Handling train wheels for ultrasound testing

Task

In the factory for train wheels, axles and wheelsets, after machining the unfinished wheels must be inspected for fractures and cavities in an ultrasound testing device.
The wheels must be submerged in a water tank at an angle of 75°. During this process the gripper is also totally submerged!
Wheel weight: max. 1,000kg
Wheel diameter: 700 - 1,270 mm
Total weight, incl. gripper: 2,200 kg

Solution

The train wheels are removed from the GÜDEL wheel magazine by means of a standard ZP-7HD dual-axis portal and submerged in the ultrasound water tank. After testing, the automatic portal moves the wheel to a visual inspection and marking station. After release by the worker, the wheels are given a unique code.
At the end of the system the finished, marked wheels are deposited on a wheel storage device and transported in stacks of six wheels for further handling in our German customer’s plant.

Scope of supply

ZP-7HD dual-axis module, incl. gripper and turn axis (hydr.)
Two wheel storage devices for 4 x 6 wheels each (max. load 29 t) with 4 x 90° rotation (GÜDEL gears), marking station, protection system, Siemens control, software, installation and initial start-up

Result

By centering the wheels in the newly developed wheel storage device using guide rails instead of a centrical mandrel, it was possible to attach the gripper vertically under the stroke axis allowing the use of a ZP-7HD portal. The waterproof gripper was a new development based on previous experience.