The after welding treatment system and method that is used for steel rail weld joint on the line
Technical field
The present invention relates to a kind of especially postweld head treatment system and method for steel rail weld joint on the line of steel rail weld joint that is used for.
Background technology
Along with the fast development of China railways gapless track technology, the rail welding quality more and more comes into one's own, and guarantees the rail welding quality, not only helps safety of railway traffic, also helps improving train running speed.Steel rail weld joint is divided into mainly in the factory that field Welding connects first two on the welding point and line.
To welding point after welding treatment in the factory, adopt the production line operation mode, the postwelding rail is moved, to carry out normalizing, aligning and finishing on carriage by positive lighter, straightener and finishing machine.
And for field Welding on the line, owing to rail has been layed on the circuit, so can't carry out after welding treatment according to bond pattern in the factory.Therefore, present stage, railway construction in China unit and worker are engaged in maintenance unit when carrying out the after welding treatment of on-the-spot joint, adopt portable continuous productive process, be after the normalizing operation is finished and locked fastener, follow-up aligning operating personnel moves to this joint and removes fastener and align, and locks fastener finishing after, follow-up profile finishing personnel movement is carried out the profile finishing to this joint, until finishing.The rail track that schematically shows with reference to figure 1 with a plurality of welding points.Welding point postwelding normalizing on the typical existing line, aligning and finishing operational method are: carry out operation along the construction direction shown in the arrow 50, at first normalizing operation group is carried the flame normalizing machine and is carried out normalized treatment at joint A place's butt joint A, carry the flame normalizing machine after normalized treatment finishes and carry out normalized treatment to joint B place's butt joint B, joints such as butt joint C, D, E are handled successively subsequently; Joint A is after normalized treatment, and aligning operation group is carried straightener and carried out straightening processing at joint A place, carries after the straightening processing end and at joint B, C, D, E place these joints is carried out straightening processing successively like the equipment class such as straightener; Behind the joint A aligning, joint finishing operation group is carried the profiling sander and is carried out the finishing processing at joint A place, and similarly, carries profiling sander to joint B, C, D, E place after the finishing processing finishes these joints are carried out the finishing processing successively.This operational method, personnel's equipment need ceaselessly scattered distribution construction in long one section circuit, and personnel amount is big, operating efficiency is low, poor stability.
Because the after welding treatment of steel rail weld joint is subjected to on-the-spot many restrictions on the line at present, for example the normalized treatment scene can't provide enough big power supply and have to adopt the flame normalizing mode, and that the logistics support of this mode requires is high, quality stability is poor, poor stability, equipment are maintainable poor, the labor strength height.In addition, the welding point straightening processing adopts ruler clearance gauge formula measurement and jim crow, track jack, jack type aligning can't guarantee flattening precision on the existing line.And existing equipment does not have reliable aligning mode to the vertical bending of welding point on the line.Line top connection finishing at present handle adopt ruler clearance gauge formula measure and profiling polishing, artificial feeding, manually push, the mode of swing, this mode influencing factors of quality is many, be subjected to that workman's technical level restricts greatly, equipment maintainable poor, precision is low, labor strength is big.In addition, the on-the-spot after welding treatment device that uses all belongs to light equipment, the quality control ability.
And in existing operational method, owing to adopt many groups personnel to carry out different operation operations, the front and back operation is difficult to coordinate mutually, therefore causes the uniformity of the post processing effect of the chain rupture of quality control and each welding point or quality low easily.
Summary of the invention
Be desirable to provide and overcome problem that above-mentioned welding point after welding treatment occurred or the system and method that can improve to some extent to small part the after welding treatment of steel rail weld joint on the existing line.
Therefore, the invention provides a kind of after welding treatment system that is used for steel rail weld joint on the line, it comprises: the postweld head treatment device; Straightener; Calibration devices; Can in described postweld head treatment device, straightener and the calibration devices any be lifted and remain on the loop wheel machine of a position of described welding point top by arm; Be used for that at least one provides the power source of power to described postweld head treatment device, straightener and calibration devices; With the traveling portion that can walk on described rail, wherein this traveling portion has the base that is used to support described postweld head treatment device, straightener, calibration devices, loop wheel machine and this power source.
The after welding treatment system that is used for steel rail weld joint on the line according to the present invention has realized on the line monommechanization, disposable finishing being handled in postweld head treatment, aligning and the joint finishing of steel rail weld joint, solve the multiple spot construction problem of steel rail weld joint after welding treatment on the line, and improved the efficient of after welding treatment significantly.Simultaneously, treating apparatus is lifted suitable position, and in processing procedure, all the time treating apparatus is provided and hang the power of carrying, at utmost reduced the welding point distortion that various treating apparatus deadweights cause, guaranteed joint glacing flatness quality by loop wheel machine.For example, when heat treatment such as normalizing, because the high temperature strength of joint is low, the deadweight of normalizing device may cause that joint sinks, thereby causes joint glacing flatness, precision to reduce.When aligning, because the rigidity of straightener needs, this device deadweight is bigger, near one ton, and this moment, joint belonged to not all locking states, when straightener is pressed in the rail joint place, also will cause the error of glacing flatness, cause the error of joint flattening precision then, influence straightening quality.During joint finishing operation, for satisfying the requirement of glacing flatness 0.2mm, its control accuracy should be 1% millimeter level, and this moment, the disturbance of outer bound pair rail very easily had influence on precision, still needed calibration devices is lifted.And studies show that be not controlled in the reasonable range as the glacing flatness after the normalizing, overproof 50% as glacing flatness, the time of aligning operation in later stage will increase twice, it is disconnected that the while easily causes joint to be aligned.Normalizing operation and aligning operation can be organically combined (for example selecting suitable aligning amount) by after welding treatment according to the present invention system, thereby can realize high after welding treatment quality and reduce joint and aligned disconnected probability based on normalizing temperature and aligning tolerance.
According to a preferred embodiment of the present invention, described postweld head treatment device comprises postwelding normalizing device, and described postwelding normalizing device comprises the coil actuation mechanism that is used to heat the opposite opened load coil of welding point and is used for this opposite opened load coil of open and close.According to the preferred embodiment, make that by the normalizing mode that adopts eddy-current heating the heat affected zone of normalizing is shorter, avoid high temperature to lose the excessive of strong district, thereby guaranteed the outward appearance of joint after the normalizing, thereby lay the glacing flatness basis for follow-up aligning operation.And, because the present invention has adopted the load coil of opposite opened, solved lasso formula load coil of the prior art effectively and can not be used for on-the-spot defective.
According to a particularly preferred embodiment of the present invention, described straightener has first bite that is used for being clamped in the welding point place, be respectively applied for the second and the 3rd bite that is clamped in the welding point upstream and downstream and can fix, vertically start and horizontal any clamping actuation mechanism of the described bite of start.More preferably, described actuation mechanism comprises main hydraulic cylinder that is used for the described bite of vertical start and the secondary hydraulic cylinder that is used for the described bite of horizontal start.Compared with prior art can carry out up and down four-way straightening processing according to the straightener of this embodiment, improve glacing flatness, the especially glacing flatness of tread face of joint significantly.And straightener according to the present invention is compared with existing system preventing that joint from damaging even fracture, guarantees that straightening quality and effect aspect have obvious improvement, and this will describe in the specific embodiment hereinafter.
Another preferred embodiment according to the present invention, described power source comprises hydraulic power unit, and described arm has and is integrated in the arm and the hydraulic line that links to each other with described hydraulic power unit and be positioned at the arm end and be used for the arm hydraulic interface that the hydraulic interface with straightener is complementary.In a nonrestrictive example, described hydraulic line for example is arranged in the inner chamber of hollow arm (perhaps the inner chamber of this hollow arm is promptly as hydraulic line), and the far-end that leads to arm is the hydraulic interface of end, thereby supplying hydraulic fluid and working environment around being subjected to hardly limits to easily when aligning operation and has very compact structure.
The preferred embodiment again according to the present invention, described power source comprises generating set, and described arm has and is installed on the arm and with the generating set wire connecting be arranged in the arm end and be used for joint with described postweld head treatment device and at least one electric connection of calibration devices.
By using pipeline and interface are integrated in the very compact structure that can realize system of the present invention in the arm of loop wheel machine, and the same a kind for the treatment of apparatus (for example postwelding normalizing device, straightener and/or calibration devices) that has the different model of general-purpose interface can be replaced or renewal and system can work on, and this is being particularly advantageous saving aspect cost and the raising versatility.
The further feature according to the present invention, described calibration devices comprise the wide face of welding point place rail head that is used to polish the polishing emery wheel, drive motor that described polishing emery wheel rotates, drive first stepping motor that described polishing emery wheel vertically moves back and forth along rail, drive second stepping motor that described polishing emery wheel laterally moves back and forth, the controller of the amount of feeding that the 3rd stepping motor of the feeding that drives described polishing emery wheel and being used to is controlled described polishing emery wheel.Calibration devices according to the present invention has adopted automation and high-precision adjusting control, especially can control the amount of feeding suitably.
Preferably, the joint that will carry out the finishing operation after the aligning operation has the polishing length limit value of 0.5mm grinding depth limit value and 900mm, to guarantee the circuit ride comfort.
Another preferred embodiment according to the present invention, this after welding treatment system also comprises loading container, wherein postweld head treatment device such as postwelding normalizing device, straightener and profile calibration devices are placed on the front portion of this container, loop wheel machine is placed at the middle part, and the power source that comprises diesel engine, generating set and hydraulic power unit is placed at the rear portion.Such integral layout is taken into account ease of use, easy operating.
The present invention also provide a kind of according to after welding treatment of the present invention system to the method that steel rail weld joint on the line carries out after welding treatment, comprising: described after welding treatment system is walked apart from the certain distance of welding point; Described postweld head treatment device is hung a position of described welding point top by the arm of loop wheel machine; With this this welding point of postweld head treatment device heat treatment; Get back on out of shape the base after the heat treatment it being hung; Described straightener is hung a position of described welding point top by arm; With this straightener straightening of kinked rail; Get back on the described base behind the aligning described straightener being hung; Described calibration devices is hung a position of described welding point top by arm; With this calibration devices finishing rail; With get back on the base after the finishing described calibration devices being hung.
In accordance with a preferred embodiment of the present invention, the aligning step comprises: the clamping and the fixing primary importance at welding point place; The clamping and the fixing second place on welding point upstream or the downstream rail; The 3rd position on clamping welding point downstream or the upstream rail, the wherein said second place and the 3rd position lay respectively at the both sides of described primary importance; Come described the 3rd position of start with at vertical and/or horizontal direction straightening of kinked rail with bending according to rail.
Preferably, finishing step comprises: drive the polishing emery wheel rotation of calibration devices and the wide face of its rail head with the welding point place is contacted; This polishing emery wheel of start vertically moves back and forth along rail; This polishing emery wheel of start laterally moves back and forth along rail; With the amount of feeding of control polishing emery wheel on vertical.
According to a preferred embodiment of the present invention, described walking step comprises makes traveling portion for example stop and be held in place in the pushed position to the pending joint 1.5-4 rice of distance of railway platform truck.
Beneficial effect of the present invention thus comprises: compare steel rail weld joint after welding treatment method on the line that has the operation break-down mobile operational process now, use system and method for the present invention can realize on the line monommechanization, disposable finishing being handled in postwelding normalizing, aligning and the finishing of steel rail weld joint, solve the multiple spot construction problem of steel rail weld joint after welding treatment on the line, utilize the method and device to carry out on the line welding point after welding treatment and can increase substantially joint after welding treatment quality, reduce construction cost, reduce the logistics supply pressure, improve efficiency of construction.Steel rail weld joint after welding treatment system and method can also provide each inter process can coordinate mutually so that the after welding treatment of better welding point to be provided on the line of the present invention.
Description of drawings
Below, describe embodiments of the invention in conjunction with the accompanying drawings in detail, wherein:
Fig. 1 schematically shows the rail track with a plurality of welding points;
Fig. 2 schematically shows according to after welding treatment of the present invention system with plan view forms;
Fig. 3 schematically shows according to after welding treatment of the present invention system with the lateral view form;
Fig. 4 shows the fundamental diagram of existing straightener;
Fig. 5 shows the fundamental diagram according to a preferred embodiment of straightener of the present invention.
Among the figure: diesel engine, 3 loop wheel machines, 4 hydraulic power units, 5 induction normalizing Setup Controllers, 6 eddy-current heating normalizing devices, 7 four-way hydraulic flattening devices, 8 calibration devices, 9 spray wind that 1 container, 2 is integrated with generating set cool off units, 12 switching doors with air pump, 10 master control cabinets, 11; 60 contact anchor clamps; 61 straightening force application points; F
rStraightening force; 62 first bites; 63 second bites; 64 the 3rd bites
The specific embodiment
Fig. 2 and 3 shows steel rail weld joint after welding treatment system on the line of the present invention, and it comprises postweld head treatment device (being eddy-current heating normalizing device 6 at this), straightener (being the four-way straightener 7 of hydraulic actuation at this) and calibration devices 8.Specifically with reference to figure 2, this after welding treatment system also comprises the loop wheel machine 3 with arm, and this arm can lift in postweld head treatment device, straightener and the calibration devices any position of described welding point top, and can hold it in this position.This after welding treatment system also comprises power source.Although not shown, also comprise the traveling portion that can on described rail, walk according to after welding treatment of the present invention system, wherein this traveling portion has the base that is used to support described postweld head treatment device, straightener, calibration devices 8, loop wheel machine and this power source.The power source of this after welding treatment system comprise be used for to portion out of shape provide power diesel engine, be integrated in being used on this diesel engine and the generating set of electric power be provided and be used for providing the hydraulic power unit 4 of hydraulic fluid to straightener to postwelding normalizing device and calibration devices.What people it will also be appreciated that other is used for that at least one provides the power source of power to described postweld head treatment device, straightener and calibration devices.
This after welding treatment system also comprises loading container 1, and above-mentioned parts major part when not working is contained in this loading container 1.Particularly with reference to figure 2 and 3, but this container front end is provided with switching door 12, and the diesel engine that is integrated with generating set 2 of electric energy and power is provided in the promising whole system of placement placed in the middle of container.Loop wheel machine 3 also is equipped with at the container middle part, be sidelong at loop wheel machine one and be equipped with hydraulic power unit 4 and induction normalizing device switch board 5, the container front portion is placed with eddy-current heating normalizing device 6, hydraulic actuation formula four-way straightener 7 and calibration devices 8, spray wind is with air pump 9 after normalizing is placed at place, angle, container 1 rear portion, and loop wheel machine 3 rear sides are placed with and are used for master control cabinet 10 and cooling unit 11 that each parts and activities are controlled.
The method of the welding point of rail on the line being carried out after welding treatment according to after welding treatment of the present invention system of using is described below.On rail, advance and carry out operation along arrow 50 described construction directions by its portion out of shape according to after welding treatment of the present invention system.After welding treatment system shown in Fig. 2,3 is pushed to the pending joint A 1.5-4 of place rice parking and in place; Next open switching door 12; Loop wheel machine 3 hangs eddy-current heating normalizing device 6 to position of welding point A top and with eddy-current heating normalizing device 6 and remains on this place, and detent mechanism by induction normalizing device, with normalizing head and rail secure fixation, make opposite opened load coil closure by the coil actuation mechanism subsequently, under the control of control system, heat, realization is to the induction normalized treatment of steel rail weld joint on the line, the opposite opened load coil was separated after normalizing was finished, unclamp the detent mechanism of normalizing head, loop wheel machine hangs back the normalizing device in the container 1.Loop wheel machine 3 hangs hydraulic actuation formula four-way straightener 7 position to the welding point A similarly subsequently, rail is carried out the four-way aligning, and by loop wheel machine straightener is retracted in the container behind aligning.Wherein this straightener comprises main hydraulic cylinder that is used for the described bite of vertical start and the secondary hydraulic cylinder that is used for the described bite of horizontal start.Further structure and working method according to straightener of the present invention will be described in further detail with reference to Figure 4 and 5.Loop wheel machine 3 hangs position to the welding point with calibration devices 8 subsequently, and to rail (the especially wide face of rail head) finishing.This calibration devices for example comprise the wide face of rail head at the welding point place that is used to polish the polishing emery wheel, drive motor that described polishing emery wheel rotates, drive first stepping motor that described polishing emery wheel vertically moves back and forth along rail, drive second stepping motor that described polishing emery wheel laterally moves back and forth, the controller of the amount of feeding that the 3rd stepping motor of the feeding that drives described polishing emery wheel and being used to is controlled described polishing emery wheel.This finishing step for example comprises the polishing emery wheel rotation that drives calibration devices and the wide face of its rail head with the welding point place is contacted thus; This polishing emery wheel of start vertically moves back and forth along rail; This polishing emery wheel of start laterally moves back and forth along rail; Realize that at the amount of feeding on vertical polishing is to reach the requirement of joint glacing flatness with control polishing emery wheel.Loop wheel machine 3 is retracted to calibration devices 8 in the container 1 subsequently, finishes after welding treatment (being that normalizing, aligning and the finishing are handled) work of a joint.
Using after welding treatment system and method for the present invention that steel rail weld joint is carried out postwelding normalizing, aligning and finishing processing can significantly reduce recruitment quantity, reduce complex procedures, and the automaticity height, human factor is few, efficient is high, helps improving the steel rail weld joint construction quality.
Below continue with reference to Figure 4 and 5, wherein Fig. 4 shows the operating principle of existing straightener.In existing straightener, have face contact anchor clamps 60, the straightening force application point 61 of a side rail (upstream or downstream rail) that is used for the clamping welding point and be used for applying straightening force F at these straightening force application point 61 places
rActuation mechanism to the rail, wherein this face contact anchor clamps 60 and this straightening force application point 61 are applied to the both sides (be meant the upstream and downstream (or claim along the longitudinal front and back side) of welding point as non-specified otherwise belonging in this article " both sides of welding point ", but not the horizontal left and right sides of the rail at welding point place) of welding point respectively.When aligning, the aligning actuation mechanism applies suitable straightening force F according to the crooked situation of welding point both sides
r(in Fig. 4 for drawing upward to) be (annotate: straightener can only apply horizontal force (lateral force) to rail on the existing line, promptly can only correct bending right and left of rail) to rail.Refer now to the operating principle of a preferred embodiment according to straightener of the present invention shown in Figure 5, this straightener has first bite 62 that is used to be clamped in the welding point place, be clamped in second bite 63 of welding point upstream and be clamped in the 3rd bite 64 (the straightening force application point that this point is this straightener) in welding point downstream.This straightener also has aligning actuation mechanism (not shown).When aligning, the aligning start is according to the crooked situation clamping of welding point both sides and a fixedly also fixedly position (for example second place of the upstream of second bite, 63 clampings place) of (being one of welding point upstream or downstream) and clamping and apply suitable straightening force F on primary importance one side of the primary importance at welding point place (first bite, 62 places), clamping
rOn (in Fig. 5 be drawing upward to) rail to the primary importance opposite side (for example the 3rd position at the 3rd bite 64 places), wherein straightener can apply horizontal and/or vertical power to rail according to the crooked situation of rail according to the present invention, thereby corrects the bending of the four direction up and down of rail.
Preferred straightener according to the present invention has significant improvement than prior art.Wherein, prior art adopts face contact type anchor clamps and a point of application, has constituted the semi girder form from the principle, thereby this causes damage to influence the quality of leveling effect and welding point to welding point easily; And preferred straightener of the present invention has three bites, wherein two points are fixed (point at welding point place must be fixed), another point is as the point of application, this has constituted the form of simply supported beam, can significantly reduce the damage of welding point and can have better leveling effect by this set.
Term in the present invention " upstream " and " downstream " are to determine with welding point and after welding treatment system position relation each other, wherein, the extension rail of nearly after welding treatment system one side is depended in " upstream " of welding point, and " downstream " refers to the extension rail away from after welding treatment system one side.
Above-described embodiment, the present invention specific embodiment a kind of more preferably just, the common variation that those skilled in the art carries out in the technical solution of the present invention scope and replacing all should be included in protection scope of the present invention.