EN
Railway Wheel U-Type Through-Feed Cleaning System for High-Speed Rail and Heavy-Haul Manufacturing
Customized turnkey solution for a major railway wheel manufacturer
Application: Railway Wheel Cleaning for High-Speed Rail and Heavy-Haul Manufacturing — First-Line Process & Post-Magnetic Particle Inspection
Workpiece: Railway Wheels — Diameter 860–1,320 mm, Weight ≤1,000 kg
Cleaning Process: High-Pressure Label Removal (33 MPa) + Low-Pressure Spray Cleaning (2.0 MPa) + Spray Rinsing + Blow-Drying + Air Knife Drying
Cleaning Pressure: Low-Pressure ≥2.0 MPa / High-Pressure ≥33 MPa (Label Removal) — customizable
Cleaning Temperature: 40–60°C (Electric Heating) — customizable
Cycle Time: ≤120 seconds per piece — customizable per production line requirements
Cleanliness Requirement: Water Residue ≤0.1 mg/kg; Metallic Residue ≤2 mg/kg (or Cleanliness Meter ≥70% Average) — customizable per customer requirements
Drying Technology: Blow-Drying + Air Knife Drying
Filtration System: Four-Stage Filtration (40 Mesh / 20 μm / 10 μm) + Paper Belt Filter — customizable
Loading/Unloading: Automatic (Gantry Robot Interface) — customizable
System Configuration: Two Cleaning Systems — First Station (Pre-Inspection Cleaning) + Second Station (Post-MPI Cleaning)
Description
Railway Wheel U-Type Through-Feed Cleaning System
The Big Bird Industrial Railway Wheel Cleaning System is developed for high-efficiency cleaning of railway wheels used in high-speed rail and heavy-haul manufacturing. The system comprises two cleaning stations: the first station located at the beginning of the inspection line removes cutting fluids, process protection fluids, oil contaminants, and process labels; the second station located after magnetic particle inspection removes magnetic particle inspection fluids.
The equipment is provided as a turnkey solution including design, manufacturing, installation, and commissioning.
Workpiece Applications
The system accommodates railway wheel components:
| Parameter | Specification |
|---|---|
| Wheel Diameter (including flange) | 860–1,320 mm |
| Tread Diameter | 800–1,260 mm |
| Overall Thickness | 130–260 mm |
| Rim Width | 120–150 mm |
| Hub Length | 140–230 mm |
| Hub Bore Diameter | 150–230 mm |
| Maximum Rim-to-Hub Distance | ≤80 mm |
| Single Weight | ≤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
First Cleaning Station (Pre-Inspection Line)
Located at the first process of the inspection line, this station removes contaminants from wheel surfaces accumulated during machining and storage:
Cutting fluids and process protection fluids
Oil and grease contaminants
Dust and particulates
Process labels from tread surfaces
The station combines high-pressure label removal (33 MPa) with low-pressure spray cleaning (2.0 MPa) for comprehensive cleaning.
Second Cleaning Station (Post-MPI)
Located after magnetic particle inspection, this station removes magnetic particle inspection fluids from wheel surfaces after non-destructive testing.
Both stations feature U-type through-feed configuration with vertical wheel positioning on pallets.
Automatic Mixed-Model Production
The system supports fully automatic production integration with:
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.
Process Integration
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
Stage 1: Loading
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.
Stage 2: High-Pressure Label Removal (33 MPa)
High-pressure nozzles positioned above the wheel deliver 33 MPa cleaning to remove process labels from the tread surface. The high-pressure system is enclosed in a soundproof enclosure to maintain noise levels below 80 dB.
Stage 3: Low-Pressure Spray Cleaning (2.0 MPa)
Spray nozzles oscillate across the wheel surface to remove cutting fluids, process protection fluids, oil contaminants, and particulates. Low-pressure cleaning ensures thorough coverage with high flow rate.
Stage 4: Spray Rinsing
The wheel undergoes spray rinsing to remove loosened contaminants and cleaning fluid residues.
Stage 5: Blow-Drying
High-velocity air nozzles remove residual moisture from the wheel surface and internal cavities.
Stage 6: Air Knife Drying
Air knives provide final drying to ensure the wheel is completely dry for subsequent dimensional inspection. Outlet temperature is controlled ≤40°C for accurate dimensional measurement.
Multi-Stage Cleaning Process — Second Station
Stage 1: Loading
The gantry robot places the wheel vertically onto the locating pallet.
Stage 2: 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:
| Parameter | Specification |
|---|---|
| Cleaning Pressure | ≥33 MPa |
| High-Pressure Pump | Uraca EP-36-28-4D, 60 L/min, 37 kW |
| Nozzle Coverage | Full tread surface coverage |
| Noise Control | Soundproof enclosure (<80 dB at 1 meter) |
| Compliance Standards | GB/T 14976-2012, GB/T 12771-2019, GB/T 28708-2012, GB/T 10544-2022 |
Technical Cleanliness Control
For railway wheel manufacturing, cleanliness affects both dimensional inspection accuracy and final product quality.
The system is designed to meet strict cleanliness requirements:
| Requirement Area | Specification |
|---|---|
| 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) |
| Surface Cleanliness | Cleanliness meter ≥70% average (5-point measurement) |
| Visual Inspection | No large water spots on wheel surfaces |
| First Station Outlet Temperature | <40°C |
| Fluid pH Range (within change cycle) | 6.8–9.5 |
Advanced Filtration Management
First Station Filtration System (Four-Stage)
| Filter Type | Capacity | Accuracy | Application |
|---|---|---|---|
| Basket Filter | 300 L/min | 40 mesh | Primary filtration (3 units) |
| Paper Belt Filter | 600 L/min | — | Secondary filtration (1 unit, label paper removal) |
| Bag Filter | 300 L/min | 20 μm | Tertiary filtration (2 active + 1 standby) |
| In-Line Bag Filter | 300 L/min | 10 μm | Quaternary filtration (1 active + 1 standby) |
Filtration Flow:
Cleaning Tank: Basket → Return Pump → Paper Belt Filter → Primary Tank → Filter Pump → In-Line Bag Filter → Booster Pump → Secondary Tank → Bag Filter → High-Pressure Pump
Rinsing Tank: Basket → Rinsing Tank → Rinsing Pump → In-Line Bag Filter
Second Station Filtration System (With Magnetic Separator)
| Filter Type | Capacity | Accuracy | Application |
|---|---|---|---|
| Basket Filter | 300 L/min | 40 mesh | Primary filtration (3 units) |
| Paper Belt Filter | 500 L/min | — | Secondary filtration (1 unit) |
| Bag Filter (with Magnetic Rods) | 300 L/min | 20 μm | Tertiary filtration (1 active + 2 standby) |
| Magnetic Separator | 200 L/min | — | Quaternary filtration (1 unit, magnetic particle removal) |
Filtration Flow:
Cleaning Tank: Basket → Return Pump → Paper Belt Filter → Primary Tank → Filter Pump → Secondary Tank → Bag Filter
Intelligent Manufacturing Integration
The system supports Industry 4.0 requirements through comprehensive data connectivity:
PCS/MES Communication
PROFINET communication protocol
TCP/IP data exchange with PCS system
Production data, equipment status, and quality data transmission
OPC UA data acquisition
Hardware Integration
Harting 24-pin connectors for safety signals (3 sets)
PN/PN couplers for PROFINET communication
Emergency stop interlock with gantry robot systems
Operator Interface
Siemens TP1200 HMI touch screen
Equipment control, parameter setting, and chart analysis
Workpiece information tracking and upload
Fault diagnosis and alarm display
Application Case
| Parameter | First Station | Second Station |
|---|---|---|
| Project | Major Railway Wheel Manufacturer — U-Type Through-Feed Cleaning System (2 Units) | |
| Workpiece | Railway Wheels — Φ860–1,320 mm, ≤1,000 kg | |
| Cycle Time | ≤120 seconds/piece | ≤120 seconds/piece |
| Cleaning Technologies | HP 33 MPa + LP 2.0 MPa + Rinsing + Drying | LP 2.0 MPa + Rinsing + Drying |
| Cleaning Temperature | 40–60°C | 40–60°C |
| Total Power | 185 kW (Heater 90 kW) | 102 kW (Heater 45 kW) |
| Tank Capacity | 3,700 L | 2,200 L |
| Compressed Air | 8 Nm³/min | 8 Nm³/min |
Complete Cleaning Solution
Big Bird Industrial provides comprehensive engineering solutions including:
Process Development
Component analysis for railway wheels
Cleaning process design for inspection line integration
Cleanliness requirement evaluation
Equipment Integration
U-type through-feed cleaning systems
High-pressure label removal technology (33 MPa)
Low-pressure spray cleaning systems
Multi-stage filtration management
Conveyor and pallet handling systems
Smart Manufacturing Connection
PCS/MES interface
Production data acquisition
Material tracking and traceability
Why Choose Big Bird Industrial
Railway Wheel Cleaning Experience
Big Bird Industrial specializes in precision cleaning solutions for railway component manufacturing, with proven experience in wheel cleaning for high-speed rail and heavy-haul applications with workpieces up to 1,320 mm diameter and 1,000 kg weight.
U-Type Through-Feed Technology
The U-type configuration enables efficient floor space utilization with automated loading/unloading from the same side. Vertical wheel positioning and pallet-based conveyance ensure stable handling for large, heavy components.
High-Pressure Label Removal (33 MPa)
The system features specialized high-pressure technology (33 MPa) for effective removal of process labels from wheel tread surfaces. The soundproof enclosure ensures noise levels below 80 dB at 1 meter.
Two-Station Turnkey Solution
The project delivers two complete cleaning systems as a turnkey solution, covering both pre-inspection cleaning (contaminants + labels) and post-MPI cleaning (magnetic particle removal) in a single project scope.
System-Level Engineering Capability
The company provides complete solutions from cleaning process development to production integration, including high-pressure cleaning, filtration management, PCS/MES integration, and gantry robot interface.
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
Cleaning process development
Customized fixture and automation design
Factory layout and production flow integration
FAQ
What components does this cleaning system process?
This system is designed for railway wheels used in high-speed rail and heavy-haul manufacturing — diameters 860–1,320 mm, weights up to 1,000 kg.
What does the two-station configuration include?
The system includes two cleaning stations: Station 1 located at the inspection line first process (removes cutting fluids, process protection fluids, oil, labels); Station 2 located after magnetic particle inspection (removes magnetic particle fluids).
What cleaning pressure is available?
Low-pressure spray cleaning at 2.0 MPa for general cleaning. Station 1 also features high-pressure label removal at 33 MPa for process label removal from tread surfaces.
What contaminants can be removed?
The system removes cutting fluids, process protection fluids, oil/grease contaminants, dust, process labels, and magnetic particle inspection fluids from wheel surfaces.
What cleanliness levels can be achieved?
Water residue ≤0.1 mg/kg; metallic residue ≤2 mg/kg (or cleanliness meter ≥70%); no large water spots; Station 1 outlet temperature <40°C.
Does it support automated production integration?
Yes. The system interfaces with gantry robots for automatic loading/unloading and PCS/MES systems for production data tracking and material traceability.
What is the typical cycle time?
The system delivers ≤120 seconds per piece, supporting high-volume railway wheel production.
Railway Wheel Cleaning in High-Speed Rail Manufacturing
Railway wheel cleaning is a critical process between machining and final inspection in high-speed rail and heavy-haul manufacturing. Wheels up to 1,320 mm in diameter and 1,000 kg in weight require advanced cleaning technologies to remove cutting fluids, process protection fluids, oil contaminants, and process labels before dimensional inspection, and magnetic particle fluids after non-destructive testing. U-type through-feed cleaning systems enable efficient integration into automated production lines.
High-Pressure Label Removal Technology
Process labels on wheel tread surfaces require specialized high-pressure technology for effective removal without damaging the wheel surface. High-pressure cleaning at 33 MPa with full tread surface coverage ensures thorough label removal. Soundproof enclosures maintain workplace noise levels below 80 dB, meeting occupational health requirements while delivering the cleaning power needed for stubborn label adhesives.
Filtration Technology for Railway Wheel Cleaning
Effective filtration is essential for maintaining cleaning quality in high-volume railway wheel manufacturing. Four-stage filtration systems with basket filters, paper belt filters (for label paper removal), bag filters, and in-line bag filters ensure cleaning fluid quality is maintained. Magnetic separators in the post-MPI station effectively remove magnetic particles from the cleaning fluid, extending fluid life and ensuring consistent cleaning results.
U-Type Through-Feed Configuration for Production Line Integration
U-type through-feed cleaning systems enable efficient production line integration with automated loading/unloading from the same side. This configuration is ideal for integration with gantry robot systems and provides excellent floor space utilization. Vertical wheel positioning on pallets ensures stable handling for large, heavy components while allowing for quick changeover between different wheel sizes and shapes.
Technical Specifications
| Specification | First Station | Second Station |
|---|---|---|
| Product Type | U-Type Through-Feed Cleaning System | U-Type Through-Feed Cleaning System |
| Application | Pre-Inspection Cleaning (Contaminants + Labels) | Post-MPI Cleaning |
| Workpiece | Railway Wheels (860–1,320 mm, ≤1,000 kg) | Railway Wheels (860–1,320 mm, ≤1,000 kg) |
| Cleaning Technology | HP 33 MPa + LP 2.0 MPa + Rinsing + Drying | LP 2.0 MPa + Rinsing + Drying |
| Cleaning Temperature | 40–60°C | 40–60°C |
| Cycle Time | ≤120 seconds/piece | ≤120 seconds/piece |
| Tank Capacity | 3,700 L (1,500 + 700 + 1,500 L) | 2,200 L (1,500 + 700 L) |
| Heating Power | 90 kW (6 heaters × 15 kW) | 45 kW (3 heaters × 15 kW) |
| Total Power | 185 kW | 102 kW |
| Compressed Air | 8 Nm³/min | 8 Nm³/min |
| Water Consumption | 3,700 L | 2,200 L |
| Filtration System | Four-Stage (40 Mesh / 20 μm / 10 μm + Paper Belt) | Four-Stage (40 Mesh / 20 μm + Paper Belt + Magnetic Separator) |
| High-Pressure Pump | 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) |
| Control System | Siemens S7-1200 PLC + TP1200 HMI | Siemens S7-1200 PLC + TP1200 HMI |
| Communication | PROFINET, TCP/IP | PROFINET, TCP/IP |
| Noise Level | <80 dB (at 1 meter) | <80 dB (at 1 meter) |
| Footprint | Per customer layout | Per customer layout |
