MOBILE WHEEL LATHE 1AK200 INSTRUCTION MANUAL (M201)

The multifunctional device for turning wheel sets of railway wagons 1АК200 is designed to eliminate peaked rolling of the wheel flange, undercut of the flange in the presence of rolling and influx of the flange. The cost of mobile wheel lathes 1AK200 is several times lower than that of stationary wheel lathe machines, and mobility and light weight are their indisputable plus and huge competitive advantage, which provides significant savings of time and money.

1. BASIC INFORMATION AND TECHNICAL DATA OF THE 1AK200 MOBILE WHEEL LATHE

Company 1AK200 produces a 1AK200 mobile wheel device designed for machining wheels of railway rolling stock on spot, 1AK200 model is designed for turning without rolling out wheel sets of railway cars.

The mobile wheel turning machine 1AK200 was invented and patented in Estonia in 2002 and in the Russia in 2003.

The first demonstration of this invention was at an international exhibition in Brussels (Belgium), where the 1AK200 mobile machine for turning wheels of railway rolling stock received a gold medal. The 1AK200 device was also exhibited in Moscow (Archimedes), Geneva (gold medal), and after certain modifications of the 1AK200 machine another gold medal was received at the EUREKA exhibition in Belgium.

The mobile wheel-rolling device 1AK200 relates to railway transport, in particular, to the wheels of locomotives, motor and freight cars and is used to eliminate some of the defects of the wheels that appear during exploitation. A stationar wheel lathes is known, when eliminating defects in the wheels of the rolling stock, it is necessary to roll out the wheel set from under the car and use lifting mechanisms for repairs in the depot. Repair of each wheel separately is carried out on a stationary wheeled lathe. When using the mobile wheel turning device 1AK200, the elimination of wheel defects that appear during operation is possible without rolling out from under the rolling stock. The mobile wheel device 1AK200 can be used wherever there is an asphalt or concrete platform at the level of the rail head available, voltage of 380 volts for a wheel pair rotator (WRD-380), and when turning wheel sets of locomotives with a modification of the 1AK200 machine ZIP is additionally needed pit.

The weight of the device 1АК200 complete with a wheel drive WRD-380 is about 350 kg. The occupied volume during transportation - 2 euro pallets - i.e. the whole set of the machine fits easily in a small cargo bus. The cost of consumables (cup cutter) is 35 euros per piece EXW. One cutter can be turned 50 or more wheels (record is 65).

The warranty for mobile wheel-turning machines 1AK200 is five years from the date of delivery (except for components that are covered by the standard manufacturer's warranty for 1 year - electric motor, jacks, frequency converter, etc.). Officially, the resource of the machines was set at 7 years, but many 1AK200 machines have been successfully operating for more than 15 years.

Technical characteristics of the wheel-mounted device 1AK200

Dimensions and weight 1AK200

• stand with a wheel pair rotator 1450x450x100 mm
• stand with a turning module 1450x450x100mm
• Diameter of the processed wheels 800-1050 mm
• insert X movement 200mm
• insert Y movement 200mm
• el.motor power 7.5 kW
• frequency converter 11.0 kW

2. PRINCIPLE OF WORK

Mobile wheel lathe 1AK200 consists of five main elements: cross slide with a toolholder and wheel set rotation unit both mounted at two special design stands, frequency converter (acts as a rheostat) and two hydraulic jacks. For wheels machining a special design holder with carbide insert is used. The wheel pair rotation unit consists of friction wheel and mechanism for adjusting traction of a friction roller, which allows to rotate the wagon wheel. Smooth start, power adjustment and engine speed are provided by a frequency converter with engine control via remote cable control.

Green button on the remote control - press and hold - lover RPM, red button - press and hold - increase RPM. Black switch - vertical position - off, left or right position - rotation of the motor shaft in one or another side. The console remembers the last preset mode, therefore, by at the end of the cycle, the speed should be reduced to the minimum value. You can also control turnover and reverse from the built-in remote control on the frequency converter (multilingual) - press the Loc / Rem button to switch between remote and integrated control panel. All elements of the 1AK200 are mobile and easy to use. The use of the 1ak200 mobile wheel device allow to parallel wheel machining and technical maintenance of wagons, which ensures traffic safety railway transport and significantly reduces downtime rolling stock under repair. The problem solved by the implementation of the wheel-turning device 1AK200 consists in extending the life of the wheels and reducing the downtime of rolling stock in repairs. The technical result obtained when solving the problem is the elimination of defects in wheel sets, such as pointed rolling of the wheel flange, undercut of the flange in the presence of rolled metal and the influx of the flange.

3. WORK WITH LATHE

For learning the device highly recommended first provide machining of old/used non production wagons/wheel sets/bogies/wagons. Check all cables before and after it is connected with electric motor and frequency converter. Before starting to work wagon must be fixed against movements with wheel stops. Place one stand with wheel rotation unit under one wheels and stand with cross slide under wheel from another side of wheel set. Place hydraulic jacks on the stands.

Simultaneously lift up wheel set with hydraulic jacks for 15-25 mm above rail heads.

Start the electric motor and move the friction roller at the smallest RPM to make the wheel set spin.

Slowly increasing the speed motor, bring the wheel into slow rotation.

Choose optimal speed of wheel set rotation for machining depending of turning inserts used.

Should focus on optimal machining speed about 70 meters/min, but this depends of turning inserts used (recommended cutting speed usually printed on inserts pack).

The RPM is visible on the frequency inverter display and machinist using the remote control can adjust wheel set rotation speed to achieve the best result when machining wheels.

The tool holder with a cutting insert is brought to the wheel surface and the machining process begins. The surface to be turned must be controlled by a profile gauge. Upon machining it is necessary to monitor the profile of the wheel, it must remain unchanged, only the wheel defects must be removed.

Chip thickness should be extremely minimal.

When machining of wheel are done - move friction wheel and turning insert away from wheel set, wait until wheel set fully stops rotation, then lower hydraulic jacks and remove stands from under wheel set.

Trained personnel are allowed to work with the lathe, preferably machinist with wheel turning skills.

All lathe elements require careful handling.

The place of work must be clean, dry, equipped fire fighting equipment.

SERVICE LIFE, STORAGE AND DISPOSAL

• The recommended use of the lathe is 7 years.
• The lifespan of the 1AK200 wheel lathe and its uptime depend on proper maintenance, timely troubleshooting, thorough preparation for work and compliance with storage rules.
• Storage conditions - store in a dry, closed warehouse at ambient temperature from +5 to + 40С. Relative humidity should not exceed 80%.
• The specified service life is valid if the consumer complies with the requirements of this guide.
• With the full using resource of the lathe, it must be disposed in compliance with all standards and rules. To do this, you need to contact a specialized company, which, observing all legal requirements, engaged in the professional disposal of equipment.

Manufacturer: 1AK200

E-mail us if you have any questions: russia@mobilewheellathe.com