Design Of Automatic Disassembly Test System For Saddles Of Railway Freight Car Bogies

The maintenance of railway freight car is an important guarantee for the railway freight to function properly.In the process of railway freight car maintenance,the maintenance of bogie is the most important.In the domestic bogie maintenance line,the disassembly and assembly process of the adapter mainly adopt manual dominated operation mode.Due to the heavy weight of the adapter,the manual operation has many problems,such as high labor intensity,low operation efficiency and hidden security risks.The disassembly,inspection and assembly of the adapter are relatively independent of each other,and the workplaces are scattered and far away from each other,so it is compulsory to transfer between the three workplaces for many times,which is a waste of manpower and time.In addition,the continuity among the disassembly,inspection and assembly processes of the adapter is deficient,which often leads to the situation of waiting for work.With the application of automatic measurement technology in adapter wear detection,the automation degree of adapter detection station has been greatly improved.Due to the small distance between the thrust shoulder and the saddle surface,it is difficult for the distance sensor and the vision camera to complete accurate measurement or effective image acquisition in this narrow space,so the innovative design of the detection device is needed.This thesis designs a set of ‘automatic disassembly and assembly system for the adapter of railway freight car bogies’,which is suitable for the bogie type of K2 and K6.The system uses industrial robot technology,AGV technology,pneumatic transmission and control technology,servo transmission technology,linear motor technology,sensor technology,machine vision and image processing technology to organically combine the disassembly,detection and assembly process of adapter.By simplifying and unifying the fixing methods of K2 and K6 adapters and side frames,the difficulty of disassembly,assembly automation and universality of adapters is effectively reduced.The automatic disassembly and assembly system for the adapter of freight car bogie mainly includes three core modules: disassembly module,wear detection module and assembly module,as well as auxiliary module and control system.In the disassembly module,the manipulator drives the disassembly fixture of the adapter to realize the automatic disassembly of the adapter.The wear detection module is provided with a first detection part and a second detection part.The first detection part is composed of a cooperative robot and a laser ranging sensor installed at the end of the cooperative robot,which is responsible for the wear detection of all surfaces except the inner side of the thrust shoulder.The second detection part uses indirect measurement method to measure the inner distance of thrust shoulder.The AGV is used as the carrier of the assembly module.The main support frame,buffer conveying unit,lifting unit of adapter,fixed hanger moving unit and positioning detection unit are integrated and installed on the AGV.Through the transportation and positioning function of AGV,the design of the assembly module of the self mobile adapter is completed.The automatic disassembly and assembly system of the adapter designed in this thesis realize the automation of the relevant procedures in the maintenance process of the bogie adapter by setting the disassembly,detection and assembly modules.In addition,the three modules are systematically integrated through the corresponding auxiliary devices to realize the combination of the disassembly,detection and assembly of the adapter under the utilization of the control system,which effectively eliminates the space constraints independence and reduces waiting time.The system solves the problem of low automation of disassembly,detection and assembly of adapter in bogie maintenance,saves manpower,reduces operation intensity and hidden security risks.