Methods and systems for manufacturing an axle

Abstract

A continuous system for automatically manufacturing an axle is provided. The system includes a plurality of sub-systems and an automated transport system. The plurality of sub-systems includes a furnace configured to heat a billet to a predetermined forging temperature, a forging system configured to forge an axle from a heated billet, and a machining system configured to form a machined axle from said axle. The automated transport system is configured to automatically transport a product to and from each of the plurality of sub-systems. The product includes the billet, the axle, and the machined axle.

1 .- 31 . (canceled) 
     
     
         32 . A continuous system for automatically manufacturing an axle, said system comprising a plurality of sub-systems and an automated transport system, said plurality of sub-systems comprising:
 a furnace configured to heat a billet to a predetermined forging temperature;   a forging system configured to forge an axle from a heated billet; and   a machining system configured to form a machined axle from said axle, wherein said automated transport system is configured to automatically transport a product to and from each of said plurality of sub-systems, said product comprising said billet, said axle, and said machined axle.   
     
     
         33 . A system in accordance with  claim 32 , wherein said automated transport system further comprises at least one of a conveyor, a robotic manipulator, and a crane. 
     
     
         34 . A system in accordance with  claim 32  further comprising a control system configured to control said plurality of sub-systems and said automated transport system. 
     
     
         35 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a receiving area at a beginning of the product transport system, said receiving area configured to at least one of receive said billet and store said billet. 
     
     
         36 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a cutting system configured to automatically cut said billet to a predetermined size, wherein said predetermined size is based on a type of axle to be manufactured from said billet. 
     
     
         37 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a tracking system configured to track said billet and any axles produced from said billet during the manufacturing process. 
     
     
         38 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a descaler comprising a high-pressure water stray, said descaler configure to direct said high-pressure water spray at said billet to facilitate removing slag from said billet. 
     
     
         39 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a heat treating system configured to automatically alter a temperature of said axle to produce an axle having predetermined metallurgical properties. 
     
     
         40 . A system in accordance with  claim 39 , wherein said heat treating system comprises:
 a post-forging cooling system configured to passively cool said axle;   a normalizing system configured to normalize said axle;   a post-normalizing cooling system configured to passively cool said axle; and   a tempering system configured to temper said axle, wherein said axle is continuously transported through said heat treating system by said automated transport system.   
     
     
         41 . A system in accordance with  claim 40 , wherein said heat system further comprises a quenching system between said normalizing system and said post-normalizing cooling system, said quenching system configured to quench said axle with water prior to axle. 
     
     
         42 . A system in accordance with  claim 32 , wherein said forging system is configured to forge said heated billet into a double axle, wherein said double axle includes a first axle having opposing ends and a second axle having opposing ends, wherein said first axle is coupled to said second axle at one end of each axle, wherein said plurality of sub-systems further comprise an axle separation system configured to separate said first axle from said second axle by forming at least one cut in said double axle. 
     
     
         43 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a straightening system configured to verify straightness of each axle before machining said axle and, if the straightness of said axle is not verified, to correct the straightness of said axle before machining said axle. 
     
     
         44 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a cooling area comprising a plurality of pallets and a conveyor system, said cooling area configured to passively cool said axle on said plurality of pallets before machining said axle, wherein said conveyor system continuously transports said axle through said cooling area, said automated transport system comprising said conveyor system. 
     
     
         45 . A system in accordance with  claim 44 , wherein said cooling area is configured to cool said axle from about 1200° F. to about 200° F. during a time period that is between approximately 6 hours and approximately 10 hours. 
     
     
         46 . A system in accordance with  claim 32 , wherein said machining system further comprises:
 an end facing system configured to end face said axle and to define a center hole in each end face of said axle; and   a series of lathes for defining at least one of a wheel seat, a bearing seat, and a barrel of said axle, wherein said automated transport system is configured to automatically transport a product to and from said end facing system and said series of lathes.   
     
     
         47 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise an inspection system comprising at least one of an ultrasonic testing apparatus, a magnetic particle testing apparatus, and an automated visual inspection apparatus. 
     
     
         48 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a laser measuring device configured to measure dimensions of said machined axle. 
     
     
         49 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise an axle marking system configured to mark said machined axle with an identification mark, said identification mark providing information relating to said machined axle and said billet from which said machined axle was formed. 
     
     
         50 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a washing system configured to wash said machined axle to facilitate preventing rust from forming on said machined axle. 
     
     
         51 . A system in accordance with  claim 32 , wherein said plurality of sub-systems further comprise a plurality of output cranes configured to automatically load a plurality of said machined axles onto at least one of a truck and a train car according to a predetermined axle shipping allocation. 
     
     
         52 . A system in accordance with  claim 32 , wherein said system is housed within a single building. 
     
     
         53 . A system in accordance with  claim 52 , wherein said single building comprises a forging side and a machining side separated at least in part by a wall, said forging side comprises said furnace and said forging system and said machining side comprises said machining system, wherein said system further comprises a venting system for creating a negative air pressure within said forging side to facilitate preventing contaminants from migrating to said machining side. 
     
     
         54 . A system in accordance with  claim 53 , wherein said venting system comprises:
 a plurality of fans located on a roof of said single building; and   a plurality of louvers located within at least one side wall of said single building.   
     
     
         55 . A system in accordance with  claim 32 , wherein said furnace and said forging system are located within a first chamber and said machining system is located within a second chamber, wherein said system further comprises a venting system for creating a negative air pressure in said first chamber for preventing contaminants from migrating to said second chamber.