Internal Combustion Locomotive Maintenance
Process and Product Introduction
Rail Transit Research Institute-Product & Solution Department
CONTENT
Part I
Bogie maintenance process and product introduction
Part II
Motor maintenance process and product introduction
Part III
Diesel engine maintenance process and product introduction
Part IV
Air brake system maintenance process and product introduction
Part V
Trackside Detect Equipment Introduction
Assembly Line Scheme of Bogie Maintenance
Layout plan of Overhaul Section of Harbin Internal Combustion Locomotive
Assembly Line Scheme of Bogie Maintenance
Wheel set
press fitting
Wheel set
running-in
Motor assembly
Car wheel lathe
Flaw detection
of phased array
Journal measurement
Press-assembling
of bearing
Shaft end nut
Assembly line of wheel-set
Storage at the same
temperature
Assembly of
axle suspension
bearing box
Axle measurement
Magnetic powder
cleaning
Magnetic particle inspection
Axle cleaning
Decomposition of axle
suspension bearing box
Wheel set
decomposition
Decomposition of
gear box of motor
Wheel set cleaning
Bearing withdrawal
Cleaning, grinding and
tooth profile inspection
Ultrasonic flaw detection of axle
Wheel set inspection
Flaw detection of magnetic
powder of wheel set
Wheel set cleaning
Decomposition overhaul line of wheel set
Incoming inspection
Assembly line of wheel-set
Overhaul line of wheel set and axle
Technological layout and flow of wheel set
Overhaul line of wheel and axle
Decomposition overhaul line of wheel set
Special Equipment of Locomotive Maintenance
Decomposition Assembly Equipment of Locomotive
Mobile electric lifting jacks for locomotive
Application:
Mainly for lifting body, separating the bogie from the
body or assembling them.
Technical parameters:
Rated lifting load: 25 t
Lifting speed: 300mm/min
Lifting height: 1600mm
Synchronous error (each group): ≤±5mm
Decomposition Assembly Equipment of Locomotive
Process bogie
Application:
Mainly for supporting the body, moving the body after
the separation of bogie and body. It includes
power bogie and non-power bogie, which are
matched in general.
Bogie Maintenance Equipment
Tractor of bogie
For traction and conveying of
decomposed bogie. The device is small
and smart, able to operate under the
body to drag the bogie to walk.
Bogie Maintenance Equipment
Bogie turntable
Equipment function:
For reversing conveying of bogie.
Bogie booster
Equipment function:
For conveying of bogie and wheel set, greatly
reducing labor strength of workers.
Introduction of Products in Bogie Maintenance Assembly Line
Automatic bogie cleaning machine
Equipment function:
The device is used for cleaning bogie. It
adopts a high pressure water cleaning
system and is configured with a bogie
traction system to finish automatic
conveying of bogie.
Introduction of Products in Bogie Maintenance Assembly Line
Decomposition assembly lifter of bogie
Application
For lifting and loading of locomotive bogie, to provide optimal operation space of
personnel for decomposition, assembly and acceptance of bogie.
Highlights of equipment:
 It has high lifting precision and special mechanical synchronous structure, to
guarantee synchronous lifting of stand column;
 It has high safety because it adopts special automatic detection device of
mechanical abrasion value, to detect cooperation gap between working
transmission pairs;
 The unique anti-falling device can avoid danger in breakage of transmission pairs;
 It has high passing ability on ground because the device is totally in the pit in idle
time to make the ground flat without barrier;
 Loading device can be configured according to demands of customers, to meet
pressurization decomposition and assembly requirements of bogie;
 It has strong compatibility because it adopts special wheel locating device to meet
different wheel bases of HX high power locomotive bogie.
Introduction of Products in Bogie Maintenance Assembly Line
Transverse turning of frame
Equipment function:
The device is pit type online device. After lifting of the
framework, it is convenient for overhaul and meets
passing transport of AGV of framework, which can be
used for repair welding of framework.
Introduction of Products in Bogie Maintenance Assembly Line
Cleaning and drying machine of frame
Equipment function:
The device is used for cleaning of framework.
Paint on framework surface can be removed
through water-sprayed sand and the surface
can be rinsed through high pressure water.
Introduction of Products in Bogie Maintenance Assembly Line
Drying room of spray lacquer of frame
Equipment function:
The device is used for paint spraying and drying of
frame. It is provided with an activated carbon
painting mist treatment device. Emission standard
can be met after treatment.
Introduction of Products in Bogie Maintenance Assembly Line
AGV car of frame and wheel set conveying
It is used for intelligent conveying of big parts
such as framework, wheel set and motor in
overhaul station room. Magnetic conducting
bar can be laid on ground to realize automatic
control of background. It reduces operating
frequency of crown block to effectively
improve power of conveying framework and
reduce accident.
Introduction of Products in Bogie Maintenance Assembly Line
Bogie static load test bench
Simulate locomotive weight, make static load to
bogie, test comprehensive static performance of
assembled bogie, to test and adjust axle weight
Introduction of Products in Wheel Set Maintenance Assembly Line
Bearing withdrawal machine
It is used for disassembling bearing of axle box of
wheel set and locating center hole. Bearing located on
both sides once can be disassembled at the same
time or independently.
Introduction of Products in Wheel Set Maintenance Assembly Line
Decomposition machine of motor
It is used for decomposition of motor and gear box of
wheel set.
It utilizes hydraulic lifting mechanism to realize lifting
of wheel set, utilizes hydraulic wrench to decompose
motor bolt, and utilizes cantilever crane
to lift wheel set motor.
Introduction of Products in Wheel Set Maintenance Assembly Line
Wheel set cleaning room
A cleaning room of wheel set is provided. The
cleaning room can automatic deal with indoor water
vapor without influence on working environment of the
workshop. High pressure water guns and artificial
washing tools are provided.
Introduction of Products in Wheel Set Maintenance Assembly Line
Automatic wheel set measuring machine
It is used for automatic measurement of motor wheel
set, to automatically measure parameters of tread of
wheel set, to provide guide suggestions of experts for
selection and repair of wheel set. The data can be
uploaded automatically, to avoid mistake of artificial
measurement.
Introduction of Products in Axle Maintenance Assembly Line
Multi-functional disassembly and assembly machine of wheel set
It is used for disassembly of worn wheel discs, assembly
of new wheel discs, disassembly and assembly of big
gears, back pressure test, etc.
It adopts center hole location and operation of double oil
cylinders. It can operate with double sides at the same
time. It provides working efficiency of assembly and
disassembly of wheel set.
Introduction of Products in Axle Maintenance Assembly Line
Decomposition machine of axle suspension bearing box
It is used for decomposing wheel set axle
suspension bearing box, to rotate axle by 90°.
Introduction of Products in Axle Maintenance Assembly Line
Step conveyor line of axle
It is used for conveying in axle overhaul
process. Step conveying mode can be
finish automatic conveying of axle.
Introduction of Products in Axle Maintenance Assembly Line
Cleaning machine of axle
It is used for cleaning of axle. It is convenient for flaw
detection of magnetic powder of wheel set. It can also be
used for cleaning of magnetic suspension after flaw
detection of magnetic powder.
Introduction of Products in Axle Maintenance Assembly Line
Magnetic particle flaw detector for axle
It is used for flaw detection of magnetic powder of
big gear of axle. It cooperates with step conveyor
line of axle, to finish synchronous conveying.
Introduction of Products in Axle Maintenance Assembly Line
Automatic measuring machine of axle
It is used for automatic measurement of axle
parameters. The data can be uploaded
automatically, for selection of assembly of wheel
discs. It cooperates with stereoscopic storehouse
of wheel set, to realize selection and assembly of
wheel before press-assembling of wheel set.
Introduction of Products in Wheel Set Maintenance Assembly Line
Wheel set fluorescent magnetic particle flaw detector
It is used for flaw detection of magnetic powder of
wheel set.
Introduction of Products in Wheel Set Maintenance Assembly Line
Automatic measuring machine of axle diameter
It is used for measuring axle diameter of wheel set, to
provide size basis for press-assembling of bearing.
The measured result is automatically uploaded to
background database. Inner hole of bearing can be
selected according to stereoscopic storehouse of
bearing.
Introduction of Products in Wheel Set Maintenance Assembly Line
Bearing press
It is used for automatic press-assembling of bearing of
axle box. It can generate press-assembling curve of
bearing automatically and give alarm of unqualified
curve in press-assembling automatically.
Introduction of Products in Wheel Set Maintenance Assembly Line
Intelligent trigger of bolts at axle end
It is used for assembling gland bolts at axle end. It
adopts Multi-axis private private server to control
torque. It can set bolt torque and record operation
result automatically, and upload it to background
database.
Introduction of Products in Wheel Set Maintenance Assembly Line
Assembly machine of motor gear box
It is used for disassembly and assembly of gear box of
motor. It provides a cantilever crane. The hydraulic
lifting device can lift wheel set to operation height.
Special tools such as hydraulic trigger are also adopted
to conduct disassembly and assembly of motor bolts.
Introduction of Products in Wheel Set Maintenance Assembly Line
Test bench of wheel set running-in
It is used for running-in test of wheel set. It provides
power source for motor of wheel set. It adopts speed
sensor to measure temperature rise and vibration
value of bearing of motor, and automatically gives
alarm of wheel set beyond standard.
CONTENT
Part I
Bogie maintenance process and product introduction
Part II
Motor maintenance process and product introduction
Part III
Diesel engine maintenance process and product introduction
Part IV
Air brake system maintenance process and product introduction
Part V
Trackside Detect Equipment Introduction
Traction Motor Maintenance Line-Layout Plan
Maintenance area: motor purging area, motor disassembly area, stator and rotor cleaning area, accessories
conveying line, accessories cleaning machine, accessories maintenance area, stator maintenance area, rotor
maintenance area, traction motor assembly area.
Traction Motor Maintenance Line-Process Flow
Traction
motor
purging
Traction
motor
disassembly
Stator & rotor
cleaning and
drying
Stator
maintenance
& test
Rotor
impregnation
& drying
Traction
motor
assembly
转子检修
试验
Rotor
maintenance
& test
Accessories
cleaning &
maintenanc
e
Traction Motor Maintenance Line-Product Introduction
Motor Purging Area
1. The traction motor to be maintained is delivered to the maintenance shop on a flat car, lifted onto the
platform of purging unit by an overhead crane and purged in the purging unit to remove external dust.
2. Equipment in motor purging area mainly include motor purging unit, etc.
Traction Motor Maintenance Line-Product Introduction
Motor Disassembly Area
1. After purging, the motor is lifted onto the disassembly bench in the disassembly area
and disassembled with special fixtures and tools.
2. Equipment in motor disassembly area includes rotary disassembly bench, transverse
pneumatic manipulator, special vehicle for rotor disassembly, rotor roll-over bench,
testing apparatus for motor disassembly, fixtures and tools for disassembly, etc.
Traction Motor Maintenance Line-Product Introduction
Accessories Conveying Line
1. Equipment on accessories conveying line includes universal ball joint rail assembly, conveying vehicle,
bush roller chain, gear speed reducer, etc.
2. The conveying line rail is paved on ground foundation with universal ball joints as supporting rail, which
is flexible, novel and reliable; the conveying vehicle gets the traction power from gear speed reducer and
is dragged by the roller chain to travel on the universal ball joint rail. The vehicle is equipped with clutch
device to allow for ready detachment from the roller chain and enters the maintenance area to assist with
maintenance activities; the conveying vehicle may be stared and shut down via remote control, allowing
for simple and convenient operation.
Traction Motor Maintenance Line-Product Introduction
Stator & Rotor Cleaning Area
1. Disassembled accessories are lifted onto the conveying line and conveyed by the conveying cart to the
special accessories cleaning machine for cleaning and air drying.
2. Equipment in the cleaning area include cleaning house, transmission system, sprinkler system, pump
station, cleaning liquid filtration and storage tank, fume exhaust system, electric control system, etc.
Traction Motor Maintenance Line-Product Introduction
Accessories Maintenance Area
1. After cleaning and drying, accessories are conveyed to the accessories maintenance area for maintenance
via the accessories conveying line and conveyed to the assembly area for use after maintenance.
2. Equipment in accessories maintenance area includes accessories manipulator, electric brush grinder, head
cover bearing removing and mounting machine, brush carrier ring maintenance bench, hand-held power tools,
storage bench.
Traction Motor Maintenance Line-Product Introduction
Stator Maintenance Area
1. After cleaning and drying, the stator is lifted onto the test bench for testing, cover paint is applied on the
surface of stator coil, any nonconforming stator is lifted onto the magnetic pole replacement bench for
replacement of magnetic pole. Painted and dried stator is transported by an overhead crane to the
assembly bench in the assembly area for use;
2. Equipment in stator maintenance area includes testing, positioning and roll-over bench, stator testing
equipment, stator magnetic pole replacement bench, stator storage bench.
Traction Motor Maintenance Line-Product Introduction
Rotor Maintenance Area
1. After cleaning and drying, the rotor is transported by an overhead crane to the transverse roll-over vehicle on the
maintenance line for testing and nonconforming rotor is moved horizontally to the ring suspension line, lifted by ring
suspension line to “dynamic balance test bay”, “undercutter bay” and “armature commutator dressing & testing bench” for
required maintenance. Rotor requiring impregnation is lifted to vacuum impregnation equipment and electric drying chamber
for impregnation and drying and lifted to the assembly center for assembly and use after drying.
2. Components of rotor maintenance line include suspension and conveying line, vacuum impregnation equipment, electric
drying equipment, stator roll-over equipment, dynamic balance equipment, commutator undercutter, commutator dressing
equipment, rotor storage and roll-over bench, etc.
Traction Motor Maintenance Line-Product Introduction
Rotor Maintenance Area
1. Equipment in motor assembly area include assembly center (rotary assembly bench, transverse
pneumatic manipulator, special vehicle for rotor assembly, fixtures an tools for assembly) and motor idle
running test equipment.
CONTENT
Part I
Bogie maintenance process and product introduction
Part II
Motor maintenance process and product introduction
Part III
Diesel engine maintenance process and product introduction
Part IV
Air brake system maintenance process and product introduction
Part V
Trackside Detect Equipment Introduction
Diesel Engine Maintenance-Product Introduction
Diesel engine roll-over stand
1. Lifting and roll-over equipment required for maintenance of 6-cylinder, 8-cylinder, 12-cylinder and 16-cylinder diesel
engines of 240 and 280 series for various internal combustion locomotives (including HXN, ND5)
Diesel Engine Maintenance-Product Introduction
Hydrostatic pump & motor test bench
1. The bench is used for integrated
testing of the hydrostatic pump and
motor of the auxiliary system of internal
combustion locomotives, such as
running-in and volumetric efficiency tests,
performance monitoring.
Diesel Engine Maintenance-Product Introduction
Cylinder head maintenance center
1. The center may be used for maintenance of cylinder heads of
diesel engines for internal combustions locomotives.
2 、 The general cylinder head maintenance center solves the
existing issues of cylinder head maintenance process and has
unique advantages in generality of various vehicles, free roll-over,
multi-bay simultaneous activities, etc. It occupies a small area and
allows for low maintenance labor intensity and convenient
management of maintenance activities. After the cylinder head is
fixed, a series of maintenance activities, such as cylinder head
hydrotest, spring installation, guide sleeve removal, oil ejector
sleeve removal and installation, valve seat grinding, etc.
3. Cylinder maintenance center is composed of frame, mobile
pallet, head assembly, head turning assembly, grinding assembly,
mutual grinding assembly, control box and hydraulic station and is
equipped with head assembly disk grinding machine.
Diesel Engine Maintenance-Product Introduction
Cooling unit pressure & flow rate test bench
1. The bench may be used to perform pickling, alkaline cleaning, pressure,
flow rate and sealing tests of diesel engine cooling water and working oil
head radiation and cooling units of various internal combustion locomotives
and power vehicles.
2. Main functions
Use quick-acting clamps to increase handling speed and efficiency.
Use pneumatic pressure to conduct pressure test. Sealing of cooling units is
observed in water, providing visual and convenient observation.
2-4 cooling units can be tested each time.
Stainless steel water tank and supports are used, allowing for easy
maintenance and use.
It can be used for units of different sizes. Support height can be adjusted
and self locked at any level.
Automatic testing design is used for testing system.
Pressure test 0.6 Mpa and hold the pressure for 8min.
Test flow rate and check the flow rate of various cooling units.
It can be used to perform pickling and alkaline cleaning of various cooling
units.
Diesel Engine Maintenance-Product Introduction
Connecting rod maintenance line
The line is used for disassembly and assembly,
online measurement and inspection of the
piston connecting rod of diesel engines.
Diesel Engine Maintenance-Product Introduction
Piston maintenance line
The line is used for online measurement,
inspection, etc. of diesel engine pistons.
CONTENT
Part I
Bogie maintenance process and product introduction
Part II
Motor maintenance process and product introduction
Part III
Diesel engine maintenance process and product introduction
Part IV
Air brake system maintenance process and product introduction
Part V
Trackside Detect Equipment Introduction
Air Brake System Maintenance-Product Introduction
Air brake system maintenance line
Air brake system maintenance line is composed of two
sections, namely, brake maintenance line and air supply
system maintenance line and can be used to complete all
process maintenance activities including parts cleaning,
disassembly, assembly, testing, etc.
Air Brake System Maintenance-Product Introduction
Brake maintenance line
Locomotive brake maintenance line follows the
direction of process flow of brake maintenance and can be
used to complete all maintenance activities of electropneumatic brake and pneumatic brake, including parts
disassembly, cleaning, drying, assembly and testing. This
line features high level of automation, accurate and
reliable testing results, high efficiency, convenient use and
equipment maintenance, aesthetic production and
environmental features, high level of modernization and
management, etc.
Air Brake System Maintenance-Product Introduction
Air supply system maintenance line
Air supply system maintenance shop is suitable for
maintenance of air compressor, air dryer, main air reservoir of
locomotive, connecting hose, etc. and is configured in a streamlined arrangement and structure to strengthen process control of
maintenance and tests. All test benches are designed in unified
model depending on their functions to achieve standard
operations, effectively improve work efficiency and quality of
locomotive maintenance, improve work environment and reduce
labor intensity.
Considering the requirements for the maintenance process of
air supply system components and parts, this maintenance line
has a process flow of centralized disassembly, parts cleaning,
maintenance and assembly, and testing. The maintenance
workshop is divided into storage area for parts to be maintained,
maintenance area, good parts storage area, assembly area and
performance test area. All functional areas are connected
through a roller conveying blet.
CONTENT
Part I
Bogie maintenance process and product introduction
Part II
Motor maintenance process and product introduction
Part III
Diesel engine maintenance process and product introduction
Part IV
Air brake system maintenance process and product introduction
Part V
Trackside Detect Equipment Introduction
Freight Weighting and Safety Inspection
High Speed Freight Weighting Systems
None stop, continuous
weighting
Application in logistic center,
iron & steel works, harbor,
power station and so on.
National key new products
56
Freight Weighting and Safety Inspection
Unbalance Measuring Systems
57
Freight Weighting and Safety Inspection
Freight Multi-Safety Inspection System
58
2. Rail Maintenance Equipment
Rail Exchanger
Rail Exchanger new type of
equipment integrating machine, and
electricity. It is set up on the
standard rail flat, to remove old rail
and lay new rail at the same time.
2. Rail Maintenance Equipment
Rail Exchanger
*
Thank You！
Rail Transit Research Institute-Product & Solution Department