Fixed rail flash welding automatic centering and measuring device
Technical Field
The invention relates to the field of steel rail welding in the railway industry, in particular to a steel rail flash welding automatic centering and measuring device arranged in a fixed steel rail flash welding machine.
Background
The smoothness of the steel rail welding joint is one of the factors of the steel rail flash welding quality, and is related to the stability and the safety of the train in operation and the workload of later maintenance. The fixed rail flash welding centering device is an important factor influencing the smoothness of a rail flash welding joint. At present, in a steel rail welding base or a production line of a welding rail factory in China, centering work before steel rail welding is finished mainly by a rigid shaft and a centering arm of a steel rail flash welding machine in a manual or semi-automatic mode, and a simple centering measuring device is designed in the welding rail factory, but the simple centering measuring device and the welding machine do not form closed-loop control, and the online recording function is not realized.
The known patent (Chinese patent CN100396421C) of a fixed steel rail flash welding machine is developed by China railway science research institute, and mainly carries out rail pre-welding centering through a three-level centering structure. The primary centering is mainly completed by adjusting the top point position of a rail bottom supporting wheel, the spiral depth of the top of a rail bottom vertical adjusting oil cylinder piston rod, the position of a rail bottom horizontal direction adjusting mechanism platform and the distance between a primary centering rail frame and a host; the secondary centering is mainly completed by adjusting a gasket at the top end of a piston rod of the rail waist horizontal clamping oil cylinder; the third-stage centering is mainly completed by driving the rack to move through a horizontal centering oil cylinder and a vertical centering oil cylinder. However, all actions of the device centering device disclosed in the patent are manually adjusted, and the device centering device is not provided with any measuring device, cannot realize automatic centering, automatic measuring and automatic recording functions, and has certain limitations in the aspects of centering precision and efficiency.
One known patent for a fixed contact butt welding rail machine (chinese patent 98105796.9) was developed by the ukrainian barton welding institute. The centering function of the welding machine in the patent is mainly to complete the manual or automatic centering function through mechanical and hydraulic components such as an automatic centering roller, a guide support, a slag blocking mechanism, a projection pushing mechanism and the like which are arranged on a fixed clamping device. The manual centering function of the welding machine mainly completes centering work by adjusting the position of the mechanism and utilizing the rigidity of a guide shaft of the welding machine, and the centering effect is judged and further adjusted by adopting a visual inspection or touch mode; the automatic centering function mainly fixes the mechanism related to centering at a certain position through calibration, and under the condition of the position, two steel rails to be welded are positioned on the same axis, so that centering is realized, but the method cannot solve errors caused by appearance difference of the steel rails and abrasion of a centering device. Similarly, the welding machine does not have any measuring device, and cannot realize automatic centering, automatic measurement and automatic recording functions.
One known resistance flash welding installation suitable for rails is the swiss schlat company invention (european patent EP0499019B 1). This patent fixed rail flash welding machine's centering device adopts the four-arm structure, and the centering of accessible centre gripping in the two side work limit positions of railhead is realized to four groups arms of railhead and is adjusted, and the accessible is adjusted the position of installing proximity switch on centering adjusting device simultaneously and is realized the automatic centering function. However, because the welder disclosed in the patent adopts a direct current welding power supply, ferromagnetic substances in the mechanical arm between the two groups of electrodes are easily magnetized and adhere to welding slag, so that centering precision is influenced; without an on-line measuring device, closed-loop centering control cannot be formed, and high-precision automatic centering cannot be realized.
Disclosure of Invention
In order to overcome the existing defects, the invention provides a fixed type automatic centering and measuring device for steel rail flash welding.
A fixed type steel rail flash welding automatic centering and measuring device comprises a steel rail pre-welding position measuring mechanism, a vertical centering mechanical part absolute position measuring mechanism, a horizontal centering mechanical part absolute position measuring mechanism, a hydraulic actuating mechanism, an electrical control system and a data management computer, wherein the steel rail pre-welding position measuring mechanism, the vertical centering mechanical part absolute position measuring mechanism and the horizontal centering mechanical part absolute position measuring mechanism are respectively communicated with the electrical control system, the electrical control system is respectively communicated with the hydraulic actuating mechanism and the data management computer, and the hydraulic actuating mechanism respectively drives the vertical centering mechanical part absolute position measuring mechanism and the horizontal centering mechanical part absolute position measuring mechanism.
The steel rail pre-welding position measuring mechanism is arranged on a static frame and a movable frame of a fixed steel rail flash welding machine, a first vertical centering mechanical part is arranged on the inner side of the static frame, and a first horizontal centering mechanical part is arranged on one side of the first vertical centering mechanical part; and a second vertical centering mechanical part is arranged on the inner side of the movable frame, and a second horizontal centering mechanical part is arranged on one side of the second vertical centering mechanical part.
The upper end of the middle part of the static frame is provided with a first measuring probe group and a second measuring probe group; and the upper end of the middle part of the movable frame is provided with a third measuring probe group and a fourth measuring probe group.
Wherein, in first measurement probe group, second measurement probe group, third measurement probe group and the fourth measurement probe group, every measurement probe group includes a support, and wherein, the support is below opening rectangle, and inside one side of support sets up first measurement probe, and the opposite side sets up second measurement probe, and the inside top of support sets up third measurement probe.
The vertical centering mechanical part absolute position measuring mechanism comprises two displacement sensors arranged on a static frame electrode clamping part and a movable frame electrode clamping part.
The absolute position measuring mechanism for the horizontal centering mechanical part comprises two displacement sensors which are arranged on a first horizontal centering mechanical part and a second horizontal centering mechanical part of the static frame.
The hydraulic actuating mechanism is arranged in the middle of the steel rail pre-welding position measuring mechanism and comprises a hydraulic valve group, a vertical electrode clamping oil cylinder, a horizontal centering adjusting oil cylinder, a first arching amount adjusting oil cylinder and a second arching amount adjusting oil cylinder.
The electric control system comprises a central processing unit, a power supply, a signal isolation transmitter circuit, a hydraulic system amplification control circuit and a communication circuit, wherein the power supply converts an external power supply into voltage required by each component in the electric control system, and the central processing unit is connected with the signal isolation transmitter, the hydraulic system amplification control circuit and the communication circuit.
The fixed steel rail flash welding automatic centering and measuring device disclosed by the invention can be used for determining the quantitative data of the actual positions of the centering arm and the steel rail by adopting a plurality of groups of displacement sensors, so that the centering conditions of the bidirectional working edge and the rail top surface and the camber of a joint before welding can be monitored, and the centering errors caused by mechanical wear and adhesion welding slag are effectively solved; the automatic centering work can be efficiently and accurately finished through the closed-loop control circuit and the proportional hydraulic circuit; the centering data before welding can be collected through upper computer software, automatic measurement and recording are realized, and data basis is provided for conditions such as later-stage process improvement, problem analysis and equipment state judgment.
Drawings
FIG. 1 is a schematic structural view of a centering device of a fixed steel rail flash welding machine;
FIG. 2 shows a mechanism for measuring the pre-welded position of a rail;
FIG. 3 is a schematic view of the measuring and centering adjustment assembly mounting location;
fig. 4 is a schematic structural diagram of an electrical control system.
Detailed Description
The following describes in detail a fixed rail flash welding automatic centering and measuring device provided by the present invention with reference to the accompanying drawings and specific embodiments.
Fig. 1 shows a fixed steel rail flash welding automatic centering and measuring device, which comprises a steel rail pre-welding position measuring mechanism 1, a vertical centering mechanical component and absolute position measuring mechanism 2, a horizontal centering mechanical component and absolute position measuring mechanism 3, a hydraulic actuating mechanism 4, an electrical control system 5 and a data management computer 6, and is characterized in that the steel rail pre-welding position measuring mechanism 1, the vertical centering mechanical component and absolute position measuring mechanism 2, the horizontal centering mechanical component and absolute position measuring mechanism 3 are respectively communicated with the electrical control system 5, the electrical control system 5 is respectively communicated with the hydraulic actuating mechanism 4 and the data management computer 6, and the hydraulic actuating mechanism 4 respectively drives the vertical centering mechanical component and absolute position measuring mechanism 2 and the horizontal centering mechanical component and absolute position measuring mechanism 3.
FIG. 2 shows that the rail pre-welding position measuring mechanism 1 is installed on a static frame 70 and a movable frame 80 of a fixed rail flash welding machine, a first vertical centering mechanical part 21 is arranged on the inner side of the static frame 70, and a first horizontal centering mechanical part 31 is arranged on one side of the first vertical centering mechanical part 21; the second vertical centering mechanism 22 is disposed inside the movable frame 80, and the second horizontal centering mechanism 32 is disposed on one side of the second vertical centering mechanism 22.
The upper end of the middle part of the static frame 70 is provided with a first measuring probe group 11 and a second measuring probe group 12; the upper end of the middle part of the movable frame 80 is provided with a third measuring probe group 13 and a fourth measuring probe group 14.
The device takes an electrical control system 5 as a core, and acquires absolute position information before welding of steel rails 100 and 101 through a steel rail before welding position measuring mechanism 1; acquiring absolute positions of the centering mechanical parts 21, 22, 31 and 32 through the vertical centering mechanical part absolute position measuring mechanism 2 and the horizontal centering mechanical part absolute position measuring mechanism 3; the electric control system 5 controls the hydraulic actuating mechanism 4 through a current signal, and simultaneously transmits the acquired and calculated data to data management software 6 installed in an industrial control computer; the hydraulic actuator 4 drives the vertical centering mechanical part and the horizontal centering mechanical part to complete primary centering and accurate centering.
Fig. 3 shows that, in the first measurement probe group 11, the second measurement probe group 12, the third measurement probe group 13, and the fourth measurement probe group 14, each measurement probe group includes a support 15, where the support 15 is a rectangle with an opening at the lower part, a first measurement probe 16 is arranged on one side inside the support 15, a second measurement probe 18 is arranged on the other side, and a third measurement probe 17 is arranged at the top end inside the support 15. The measuring probes are respectively used for completing the position measurement of the two working edges and the top surface of the rail.
The vertical centering mechanism part absolute position measuring mechanism 2 includes two displacement sensors mounted on the stationary frame electrode clamping part 71 and the movable frame electrode clamping part 81. The absolute position of the top surface of the steel rail is judged by measuring the position of an electrode arranged at the end part of a piston rod of the oil cylinder.
The absolute position measuring mechanism 3 for the horizontal centering mechanical part comprises two pull rod type or pull wire type displacement sensors which are arranged on a static frame horizontal centering part 31 and a movable frame horizontal centering part 32, and the absolute positions of two working edges of the steel rail are judged by measuring the mechanical position of a centering arm.
The hydraulic actuating mechanism 4 comprises a hydraulic valve group, a vertical electrode clamping oil cylinder, a horizontal centering adjusting oil cylinder, a first arching amount adjusting oil cylinder 90 and a second arching amount adjusting oil cylinder 91. Used for finishing the actions required by centering adjustment and arching amount adjustment.
Fig. 4 shows that the electrical control system 5 includes a central processing unit 51, a power supply 52, a signal isolation transmitting circuit 53, a hydraulic system amplification control circuit 54 and a communication circuit 55, wherein the power supply 52 converts an external power supply into voltages required by each component in the electrical control system 5, and has functions of power supply and voltage stabilization. The central processor 51 is connected with a signal isolation transmitter 53, a hydraulic system amplification control circuit 54 and a communication circuit 55, and completes data acquisition of measurement data, calculation and screening of data, generation and sending of control instructions and data transmission of centering information.
Examples
In actual operation, after the two rails 100 and 101 to be welded enter the welding position of the welding machine, the vertical centering mechanical parts 21 and 22 and the horizontal centering mechanical parts 31 and 32 are moved from the standby position (position away from the rails 100 and 101) to the working position (position clamping the rails) by manual operation or automatic operation.
The electric control system 5 drives the vertical centering mechanical parts 21 and 22 and the horizontal centering mechanical parts 31 and 32 to be positioned at standard positions through the hydraulic actuator 4 according to the standard centering data memorized at the last time, so that the output data of the displacement sensors in the vertical centering mechanical part absolute position measuring mechanism 2 and the horizontal centering mechanical part absolute position measuring mechanism 3 are consistent with the standard data, and the primary centering work is completed.
After the arching amount adjusting cylinders 90 and 91 are controlled to move from the standby position to the working position in a manual or automatic control mode, the rail pre-welding position measuring mechanism 1 respectively collects the position data of two working edges and the rail top surface of the rails 100 and 101 to be welded and transmits the position data to the central processor 51 in the electrical control system 5.
The central processing unit 51 calculates the acquired data to obtain data such as straightness, misalignment amount, arching amount and the like of the steel rails 100 and 101 to be welded before welding. If any one of the above data exceeds the set alarm value, the central processor 51 will send a fault alarm signal to the management software 6 in the industrial control computer. The management software 6 in the industrial control computer sends out warning patterns or characters to the operator through a human-computer interaction interface, and the operator is required to check the equipment state. If the data such as the straightness, the misalignment amount, the arching amount and the like are larger than the set error value but smaller than the set alarm value, the central processor 51 sends an adjusting instruction containing the movement direction and the movement speed to the hydraulic control system amplifying circuit, and the corresponding vertical centering mechanical components 21 and 22 or the corresponding horizontal centering mechanical components 31 and 32 are driven by the hydraulic actuator 4 to be accurately centered. In the process of accurate centering, the rail pre-welding position measuring mechanism 1 collects and continuously collects rail position data and transmits the rail position data to the central processing unit 51 for calculation, and when the calculation result is within a set error range, accurate centering is completed, and the positions of the vertical centering mechanical components 21 and 22 and the horizontal centering mechanical components 31 and 32 are locked.
After the precise alignment is completed, the cpu 51 in the electrical control system 5 transmits the measurement results of the pre-rail-welding position measuring mechanism 1, the vertical alignment mechanical component absolute position measuring mechanism 2, and the horizontal alignment mechanical component absolute position measuring mechanism 3 to the management software 6 in the industrial control computer, and the management software 6 in the industrial control computer stores and manages the measurement results.
The invention aims to change the current situation that the current rail pre-welding centering and inspection mainly comprises manual centering, visual inspection and touch inspection based on the higher requirement of the current high-speed and heavy-duty railway on the smoothness of a rail welding joint, and realize the automation and the intellectualization of the pre-welding centering through links of preliminary mechanical centering, online measurement, closed-loop accurate centering, automatic recording and the like.
By means of the quantitative monitoring mode for the horizontal position of the centering arm, the control system can accurately monitor the horizontal position of the railhead, meanwhile, the early-stage centering position can be memorized, and preliminary mechanical centering can be automatically and quickly completed;
the online measuring device arranged at the positions of the static frame and the movable frame realizes the accurate measurement of the straightness and the arching amount of the steel rail, can correct errors caused by the conditions of abrasion of a clamping jaw of a centering arm, welding slag adhesion and the like, and guides secondary accurate centering;
through the variable speed closed-loop centering control device, the steel rail adjustment amount is calculated according to the measurement result, the steel rail is moved at a proper speed, and accurate centering is quickly completed;
by the automatic recording system for the smoothness of the steel rail welding joint, the centering condition of the steel rail to be welded before welding is collected, and a data basis is provided for later-stage production and equipment state analysis.
Finally, it should be noted that the above examples are only intended to describe the technical solutions of the present invention and not to limit the technical methods, the present invention can be extended in application to other modifications, variations, applications and embodiments, and therefore all such modifications, variations, applications, embodiments are considered to be within the spirit and teaching scope of the present invention.