The bolster spring seat of a railway locomotive is a waist-shaped, barrel-like structure composed of two pillow-type hoarding plates and a small bolster cover plate. The small bolster cover is 30mm thick and made from 16MnDR steel, while the pillow-shaped hoarding plates are 16mm thick and also constructed from 16MnDR. As locomotive production has significantly increased, traditional manual welding methods—known for their low efficiency, high labor intensity, and frequent rework—have struggled to keep up with modern manufacturing demands. To address this, robot welding has been introduced as a more efficient and reliable alternative.
The weld joints on the bolster spring seat are designed in accordance with EN 15085, the standard for railway and component welding. The joint between the small pillow cover and the pillow waist section is a T-joint, classified under CPB quality grade and CT1 inspection level. This requires 100% visual, surface, and internal inspections to ensure the highest level of safety and reliability.
In contrast, the joint between the two pillow-type hoarding plates is a V-groove butt weld, also rated at CPB quality and CT1 inspection level. However, only 100% visual and surface inspections are required for this joint, as it is less critical compared to the T-joint.
The welding sequence follows a carefully planned process. First, the small pillow cover is mounted onto a specialized rotating tool and positioned. Then, the pillow waist panel is installed, with a gap reserved for proper alignment and welding. To accommodate the weld quality requirements and account for welding shrinkage, a 4mm gap is left for the 4HVa3 weld seam, and a 3mm gap is used for the 16V weld. These precise measurements help prevent distortion and ensure a strong, durable weld.
This structured approach not only improves welding consistency but also enhances overall product quality, making robot welding an essential part of modern locomotive manufacturing.
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