How Important The Axle Box to The Railway Locomotive?

Overview of The Locomotive Axle Box

In the speeding rail transit system, if the bogie is compared to the “legs” of a train, the axle box body is the key “joint” that connects the bones and muscles. This seemingly bulky metal component is actually the core part that ensures the safe, smooth and efficient operation of the train. As the connection hub between the wheel and axle system and the bogie, the axle box body always plays three roles throughout the entire life cycle of the train – the central nervous system for mechanical transmission, the last line of defense for operational safety, and the core carrier for intelligent operation and maintenance.

First,The core hub of the mechanical transfer system

The axle box, through a unique geometric structure design, scientifically decomposes the vertical impact force generated by the wheel-rail contact, the lateral centrifugal force when the curve passes through, and the longitudinal inertial force during braking and acceleration. The internal stress distribution has been optimized by the finite element method, which can reduce the maximum load at a single point from 38MPa in the traditional design to 22MPa, equivalent to reducing the dynamic load of 2.5 tons for each carriage.

Second,Intelligent filter for vibration energy

It adopts a layered damping structure design with embedded high-molecular shock-absorbing materials and hydraulic buffer units to form a composite vibration-damping system. The measured data show that this structure can attenuate the vibration energy within the frequency range of 5-80Hz by 65%, reduce the high-frequency noise by 12 decibels, and directly improve the passenger comfort level index (ISO 2631) by 0.3 grades.

Third, Precise guidance instrument for power transmission

The positioning accuracy of the bearings inside the axle box body reaches the level of 0.02mm, which is equivalent to one-third of the diameter of a human hair. This ultra-precise coordination ensures that the power transmission efficiency remains above 98.7%. Compared with the traditional structure, it reduces energy loss by up to 15%, and a single train can save 42,000 kilowatt-hours of electricity annually.

Fourth, Guardian of extreme working conditions

In an extremely cold environment of -50℃ and a braking high temperature of 120℃, the axle box body cast with special alloys can still maintain stable mechanical properties. Its material fatigue strength reaches 550MPa, capable of withstanding the continuous impact of water pressure (25MPa) equivalent to the height of a 20-story building. The design safety factor is as high as 3.2, far exceeding the 2.5 standard requirements of the International Union of Railways (UIC).

Fifth, Fault isolation firewall

The unique modular structure enables the axle box body to form an independent sealing unit. When the bearing malfunctions, the multi-layer labyrinth sealing structure can isolate the fault within a 1.2 cubic meter space. Combined with the fuse safety device, the probability of mechanical failure causing derailing is reduced to 0.003 times per million kilometers.
The sensor network integrated into the axle box body can monitor 12 parameters, such as temperature, vibration and displacement, in real-time, with a sampling frequency of up to 20kHz. Through edge computing technology, an abnormal bearing clearance of 0.01mm can be identified within 30 milliseconds, which is 400 times more efficient than manual detection.

Sixth, An outpost for intelligent monitoring

The sensor network integrated in the axle box body can monitor 12 parameters such as temperature, vibration and displacement in real time, with a sampling frequency of up to 20kHz. Through edge computing technology, an abnormal bearing clearance of 0.01mm can be identified within 30 milliseconds, which is 400 times more efficient than manual detection.
 

Supplier

Luoyang Fonyo Heavy Industries Co., Ltd,founded in 1998,is a manufacturer in cast railway parts.Our factory covers an area of 72,600㎡, with more than 300 employees, 32 technicians, including 5 senior engineers, 11 assistant engineers, and 16 technicians.Our production capacity is 30,000 tons per year. Currently, we mainly produce casting, machining, and assembly for locomotive,railcar,high-speed trains, mining equipment,wind power,etc.Our products have been exported to Russia, the United States, Germany, Argentina, Japan, France, South Africa,Italy and other countries.
Contact:Cathy
Email:sales@railwaypart.com
Mobile:008615515321683