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Underfloor Lathe PUS 1435/80 CNC

Picture of the PUS 1435/80 CNC

Introduction

  • Our company has developed and introduced a new type of universal underfloor lathe for productive machining of tramcar wheels without necessity to disassemble the bogie
  • The lathe is a part of a complex underfloor lathe workplace intended for all types of currently operated tramcars including the low-floor ones
  • Modified technical solution with the carrying capacity of 200 (250) kN is designed for railway truks or underground railway trucks

Basic Characteristics and Machine Virtues

  • New, so far unused technical solution of supporting and driving roller sets enables the lathe to be used for all types of rail vehicles without necessity of centering and wheelset surcharge
  • Possibility of machining wheelset also on a disassembled bogie
  • Synchronous machining with two completely independent cross supports
  • Simple and quick clamping of the machined wheelset without necessity of the operator´s intervention
  • Automatic centering of the wheelset to the axle of machining
  • Automatic levelling of the wheelset horizontal axle before and in the course of machining
  • Automatic lifting of not machined wheelset avoids influence of the possibly deformed bogie on the machining process
  • Quick measurement of running profile wear and diametres of all vehicle wheels of the set always simultaneously on both wheelsets of one bogie including printing of the measurement record
  • Possibility of diagnostics of bogie geometry including the graphic visualisation and printing of the measurement record
  • Cost saving due to performing the analysis of necessity and the scope of repair on the basis of measured results
  • Possibility to optimize the machining depth for keeping the tolerable deviation of diameters of the wheels on a wheelset, a bogie, a vehicle and a set of vehicles
  • Achieving the perfect geometry of the machined wheel thanks to clamping the axial driving rollers exactly behind the tire and removing unfavourable impact of springy rubber wheel enclousures for accuracy during machining
  • Possibility of machining economic repair profiles
  • Monitoring of the machining process with a videocamera system
  • Possibility of the accessory supply for machining of inner and outer brake discs
  • Elimination of necessity to remove side covers of a tram which causes increasing labour productivity significantly
  • Enhancement work safety thanks to minimizing the necessity of manual operator´s interventions before and in the course of machining
  • Safe shifting of a set of vehicles disconnected from the trolley wire with a chain transport device located under the floor level
  • Verification of identification of measured or machined wheelset by scanning the position of a transporting trolley
  • Efficient, user-friendly and well-arranged control system and a score computer
  • Automatic verification of cutting plate wear
  • Calibration support of checking positions of machinery moving parts
  • Control system and score computer monitoring for the purpose of diagnostics of possible disorder with the method of remote access from the seat of the service firm

Technical Parameters

  PUS..../80 CNC PUS..../200 CNC
Rail Gauge 1000, 1435, 1524 mm
 
The largest diameter of the machined wheel on the connecting circle 800 mm 1600 mm
The smallest diameter of the machined wheel on the connecting circle 400 mm 500 mm
Maximum width of the machined wheel 100 mm 150 mm
 
Machining accuracy:
In case of wheels with ruber enclousures it is necessary to add to the mantioned values < 0,30 mm
- Toleration of the wheel diameter on the surface circle < 0,10 mm
- Profile shape < 0,10 mm
- Toleration of the wheel diameters on the wheel set < 0,10 mm
- Toleration of the wheel diameters on the bogie < 0,30 mm
 
Roughness of the machined surface Ra (in dependence on feed) 3,2 - 12,5 µm
 
Feed 0,12 - 1 mm/ot.
 
Cutting speed:  
- Wheel machining 40-110 m/min
- Machining of brake discs 40-155 m/min
 
Maximum swarf cross-section 5 mm2 8 mm2
Maximum swarf depth 8 mm 8 mm
 
Machine dimensions:  
- length (in the axle of machining) 3980 mm 3660 mm
- width 2280 mm 2380 mm
- height 1955 mm 2300 mm
 
Total maximum load of lifting rollers 80 kN 200 kN
Machine weight 18 000 kg 25 000 kg
 
Equivalent noise level 72,9 dB (A)
 
Control system level CNC
Type of control system OMRON series C200 HX-CPU44
 
Supply voltage 3N~50Hz 400 V/TT
Output of driving roller drives 4 × 9,2 kW 4 × 15 kW
Installed capacity of the workplace 67 kW 75 kW
 
Dimensions of the working pit:  
- length (parallel with the rail axle) 10 690 mm
- width (perpendiclarly on the rail axle) 5 500 mm
- depth (from the top of the rail surface) - pit bottom / channels 2650/3210 mm
 
Length of the leading line of the transport device According to the customer´s request

Scope of Delivery

Delivery includes

  • Complete underfloor workplace including assemblage, activation and puttig into service:
    • Underfloor lathe PUS ..../.... CNC:
      • Machinery part
      • Control system and electric equipment
      • Diagnostic system and measurement
      • Hydraulic unit
      • Pneumatic system
      • Equipment for machining of two coupled wheel sets of a wheel base 1900 - 2500 mm
      • System of safeness and protection of the machine operating staff
      • Monitoring of the machining process with a videocamera system
      • Checking system of slipping the driving rollers
      • Lighting of the machining zone
    • The part of the basic software equipment is:
      • Operating system Windows
      • System of distance diagnostic of the machinery
      • Possibility to connect the control system on a user´s internal computer network
      • One required shape of the driving profile on which the wheel will be machined
      • Database of constructional types of wheels, which will be able to be automatically clamped
      • Possibility of machining the repair profiles
      • Control device in automatical and service mode
      • Error message displaying of the machinery conditions
  • Swarf handling:
    • collecting conveyer
    • discharge conveyer
    • 350 l open container with little wheels and automatic tilting
  • Transport device
  • Hydraulic aggregate
  • Compressor
  • Equipment (apparatuses, measuring instruments and tools)
  • Set of exposed spare parts
  • Accompanying technical documentation, service and maintenance manual and spare parts catalogue
  • EC Declaration of Confirmity
  • Exhaust-emission measurement report EMC
  • Training of the service staff in the range of two weeks before handing to the permanent usage
  • Optional accessory:
    • Device for machining of the inner and outer brake discs
    • System for bogie geometry measuring
    • Dust and smoke exhaust
    • Swarf crusher
    • System of central lubrication of cross supports

Delivery does not include

  • Structural readiness of the service pit
  • Complete lighting of the workplace
  • Ventilation and heating of the workplace
  • Edging and covers of channels and shafts
  • Staircase and rail of the service pit
  • "PSP" Switchboard attachement on the main switchboard of the hall

References

Underfloor Lathe Workplace of the Transport Company of Liberec
Delivered in the year 2000

Transport of the tramcar Underfloor lathe workplace Axial driving rollers
Inner and outer lifting rollers Withdrawable rails Machining support

Underfloor Lathe Workplace of the Engine House Strogino Moscow
Delivered in the year 2002

Tramcar type T3 over the lathe Underfloor lathe workplace
Turning control panel Headstock with clamping chuck Contacting probe and a double machining cutter

Underfloor Lathe Workplace of the Transport Company of Prague the Capital - Repair Service Hostivar
Delivered in the year 2004

Tramcar type 14T Underfloor lathe workplace Tramcar type T3 during machining
Turning control panel with PC and PLC Stabilizing jacks for machining of wheel brake discs
(c) 2012 UNIT PLUS s.r.o.
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