Wheelset presses

NEU
Wheelset presses from MAE –
sheer power
and precision

Innovative technical solutions, a close relationship with our customers,

qualified employees and a wealth of experience from diverse projects:
for over 50 years, MAE has been developing and supplying rail vehicle
wheelset assembly presses and set the trends that prove their worth in
daily use at our customers the world over.

From low-cost workshop presses through to fully automatic high-per-

formance presses, we offer a wide range of standard products that can
be specially tailored to suit your specific application.

Design, assembly, commissioning and service: we have the specialists

in-house. That is why MAE is a byword for innovative engineering
„made in Germany“ offering products and services of the highest
quality, reliability and value for money.

03
Powerful concepts –
for growing demands
The demands on modern assembly processes have been steadily increasing worldwide.
Vehicle manufacturers and operators are becoming more aware of the integrity of these
processes and this is underlined by increasingly stringent regulations. Conventional wheelset
press technology has seen significant advances in this area over the last two decades.
MAE offers powerful concepts that are geared to meet these demands.

Centering cylinders for wheelset shafts and mounting sleeves for

wheel and brake discs replace manual positioning with lifting applian-
ces and enable exact component alignment. For loading and unloa-
ding the press, wheelset carriages have replaced tedious and dange-
rous crane handling operations. The heart of the press is a
high-performance control computer. In combination with a force and
displacement measuring system, it guarantees a precise assembly
process conforming to relevant standards and extensively documents
the quality of the product.
Today, centering cylinders, wheelset carriages and control computers
are standard equipment even on simple workshop presses. High-per-
formance presses for wheelset manufacturers or large maintenance
companies are characterised by a high degree of automation of all
operations and processes, including loading and unloading and press
tool positioning.

MAE has taken all this into account. The current range of presses for all
applications is based on one, particularly efficient basic concept that
offers outstanding operating convenience and precise, safe process
sequences also for companies operating with small series production
and a limited budget.

05
RADS series – the
innovative basic machine

• Low space requirement, high precision and exceptional stability due to

the compact monoblock frame concept.
• Large, basic tools stored directly in the press frame for easy pressing
operations also for critical wheelsets with limited space.
• Excellent ergonomics, easy access to the working area.
• Press tools are easy to move and protected against contamination.
• High energy efficiency due to demand-controlled hydraulic system.
• Certified, safety concept geared to the needs of the workplace.
07
Loading and unloading systems –
for efficient handling
The performance capability of a wheelset press depends largely on rational
loading and unloading conveying systems. MAE offers with three basic systems,
demand-orientated solutions for all applications.

Manual wheelset transport carriage

This manually movable wheelset transport carriage
is a low cost variant for single piece and small series
production. Easy to adjust horizontal and vertical
support elements for the wheelset shaft as well as
for attached drive units enable it to be converted
quickly and flexibly. Loading takes place outside the
press space; tilt protection makes the carriage
suitable for use as a pre-assembly stand.

MAE MoviS wheelset manipulator

Since 2001, this patented MoviS wheelset manipulator has been our
tried and tested concept for large production quantities. With a
rail-guided lower carriage, rotatable and liftable upper carriage,
width-adjustable wheelset support arms, it has three freely
programmable motor-driven axes.
MoviS is able to pick up wheelsets
fully automatically or manually
controlled from feed lines or a
pre-assembly stand and
transport them to the press.
After being pressed, the
wheelsets are continuously
deposited behind the press or
alternatively transported to the
front again.
MAE MoGiS heavy-duty wheelset carriage
In order to transport heavy locomotive wheelsets safely, engine and
gear units must be securely supported during the loading, unloading
and pressing process. MAE offers with the MoGiS system a particularly
efficient and flexible solution for this complex task. The wheelsets can
be placed on the manual or motor-driven transport truck with height
and width-adjustable attachment points for the wheelset shaft and
drive unit by crane.

09
Options – tailored to your
requirements
Do you need special equipment, tools and services or tailor-made components for
special tools or even customised software? Simply contact us if you are looking for a
concept that is specially tailored to meet your specific requirements.

Bridge crane
This bridge crane, which is designed specially for use in specific
space conditions, makes the wheelset press independent of the
availability of a workshop crane. It transports wheelset shafts and
wheels and brake discs from the temporary storage facility in the
area of the press to the pre-assembly stand via three individually
or synchronously controllable hoists. Complete wheelsets can also
be picked up and deposited at any required point. Today, cranes
are hardly used for directly loading presses; however, this is easily
possible with appropriate lifting appliances.
Pre-assembly stand
For high productivity, an independent
workstation should be available for the
pre-assembly of wheel and brake discs in order to
prepare the next wheelset at the same time as the
pressing process.
MAE offers two basic pre-assembly stands: a simple version with
one working stand and a double pre-assembly stand, where one
component can be pre-assembled by a worker at a station, whilst a
second can be simultaneously loaded or unloaded.

High-pressure pumps
The wheel and brake discs of locomotives, railcars and passenger
carriages today usually have connections for hydraulic lines for
removal without damage.
MAE offers manual or automatically operated high-pressure pumps as
well as associated hoses and quickly interchangeable connection
adapters. By using collecting tanks, optimised hose routing and an
enclosed machine frame, fouling is kept to a minimum and the risk of
accidents and contamination is reduced.

Tools and engineering

Although the wheelset press can be considered as a standard
product latest during the design phase of the special assembly tools
for your vehicle fleet customized designs are required.

If your press needs to be designed for additional wheelset types,

we can produce the necessary equipment including assembly and
commissioning.

11
Modern measuring and
control systems – for
safe processes
The measuring and control system of a wheelset press is decisive for process
safety, accuracy and ease of use. MAE took account of this at any early stage
and has set new standards with the MAE RACOS control computer and freely
programmable measuring system.

MAE-RACOS measuring computer

The MAE-RACOS which is based on a high-performance industrial PC
was presented for the first time in 1995. In the meantime, we have
realised several new generations with increasingly efficient hard- and
software as well as a particularly comfortable operator interface.

The RACOS system handles all process information and encoder

signals for positions and forces. It controls the automatic operation of
all press cylinder drives, tool motions and loading system sequences
in a freely programmable cycle.

The computer is installed in the computer cabinet directly next to the

press. The large touchscreen LC display visualises the process in clear
detail. Windows operator interface, Ethernet interface ports for
customer wheelset databases, DVD drive and remote diagnosis are
further features.

UIC - International Union of Railway AAR - Association of American Railroads DB - Deutsche Bahn EU - Europäische Union
Curve evaluation
The force-displacement curve displayed in real time is the
central quality feature for the pressing process. There are
many global regulations and criteria that must be taken into
account in addition to the specifications of wheelset
manufacturers. The RACOS system offers the option of
automatic curve evaluation and highly flexible programming
of key data. Key specification data is simultaneously
displayed.

Measuring head
This universal measuring device allows the recording of all
wheelset geometric data of relevance to the pressing
process in an automatic sequence. The axial positions of
wheel and brake discs, gear components and shaft refe-
rence surfaces as well as the seat diameter on the wheelset
shaft are taken into account. Axial and radial runout errors
of shaft, wheels and brake discs can also be measured with
the wheelset rotating.

Depending on the particular application, tactile or laser

measuring heads are used.

13
Rail engineering at MAE –
not only for wheelset
presses
According to our motto „Controlling the power“ we offer in the area
of rail engineering other assembly and straightening machines and
systems.

Mounting facility for single-ring resilient wheels

Our range includes appropriate devices for mounting single-ring
resilient wheels. Depending on the production quantity, vertically or
horizontally acting versions with manual or automatic control are
used; this function can also be integrated in a wheelset press.

Mounting devices
For the removal of wheel and brake discs as well as fitting and
removal of bearings, we offer low-cost horizontal presses with
manual control.
Straightening machines
MAE precision straightening machines with stroke control are available
in two variants:
For the manufacture of switchpoints and track maintenance, manual
or semi-automatic horizontal C-column presses are used, either with
one or two straightening cylinders.
For manufacturers of rails we offer four-point action, fully automatic
straightening machines with integrated laser measuring system.
The patented four-point straightening process and innovative column
design guarantee particularly fast and sensitive workpiece straighte-
ning.

15
After-sales service –
for lasting success
We would like to keep in touch with you and your MAE press! This is why
we offer services to ensure that your press operates reliably and is state
of the art.

Calibration service
We carry out periodically prescribed tests and adjustments to the
force-displacement measuring system in cooperation with certified
calibration companies.

Maintenance contracts
We provide an efficient maintenance and repair service with our
globally operating service department with a team of highly qualified
personnel. These services can be either on a request basis or in the
form of a low-cost maintenance contract.

Upgrades and „retrofitting“

MAE wheelset presses are traditionally built to last. However, to
ensure that they conform to current technological standards, we can
upgrade machines to include modern control systems or renew the
hydraulic drives. This ensures that old machines operate more
efficiently and reliably.
17
 References
worldwide

Take advantage of our more than 50 years of experience with

diverse rail vehicles worldwide, from the almost 100-year-old narrow
gauge locomotive with rack and pinion drive to modern high-speed
trains.
 MAE Maschinen- und Apparatebau Götzen GmbH
40699 Erkrath, Steinhof 65, Germany
40673 Erkrath, P.O. Box 1362
Phone +49 211 / 9 24 83-0
Fax +49 211 / 9 24 83-52
email: sales@mae-group.com
www.mae-group.com

MAE-EITEL Inc.
97 Pinedale Industrial Rd.
Orwigsburg, PA 17961, USA
Phone +1 570 / 366-0585
Fax +1 570 / 366-2536
email: nwalker@mae-group.com
www.mae-group.com

MAE Machine (Beijing) Co., Ltd.

Room 708, Building 2, Guangqujiayuan, Dongcheng District,
Beijing, Post Code: 100022, China
Phone +86 10 / 87513901
Fax +86 10 / 87513902
email: lucy@mae-group.com
www.mae-group.com

www.wibo-agentur.de | MAE-14079

A company of the GESCO group Our brands: