CN110954397A - System and method for detecting load condition of railway engineering - Google Patents
System and method for detecting load condition of railway engineering Download PDFInfo
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- G—PHYSICS
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Abstract
The invention relates to a detection system and a detection method for a railway engineering load condition, which comprises a base station, double disks and a hydraulic cylinder, wherein a steel rail is arranged at the upper end of the base station, the double disks are connected to the upper end of the steel rail, an output shaft of the hydraulic cylinder is connected with the double disks through a connecting rod, a fixed shaft is arranged at the upper end of the hydraulic cylinder, and two sides of each double disk are connected with the upper surface of the base station through supporting components; the detection system provided by the invention simulates the load and friction damage of a train to the steel rail through the double discs and the testing machine, truly simulates the actual working condition of the steel rail in the service process, the normal load is conveniently applied to the steel rail through the up-and-down motion of the hydraulic cylinder, the fatigue and abrasion phenomena of the sample can be generated by the continuous cyclic rolling of the wheel rail sample, the accurate detection of the composite load of the steel rail is realized, the reliability of the tested data result is high, the artificial error is avoided, the test repeatability is good, the operation is simple and convenient, and the labor intensity is reduced.
Description
Technical Field
The invention belongs to the technical field of detection tools and detection methods, and particularly relates to a detection system and method for a railway engineering load condition.
Background
Under the conditions of manufacturing, welding, wheel rolling and the like, the steel rail is easy to generate cracks, crushing, depression and other damages on the surface, the safety accidents and the economic losses caused by the damages are huge each year, the rolling contact of the wheel rail is accompanied with the occurrence of fatigue and abrasion, and the following problems are mainly reflected on the steel rail: firstly, the problem of rail side grinding on the curve section is outstanding, and it is serious to peel off the piece problem, secondly on the straightway, because the pressure that the rail bore is very big, the overlap phenomenon can take place for the railhead, thirdly because the wheel rolls the effect to the frequent reciprocal of rail, makes the railhead top layer appear tiredly, arouses the railhead top layer to peel off the piece, fourthly the increase of train axle load and operation frequency degree has aggravated the piece that hinders of peeling off of rail.
The rail is a key component in the track structure, directly bears weight in wheel-rail contact, receives the cyclic reciprocating action of train load, transmits the load to sleepers and ballast, plays a role in bearing and breaking down in railway transportation, and the fatigue damage of the rail is mostly nuclear damage generated on rail heads, the damage is increased along with the increase of total load passing through the rail, the fatigue crack source is usually initiated by inclusions in the rail, and under the repeated action of alternating load, the crack can be gradually expanded, finally, the crack is formed into nuclear damage and the surface damage is penetrated, and the crack is oxidized to form a black core.
Under the influence of environment, load, construction factors and the like, a steel structural member inevitably has a working state with crack defects, the steel rail generates contact stress concentration due to long-time cyclic rolling of wheels, fatigue damage can be generated in the service process, the rolling contact fatigue of the wheel rail is realized, not only can cracks on the surface of the steel rail develop to a certain depth to cause the nuclear damage of the steel rail, pits can be formed after the surface of a rail head is stripped and chipped, cracks which are re-initiated at the bottoms of the pits can also cause the nuclear damage, but also can have a working state with cracks in the service process, the cracks can possibly expand under the cyclic load of the wheels to cause the fracture damage of the steel rail, so that serious accidents are caused, and therefore, the detection of the safety of the crack defects of the steel rail has important significance.
Disclosure of Invention
The invention aims to solve the problems in the background technology, and provides a detection system and a detection method for the railway engineering load condition, which have the advantages of high reliability of the test data result, avoidance of human errors and good test repeatability for the accurate detection of the composite load of the steel rail.
The purpose of the invention is realized as follows:
the utility model provides a detecting system of railway engineering load situation, includes base station, two discs and pneumatic cylinder, the rail is established to the upper end of base station, two discs are connected to the upper end of rail, the output shaft of pneumatic cylinder passes through the connecting rod and connects two discs, the fixed axle is established to the upper end of pneumatic cylinder, the upper surface of base station is all connected through supporting component in the both sides of two discs, supporting component includes bracing piece, horizontal pole and montant, two discs are connected to the one end of bracing piece, the one end of horizontal pole is connected to the other end of bracing piece, the montant is connected perpendicularly to the other end of horizontal pole.
Furthermore, a mounting flange is arranged in the double disks, a plurality of mounting holes are formed in the flange, and the connecting rod and the supporting rod are connected with the flange through mounting holes and bolts.
Further, the upper end of the fixed shaft is connected with a testing machine; the testing machine is a compression testing machine, the compression testing machine comprises a second hydraulic cylinder, and a second output shaft on the second hydraulic cylinder is fixedly connected with the upper end of the fixed shaft. And the cylinder body of the second hydraulic cylinder is fixedly connected with the base station through a fixing rod.
Further, the axes of the first hydraulic cylinder, the second hydraulic cylinder, the first output shaft and the second output shaft are overlapped.
Furthermore, the axes of the first hydraulic cylinder, the second hydraulic cylinder, the first output shaft and the second output shaft and the gravity center of the double disks are on a vertical straight line.
Furthermore, the cross rod and the vertical rod are both connected with the base station through bolts.
Furthermore, the bottom of the steel rail is connected with the upper surface of the base station through a sensing base plate, the sensing base plate replaces an existing standard component, namely an insulating buffer base plate, installed below the railway steel rail, and the sensing base plate and the insulating buffer base plate have the same mechanical performance.
Furthermore, the support rod is made of a steel structure made of the same material as the steel rail, and the horizontal included angle between the support rod and the base platform is 15-60 degrees.
Furthermore, a rotating motor is arranged at the upper end of the base station, and an output shaft of the rotating motor is connected with the axle center of the double disks.
Further, the maximum contact stress Q of the steel rail satisfies the following conditions:
Q=3P(E1+E2)/2π(ν1+ν2),
wherein P is the vertical load (N) borne by the steel rail, E1 and E2 are the elastic moduli of the double discs and the steel rail material respectively, the unit is MPa, and ν 1 and ν 2 are the Poisson's ratio of the double discs and the steel rail material respectively.
Further, the wear rate of the steel rail meets the following requirements:
V=m/t，
wherein V is the wear rate (g/m) of the steel rail, m represents the wear quality (g), and t represents the wear time (min).
A method for using a detection system of railway engineering load conditions comprises the following steps:
s1, processing the steel rail test piece according to the size requirement of the test piece, cleaning the surface of the test piece by using an ultrasonic cleaning instrument, cleaning and wiping the surface by using alcohol, drying the cleaned surface, and then using the cleaned surface with the precision of 10-4g, measuring the mass of the samples by using an electronic balance, measuring each sample for three times, averaging, and finally classifying and packaging the samples to prepare for testing for later use;
s2, fixing the sample on the upper end of the base station, installing coaxial flange plates in the double disks, and fixedly connecting the two sides of the double disks with the base station through the supporting components;
s3, symmetrically connecting the two sides of the output shaft of the hydraulic cylinder to the two sides of the flange plate through connecting rods, keeping the axes of the output shaft of the hydraulic cylinder and the double disks superposed, and simultaneously connecting the testing machine to the upper end of the hydraulic cylinder through a fixed shaft;
s4, driving the double disks to rotate on the sample through the rotating motor, applying load to the sample through the testing machine, respectively testing the double disks at different rotating speeds, wherein the test is carried out in a rolling friction state, and the friction working condition is dry friction, so that the rolling abrasion test is completed;
s5, cleaning and weighing the steel rail, and solving the wear loss by using the mass difference of the steel rail before and after the test;
and S6, applying different loads through a testing machine, repeating the steps S4 and S5, cutting the steel rail sample into proper sizes by adopting a wire cutting machine, and observing the surface appearance and the surface grinding marks of the sample under different rotating speeds and load conditions by using an optical microscope.
Further, the rotating speed of the double disks is 200r/min and 400r/min, and the test cycle is 50000 revolutions.
Further, the maximum test force of the testing machine is 2000N, and the maximum friction torque of the double-disc is 15N · m.
Further, the axle load of the train is simulated, and the applied loads applied to the sample steel rail are respectively 430N, 500N, 570N and 650N.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the detection system for the load condition of the railway engineering, the load and the friction damage of the train to the steel rail are simulated through the double discs and the testing machine, the actual working condition of the steel rail in the service process is truly simulated, the normal load is conveniently applied to the steel rail through the vertical movement of the hydraulic cylinder, the fatigue and abrasion phenomena of the sample can be caused by the continuous cyclic rolling of the wheel rail sample, the accurate detection of the composite load of the steel rail is realized, the reliability of the tested data result is high, the artificial error is avoided, the test repeatability is good, the operation is simple and convenient, and the labor intensity is reduced.
2. According to the detection system for the load condition of the railway engineering, the double disks are laterally connected through the support assembly screws, the angles of the support rods can be quickly changed through lateral installation and disassembly of the screws, and the test operation is simpler and more convenient.
3. The invention provides a method for detecting the load condition of railway engineering, which comprises the steps of testing the mechanical properties of two materials through the vertical load of a testing machine, obtaining the basic mechanical property data of yield strength, tensile strength and the like of the two steel materials, carrying out rolling wear tests under different loads and different rotating speeds, measuring and recording each parameter by a computer and special software in the test process, displaying and recording a time-friction coefficient curve in real time, carrying out sorting analysis on the recorded time-friction coefficient curve to obtain the friction coefficient value under different conditions, analyzing the influence of different loads on the wear rate of a steel rail sample, and analyzing the wear morphology of the surface of the sample and the plastic deformation layer of the sample.
Drawings
Fig. 1 is a schematic view of the prior art connection of a railway wheel set to a rail.
Fig. 2 is a schematic structural diagram of a railway engineering load condition detection system.
Fig. 3 is a schematic view of the connection between the steel rail and the abutment according to the present invention.
Figure 4 is a schematic view of the dual disk and base station connection of the present invention.
Fig. 5 is a schematic view of a double disk of the present invention.
FIG. 6 shows the mean and standard deviation plots of the double disc and rail under different loads according to the invention.
FIG. 7 is a graph showing the change in coefficient of friction under different loads in accordance with the present invention.
Figure 8 is a graph showing the wear rate of the rail of the present invention as a function of load.
In the figure: 1. a base station; 2. a double disc; 3. a connecting rod; 4. a hydraulic cylinder; 5. a fixed shaft; 6. a testing machine; 7. a steel rail; 8. a rotating electric machine; 9. a support bar; 10. mounting holes; 11. a cross bar; 12. a vertical rod; 13. a flange plate.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below with reference to the accompanying drawings, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, rather than all embodiments, and all other embodiments obtained by those skilled in the art without any creative work based on the embodiments of the present invention belong to the protection scope of the present invention.
Example 1
With reference to fig. 1-5, a detection system for railway engineering load conditions, includes base station 1, double disc 2 and pneumatic cylinder 4, rail 7 is established to the upper end of base station 1, double disc 2 is connected to the upper end of rail 7, establish installation ring flange 13 in the double disc 2, the output shaft of pneumatic cylinder 4 passes through connecting rod 3 and connects mounting hole 10 on the ring flange 13 in the double disc 2, fixed axle 5 is established to the upper end of pneumatic cylinder 4, the testing machine is connected to the upper end of fixed axle 5, the upper surface of base station 1 is all connected through supporting component in the both sides of double disc 2, rotating electrical machines 8 is established to the upper end of base station 1, the axle center of the output shaft of rotating electrical machines 8 double disc 2.
Load and friction damage of a train to a steel rail are simulated through the double discs and the testing machine, actual working conditions of the steel rail in the service process are truly simulated, normal load is conveniently applied to the steel rail through up-and-down movement of the hydraulic cylinder, fatigue and abrasion of a sample can be caused by continuous cyclic rolling of a wheel rail sample, accurate detection of composite load of the steel rail is achieved, reliability of a tested data result is high, human errors are avoided, test repeatability is good, operation is simple and convenient, and labor intensity is reduced.
Example 2
On the basis of the embodiment 1, the bottom of the steel rail is connected with the upper surface of the base station through the sensing base plate, the sensing base plate replaces an existing standard component, namely an insulating buffer base plate, installed below the steel rail of the railway, the sensing base plate and the insulating buffer base plate have the same mechanical performance, the overall rigidity of the track structure can be kept consistent, the sensing base plate and the insulating buffer base plate have interchangeability in structure and mechanical performance, the sensing base plate can sense and solve the external acting force borne by the steel rail and send the external acting force to the wireless communication repeater in a radio frequency mode, the wireless communication repeater is responsible for transmitting data collected and solved by the sensing base plate in real time, and the real-time load condition of the steel rail can be accurately analyzed according to the data.
Example 3
On the basis of embodiment 1, a detecting system of railway engineering load condition, includes base station 1, double disc 2 and pneumatic cylinder 4, rail 7 is established to the upper end of base station 1, double disc 2 is connected to the upper end of rail 7, establish installation ring flange 13 in the double disc 2, the output shaft of pneumatic cylinder 4 passes through connecting rod 3 and connects mounting hole 10 on the ring flange 13 in the double disc 2, fixed axle 5 is established to the upper end of pneumatic cylinder 4, the testing machine is connected to the upper end of fixed axle 5, the upper surface of base station 1 is all connected through supporting component to the both sides of double disc 2, rotating electrical machines 8 is established to the upper end of base station 1, the axle center of the output shaft of rotating electrical machines 8 connection double disc 2.
Combine fig. 4, the supporting component includes bracing piece 9, horizontal pole 11 and montant 12, double round disc 2 is connected to the one end of bracing piece 9, the one end of horizontal pole 11 is connected to the other end of bracing piece 9, montant 12 is connected perpendicularly to the other end of horizontal pole 11, the equal bolted connection base station 1 of horizontal pole 11 and montant 12, bracing piece 9 adopt the steel construction with the same material of rail 7, bracing piece 9 is 30 with the horizontal contained angle of base station 1, through the bracing piece 9 that the slope set up, can verify the stress of rail on the incline direction, perfect the integrality of the load that the rail received.
The upper end of the fixed shaft is connected with a testing machine; the testing machine is a compression testing machine, the compression testing machine comprises a second hydraulic cylinder, and a second output shaft on the second hydraulic cylinder is fixedly connected with the upper end of the fixed shaft. And the cylinder body of the second hydraulic cylinder is fixedly connected with the base station through a fixing rod.
The axes of the first hydraulic cylinder, the second hydraulic cylinder, the first output shaft and the second output shaft are overlapped.
Furthermore, the axes of the first hydraulic cylinder, the second hydraulic cylinder, the first output shaft and the second output shaft and the gravity center of the double disks are on a vertical straight line.
Example 4
A method for detecting the load condition of railway engineering comprises the following steps:
s1, processing a steel rail 7 test piece according to the size requirement of the test piece, cleaning the surface of the test piece by using an ultrasonic cleaning instrument, cleaning and wiping the surface by using alcohol, drying the cleaned surface, and then using the cleaned surface with the precision of 10-4g, measuring the mass of the samples by using an electronic balance, measuring each sample for three times, averaging, and finally classifying and packaging the samples to prepare for testing for later use;
s2, fixing the sample on the upper end of the base station 1, installing a coaxial flange plate 13 in the double-disc 2, and fixedly connecting the two sides of the double-disc 2 with the base station 1 through the supporting components;
s3, symmetrically connecting the two sides of the output shaft of the hydraulic cylinder 4 to the two sides of the flange plate 13 through the connecting rods 3, keeping the axes of the output shaft of the hydraulic cylinder 4 and the double discs 2 superposed, and simultaneously connecting the testing machine 6 to the upper end of the hydraulic cylinder 4 through the fixed shaft 5;
s4, driving the double disks 2 to rotate on the sample through the rotating motor 8, applying load to the sample through the testing machine 6, respectively testing the double disks 2 at different rotating speeds, wherein the test is carried out in a rolling friction state, and the friction working condition is dry friction, so that a rolling abrasion test is completed;
s5, cleaning and weighing the steel rail 7, and solving the abrasion loss by using the mass difference of the steel rail 7 before and after the test;
s6, applying different loads through the testing machine 6, repeating the steps S4 and S5, cutting the steel rail 7 sample into proper size by adopting a wire cutting machine, and observing the surface appearance and the surface grinding marks of the sample under different rotating speeds and load conditions by using an optical microscope.
Example 5
A method for detecting the load condition of railway engineering comprises the following steps:
s1, processing a steel rail 7 test piece according to the size requirement of the test piece, cleaning the surface of the test piece by using an ultrasonic cleaning instrument, cleaning and wiping the surface by using alcohol, drying the cleaned surface, and then using the cleaned surface with the precision of 10-4g, measuring the mass of the samples by using an electronic balance, measuring each sample for three times, averaging, and finally classifying and packaging the samples to prepare for testing for later use;
s2, fixing the sample on the upper end of the base station 1, installing a coaxial flange plate 13 in the double-disc 2, and fixedly connecting the two sides of the double-disc 2 with the base station 1 through the supporting components;
s3, symmetrically connecting the two sides of the output shaft of the hydraulic cylinder 4 to the two sides of the flange plate 13 through the connecting rods 3, keeping the axes of the output shaft of the hydraulic cylinder 4 and the double discs 2 superposed, and simultaneously connecting the testing machine 6 to the upper end of the hydraulic cylinder 4 through the fixed shaft 5;
s4, driving the double disks 2 to rotate on the sample through the rotating motor 8, applying load to the sample through the testing machine 6, circulating 50000 times of the test under the rotating speeds of 200r/min and 400r/min of the double disks 2 respectively, carrying out the test in a rolling friction state, and finishing the rolling abrasion test under the dry friction working condition;
s5, cleaning and weighing the steel rail 7, and solving the abrasion loss by using the mass difference of the steel rail 7 before and after the test;
s6, applying different loads through a testing machine 6 to simulate the axle load of a train, wherein the applied loads applied to the sample steel rail are respectively 430N, 500N, 570N and 650N, repeating the steps S4 and S5, cutting the steel rail 7 sample into a proper size by adopting a wire cutting machine, and observing the surface appearance and the surface grinding marks of the sample under different rotating speeds and load conditions by using an optical microscope.
The maximum contact stress Q of the steel rail meets the following requirements: q = Q =3P (E1+ E2)/2 pi (v 1+ v 2), wherein P is the vertical load (N) borne by the steel rail, E1 and E2 are the elastic moduli of the double-disc and the steel rail material respectively, and v 1 and v 2 are the Poisson ratios of the double-disc and the steel rail material respectively.
The wear rate of the steel rail meets the following requirements: v = m/t, where V is the wear rate of the rail (g/m), m represents the wear mass (g), and t represents the wear time (min).
In order to make the contact condition of the tested wheel rail sample similar to the contact condition of a real wheel rail, the hertzian simulation criterion is adopted in the test, so that the average contact stress between the wheel rails under the simulation test condition is the same, and the average value and the standard deviation of the double discs and the steel rail under different loads are shown in fig. 6.
In the test process, each parameter is measured and recorded by a computer and special software, a time-friction coefficient curve can be displayed and recorded in real time, the recorded time-friction coefficient curve is sorted and analyzed, and the friction coefficient change under different friction coefficient values and different loads under different conditions can be obtained as shown in fig. 7, the whole level change of the friction coefficient under different axle weights is not large, the friction coefficient is slowly increased when the load is increased from 430N to 650N, and the friction coefficient when the rotating speed is 400r/min is slightly larger than the friction coefficient when the rotating speed is 200 r/min.
The wear rate of the steel rail varies with the load as shown in fig. 8, the wear rate increases from 430N to 650N, the wear rate is at a lower level when the axle weight is smaller at 430N and 500N, the wear rate increases rapidly when the axle weight is increased to 570N and 650N, and the wear rate increases at higher rotation speeds. This indicates that an increase in load and rotational speed can exacerbate wear of the wheel-rail contact.
The above description is only a preferred embodiment of the present invention, and should not be taken as limiting the invention, and any modifications, equivalents and substitutions made within the scope of the present invention should be included.
Claims (8)
1. A detection system for railway engineering load condition is characterized in that: including base station (1), two disc (2) and pneumatic cylinder (4), rail (7) are established to the upper end of base station (1), two disc (2) are connected to the upper end of rail (7), two disc (2) are connected through connecting rod (3) to the output shaft of pneumatic cylinder (4), fixed axle (5) are established to the upper end of pneumatic cylinder (4), the upper surface of base station (1) is all connected through supporting component in the both sides of two disc (2), supporting component includes bracing piece (9), horizontal pole (11) and montant (12), two disc (2) are connected to the one end of bracing piece (9), the one end of horizontal pole (11) is connected to the other end of bracing piece (9), montant (12) is connected perpendicularly to the other end of horizontal pole (11).
2. A railway work load condition detection system as claimed in claim 1, wherein: establish installation ring flange (13) in two disc (2), establish a plurality of mounting hole (10) on ring flange (13), connecting rod (3) and bracing piece (9) are all through mounting hole (10) bolted connection ring flange (13).
3. A railway work load condition detection system as claimed in claim 1, wherein: the upper end of the fixed shaft (5) is connected with a testing machine (6).
4. A railway work load condition detection system as claimed in claim 1, wherein: the transverse rod (11) and the vertical rod (12) are both connected with the base station (1) through bolts.
5. A railway work load condition detection system as claimed in claim 1, wherein: the support rod (9) is made of a steel structure made of the same material as the steel rail (7), and the horizontal included angle between the support rod (9) and the base platform (1) is 15-60 degrees.
6. A railway work load condition detection system as claimed in claim 1, wherein: the upper end of the base station (1) is provided with a rotating motor (8), and an output shaft of the rotating motor (8) is connected with the axle center of the double-disc (2).
7. A method of detecting a load condition in railroad work according to claim 7, wherein: the rotating speed of the double discs (2) is 200-400r/min, and the test cycle is 50000 turns.
8. A method of detecting a load condition in railroad work according to claim 7, wherein: the maximum test force of the testing machine (6) is 2000N, and the maximum friction torque of the double discs (2) is 15N-m.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114925498A (en) * | 2022-04-24 | 2022-08-19 | 西南交通大学 | Three-dimensional elastic-plastic wheel rail normal load rapid calculation method considering curvature transition |
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| CN102607869A (en) * | 2012-03-26 | 2012-07-25 | 西南交通大学 | Simulation experiment device of high-speed wheel rail |
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