Case Background

A 32-ton double-beam bridge crane at a car tire manufacturing plant in Thailand (Japanese-owned enterprise) appeared in 2023:

• Metal noise when the vehicle is running

• Asymmetric wheel wear on both sides of the track (the left wheel flange wears up to 8mm)

• Frequent grease leakage from wheel hub bearings

Problem diagnosis process

1. 3D detection :

   • The laser distance meter found that the track span deviation was 15mm (exceeding the DIN 2056 standard)

   • The wheel diameter difference is as much as 4.5mm (causing one-sided rail gnawing)

   • Wheel load test shows uneven load distribution (maximum deviation 28%)

2. Failure Analysis :

   • The wheel hub seal material is not resistant to moisture and heat (originally made of nitrile rubber, the average annual humidity in Thailand is 82%)

   • Insufficient wheel tread hardness (original HB260, lower than the abrasion requirements of Thai tropical hardwood dust)

Solution

Special environmental measures

1. Anti-corrosion treatment :

   • Wheel axle adopts Dacromet coating (salt spray test > 800h)

   • Apply Loctite 577 sealant to bolted joints

2. High temperature adaptation :

   • Use synthetic hydrocarbon high temperature grease (dropping point 280℃)

   • Add wheel hub cooling fins (actually measured temperature reduction of 12°C)

Localization service strategy

1. Logistics Optimization :

   • Stock in Bangkok bonded warehouse (common wheel model STB-Φ600)

   • Urgent orders delivered within 72 hours (taking advantage of Thailand's Eastern Economic Corridor policy)

2. Technical training :

   • Provide Thai and English bilingual "Wheel Alignment Manual"

   • On-site demonstration of the process of replacing a wheel set using a hydraulic jack

Comparison of results

Lessons Learned

1. Special attention should be paid to the Southeast Asian market:

   • Electrochemical Corrosion in High Humidity Environment

   • Local workers are not proficient in using precision adjustment tools (such as dial indicators)

2. Recommended configuration:

   • Anti-skid grooves are added to the wheel tread (to cope with water accumulation on the workshop floor during the rainy season in Thailand)

   • Provided with a simple centering fixture (reduces installation difficulty)