用,設備運行穩(wěn)定。(5車輪探傷機。德國新近研制出的相控陣探頭,能對車輪輪輞、輪幅及其兩者過渡區(qū)進行無損檢測,能調節(jié)探頭的入射角及聚焦深度范圍,從而使得探頭數量大為減少,整個探頭系統結構緊湊,操作靈活,圖像完整細微,便于缺陷評估分析等,該設備特別適合帶有輪裝制動盤的車輪。4結論(1輪軸分解、組裝采用流水作業(yè)檢修方式,集控制、物流、設備、工位等一體的檢修線模式。(2流水線上按工序配置的設備要確保整個系統功能可靠、能力滿足要求、物流自

17、動快速、工序柔性安全、維修操作方便,其總體技術水平要達到當今國內外同類產品的領先水平。(3引進核心部件的設備,要逐步進行國產化配套,有條件時應盡快形成具有自主知識產權的產品。收稿日期2009-02-25 d =2(l2+(l -h 22(4(上接第24頁有關的斜剖面圖,由于傳感器相對于鋼軌的安裝位置是固定的,而車輛運行速度已知,因此,通過幾何運算,可以得到二維的車輪外形圖,并可分別計算輪緣高度和輪緣厚度。3.4輪徑測量鋼軌外側安裝了2只激光位移傳感器,其安裝角度為36°,分別掃描出輪緣及踏面的端面后,在速度已知的條件下,可得到弦長l ,而兩激光束高度h 可以通過激光位置傳感器測量系統

18、測量得到,通過幾何運算可得車輪直徑d (圖8。3m,而且傳感器安裝結構設計要保證與鋼軌的電氣絕緣。(2傳感器防護。由于地鐵環(huán)境內存在部分的粉塵,作為一種光學檢測設備,激光位移傳感器必須采取一定的防護措施。防護機構應安裝在預留設備坑里,防護門由轉角電機控制,當控制系統檢測到來車時,打開防護門,實現探測,平時防護門處于關閉狀態(tài)。(3設備限界要求。設備安裝前應進行尺寸測算,仔細確認所涉及的安全限界,標出全部的限界尺寸,保證所有設備均不得侵入地鐵車輛、設備限界,以免影響地鐵列車的安全運行。(4設備防電磁干擾要求。所有設備應具有防電磁干擾的能力,且不能對地鐵車輛上安裝的各類設備及地鐵地面上安裝的各類設備

19、造成干擾。(5設備自保護要求。系統應具有自保護功能,其原始數據任何情況下均不得丟失(可實時自動轉存,且任何人均無法修改。電路的設計應保證當其某一元器件發(fā)生故障時,對系統中任何其他元器件帶來的間接損壞為最小,同時應保證系統的故障不擴大化。(6系統報警軟件設計時,需根據實際合理設置報警條件,增加標準參數與實測參數的對比曲線,避免誤報警次數太多,增加不必要的人工檢查次數。收稿日期2008-12-29圖8輪徑測量示意圖hl4注意事項(1傳感器安裝。所有傳感器的安裝必須方便可靠,不得大范圍破壞現有路軌條件的基礎施工(傳感器安裝基礎施工橫跨路軌范圍ABSTRACTS Applying the Scient

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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