铁路货车轮轴四级修检修流水线改造研究

Research on the Renovation of the Railway Freight Car Axle Fourth-Level Repair Assembly Line

摘要

针对湖东车辆段既有轮轴四级修流水线关键设备短缺、工艺布局不合理、安全隐患大、设备老化、两班生产等问题，本文 系统分析了既有流水线工艺布局及检修规模，提出了改造基本原则与方案。改造方案重构车轴与轮对组装工艺布局，将车 轴设备整体旋转换位并改用机械手输送，轮对组装单元整体旋转 90°后并行新增组装工位，解决既有空间局促无法扩容的 布局难题。遵循利旧降耗、工序节拍匹配原则，增补数控磨床、镗床、机械手、AGV 小车及轴承智能退卸等设备。改造后 新轴日加工量由 16 根增至 40 根，轮对组装节拍由 6min / 条缩短至 3min / 条，全工序实现单班日产 100 条轮对。本次改造 解决了交叉作业安全隐患，消除了生产节拍制约点，解决精简一线作业人员10人，在产能、安全、人力及节能方面成效显 著。研究方案可为国内重载铁路车辆段轮轴检修流水线升级改造提供实践参考。

Abstract

Addressing the issues of key equipment shortages, unreasonable process layout, significant safety hazards, aging equipment, and two-shift production on the existing wheel and axle level four repair assembly line at the Hudong Vehicle Depot, this paper systematically analyzes the existing assembly line’s process layout and repair scale, and proposes basic principles and solutions for its transformation. The transformation plan restructures the axle and wheelset assembly process layout, rotating and repositioning the axle equipment as a whole and replacing it with robotic arms for transport. The wheelset assembly unit rotates 90° and adds parallel assembly stations, solving the layout problem of limited space that prevents expansion. Following the principles of reusing existing equipment and reducing costs, and matching process cycle time, CNC grinding machines, boring machines, robotic arms, AGV trolleys, and intelligent bearing unloading equipment are added. After the transformation, the daily processing capacity of new axles increases from 16 to 40, and the wheelset assembly cycle time is shortened from 6 minutes/wheelset to 3 minutes/wheelset, achieving a single-shift daily production of 100 wheelsets. This upgrade resolved safety hazards associated with overlapping operations, eliminated production cycle constraints, and reduced the number of frontline workers by 10, achieving significant results in terms of capacity, safety, manpower, and energy conservation. The proposed solution can provide practical reference for the upgrading and transformation of wheel and axle maintenance production lines in heavy-haul railway vehicle depots across China.

关键词

湖东车辆段 / 轮轴四级修 / 流水线 / 工艺改造

Key words

Hudong depot / level 4 maintenance of wheelset / assembly line / process modification

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