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Rail Wheels Final Inspection Line (FIL-1)

The Final Inspection Line (FIL) for railroad wheels was designed to perform acceptance testing of railroad wheels with full-profile mechanical surface treatment in accordance with Russian and International standards (GOST 9036-88, GOST 10791-2004, ISO 1005-6-94).

Within the framework of this project SME Tomsk Electronic Company being a General Contractor provided the following services:

  • Technical requirements generation for process units of the line
  • Process plan development including construction task preparation
  • Designing PCS, data communications networks, video control systems and dispatch systems
  • Selection and process units supply in accordance with the technical requirements worked out and approved by the Customer
  • Development of construction documentation and manufacture of the equipment for conveying system
  • Installation supervision and commissioning including connection with the ultrasonic unit supplied by the Fraunhofer Institute for Applied Research

Introduction of Wheels Final Inspection Line enabled:

  • Increasing the annual capacity and improving products quality
  • Fully automating railroad wheels acceptance test cycle
  • Changing-over to production of railroad wheels in accordance with the relevant worldwide standards
  • Information tracking and forming a full electronic certificate of the wheel with the records of all parameters and properties of the wheel (paint quality, roto-blast hardening, internal structure etc.) and control of its travel along the handling line
  • Integrating data transmission system and the existing shop network for creation of the unified data transmission infrastructure for the entire shop floor. This network combines such applications as: data file transfers, video transmissions, and digital speech communications

Final Inspection Line data

 Annual capacity, wheels per year

350000

 Annual running time, hours

6855

 Line cycle, sec per piece

70

 Line capacity, pieces

115

 Conveying equipment weight, t

500

 Conveying equipment capacity, kW     

500

 External wheel diameter, mm

  790...1260

 Wheel mass, kg

   350...1100  

The automated inspection line executes the following technical functions:

Preparation of wheels for acceptance testing:

  • Chemical treatment of the wheel surface

Transporting individual wheels on the sector processing chain:

  • Un-stacking and handling of individual wheels along the transportation line
  • Wheel handling and tilting
  • Handling of wheels for process operations
  • Preparation of wheels for overhead crane transportation (stack assembly, or stacking into holder)
  • Stack assembly of discarded (unacceptable) wheels

Performance of acceptance process operations:

  • Identification of wheel marking
  • Control of wheel geometry parameters (optional)
  • Visual inspection for surface defects and wheel geometry
  • Ultrasonic inspection for internal flaws
  • Magnetic particle inspection of the wheel surface for surface connected flaws (random, up to 50% - 175,000 wheels/year)
  • Control of residual voltage (optional)
  • Hardness testing of the wheel rim butt-end (single point)
  • Wheel check by customer representatives

Additional technical operations:

  • Roto-blast (shot blasting) treatment of wheel disks to improve endurance and strength
  • Anticorrosive protective coating of wheels

Information tracking of railroad wheels acceptance test:

  • Control of handling operations
  • Compilation of wheel certification
  • Display of operational data at workstations
  • Assembly of test/acceptance information databases
  • Diagnostics/testing of test equipment functionality

Line Operation Description

PFD

PCS Structure