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Systema de Purificatio per Alimentationem Transversam in Forma U pro Rotis Ferroviariis pro Fabricatione Rerum Velocissimarum et Gravissimarum
Solutio clavis-in-mano ad libitum pro fabricante maximo rotarum ferroviariarum
Applicatio: Purificatio Rotarum Ferroviariarum pro Altis Velocitatibus et Magnis Onibus — Processus Primarius et Post Inspectionem Particularem Magneticam
Workpiece: Rotae Ferroviariae — Diameter 860–1 320 mm, Pondus ≤1 000 kg
Processus Purificationis: Remotio Etiquettarum Sub Alta Pressione (33 MPa) + Purificatio Sub Basse Pressione (2,0 MPa) + Lavatio per Aspersionem + Siccatio per Flumen Aerae + Siccatio per Cultrum Aeris
Pressio purgationis: Pressio Bassa ≥2,0 MPa / Pressio Alta ≥33 MPa (Remotio Etiquettarum) — ad libitum
Cleaning Temperature: 40–60°C (Calefactio Electrica) — personalizabilis
Tempus cycli: ≤120 secunda per partem — ad libitum secundum necessitates lineae productionis
Cleanliness Requirement: Residuum Aquae ≤0,1 mg/kg; Residuum Metallicum ≤2 mg/kg (aut Metrum Munditiae ≥70 % in medio) — ad libitum secundum necessitates clientis
Drying Technology: Siccatio per Flumen Aerae + Siccatio per Cultrum Aeris
Filtration System: Filtratio Quattuor Graduum (40 Mesh / 20 μm / 10 μm) + Filtrum Cinguli Papiracei — ad libitum
Impositio/Expositio: Automatica (Interfacs Robotis Ganeae) — ad libitum
Configuratio Systematis: Duo Systemata Purificationis — Prima Statio (Purificatio Ante Inspectionem) + Secunda Statio (Purificatio Post MPI)
DESCRITIO
Systema de Purificatio per Alimentationem Transversam in Forma U pro Rotis Ferroviariis
Systema Industriale Purificationis Rotarum Ferroviariarum 'The Big Bird' est elaboratum ad purgationem efficacem rotarum ferroviariarum, quae in fabricatione rerum velocitatis altissimae et onerum gravium utuntur. Systema duos stationes purgationis continet: prima statio, quae in initio lineae inspectionis sita est, fluida sectionis, fluida protectionis processus, oleaginosa contaminantia et etiquettas processuales removet; secunda statio, quae post inspectionem particulae magneticas sita est, fluida inspectionis particulae magneticas removet.
The equipment is provided as a turnkey solution including design, manufacturing, installation, and commissioning.
Workpiece Applications
Systema componentes rotarum ferroviariarum suscipit:
| Parametrus | Specificatio |
|---|---|
| Diameter Rotae (cum flangia) | 860–1 320 mm |
| Diameter Tractionis | 800–1 260 mm |
| Crassitudo Totalis | 130–260 mm |
| Latitudo rimorum | 120–150 mm |
| Longitudo axis | 140–230 mm |
| Diameter Foraminis Axis | 150–230 mm |
| Maximum Rim-to-Hub Distance | ≤80 mm |
| Pondus singulare | ≤1,000 kg |
| Main Product Sizes | φ840, Φ860, Φ915, Φ920, Φ1260 wheels |
| Product Shapes | S-web, Corrugated-web, Inclined, Straight, Stepped-web |
All workpieces are railway wheels for high-speed rail and heavy-haul applications. The system is designed to handle a wide range of wheel sizes and shapes with manual changeover ≤10 minutes.
Two-Station Cleaning Configuration
Prima Statio Purificationis (Linea Prae-Inspectionis)
Situs in primo processu lineae inspectionis, haec statio removet contaminantes a superficiebus rotarum, quae accumulantur dum machinatur et servatur:
Liquida sectionis et liquida protectionis processus
Contaminantes olei et graxis
Pulvis et Particulae
Etiquettas processus ab superficiebus tractus
Haec statio combinat altam pressionem ad removendum etiquettas (33 MPa) cum pulverisatione lavativa ad pressionem infimam (2.0 MPa) pro purificatione completa.
Secunda Statio Purificationis (Post-MPI)
Situs post inspectionem per particulas magneticas, haec statio removet liquida inspectionis per particulas magneticas ab superficiebus rotarum post examen non-destructivum.
Utraque statio habet configurationem U-formis trans-ductus cum positione verticali rotarum super palletis.
Productio automatica mixta modello
Hoc systema suadet integratum productionem plene automaticam cum:
Automatic Loading/Unloading
First Station: Interfaced with gantry robot #1 (angled gripper)
Second Station: Interfaced with gantry robot #4/#5 (straight gripper)
Vertical wheel positioning on locating pallets
Automatic Model Changeover
Changeover time ≤10 minutes with changeover procedures designed for all wheel variants.
Integratio Processus
Full automatic operation with PCS system control
Material tracking and production data upload
Safe interlock with gantry robot systems
Multi-Stage Cleaning Process — First Station
Gradus 1: Onus
The gantry robot places the wheel vertically onto the locating pallet. The motor-driven conveyor transfers the wheel and pallet to the cleaning chamber. The process label is positioned in the upper area of the wheel via pre-scanning for optimal high-pressure removal.
Gradus 2: Remotio Etiquettarum Sub Alta Pressione (33 MPa)
Ductus sub alta pressione, positos supra rotam, adhibent aquam ad pressionem 33 MPa ut etiquettas processuales a superficie treads removant. Systema sub alta pressione in clausura phonoabsorbente inclusum est, ut sonus infra 80 dB maneat.
Gradus 3: Pulverizatio Sub Basse Pressione (2,0 MPa)
Ductus pulverizantes oscillant per superficiem rotae ut liquida sectionis, liquida protectionis processualis, olei contaminantes et particulae removantur. Pulverizatio sub basse pressione certificat amplitudinem integram cum alto fluxu.
Gradus 4: Lavatio per Pulverizationem
Rota lavatur per pulverizationem ut contaminantes soluti et residua liquidi lavantis removantur.
Gradus 5: Asciugatio per Flumen Aeris
Ductus aeris ad altam velocitatem umorem residuum a superficie rotae et ab internis cavitatibus removunt.
Gradus 6: Asciugatio per Aeris Gladium
Gladii aeris asciugationem finalem praebent, ut rota omnino sicca sit pro inspectione dimensionali subsequente. Temperatura effluentis regitur ut ≤40°C maneat, ad exactam mensuram dimensionalem.
Multi-Stage Cleaning Process — Second Station
Gradus 1: Onus
The gantry robot places the wheel vertically onto the locating pallet.
Stage 3: Empty Station (Buffer)
The wheel is staged at the empty station to allow for smooth production flow.
Stage 3: Spray Cleaning (2.0 MPa)
Spray nozzles oscillate across the wheel surface to remove magnetic particle inspection fluids from all surfaces.
Stage 4: Blow-Drying
High-velocity air nozzles remove residual moisture from the wheel surface.
Stage 5: Air Knife Drying
Air knives provide final drying to ensure the wheel is completely dry for subsequent operations.
High-Pressure Label Removal Technology
The first cleaning station features specialized high-pressure technology for label removal:
| Parametrus | Specificatio |
|---|---|
| Pressio purgationis | ≥33 MPa |
| Pompa alti pressionis | Uraca EP-36-28-4D, 60 L/min, 37 kW |
| Nozzle Coverage | Full tread surface coverage |
| Sonitus Imperium | Soundproof enclosure (<80 dB at 1 meter) |
| Normae Conformitatis | GB/T 14976-2012, GB/T 12771-2019, GB/T 28708-2012, GB/T 10544-2022 |
Controlus Puritatis Technicae
For railway wheel manufacturing, cleanliness affects both dimensional inspection accuracy and final product quality.
Systema ad strictas exigentias munditiae designatum est:
| Area requisiti | Specificatio |
|---|---|
| Water Residue | ≤0.1 mg/kg (verified by tissue paper weight difference) |
| Metallic Residue | ≤2 mg/kg (2L test fluid at 0.2 MPa, 5 μm filter membrane) |
| Puritas superficiei | Cleanliness meter ≥70% average (5-point measurement) |
| Inspectio visualis | No large water spots on wheel surfaces |
| First Station Outlet Temperature | <40°C |
| Fluid pH Range (within change cycle) | 6.8–9.5 |
Gestio Advanced de Filtratio
First Station Filtration System (Four-Stage)
| Genus Filtrum | Capacity | Accuratio | Applicatio |
|---|---|---|---|
| Basket Filter | 300 L/min | 40 reticulum | Primary filtration (3 units) |
| Filtrum Cinguli Papirei | 600 L/min | — | Filtratio Secundaria (1 unitas, removens etiquettas papireas) |
| Sacculum filter | 300 L/min | 20 μm | Filtratio Tertia (2 activae + 1 in expectacione) |
| Filtrum Saccus In-Line | 300 L/min | 10 μm | Filtratio Quarta (1 activa + 1 in expectacione) |
Fluxus Filtrationis:
Cisterna Purificationis: Cestus → Pompa Reditus → Filtrum Cinguli Papirei → Cisterna Prima → Pompa Filtrationis → Filtrum Sacculare In-Line → Pompa Auxiliaris → Cisterna Secunda → Filtrum Sacculare → Pompa Altae Pressionis
Cisterna Lavationis: Cestus → Cisterna Lavationis → Pompa Lavationis → Filtrum Sacculare In-Line
Systema Filtrationis Stationis Secundae (Cum Separatore Magnetico)
| Genus Filtrum | Capacity | Accuratio | Applicatio |
|---|---|---|---|
| Basket Filter | 300 L/min | 40 reticulum | Primary filtration (3 units) |
| Filtrum Cinguli Papirei | 500 L/min | — | Filtratio Secundaria (1 unitas) |
| Filtrum Sacculare (Cum Virgis Magneticis) | 300 L/min | 20 μm | Filtratio tertia (1 activa + 2 in expectacione) |
| Separator magneticus | 200 L/min | — | Filtratio quarta (1 unitas, removens particulas magneticas) |
Fluxus Filtrationis:
Cisterna purgationis: cestus → pompa reditus → filtrum fasciculi papyracei → cisterna prima → pompa filtrationis → cisterna secunda → filtrum sacci
Intelligent Manufacturing Integration
Systema ad requisita Industriae 4.0 suffragat per integram connexione datorum:
Communicatio inter PCS et MES
Protocolum communicationis PROFINET
Commutatio datorum per TCP/IP cum systemate PCS
Transmissio datorum productionis, status machinarum, et datorum qualitatis
Acquisitio datorum per OPC UA
Integratio Hardware
Conectora Harting 24-pin pro signis securitatis (3 copiae)
Accoplatora PN/PN pro communicatione PROFINET
Interblocco di arresto di emergenza con sistemi robotici a portale
Interfacing operatoris
Schermo tattile Siemens TP1200 HMI
Controllo dell’attrezzatura, impostazione dei parametri e analisi grafica
Tracciamento e caricamento delle informazioni sul pezzo in lavorazione
Diagnosi dei guasti e visualizzazione degli allarmi
Applicationem Causa
| Parametrus | Stazione Prima | Stazione Seconda |
|---|---|---|
| Project | Principale produttore di ruote ferroviarie — Sistema di pulizia a passaggio continuo a forma di U (2 unità) | |
| Workpiece | Ruote ferroviarie — Φ860–1.320 mm, ≤1.000 kg | |
| Exolvuntur tempore | ≤120 secondi/pezzo | ≤120 secondi/pezzo |
| Technologiae Purificationis | HP 33 MPa + LP 2.0 MPa + Rinsing + Drying | LP 2.0 MPa + Rinsing + Drying |
| Temperatura de purgatio | 40–60°C | 40–60°C |
| Summa potentia | 185 kW (Heater 90 kW) | 102 kW (Heater 45 kW) |
| Capacitas vasculi | 3,700 L | 2,200 L |
| Air comprimé | 8 Nm³/min | 8 Nm³/min |
Solutio Purificationis Completa
Big Bird Industrial praebet solutiones technicas comprehensivas, inter quas:
Developementum Processus
Component analysis for railway wheels
Cleaning process design for inspection line integration
Aestimatio necessitatum de munditia
Integratio Instrumentorum
U-type through-feed cleaning systems
High-pressure label removal technology (33 MPa)
Systema de purgatio per pulverisationem ad pressionem parva
Gestio multifasa filtrationis
Systema de tractatio per convectores et palletas
Coniunctio Fabricationis Intellegentis
Interfacies inter PCS et MES
Acquisitio datum productionis
Custodia et reperibilitas materialis
Cur Big Bird Industrial eligeres
Experientia de purgatio rotarum ferroviariarum
Big Bird Industrial specializatur in solutionibus de purgatio praecisa pro fabrica componentium ferroviarium, cum experientia probata in purgatione rotarum pro applicatis velocitatis altissimae et oneris gravissimi, ubi opera usque ad diametrum 1 320 mm et pondus 1 000 kg tractantur.
Technologia U-Type Through-Feed
Configuratio U-type permittit utilitatem efficientem spatii soli cum oneratione et deoneratione automatica ex eodem latere. Positio verticalis rotarum et translatio per palletas garantunt tractationem stabilem pro magnis et gravibus componentibus.
Remotio Etiquettarum ad Pressionem Altam (33 MPa)
Hoc systema habet technologiam specialem ad pressionem altam (33 MPa) pro remotione efficaci processualium etiquettarum ab superficiebus rotarum. Inclosura sonorifuga certificat ut sonus sit infra 80 dB ad distantiam unius metri.
Solutio Clavis-in-Manu Bistationis
Hoc opus duas perfectas systematum purgationis machinas praebet ut solutio clavis-in-manu, quae utramque purgationem — ante inspectionem (ad eliminandos contaminantes et etiquettas) et post inspectionem per particulas magneticas (ad removendos liquores particularum magneticarum) — in uno eodem opere complectitur.
Capacitas Ingenieriae ad Nivellem Systematis
Haec societas solutiones integras praebet, a developmente processus purgationis usque ad integrationem in productione, inter quas purgatio altae pressionis, administratio filtrationis, integratio PCS/MES, et interfacies robotis ganeae.
Customized Non-Standard Engineering
Each component and production line has unique requirements. Big Bird Industrial provides customized engineering solutions based on:
Component structure and material analysis
Evolutio Processus Purgationis
Customized fixture and automation design
Factory layout and production flow integration
Întrebări frecvente
Quae componentia hoc systema purgat?
Hoc systema ad rotas ferroviarias, quae in fabrica velocitatis altissimae et oneris gravissimi utuntur, designatum est — diametri 860–1 320 mm, pondera usque ad 1 000 kg.
Quid configurationis bistationis includit?
Systema duas stationes purgationis includit: Stationem 1 in primo processo lineae inspectionis (ad removendos liquores sectionis, liquores protectionis processus, oleum, et etiquettas); Stationem 2 post inspectionem per particulas magneticas (ad removendos liquores particularum magneticarum).
Quae pressio purgationis disponibilis est?
Pulverizatio ad pressionem parvam (2,0 MPa) pro munditia communis. Statio 1 etiam habet pulverizationem ad pressionem magnam (33 MPa) ad tollendas tabellas processuales ab superficiebus tread.
Quae contaminantia removeri possunt?
Hoc systema tollit liquida sectionis, liquida protectionis processualis, oleum/grasum contaminans, pulverem, tabellas processuales, et liquida inspectionis particulae magneticis ab superficiebus rotarum.
What cleanliness levels can be achieved?
Residuum aquae ≤0,1 mg/kg; residuum metallicum ≤2 mg/kg (aut metrum munditiae ≥70%); nullae maculae aquosae magnae; temperatio egressus Stationis 1 <40°C.
Num integratio productionis automaticae suportatur?
Ita. Hoc systema interfacit cum robotibus gantry pro onerando/deonerando automatico et cum systematibus PCS/MES pro observatione datorum productionis et traciabilitate materialis.
What is the typical cycle time?
Hoc systema confert ≤120 secunda per partem, subtenens productionem rotarum ferroviariarum magni voluminis.
Purificatio Rotarum Ferroviariarum in Fabricatione Rerum Velocitatis Altissimae
Purificatio rotarum ferroviariarum est processus criticus inter fabricandam et inspectionem finalem in fabrica velocitatis altissimae et oneris gravissimi. Rotae usque ad 1320 mm diametri et 1000 kg pondus technologias purgationis provectas postulant ut liquores sectionis, liquores protectionis processus, contaminantes oleosi, et notae processus ante inspectionem dimensionalem removantur, atque liquores particulae magneticis post examen non-destructivum. Systemata purgationis U-formis per-fluentia efficienter integrari possunt in lineas productionis automaticas.
High-Pressure Label Removal Technology
Notae processus in superficiebus rotarum necessitant technologiam specialem altae pressionis ad efficiendam remotionem sine damno superficiei rotarum. Purificatio altae pressionis ad 33 MPa cum tota superficie rotarum comprehensa certificat remotionem perfectam notarum. Inclosure soni obscurantis tenent niveles soni in loco operis infra 80 dB, requisita sanitatis occupacionalis implentes dum potestas purgationis pro adhaesivis obstinatis notarum praebetur.
Technologia filtrationis pro purificatione rotarum ferroviarium
Filtratio efficax necessaria est ad qualitatem mundandi in fabrica rotarum ferroviariarum magni voluminis servandam. Systemata filtrandi quattuor graduum, cum filtris cestis, filtris fasciculorum papyraceorum (ad removendum papyrum adnotativam), filtris saccularibus et filtris saccularibus in linea, qualitatem liquidi mundandi conservant. Separatores magnetici in statione post MPI particulas magneticas ex liquido mundando efficaciter removunt, vitam liquidi prolongantes et resultata mundandi constantia assurantes.
Configuratio U-Typica per-Admissionis pro Integratione Lineae Productionis
Systemata mundandi U-typica per-admissionis efficienter lineam productionis integrare permittunt, cum oneratio et deoneratio automatica eadem parte. Haec configuratio optima est pro integratione cum systematibus robotorum gantry et optimam utilisationem spatii soli praebet. Positio verticalis rotarum in palletis tractationem stabilem magnorum et gravium componentium assurat, simul permittens mutationem celerem inter diversas magnitudines et formas rotarum.
Specificationes technicae
| Specificatio | Stazione Prima | Stazione Seconda |
|---|---|---|
| Typus Producti | Systema Mundandi U-Typicum per-Admissionis | Systema Mundandi U-Typicum per-Admissionis |
| Applicatio | Prae-Inspectionis Pulveris Remotio (Contaminantia + Etiquettae) | Post-MPI Pulveris Remotio |
| Workpiece | Rotae Ferroviariae (860–1 320 mm, ≤1 000 kg) | Rotae Ferroviariae (860–1 320 mm, ≤1 000 kg) |
| Technologia purgandi | HP 33 MPa + LP 2.0 MPa + Rinsing + Drying | LP 2.0 MPa + Rinsing + Drying |
| Temperatura de purgatio | 40–60°C | 40–60°C |
| Exolvuntur tempore | ≤120 secondi/pezzo | ≤120 secondi/pezzo |
| Capacitas vasculi | 3 700 L (1 500 + 700 + 1 500 L) | 2 200 L (1 500 + 700 L) |
| Vires calefaciendi | 90 kW (6 calefactores × 15 kW) | 45 kW (3 calefactores × 15 kW) |
| Summa potentia | 185 kW | 102 kW |
| Air comprimé | 8 Nm³/min | 8 Nm³/min |
| Consumptio aquae | 3,700 L | 2,200 L |
| Systema filtationis | Quattuor Graduum (40 reticula / 20 μm / 10 μm + Cingulum Papiraceum) | Quattuor Graduum (40 reticula / 20 μm + Cingulum Papiraceum + Separator Magneticus) |
| Pompa alti pressionis | Uraca EP-36-28-4D (37 kW, 60 L/min, MAX 33 MPa) | — |
| Low-Pressure Pump | CNP CDLK32-140/14-2 (30 kW, 500 L/min, 2.0 MPa) | CNP CDLK32-140/14-2 (30 kW, 500 L/min, 2.0 MPa) |
| Systema regens | Siemens S7-1200 PLC + TP1200 HMI | Siemens S7-1200 PLC + TP1200 HMI |
| Communicatio | PROFINET, TCP/IP | PROFINET, TCP/IP |
| Gradus strepitus | <80 dB (at 1 meter) | <80 dB (at 1 meter) |
| Vestigium | Per customer layout | Per customer layout |
