Abstract:
In this era of automation technologies, production sectors have placed very high demands on fast and reliable production methods. This work consists of the evaluation and analysis of the existing fixing system. The current system uses manual clamping of fixtures to hold the part in the proper position while the welding process is being performed on the part. The evaluated system uses hydraulic vertical rotating clamps to hold the workpiece driven by a hydraulic power unit. Thus, the new system achieves automatic and simultaneous attachment of accessories.
Introduction
The automatic clamping systems in this document are designed to work with the hydraulic actuation system (power pack). Clamp automation using hydraulic vertical rotary clamps is designed to work in sophisticated, precise, reliable, safe and accurate production methods. Fastening systems are designed to withstand the enormous holding forces applied from the working component to the fastening elements. The working component used is a lower structure of a train car. The lower structure is nothing more than the basic structure of a train car. Fastening systems are designed to secure the side sills of a lower structure. The welding operation is performed to weld the end frames, cross members and various other components to the side sills of a lower structure. Also fastening systems are analyzed to test the load capacity of a fastening system. Providing the appropriate work platform is an important issue in any type of operation performed on the work component. In this way, automation has played a vital role in providing a reliable and fast clamping system that will reduce clamping cycle time with increased precision, thereby decreasing possible damage to the workpiece. 1.1 Body Structure: The train body consists of the following main substructures.
1. Under frame structure
2. End wall structure
3. Sidewall structure
4. Cab structure
5. Roof structure
Luminaire automation using hydraulic power pack for bogie undercarriage Hydraulic Circuits
A hydraulic circuit is a system comprising an interconnected set of discrete components that transport liquid. The purpose of this system is to control where fluid flows (as in a network of refrigerant tubes in a thermodynamic system) or to control fluid pressure (as in hydraulic amplifiers). The approach of describing a fluid system in terms of discrete components is inspired by the success of electrical circuit theory. Just as electrical circuit theory works when the elements are discrete and linear, hydraulic circuit theory works best when the elements (passive components such as pipes or transmission lines, or active components such as power units or pumps) are discrete and linear. This generally means that hydraulic circuit analysis works best for long, thin tubes with discrete pumps, such as those found in chemical process flow systems or microscale devices.
Components: The circuit comprises the following components:
Active components – Hydraulic power unit Transmission lines – Hydraulic hoses Passive components – Hydraulic cylinders
Proposed system
Objective of the work: The objective of this work is to study and optimize the performance of chassis templates used in the production of train cars. The suggested approach would be to automate clamping using hydraulics which would reduce operating cycle time, eliminate human errors and could minimize damage to the actual product at clamping locations. The total time required for automatic fixing will be 4-6s. This system was designed to work with automatic fixing of all luminaires simultaneously, which includes a total of 18 luminaires.
Advantages of the system The advantages of the proposed system are as follows:
- Reduces cycle time.
- Reduces the need for labor.
- System simplicity.
- Increases flexibility.
Disadvantages of the system The disadvantages of the proposed system are as follows:
- Requires regular maintenance.
- Loading/unloading time may increase slightly due to the need to connect hydraulic hoses.
Reference Report and Download:
