Germany – CNC lathe – Tandem-Unterflur-Radsatz-Drehmaschine (URD) für das Werk Düsseldorf, DB Regio AG

DB Regio AG operates two adjacent single underfloor wheel set turning machines (URD) on tracks 63 and 64 in a URD hall at the Düsseldorf site, which are control-engineering linked to each other via a common chip conveyor. The existing machine on track 63 is to be replaced by a CNC-controlled tandem URD (new procurement). For this purpose, the existing machine on this track must be dismantled and recycled. After the dismantling of the existing machine, the foundation will be modified by the client for the installation of the tandem URD. During the entire conversion measure, the operation of the URD located on the adjacent track (track 64) is to be ensured. Measures required for this (e.g. a temporary chip disposal concept, protective measures) are part of the bidder's scope of services. The present publication refers to the manufacture, delivery, assembly, commissioning, training, test operation and final acceptance of the machine with integrated measuring system incl. all necessary peripherals as well as the associated dismantling of the existing machine with integrated measuring system incl. associated peripherals for the Düsseldorf plant. The machine is mainly used to measure and process wheel sets of DB Regio AG in standard gauge 1,435 mm. For the following tasks/functions, the tandem URD must be suitable: --- automatic measurement of the wheel sets in at least the usual wheel set dimensions a1, a2, d, ∆d, e, h, qR, G and H --- measurement/processing of the wheel sets in the installed state or as individual wheel sets with bearings/bearing housings - wheel sets can be internally or externally mounted - externally mounted wheel sets can sometimes be mechanically coupled to each other within a vehicle (up to 4 coupled wheel sets) --- automatic reprofiling of the wheel rims/running surface on monobloc and tyred wheel discs with profiles according to DIN EN 13715 or DB-specific specifications in various diameters and widths as well as: - processing of brake discs (planing) - removal of overrolling and re-engraving of the identification groove --- proof of the compliant condition of the wheel sets after processing with regard to the parameters d1,2, ∆d1,2, e1,2, h1,2, qR1,2, H1,2, G1,2, a1 and a2 with an integrated measuring system according to DIN 27201-9 --- automated transfer possibility of measuring and identification data of the wheel set to the internal ERP system (SAP ISI) as well as the automated storage of pdf/A processing protocols on the systems of the DB --- possibility of remote maintenance access via "secure remote maintenance" --- output of defined machine information via OPC-UA interface --- registration/deregistration of operators via DB corporate ID and assignment of corresponding authorizations --- preparation for "upgraded turning" of vehicles with electric traction --- taking over the chips of the adjacent single URD incl. control-engineering linking of the chip disposal system of both machines. The URD is to be designed with an automatic chip disposal system with chip breaker, a smoke and dust extraction system, a hydraulic system and further functionally necessary peripherals according to CE conformity to the latest state of the art. The primary measuring circle diameter range to be processed is between 580 mm and 1,250 mm. The axle distances within a bogie are between 1,800 mm and 3,500 mm. The wheel set shaft length including the bearings/bearing housings is a maximum of 2,600 mm and the axle load acting on the machine is a maximum of 225 kN (plus any holding-down forces to be introduced).