Railway Double-layer Spring Washer Manufacturing Machine/Customized mining track elastic rail clip railway fastener forming machine
Overcoming Core Challenges in Railway Fasteners – Yinfeng Spring Equipment's Technological Breakthro
1. Introduction: Industry Demands and Technical Challenges
With the rapid development of China's railway transportation toward high-speed and heavy-haul directions, unprecedented high requirements have been placed on the safety, stability, and durability of track fastener systems. As a key elastic component in the fastener system, the double-layer spring washer (or elastic rail clip) plays a crucial role. It securely locks the rail to the base through continuous elastic pressure, effectively absorbing impacts and vibrations caused by train operation.
However, manufacturing such washers faces severe technical challenges:
Special Wire Material: The use of 10mm (width) * 6mm (thickness) rectangular flat wire, compared to ordinary round wire, presents more complex issues regarding feed stability and bending formability.
Precise Structure: The small inner diameter, high number of coils, and double-layer nested structure impose extremely high demands on the equipment's spatial interference control and forming accuracy.
High Performance Requirements: The product must possess consistent preload, fatigue life, and corrosion resistance. Even minor dimensional deviations can directly affect the reliability of the entire fastener system.
Leveraging years of technical expertise in spring forming equipment, Yinfeng Spring Equipment Factory has successfully developed a customized forming machine for mining track elastic rail clips/railway fasteners, achieving stable, efficient, and high-precision mass production for such challenging products.
2. Core Solutions: Innovative Design of Yinfeng Custom Equipment
To overcome the challenges mentioned above, our equipment has undergone specialized optimization and innovation in the following core systems:
1. High Rigidity, High Precision Wire Feeding System
Special Wire Feed Wheel Sets: Addressing the tendency of 10*6mm flat wire to twist and jam, we designed dedicated feed wheel sets combining V-groove and flat profiles. The wheel grooves are precision ground to perfectly match the flat wire dimensions, ensuring the wire does not rotate during feeding, guaranteeing straightness and stability.
Powerful Servo Feeding Mechanism: Utilizes high-torque, highly responsive servo motors to provide smooth and powerful feeding force, effectively overcoming friction resistance of the flat wire within the guide tube, and ensuring precise feed length.
2. Intelligent, Flexible Curling and Variable Diameter System
"Interference-Free" Mandrel Design: This is the key to achieving the small inner diameter and double-layer structure. We use extra-slim, high-strength mandrels manufactured with special materials and processes, and optimize their support structure. This ensures a safe clearance between the curling tools and the already formed first layer during the second layer curling, completely preventing interference and scratches.
Multi-Axis Servo Control Technology: Precisely controls actuators like the curling arm and variable diameter shaft through an independent, precise servo control system. The equipment can accurately control the pitch and inner/outer diameter changes of each coil, easily achieving a smooth transition from the inner layer to the outer layer, ensuring the geometric dimensions of the double-layer structure fully comply with the design drawings.
3. Precision Straightening and Wire Guidance System
Multi-Wheel Set 3D Straightening: Configures multiple sets (typically 7-9 sets) of adjustable straightening rollers before the feed to perform three-dimensional straightening on the incoming flat wire, eliminating bending and torsional stress in any direction, laying a stable foundation for subsequent forming.
Low-Friction Guide Tubes: Uses guide tubes made of high-wear-resistant alloy material with smooth inner walls and proper clearance fit with the flat wire, minimizing feeding resistance and protecting the surface quality of the wire.
4. Powerful CNC System and User-Friendly Interface
Self-Developed YF-CNC Control System: The system comes with built-in specialized process modules for products like springs and fasteners. Operators only need to input key parameters (such as inner diameter, number of coils, pitch, layers, etc.), and the system can automatically generate the processing program, significantly reducing debugging difficulty and dependence on operator experience.
Parametric Programming: Supports product parameter storage and recall, allowing quick and easy model changeovers, significantly improving efficiency for small-batch, multi-variety production.
3. Production Practice and Results
Using Yinfeng custom equipment to produce 10*6mm flat wire double-layer spring washers has yielded remarkable results:
High Precision: Product inner diameter tolerance can be stably controlled within ±0.1mm, with excellent consistency in free height, fully meeting the stringent standards of the railway industry.
High Stability: The equipment runs continuously for 24 hours with stable forming actions and a very low product defect rate.
High Efficiency: Compared to traditional equipment or manual production, efficiency has increased by over 300%, with a significant reduction in per-unit production cost.
Zero Surface Damage: The optimized mechanical structure and precision guidance system ensure a scratch-free and indentation-free process from wire to finished product, safeguarding the product's corrosion resistance and fatigue strength.
4. Conclusion
Railway safety is no trivial matter. Yinfeng Spring Equipment Factory is always committed to providing the most reliable spring forming solutions for high-end manufacturing sectors such as rail transportation and mining machinery. This equipment customization for railway double-layer flat wire spring washers is not only a successful validation of our R&D capabilities but also demonstrates our commitment to solving practical problems for our customers and creating core value.
We believe that only through continuous technological innovation and precision manufacturing can we inject more solid strength into the backbone of "Made in China."
We welcome industry peers to exchange views and correct us, working together to advance technological progress in the industry!
Yinfeng Spring Equipment Factory
Focus · Precision · Reliability
