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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).
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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
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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
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Final Inspection Line data
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Annual capacity, wheels per year
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350000
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Annual running time, hours
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6855
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Line cycle, sec per piece
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70
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Line capacity, pieces
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115
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Conveying equipment weight, t
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500
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Conveying equipment capacity, kW
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500
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External wheel diameter, mm
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790...1260
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Wheel mass, kg
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350...1100
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The automated inspection line executes the following technical functions:
Preparation of wheels for acceptance testing:
- Chemical treatment of the wheel surface
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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
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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
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Additional technical operations:
- Roto-blast (shot blasting) treatment of wheel disks to improve endurance and strength
- Anticorrosive protective coating of wheels
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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
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Line Operation Description
PFD
PCS Structure