RAILWAY WHEELSET MAINTENANCE PRESSING GUIDE
An engineering approach for safe, traceable, and standards-compliant maintenance processes.
The wheelset is one of the most critical components of a railway vehicle.
The pressing, dismounting, mounting, and testing operations performed during every maintenance cycle have a direct impact on vehicle safety, vibration performance, and service life.
INOTIM makes this process measurable, traceable, and safe through its pressing systems developed in accordance with ECM (Entity in Charge of Maintenance) requirements.
⚙️ Main Stages of the Pressing Process
1️⃣ Dismounting
Wheels, bearings, gears, and other components mounted on the axle are removed using controlled hydraulic force.
The hydraulic system records the force–time curve.
Proportional valve-controlled pressure is used to prevent damage to the components.
💡 INOTIM WD and WMD series presses automatically detect the dismounting force and minimize operator error.
2️⃣ Inspection and Measurement
Axles, gears, and wheel components are evaluated visually and dimensionally.
Axle diameter, surface roughness, and centering tolerances are measured.
Compliance is assessed according to EN 13260 and EN 13261 standards.
3️⃣ Mounting (Pressing)
Components are positioned according to the required pressing sequence, for example: wheel → gear → bearing.
Full seating is verified using force, stroke, and position sensors.
The pressing curve (force–displacement curve) is automatically recorded in the system.
💡 INOTIM presses allow a separate recipe to be defined for each operation, providing full traceability.
4️⃣ Testing and Verification
After pressing, eccentricity, run-out, and centering tolerances are measured.
Test results are automatically converted into a PDF report.
Data is transferred to the digital maintenance archive (ECM record system).
🧠 Critical Parameters in the Pressing Process
| Parameter | Definition | Control Method |
|---|---|---|
| Force (Ton) | Compression force applied by the hydraulic press | Pressure sensor / PID control |
| Stroke (mm) | Seating distance of the component | Linear encoder |
| Speed (mm/s) | Movement speed during the pressing process | Proportional valve control |
| Temperature (°C) | Component temperature for thermal expansion control | IR sensor / Thermocouple |
| Centering (µm) | Eccentricity and alignment measurement | Laser measurement device |
💡 INOTIM presses automatically monitor all these parameters and stop the system if values fall outside the permitted limits.
🛡️ Safety and Standardization
Control system compliant with EN ISO 12100 and EN 13849-1
Two-hand control and light curtain safety functions
CE Declaration of Conformity and risk assessment report
Operator training protocol integrated with the Press Activation module
📊 Maintenance and Traceability Advantages
Every pressing operation is recorded with a unique ID
Force–time–stroke curves are transferred to the digital archive
Component-based maintenance history is created: axle → wheel → bearing
A “Pressing Report” is automatically generated for ECM audits
💡 INOTIM systems fully digitalize the maintenance process.
🌿 Energy-Efficient and Environmentally Responsible Approach
Up to 20% energy savings with ECO mode
Heat recovery through the oil circulation system
Hydraulic fluid filtration for extended service life
Compliance with the ISO 14001 Environmental Management System
🔩 The Engineering Difference of INOTIM Pressing Systems
WMD Series: Wheel mounting and dismounting presses
WD Series: Dismounting-only applications
BPP Series: Bearing pressing & testing systems
Full Traceability: Force, temperature, position, and operator logs
CE and ECM Compliant: Full integration with European maintenance regulations
Conclusion
The railway wheelset pressing process requires a safe, controlled, and fully traceable system.
INOTIM engineering transforms this process from a purely mechanical operation into a digital, data-driven, and standards-compliant maintenance process.
As a result, every maintenance operation delivers documented quality and contributes to extended component service life.
