Wheel flange lubrication

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Problem solution



Problem solution
The problem was solved:

Dominating component
of the hydraulic system is the compact tank system.
Outside the tank system, for economical and thermal reasons, you can only find components
IN LIMITED extent.
System is created by:
feed pump, as suitable pressure generator, preferably a gear pump and
heating, preferably an electric insert heating element with six tubular heating bodies and a temperature controller; hydraulic, round-going, heated feed-, or feed- incl. pressure flow is produced.

Circulating volume flow, as closed heated system, is almost completely separated from outside temperatures. This is possible by using elements with suitable isolating materials. This shall prevent the system from great heat loss.

Lubrication system contains purposely
ONLY components which let the lubricator FLOW CONSTANTLY.
The valve nozzles (V4A: valve base body, inset incl. nozzle drilling, stud) and compact reservoir as
a robust weldment construction are, depending on measurements/material adapted or new developed parts. Almost all the other parts are purchased parts.
All hydraulic components have nearly the same (lubricator) flow
CROSS-SECTION to SPECIFICALLY prevent tube constrictions, flow-resistances, “rapids” and the resulting disadvantages.
All components have
smooth surfaces without dead space to avoid residue in fluidic aspects.

Lubrication system shows a compact,
appropriate construction just as fast and uncomplicated handling. No special tools are needed for assembly/disassembly.

All components are, concerning the flow rate direction, switched up in a row, so that the flow rate, preferably warmed
FLUID lubricator and SOLID PART graphite, flows from one component to the next, in a kind of CLOSED CIRCULAR PIPELINE.

⇒ Reservoir in tank system constantly shows
PRESSURELESS volume flow, (especially in the “upwards OPENED” reservoir).

⇒ closed circular pipeline shows from
EXIT to ENTRANCE tank system either:
     - ALMOST PRESSURELESS ( = flow rate) or
UNDER HIGH PRESSURE (preferably 24 bar) STANDING (= flow incl. pressure rate) volume flow
        (especially in flexible conducting pieces and valve nozzles).

Overall the volume flow circles “endlessly”. That way the spray
 able medium which preferably is lubricator (with graphite) constantly stays in movement and “durable” in its consistency – it doesn't “bleed”.
Principally in all seasons:
CIRCULATION in the closed circular pipeline to avoid segregations, furthermore
HEATING (preferably 70°C) of the circulation in the closed circular pipeline to maintain full function and warranty
  respectively of the lubrication system. Heating not only supplied at low outside temperatures.

All components, altogether robust and solid mounted to the rolling stock withstand violent
vibrations, which each rolling stock is exposed to.

From part to part, volume flow supporting closed circular pipeline consists of various interrupted, almost completely
flexible conducting pieces. Beginnings and endings of the pipes are assembled with connecting elements as transitions to components (preferably interlocked).

Flexible pipes are used because:
- valve nozzles, e.g. mounted to independent wheels, can make free
relative motions unlike ones which are mounted to the rigid vehicle
vibrations and noises, caused by electric switching operations of the valves (or feed pump)
  and associated swinging between pressureless and pressured volume flow are

Lubrication system, especially with reservoir with hydraulic elements, should be placed
inside the vehicle (vehicle body)
near the bogie or wheels.

Closed circular pipeline should be as short as possible.

System works very economically in two steps.

In this specific case the flexible pipes, meaning hydraulic
transmission links, fulfill functions as:
- pipe in almost pressureless circulation ( = low system pressure while static load) and as
- pipe in pressured circulation ( = high system pressure while fluctuating load).

Both fixed
INSTALLED pipes and in each component, the relative cross-sectioned sized, “FUNCTIONAL LIQUID FLOW PIPES” show SUFFICIENT bend radii, so that the medium's flow-resistance is kept at a MINIMUM. This grants an almost free, endless circulation of the medium in the closed circular pipeline.

Pipes cross-section
The closed circular pipeline's flow cross-section IS PURPOSELY ENLARGED, so that the liquid with solid parts can FLOW
unhindered (preferably IN: (reservoir), connections, flexible/fixed pipes, pressure control valve, valve nozzles which are flown
through, ball valve, pipe parts). Preferably during spray
 ing process a RESERVE shall be build up due to AUTOMATIC

Valve nozzles which are flown through, perferably a combination of:
- 12 valve nozzles on 4
wheels and/or
-   6 valve nozzles on 2
are integrated to a closed circular pipeline and show characteristic design.
Valve nozzles are flown through unhindered by a liquid medium (incl. solid parts), preferably lubricator with graphite. They are heated at the same time and keep warm. Valve nozzles should not be operated under a temperature of 70°C and pressure of 24 bar in the closed circular pipeline.

Valve nozzle – basic body has a built in surface so it can be
fixed to the holder.

Valve nozzle's volume flow dispension, even under
continued usage is significantly lower as volume flow produced by feed pump.

After the last valve nozzle switched in a row, the closed circular pipeline runs through many pipe parts and flexible pipes back to the tank's connection.

Due to pressure balance it is
NECESSARY that air flows overtop of the used medium.

As soon as
USEABLE lubricator stock is used up, the power shuts down automatically due to the magnetic swimmer. The system shuts itself off.

Thermometers, adjustment elements on parts are left away from system PURPOSELY. They are not necessary. Parts could cause malfunctions and would unnecessarily raise production costs.

Medium of high
density, which is not sidetracked by airstream hits the air gap as a dosed, high pressured jet and gets to the wheel tire's sidewalls and running surfaces. The jet hits the wheel tires targeted area on the spot and afterwards spreads itself as a thin circular lubricating film.

The usage of a low pulsation gear pump has a positive effect to the parts
life and low wear off.

VENTILATION of the system is not necessary.
Air bubbles which may be in the closed circular pipeline
NOT effect the system's functionality
are transported with the flow and vent through the air filter of the tank system
also have the possibility to leave the system during a spray
 ing process through an opened valve nozzle (step 2).

Soiling inside the system is not possible.
Reservoir can be
TANKED at any time – in ON and OFF mode.

Three phase short-circuit motor of the electric pump could be frequency or voltage influenced this means it could run in two
speed levels by electrical/electronic control.

Liquid with/without solid parts
In the
reservoir's UPPER part is the USEABLE liquid (incl. solid parts), which gets smaller due to volume flow and which can be tanked when needed.
Reservoir has a large capacity of
USEABLE liquid (incl. solid parts), preferably lubricator with graphite.
In the reservoir's middle a partitioning disk (bulkhead plate) is welded in to steady the medium.
mainplate has a tilt angle of 3 degrees. Lubricator pump aspirates at the deepest point of the reservoir.

Characteristic for the tank system are the hydraulic pipe and electric cable connections which are fastened to a plate on the front and outside. These connections for hydraulics and electrics are separated from each other and easy to reach for installation. This grants a fast and uncomplicated installation of the reservoir and its hydraulic parts.

Shut-up valve (electrical ball valve)
The control of the shut-up valve and the resulting load changes of the feed pump or
duty cycle and valve nozzle's switching rate depend on:
- curve radii of the curved track
- rail's form, meaning headrail or grooved rail
- curve travel frequency of the rolling stock
- rolling stock's speed
- weight and measurements of the rolling stock or the rails and
- usage of independent wheels or wheelset axles with both-sided pressed on wheel bodies.

Practically, valve nozzles are controlled by electrical/electronic controller or if suitable by Global Positioning System (GPS) for positioning and timing.

The “giver” mounted to the first bogie (looking in travel direction) can be used to signal the beginning of a curve. These untouchable, almost free of wear off switches are moulded, adjusted once and function weatherproof in high temperature levels.

An electric switch can enable the switching of the lubrication system. This depends on the rolling stocks travelling on:
- head- or
- grooved rail.

In cities (circa 200,000 inhabitants) with a large and frequently used tramway networks, the RAIL must be lubricated
several times a day. To significantly reduce wear-offs it is adviseable to plan the daily usage (in my evaluation) of at least 50 litres (13,21 gallons) of lubricator in total.
In Intervalls, e.g. spray for 0.25 sec. , pause for 1.0 sec., small amounts of lubricator should be applied so that the CURVETRACKS (curves) show a thin and nearly even
film of lubricator that lasts.
Optimized valve nozzles have nozzle bore Ø 0.2 mm and Suppressor diode (Stand-off voltage 31 V).


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