How Hot 3D Laser Measurement Guarantees Accurate Railway Wheels

1. Railway Wheels and Inspection

Railway wheels are a very important component of train operation. Their dimensional and geometric accuracy are directly related to the safety and performance of the train. Even small deviations can lead to big problems. If the wheels have dimension problems, they will accelerate the wear of the train, as well as increase energy consumption, or potential safety risks. Therefore, precise dimensional inspection during the wheel production process is very important.

Traditional cold inspection methods typically require the wheel to cool completely before measurement. This not only delays problem identification but may also fail to accurately reflect the wheel’s true shape after the forging process.

So in order to overcome this limitation, we have introduced the Hot 3D Laser Measurement System. It enables direct measurement of wheels be possible when they are still at a very high temperature, this temperature approximately is 1150°C. By doing this, we can make sure that each wheel is perfectly formed before leaving the factory.

2. Why is Inspecting Forged Railway Wheels So Important?

The production of forged wheels involves some stages, such as hot forging, cooling, and finishing. Under high temperatures, metal expands and can deform. If we do not inspect the dimensions of wheels on time, wheels may have some problems, such as dimensional inaccuracies, irregular shapes, or rim anomalies.

Traditional inspection methods measure wheels only after they have cooled. This extends the production cycle, and the cooled dimensions may not accurately represent the true post-forging condition. So we need this kind of technology, which is kind of hot, in-line, non-contact measurement technology, which is particularly important for wheel manufacturing.

3. What is a Hot 3D Laser Measurement System?

The Hot 3D Laser Measurement System is a high-precision, non-contact measurement device that combines high-temperature measurement, laser scanning, and 3D imaging technology.

High-Temperature Measurement: In this step, we can measure dimensions directly on wheels up to 1150°C, with no waiting for cooling.

3D Scanning: Rapidly scans the entire wheel surface with a laser beam to capture complete 3D geometric data.

High Precision: Measurement accuracy up to ±0.2 mm, ensuring dimensional errors are kept within an extremely small range.

Visualisation: The system generates a 3D cross-sectional view of the wheel, allowing engineers to clearly and intuitively observe its shape and dimensions.

In simple terms, it allows engineers to “see” the true shape of the hot wheel and quickly determine if its formation is qualified.

4. How Does Hot Measurement Inspect Forged Wheels?

The inspection process using the Hot 3D Laser Measurement System mainly includes the following steps:

Wheel Exit from Forging: The wheel is still at a very high temperature of around 1150°C after forging.

Laser Scanning of Surface: A laser beam quickly scans the entire wheel surface; by doing this, we can collect high-density 3D coordinate data.

Generating a 3D Profile: This process is based on the scan data; the system generates a 3D cross-sectional view. By doing this, we can get to showing key areas like the rim, hub, and tread, and can clearly present the wheel’s dimensions and shape.

Comparison with Design Data: The measurement data is automatically compared against design standards. The system flags any dimensional or shape deviations, helping engineers quickly assess the wheel’s formation quality.

Through this process, any issues can be detected immediately, effectively reducing rework and scrap.

5. How Does Measurement Data Improve Wheel Quality?

As we can see, the Hot 3D Laser Measurement System really help us with production the accurate railway wheels. we can not only measure dimensions but also analyse shape, profile, and rim curvature, providing valuable data for production decisions. Using this data, we can get the following results.

Adjust Forging Processes Quickly: If deviation trends are detected, forging parameters can be promptly adjusted to ensure subsequent wheels meet standards.

Reduce Rework and Scrap Rates: Immediate inspection in the hot state is more efficient than cold inspection, significantly reducing waste of materials and time.

Accumulate Production Data: Long-term data accumulation helps optimise forging processes, predict quality trends, and thereby enhance overall production efficiency.

This data-driven approach ensures every wheel leaving the factory meets stringent quality standards.

6. Advantages of the Hot 3D Laser Measurement System

By adopting the Hot 3D Laser Measurement System, we achieve fast, precise, and intuitive high-temperature inspection of wheels. Here is some main advantages.

1. High Precision: ±0.2 mm measurement accuracy. This accuracy ensure wheels strictly comply with design requirements.
2. High Efficiency: No waiting for cooling. This means the measurement process is fast and does not slow down the production pace.
3. Clarity and Reliability: The 3D cross-sectional view makes dimensions and shape immediately apparent, facilitating quality judgment.
4. Process Optimisation: Accumulated measurement data provides a scientific  basis for improving forging processes and production workflows.

So we can see that the Hot 3D Laser Measurement System is more than an advanced inspection tool, it is essential for ensuring every forged wheel is perfectly formed and meets the highest quality standards. At Luoyang Fonyo Heavy Industries Co., Ltd. we specialize in producing high-performance railway wheels that are crafted and inspected with these advanced technologies. To learn more about our products and capabilities, visit us at www.railwaypart.com

For more in-depth information on railway wheels

You might also be interested in our other articles:

Railway Wheel Heat Treatment Explained for performance improvements

Ultrasonic Testing of Railway Wheels to understand internal inspections

Railway Wheel Structure and Composition for a complete guide

Visual Inspection Methods for Railway Wheels to spot surface defects

How NDT and Non-Destructive Quality Inspection Guarantee Railway Wheels to ensure wheel reliability and detect hidden defects

If you have any requirement for railway wheels or other railway parts, please contact us.
Our engineering team will be glad to discuss your operating conditions and technical requirements.