Automated high-pressure paint stripping optimizes throughput times and operating costs
Robot-assisted paint stripping of impact protection on wheelset axles for maintenance
In the maintenance of rail vehicles, paint stripping of wheelset axles is a key process step. Existing coating systems must be removed completely to ensure that subsequent inspection and recoating processes can be carried out reliably. At the same time, demands for process reliability, gentle surface treatment, environmental compatibility, and cost efficiency continue to increase. Against this backdrop, automated and media-efficient paint-stripping processes are becoming increasingly important.
Fully automated high-pressure paint stripping for series operation
A plant operated by a major maintenance provider in Germany has selected a fully automated, high-pressure paint-stripping system of the Geyser type from BvL Oberflächentechnik GmbH for stripping wheelset axles from running and driven wheelsets. The system removes impact-protection coatings exclusively using high-pressure water jets. The process is non-abrasive and provides gentle surface processing. After stripping, all previously coated areas are returned to bright metal and provided with a temporary corrosion protection. The wheelset axles can then be transferred directly to subsequent steps such as ultrasonic testing (UT), magnetic particle inspection (MT/MPI), or a new coating build-up.
Robot-assisted process ensures precision and consistent quality
Paint stripping is performed using a robot-assisted process. The robot guides a high-pressure water tool precisely to the outer surface of the rotating axle. While the axle rotates around its longitudinal axis, a multi-jet rotary nozzle traverses along the axle axis until the entire surface has been processed uniformly. Robotics enable high repeatability and flexible movement paths while also improving working conditions. The specified cycle time is < 23 minutes per axle.
Integration into existing maintenance workflows
The system is integrated into the existing maintenance flow. Conveyor technology for automated transport of the components into and out of the system is part of the overall
concept. During system layout, BvL takes into account the existing building geometry and the available space on site.
Closed-loop operation reduces media consumption and maintenance effort
Another key focus is media and energy efficiency. The high-pressure paint-stripping system operates in a closed-loop process. Effective filtration technology and media preparation systems reduce consumption and help keep operating costs low. By recirculating the process medium, operating costs are reduced significantly while also conserving the environment—especially the valuable resource of water. This makes the system an important contribution to sustainability and supports even more environmentally friendly rail operations. After each stripping cycle, the cleaning chamber is automatically cleaned, which significantly reduces maintenance and cleaning effort. Optionally, an air-blast unit can be installed downstream for additional drying.
Broad system portfolio for the railway industry
Component cleanliness is a key quality attribute in the maintenance of railway components. It is the prerequisite for reliable inspections, maintenance work, and coating processes. BvL Oberflächentechnik GmbH has extensive experience and references in the railway sector and offers a broad portfolio of cleaning systems—for example for wheelsets, wheel bearings and their housings, motors, gearboxes, heavy bogies, traction motors, and many other railway components. In addition to cleaning performance, system design focuses on economic efficiency, energy efficiency, ease of operation, and long-term reliable use. Test cleanings at BvL’s in-house technology center are used to identify the right process technology, and each system is tailored specifically to the component, the process, and customer requirements.
Further information: https://www.bvl-cleaning.com/en/industries/railway-industry
Company information:
BvL Oberflächentechnik GmbH is one of Germany’s largest suppliers of water-based industrial cleaning systems. As a systems partner, BvL provides custom solutions—from compact wash systems and filtration/automation solutions through to complex, customer-specific large-scale projects with process monitoring—always complemented by reliable service. As part of a long-established family business with roots dating back to 1860, the owner families in the fifth generation stand for technical excellence, innovation, and absolute reliability. The company currently employs around 170 people. In export markets, BvL holds a strong position with a comprehensive sales and service network in 20 countries.
Contact
BvL Oberflächentechnik GmbH
Grenzstr. 16
48488 Emsbüren
Tel.: 05903 951-60
Fax: 05903 951-90
info@bvl-group.de
www.bvl-cleaning.com
Christine Brühöfner
Marketing
Tel.: 05903 951-509
Fax: 05903 951-90
christine.bruehoefner@bvl-group.de
