Innovation of Processing Technology for Train Coupler Buffers: Multi-process Integration Ensures Track Safety

Another technological breakthrough has been reported in the field of railway equipment manufacturing. A certain enterprise has successfully developed an intelligent processing line for the train coupler buffer. Through the seamless connection of 12 processes such as turning, milling, and heat treatment, the fatigue life of key components has been increased by 30%. This technology has been applied to high-speed rail EMUs and heavy-haul freight trains, contributing to the upgrading of rail transit equipment. "The core of the processing of the train coupler buffer lies in the analysis of multi-physical field coupling." The technical director demonstrated the simulation model. It is difficult for traditional processes to balance impact absorption and energy dissipation. The new solution uses a topology optimization algorithm to reconstruct the structure of the buffer at the micrometer level. "This is equivalent to endowing the metal with a'memory function'." After testing, under 3 million cycles of impact, the plastic deformation of the new buffer is controlled within 0.2mm. In order to improve the processing accuracy, the team has introduced industrial CT detection technology. After the forging process of the buffer, the internal pores are scanned with a 200kV ray, and a processing allowance compensation plan is automatically generated. "This has increased the subsequent machining efficiency by 45%." The project leader introduced that the supporting automated logistics line can achieve 24-hour unmanned production. A certain railway company has reported that the longitudinal impact force of the coupler equipped with the new buffer has been reduced by 18% under extreme working conditions, and the reliability of vehicle coupling has been significantly improved. "Especially its performance in low-temperature environments far exceeds that of traditional products." The director of the maintenance workshop said that the decrease in the equipment failure rate has reduced the maintenance cost by 22%. The enterprise has established a digital twin platform for buffer processing, covering the full-process data from raw material inspection to finished product assembly. The R&D team revealed that they are developing a quality traceability system based on blockchain, which will enable full life cycle management in the future. "This will promote the transformation of the processing of train coupler buffers towards intelligence and greenness." With this technology passing the CRCC certification, the level of autonomy of core components of China's rail transit has reached a new height, providing more reliable equipment support for railway projects along the Belt and Road Initiative.