The bolster spring seat of a railway locomotive is a waist-shaped cylindrical structure, composed of two pillow-type hoarding plates and a small bolster cover plate. The small bolster cover plate is 30mm thick and made from 16MnDR steel, while the pillow-type hoarding plates are 16mm thick and also constructed from 16MnDR. As locomotive production has significantly increased, traditional manual welding methods—known for low efficiency, high labor intensity, and a high rework rate—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 railway and component welding standards. The joint between the small pillow cover and the pillow waist section is a T-joint, classified under CPB weld quality and CT1 inspection grade. This requires 100% visual, surface, and internal inspections to ensure the highest level of quality and safety.
The joint between the two pillow-type hoarding plates is a V-groove butt joint, also rated at CPB quality and CT1 inspection grade. However, for this joint, only 100% visual and surface inspections are required, as it is less critical compared to the T-joint.
The welding sequence follows a specific process: first, the small pillow cover is mounted on a specialized rotating tool and positioned accurately. Then, the pillow waist panel is installed, with a gap left for proper alignment. After positioning, tack welding is performed. Based on the weld quality requirements and the expected welding shrinkage, a 4mm gap is maintained for the 4HVa3 weld seam, and a 3mm gap is used for the 16V weld. This careful planning helps ensure structural integrity and reduces the risk of distortion during the welding process.
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