Robotic Bogie Wash

Maxi-Steam Cleaning Systems totally modernise the cleaning of bogies.

The robotic bogie wash plant is fully automated, the robots programmed to accurately follow the bogie surface This very effectively removes rust, oil and metal debris, while filtering and recycling the washing solution used in the system. This very efficient cleaning process has created huge productivity increases in what was a dirty and ineffcient task.

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The cleaning of bogies has conventionally been a very dirty hand operation, the contaminants being cleaned off the surface splashing in all directions and over anyone or anything close to the operation. In addition, the standard of cleaning requires a degree of expertise to be shown by the operator, meaning that someone relatively skilled is required to undertake the task. This deprives the production area of that operator's skills for the duration of the bogie cleaning time.

With the introduction of the new Robotic Bogie Washing Plant, robots in a specially constructed and enclosed booth deliver the service. The bogie itself is automatically advanced through the booth after being attached to the progression system and emerges perfectly dry and clean 90 minutes later. Importantly, of those 90 minutes, only 10 minutes comprise operator time, compared to 3 hours previously.

The system can be programmed to wash the bogies in several configurations. The bogie can be given a clean before stripping, as a bare frame or as a disabled bogie which has a 'locked wheelset'. The system permits other large parts to be cleaned by installing special racks to hold the components. The robots can then be programmed to wash these components to the same degree as the bogie frames.

ENVIRONMENTAL RESPONSIBILITY
The complete washing process is performed within an enclosed booth, which retains all the steam and mist as well as preventing the sprayed oil, grease and other contaminants from being splashed onto the cleaning personnel. The steam and mist is extracted via an exhaust duct to the outside environment and not into the workshop area.

The same bogie after completion of the wash - the results are self-evident!

The system recycles the wash solution through a filter which removes and automatically discharges the contaminants to a waste treatment plant for disposal. The filtered wash solution is then returned to a holding tank for re-use, where the detergent concentration is checked and made up as necessary.

The energy requirements of the system are minimised by turning the plant to 'heat' when not in operation, and a heat exchanger in the insulated tanks maintains the water temperature without the need for high booster heaters being turned on prior to operation.

SAFETY FEATURES
Access to the inside of the cleaning booth is not permitted during the cleaning cycle. The spray barriers are interlocked with the automatic control to prevent any entry. The robots return to their 'Home' position prior to the bogie being moved and an alarm alerts the operator to the impending movement of the bogie.

Every stage of the cycle and plant is constantly monitored for correct operation, and an alarm alerts the operator if a fault is detected. Depending on the severity of the fault, the plant may shutdown automatically, if required.

ADVANTAGES OVER OTHER BOGIE WASH SYSTEMS
The Maxi-Steam Robotic Bogie Washing Plant is energy efficient, using less than 200 amps while other systems use upwards of 400 amps for heating and 70 amps for powering pumps and other machinery. Heat loss is limited to about 4 deg C per day from insulated hot water heaters compared with large uninsulated surfaces on other systems.

The Robotic Bogie Washing Plant requires much less water to operate, using 1300 litres compared to 8 tonnes of water, all of which is filtered and recycled. Detergent concentration is kept very low and relies on the low flow at high pressure of the spray for the washing impact rather than high flow at low pressure and high detergent concentration to achieve the washing process as used by other washing systems.

The complete Robotic Bogie Wash Plant, showing the Progressor system with a stripped bogie. The control cubicle and high-pressure pumping system is located behind the stainless steel panels to the right foreground, while the filtration system is located on the far side of the spray booth. One of the robots is shown in the 'Home' position. High speed roller doors are located at each end of the spray booth (enclosed in the blue canopy) and close as soon as the bogie enters the booth.