EP1652593B1 - Method for straightening rolled metal sections - Google Patents

Method for straightening rolled metal sections Download PDF

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Publication number
EP1652593B1
EP1652593B1 EP05292194A EP05292194A EP1652593B1 EP 1652593 B1 EP1652593 B1 EP 1652593B1 EP 05292194 A EP05292194 A EP 05292194A EP 05292194 A EP05292194 A EP 05292194A EP 1652593 B1 EP1652593 B1 EP 1652593B1
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EP
European Patent Office
Prior art keywords
profile
curve
straightening
straightness
pressing
Prior art date
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Not-in-force
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EP05292194A
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German (de)
French (fr)
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EP1652593A1 (en
Inventor
Jacques Huart
Gilles Noel
Thierry Helle
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Societe des Anciens Etablissements Lucien Geismar SAS
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Societe des Anciens Etablissements Lucien Geismar SAS
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Publication of EP1652593A1 publication Critical patent/EP1652593A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
    • B21D3/10—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts between rams and anvils or abutments

Definitions

  • the invention relates to a process for straightening rolled metal sections, such as track rails, with the aid of a press comprising a device for measuring the straightness of a profile to be straightened and for establishing the deformation of the profile, and a pressing assembly comprising at least one device for deforming the rail by bending in a predetermined longitudinal plane of the profile, which comprises at least three members capable of coming into contact with the profile, at least one of which is a tool for pressing the profile or a support member on the profile and the others are support members or pressing.
  • Processes of this type and presses to be used for this purpose are particularly known for straightening rails of railroad tracks.
  • it is a press operator who executes the various consecutive operations of a straightening.
  • the operator controls for this purpose the actuator members of the press by means of push buttons, switches and manipulators, from a representation of the deformation of the rail to be straightened on a display screen. Therefore, the operator is the only judge of the levels of force to apply to the rail and must have good experience to reconcile quality and productivity.
  • the present invention aims to provide a method and a press that overcome these disadvantages. This object is achieved by the method according to claim 1 and the press according to claim 12.
  • the method according to the invention contains the characteristic that is brought to the press to acquire and automatically process in real time data concerning the relationship between the pressing forces exerted by the pressing tool on the profile and moving the tool for this purpose and applying the pressing force necessary to obtain the deformation determined from these data, to achieve the desired straightening of the profile, and the characteristic that is established the characteristic curve of the pressing forces of the tool on the profile as a function of the displacement of the tool in the fields of elastic and plastic deformation and validates the stopping condition of the straightening process for producing the desired residual deformation from this curve.
  • the stop condition of the straightening process is determined when the pressing force reaches a value such that the horizontal distance between the position on the abscissa which indicates the beginning of the zone plastic f and the actual position on the curve is equal to the plastic deformation to achieve.
  • the straightness of the section to be straightened is measured and, after processing of the measurement data, a straightness curve is established.
  • out-of-tolerance zones of the section to be straightened are determined to be located outside a tolerance corridor of a predetermined length and height that is moved along the curve. with the endpoints representative of the zero tolerance sliding on the curve.
  • the tolerance corridor is formed by a virtual rule.
  • an operation for detecting and eliminating defects in the straightness curve is carried out by filtering and smoothing the measurement data constituting this straightness curve.
  • ratios of the profile section measured are calculated by progressing step by step from one end to the other of this section.
  • a deformation ratio is established by sliding a straight line whose length corresponds to a real separation of the two external contact members, keeping the ends of this straight line on the straightness curve and Retain as ratio the difference of the algebraic areas and between the curve and the line above and below it, divided by the square of the spacing.
  • a deformation ratio value is established for each position of the aforementioned straight line for all the spacings between a maximum spacing value and a minimum spacing value.
  • an external contact member and the contact member located between the external members may constitute a variable to be taken into account during straightening.
  • the area to be straightened from the profile is chosen to be that having a maximum deformation ratio, with the point of application of the pressing force included in an out-of-tolerance zone.
  • the straightening press of rolled sections comprises, for the implementation of the method, an automatic device for the acquisition and processing in real time of data relating to the profile to straighten and calculation of the straightening operation according to a predetermined software.
  • the straightening press which is a hydraulic press, is intended in particular to straighten horizontally and vertically either the ends of the short rails or welded joints made between two short rails to obtain welded long rails. It is this latter application that will be described, without this being limiting.
  • This press which is designated in the figures by the general reference number 1, is mounted on a platform 2 capable of moving on rails 3 with the aid of axles 4.
  • the press 1 essentially comprises a set 6 of press a straightening rail indicated at 7, which is disposed in the central part of the press, a measuring device 8 of the rails to be treated and rail moving means 7 through the machine, in a horizontal plane. These means are not specifically represented.
  • the pressing assembly 6 comprises a device for straightening the rail in a vertical plane, which comprises an upper vertical jack 10 intended to actuate a hammer 11 constituting the pressing tool and which is vertically movable, a lower vertical jack 12 arranged vertically. Below the upper cylinder 10 and the hammer 11, and on either side of the cylinders, in the longitudinal direction of the rail, two articulated upper movable ablots 13 and 14 and two movable ablots lower 15, 16. The upper and lower ablots are respectively disposed above and below the rail 7 and intended to retain the rail during straightening.
  • the pressing assembly 6 further comprises a device for horizontal straightening of the rail 7, which comprises a member 18 for horizontal support of the rail, called the iron hand located at the vertical cylinders 10 and 12 and which is associated with a horizontal hydraulic jack actuator 19, and two iron hand members 20, 21 horizontally retaining the rail 7, each disposed at the level of the lower movable ablots 15 and 16.
  • a device for horizontal straightening of the rail 7, which comprises a member 18 for horizontal support of the rail, called the iron hand located at the vertical cylinders 10 and 12 and which is associated with a horizontal hydraulic jack actuator 19, and two iron hand members 20, 21 horizontally retaining the rail 7, each disposed at the level of the lower movable ablots 15 and 16.
  • the device 8 for measuring the straightness of the rails to be straightened 7 essentially comprises a measuring carriage 21 ( figure 5 ) provided with a vertical laser sensor 22, which is arranged in the vertical plane of symmetry of the rail 7 to measure the straightness of the rail in its vertical plane and, on either side of the rail head 23, in the same plane horizontal, two laser sensors 24, 25 for measuring the straightness of rail in its horizontal plane.
  • the measuring carriage 21 is movable along a horizontal guiding device 26, which is fixedly mounted on the structure of the press.
  • This method comprises a first phase of measuring the straightness of a section of the rail.
  • Straightness is measured by the measuring carriage 21 by continuously acquiring the signals via the laser sensors 22, 24 and 25.
  • the measurement values are acquired automatically during the carriage stroke on the rail section corresponding to the position of the press along its horizontal guiding device 26, under the control of appropriate computer equipment, acting according to a measuring software, according to the invention.
  • the measuring device establishes, by calculation of the algebraic average over a predetermined number of samples, the shape of the rail section considered. Then we proceed to a storage, for example every millimeter.
  • the absolute position of the carriage is given by an incremental encoder and a laser barrier fixed to the measuring beam.
  • the measuring device represents the shape of the section of rail considered on a display screen, in the form of a curve CR, as seen on the figure 6 .
  • This curve indicates the length of the section, the deviations of the rail, that is to say the deformation, of the reference axis R representative of the zero difference over the length of the section.
  • the rail section may have local straightness defects such as for example places where two short rails have been welded to each other for the realization of a long rail. These local defects are manifest in the form of sudden variations in the concavity of the straightness curve CR, as seen for example at the location S indicated by a dashed line, which could be a weld bead. More precisely, a local fault is considered as present when two successive and symmetrical variations are located in a zone of short length.
  • a second phase of the method according to the invention lies in the detection and the mathematical elimination of the defects found by a mathematical analysis from the data of the measure of straightness.
  • Each defect identified is eliminated by performing a replacement of the area concerned by a segment linear.
  • the qualitative data of each defect are kept for traceability of the rail.
  • the figure 6 illustrates the elimination of the defect S in the manner just indicated.
  • the measurement data of the straightness is extracted and filtered.
  • the raw measurement data are filtered to eliminate small irregularities in the curve.
  • smoothing is done.
  • the filtered measurement data are for this purpose extracted by sampling according to predetermined steps, for example every centimeter. Thus, on a measurement section with a length of 3000 millimeters, 300 steps are thus retained.
  • a tolerance corridor is characterized by its length and height, which are chosen according to the desired straightness qualities of the rail.
  • the determination of the out-of-tolerance zones is carried out by placing a virtual rule 28 of predetermined length and height which respectively represent the length and the height of the aforementioned tolerance corridor and by moving this rule along the whole of the CR curve in a step of constant value, the two ends 29, 30 of the rule still being on the curve of straightness, as seen on the figure 8 .
  • a virtual rule 28 of predetermined length and height which respectively represent the length and the height of the aforementioned tolerance corridor
  • this rule along the whole of the CR curve in a step of constant value, the two ends 29, 30 of the rule still being on the curve of straightness, as seen on the figure 8 .
  • the value of the ratio R is always positive and gives the indication of the deformation without precision of the direction of deformation which could be a hollow or a bump.
  • the line connecting the two points of support (as defined on the figure 10 ) on the straightness curve delimits with this one on the left a negative area A - and on the right a positive area A + since these two areas are respectively below and above the right.
  • the sixth phase that follows concerns the choice of the area to straighten, the measured rail section.
  • This zone is selected according to two criteria, namely the ratio R (p, e) maximum and the point of application of the effort to be made by the pressing tool, in an out of tolerance zone established during phase 4
  • the maximum ratio R (p, e) as well as the points of support and the position p of the pressing hammer, that is to say the point of application of the pressing force, which are associated with this maximum value R are deduced directly from Table I.
  • the distance of a tool ablot could be different from the distance of the tool of the other ablot and thus constitute a variable to be treated in a similar way away from the above.
  • the form factor is used to modulate the final state of straightness in order to obtain an optimal shape for the possible treatment after straightening.
  • the rail could be voluntarily "curved" to optimize the quality of a subsequent grinding operation.
  • the straightening process is a cycle consisting of a succession of a plurality of work steps, namely an exit step of the pressing tool, the approach of the rail to the vacuum, the contacting of the tool with the rail and a cycle part characterized by the repetition of a sequence of three successive work steps, that is the loading of the rail and / or a simultaneous control of the residual deformation while working in the zone of elastic deformation, loading at constant speed in plastic deformation zone of the rail, then unloading.
  • This figure 12 illustrates the relation between the hydraulic pressure P generating the pressing force indicated on the ordinate and the displacement X of the tool indicated on the abscissa, in different work situations.
  • the figure 12 firstly illustrates the first three steps of the straightening cycle, namely the steps of exit of the pressing tool and the no-load movement, both indicated by the reference a, and the step of contacting the the tool with the rail, indicated by the reference b. It is found that, during the first two steps, exit of the pressing tool then empty displacement, the pressure P can be assimilated to a constant.
  • the purpose of the output step is to overcome the disturbances of the pressure and position signals related to the use of certain components and to guarantee the stability of the control information. In the event that the stability of the signals is not validated, the straightening cycle is interrupted.
  • the contacting step b is characterized by a specific concavity of the pressure / displacement curve.
  • the figure 12 also illustrates the step of loading the rail by the tool in the elastic deformation zone c of the rail, which is characterized in that the curve is substantially rectilinear and follows the zone b.
  • the following plastic deformation zone denoted by f is characterized by the fact that the pressure / displacement curve has a convex shape, that is to say the curve deviates from the curve assimilable to a line defining the elastic zone c.
  • the estimate of the plastic deformation is defined and calculated from the horizontal difference between the position on the abscissa which indicates the start of the plastic zone f and the actual position on the curve. The loading step is completed to obtain the desired deformation established during the 7 th phase.
  • the elastic return zone g corresponding to the unloading step consists of a controlled return of the pressing tool ensuring that the tool is always in contact with the rail.
  • the figure 12 illustrates finally, the step of controlling the residual deformation by elastic reloading. This loading is done according to a curve comparable to a line h which presents the same slope as the initial elastic part c.
  • the horizontal distance of the two straight portions c and h represents the plastic deformation of the rail that the tool has made. Therefore, to obtain the desired deformation d, it was therefore necessary to go on the curve portion f up to the pressure P max .
  • the control of the residual deformation is performed only from a second loading sequence, after the first plastic deformation sequence. If it turns out that the desired deformation is not yet fully realized during the first loading step, the invention provides that the deformation control step continues in a new loading step.
  • TDP (x) the terms DP (x) constitute the delta-pressure measured at the position x
  • DP (x-1), DP (x-2) and DP (x-3) constitute the values measured at the three previous positions.
  • the establishment of the delta-pressure trend TDPn (x) makes it possible to note the engagement of the pressing tool with the rail since, at this instant of time, the threshold of n successive delta-pressure values exceeding a minimum difference is reached.
  • This position corresponds to the pressure rise zone b.
  • the beginning of the elastic zone c is observed when the pressure / displacement curve can be likened to a straight line, that is to say when the delta-pressure trend remains constant.
  • the pressure / displacement curve enters the plastic zone when this curve loses its linear characteristic and takes a convexity detected by the decay on n successive samples of the delta-pressure value.
  • the software calculates the ideal slope corresponding to the real elastic zone.
  • the difference between the line representative of the elastic zone and the curve in the plastic zone gives the residual plastic deformation.
  • the beginning of the plastic zone can be readjusted if the convexity of the pressure / displacement curve is lost.
  • Each of the readjustments of the plastic zone corresponds to a recalculation of the directing coefficient of the straight line of elastic characteristic, namely of the slope, and also of the residual plastic deformation to be achieved.
  • the partial residual plastic deformation is calculated before the readjustment of the plastic zone and then stored for cumulation.
  • the total residual plastic deformation corresponds to the set of partial residual plastic deformations detected during the complete straightening cycle.
  • Total residual plastic deformation is the sum of the partial residual plastic deformations detected during the cycle.
  • the invention is based on the acquisition and the real-time processing of the effort / displacement torque implemented by controlled elasto-plastic flexion.
  • the data processing allows the identification and use of the intrinsic behavior of the material, independently of the product being processed, in order to detect the transition between the elastic domain and the plastic domain, characterized by a slope break of the stress / strain curve. displacement and this in order to faithfully predict the effective plastic deformation after release.
  • the method makes it possible to perform measurement and analysis of the product deformations between each pressing phase and determines the optimal positioning of the support points.
  • the press and the method can be modified in many ways within the scope of the invention. Thus, it is not mandatory to use for a straightening in one plane a pressing tool and two ablots. We could also use two tools and an ablot or another configuration of tools and ablots support.
  • the invention is advantageously used for the manufacture of rails, but relates, in general, the straightening or reshaping of bars, tubes and metal profiles.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Straightening Metal Sheet-Like Bodies (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Control Of Heat Treatment Processes (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Machines For Laying And Maintaining Railways (AREA)
  • Laminated Bodies (AREA)

Abstract

The method involves guiding a straightening press (1) to automatically acquire and process data in real time. The data concerns relation between pressing forces exerted by a hammer (11) on a track (7) and movement of the hammer, where the track is disposed in a central part of the press. The press is guided to apply pressing force necessary for obtaining the determined deformation based on the data, for straightening the track. An independent claim is also included for a rolled metal section straightening press.

Description

Le document JP-A-57146422 divulgue en combinaison les caractéristiques mentionnées dans le préambule des revendications 1 et 12.The document JP-A-57146422 discloses in combination the features mentioned in the preamble of claims 1 and 12.

L'invention concerne un procédé de redressage de profilés métalliques laminés, tels que des rails de voie ferrée, à l'aide d'une presse comportant un dispositif de mesure de la rectitude d'un profilé à redresser et d'établissement de la déformée du profilé, et un ensemble de pressage comportant au moins un dispositif de déformation du rail par flexion dans un plan longitudinal prédéterminé du profilé, qui comporte au moins trois organes susceptibles de venir en contact avec le profilé, dont au moins un est un outil de pressage du profilé ou un organe d'appui sur le profilé et dont les autres sont des organes d'appui ou de pressage.The invention relates to a process for straightening rolled metal sections, such as track rails, with the aid of a press comprising a device for measuring the straightness of a profile to be straightened and for establishing the deformation of the profile, and a pressing assembly comprising at least one device for deforming the rail by bending in a predetermined longitudinal plane of the profile, which comprises at least three members capable of coming into contact with the profile, at least one of which is a tool for pressing the profile or a support member on the profile and the others are support members or pressing.

Des procédés de ce type et des presses à utiliser à cette fin sont notamment connus pour redresser des rails de voie ferrée. Dans le cadre de ces procédés, c'est un opérateur de la presse qui exécute les différentes opérations consécutives d'un redressage. L'opérateur commande à cette fin les organes actionneurs de la presse par l'intermédiaire de boutons poussoirs, commutateurs et manipulateurs, à partir d'une représentation de la déformée du rail à redresser sur un écran de visualisation. Par conséquent, l'opérateur est seul juge des niveaux de force à appliquer au rail et doit avoir une bonne expérience afin de concilier la qualité et la productivité.Processes of this type and presses to be used for this purpose are particularly known for straightening rails of railroad tracks. As part of these processes, it is a press operator who executes the various consecutive operations of a straightening. The operator controls for this purpose the actuator members of the press by means of push buttons, switches and manipulators, from a representation of the deformation of the rail to be straightened on a display screen. Therefore, the operator is the only judge of the levels of force to apply to the rail and must have good experience to reconcile quality and productivity.

Or, cette dépendance de la qualification de l'opérateur constitue un inconvénient majeur des procédés et des presses connus.However, this dependence of the qualification of the operator is a major drawback of known processes and presses.

La présente invention a pour but de proposer un procédé et une presse qui permettent de pallier à ces inconvénients. Ce but est atteint par le procédé selon la revendication 1 et la presse selon la revendication 12.The present invention aims to provide a method and a press that overcome these disadvantages. This object is achieved by the method according to claim 1 and the press according to claim 12.

Pour atteindre ce but, le procédé selon l'invention contient la caractéristique que l'on amène la presse à acquérir et traiter automatiquement en temps réel les données concernant la relation entre les forces de pressage exercées par l'outil de pressage sur le profilé et le déplacement de l'outil à cette fin et à appliquer la force de pressage nécessaire pour obtenir la déformée déterminée à partir de ces données, pour réaliser le redressage souhaité du profilé, et la caractéristique que l'on établit la courbe caractéristique des forces de pressage de l'outil sur le profilé en fonction du déplacement de l'outil dans les domaines de déformation élastique et plastique et valide la condition d'arrêt du processus de redressage pour la réalisation de la déformée résiduelle souhaitée à partir de cette courbe.To achieve this goal, the method according to the invention contains the characteristic that is brought to the press to acquire and automatically process in real time data concerning the relationship between the pressing forces exerted by the pressing tool on the profile and moving the tool for this purpose and applying the pressing force necessary to obtain the deformation determined from these data, to achieve the desired straightening of the profile, and the characteristic that is established the characteristic curve of the pressing forces of the tool on the profile as a function of the displacement of the tool in the fields of elastic and plastic deformation and validates the stopping condition of the straightening process for producing the desired residual deformation from this curve.

Selon une caractéristique préférée de l'invention, l'on détermine la condition d'arrêt du processus de redressage quand la force de pressage atteint une valeur telle que l'écart horizontal entre la position sur l'abscisse qui indique le début de la zone plastique f et la position réelle sur la courbe est égal à la déformation plastique à réaliser.According to a preferred characteristic of the invention, the stop condition of the straightening process is determined when the pressing force reaches a value such that the horizontal distance between the position on the abscissa which indicates the beginning of the zone plastic f and the actual position on the curve is equal to the plastic deformation to achieve.

Selon encore une caractéristique préférée de l'invention, on mesure la rectitude du profilé à redresser et établit après traitement des données de mesure une courbe de rectitude.According to another preferred feature of the invention, the straightness of the section to be straightened is measured and, after processing of the measurement data, a straightness curve is established.

Selon encore une caractéristique préférée de l'invention, on détermine des zones hors tolérances du profilé à redresser comme étant situées hors d'un couloir de tolérances d'une longueur et d'une hauteur prédéterminées que l'on déplace le long de la courbe avec les points d'extrémité représentatifs de la tolérance zéro glissant sur la courbe.According to another preferred feature of the invention, out-of-tolerance zones of the section to be straightened are determined to be located outside a tolerance corridor of a predetermined length and height that is moved along the curve. with the endpoints representative of the zero tolerance sliding on the curve.

Selon encore une caractéristique préférée de l'invention, le couloir de tolérances est formé par une règle virtuelle.According to another preferred feature of the invention, the tolerance corridor is formed by a virtual rule.

Selon encore une caractéristique préférée de l'invention, avant l'établissement des zones hors tolérances, on effectue une opération de détection et élimination des défauts de la courbe de rectitude en procédant à un filtrage et lissage des données de mesure constituant cette courbe de rectitude.According to another preferred feature of the invention, before the establishment of the out-of-tolerance zones, an operation for detecting and eliminating defects in the straightness curve is carried out by filtering and smoothing the measurement data constituting this straightness curve. .

Selon encore une caractéristique préférée de l'invention, on établit par calcul des ratios de la section de profilé mesurée en progressant pas à pas d'une extrémité à l'autre de cette section.According to another preferred feature of the invention, ratios of the profile section measured are calculated by progressing step by step from one end to the other of this section.

Selon encore une caractéristique préférée de l'invention, un ratio de déformation est établi en faisant glisser une ligne droite dont la longueur correspond à un écartement réel des deux organes de contact extérieur, en maintenant les extrémités de cette droite sur la courbe de rectitude et retient comme ratio la différence des aires algébriques et entre la courbe et la droite au-dessus et en dessous de celle-ci, divisé par le carré de l'écartement.According to another preferred feature of the invention, a deformation ratio is established by sliding a straight line whose length corresponds to a real separation of the two external contact members, keeping the ends of this straight line on the straightness curve and Retain as ratio the difference of the algebraic areas and between the curve and the line above and below it, divided by the square of the spacing.

Selon encore une caractéristique préférée de l'invention, une valeur de ratio de déformation est établie pour chaque position de la droite précitée pour tous les écartements entre une valeur d'écartement maximale et une valeur d'écartement minimale.According to another preferred feature of the invention, a deformation ratio value is established for each position of the aforementioned straight line for all the spacings between a maximum spacing value and a minimum spacing value.

Selon encore une caractéristique préférée de l'invention, un organe de contact extérieur et l'organe de contact situé entre les organes extérieurs peut constituer une variable à prendre en compte lors du redressage.According to another preferred feature of the invention, an external contact member and the contact member located between the external members may constitute a variable to be taken into account during straightening.

Selon encore une caractéristique préférée de l'invention, la zone à redresser du profilé est choisie comme étant celle présentant un ratio de déformation maximal, avec le point d'application de l'effort de pressage inclus dans une zone hors tolérances.According to another preferred feature of the invention, the area to be straightened from the profile is chosen to be that having a maximum deformation ratio, with the point of application of the pressing force included in an out-of-tolerance zone.

La presse de redressage de profilés laminés, selon l'invention, du type comportant un dispositif de mesure de la rectitude du profilé et d'établissement de la déformée de celui-ci, un ensemble de pressage comportant au moins un dispositif de déformation du profilé par flexion dans un plan longitudinal prédéterminé de celui-ci, comporte, pour la mise en oeuvre du procédé un dispositif automatique d'acquisition et de traitement en temps réel des données relatives au profilé à redresser et de calcul de l'opération de redressage selon un logiciel prédéterminé.The straightening press of rolled sections, according to the invention, of the type comprising a device for measuring the straightness of the profile and establishing the deformation thereof, a pressing assembly comprising at least one deformation device of the profile by bending in a predetermined longitudinal plane thereof, comprises, for the implementation of the method, an automatic device for the acquisition and processing in real time of data relating to the profile to straighten and calculation of the straightening operation according to a predetermined software.

L'invention sera mieux comprise, et d'autres buts, caractéristiques, détails et avantages de celle-ci apparaîtront plus clairement au cours de la description explicative qui va suivre faite en référence aux dessins schématiques annexés donnés uniquement à titre d'exemple illustrant un mode de réalisation de l'invention et dans lesquels :

  • la figure 1 est une vue latérale d'une presse de redressage de rails de chemin de fer selon l'état de la technique ;
  • la figure 2 est une vue de dessus de la presse selon la figure 1 ;
  • la figure 3 est une vue en coupe selon la ligne III-III de la figure 1 ;
  • la figure 4 est une vue en coupe selon la ligne IV-IV de la figure 1 ;
  • la figure 5 est une vue en coupe selon la ligne V-V de la figure 1 ;
  • la figure 6 illustre la courbe représentative d'une section d'un rail de voie ferrée à redresser, établie par le dispositif de mesure de la rectitude du rail équipant les presses selon les figures 1 à 5, et représentée sur un écran de visualisation ;
  • la figure 7 montre la représentation sur l'écran de visualisation de la section de rail selon la figure 6, après une opération de lissage des données de mesure ;
  • les figures 8 et 9 illustrent deux phases de l'opération de détermination d'une zone hors tolérance de la section de rail selon la figure 7 ;
  • les figures 10 et 11 illustrent l'opération de calcul des ratios de déformation globale de la section de rail selon la figure 7 ;
  • la figure 12 illustre quatre phases successives de l'opération de redressage d'un rail, exécutées suite aux opérations représentées sur les figures 6 à 10.
The invention will be better understood, and other objects, features, details and advantages thereof will appear more clearly in the following explanatory description made with reference to the accompanying schematic drawings given solely by way of example illustrating a embodiment of the invention and in which:
  • the figure 1 is a side view of a railroad straightening press according to the state of the art;
  • the figure 2 is a top view of the press according to the figure 1 ;
  • the figure 3 is a sectional view along line III-III of the figure 1 ;
  • the figure 4 is a sectional view along line IV-IV of the figure 1 ;
  • the figure 5 is a sectional view along line VV of the figure 1 ;
  • the figure 6 illustrates the representative curve of a section of a track rail to be straightened, established by the device for measuring the straightness of the rail equipping the presses according to the Figures 1 to 5 , and represented on a display screen;
  • the figure 7 shows the representation on the display screen of the rail section according to the figure 6 after a smoothing operation of the measurement data;
  • the Figures 8 and 9 illustrate two phases of the operation of determining an off-tolerance area of the rail section according to the figure 7 ;
  • the Figures 10 and 11 illustrate the operation of calculating the overall deformation ratios of the rail section according to the figure 7 ;
  • the figure 12 illustrates four successive phases of the straightening operation of a rail, executed following the operations represented on the Figures 6 to 10 .

L'invention sera décrite ci-après, à titre d'exemple non limitatif, dans son application au redressement des rails d'une voie ferrée. A cette fin, on décrira tout d'abord, en se référant aux figures 1 à 5, brièvement, autant que cela est nécessaire pour la compréhension de l'invention, la structure générale d'une presse de redressage des rails de voie ferrée qui permet la mise en oeuvre du procédé selon l'invention et qui comporte à cette fin certaines caractéristiques nouvelles et spécifiques qui ressortiront de la description faite ensuite, du procédé proprement dit.The invention will be described below, by way of non-limiting example, in its application to the straightening of rails of a railway. To this end, we will first describe, referring to the Figures 1 to 5 briefly, as far as is necessary for the understanding of the invention, the general structure of a straightening press of the railway tracks which allows the implementation of the method according to the invention and which comprises for this purpose certain characteristics new and specific that will emerge from the description made next, of the process itself.

La presse de redressage qui est une presse hydraulique, est notamment destinée à redresser horizontalement et verticalement soit les extrémités des rails courts, soit les joints soudés réalisés entre deux rails courts pour obtenir des rails longs soudés. C'est cette dernière application qui sera décrite, sans que cela ne soit limitatif.The straightening press, which is a hydraulic press, is intended in particular to straighten horizontally and vertically either the ends of the short rails or welded joints made between two short rails to obtain welded long rails. It is this latter application that will be described, without this being limiting.

Cette presse qui est désignée sur les figures par le numéro de référence général 1, est montée sur une plateforme 2 susceptible de se déplacer sur des rails 3 à l'aide d'essieux 4. La presse 1 comporte essentiellement un ensemble 6 de pressage d'un rail à redresser indiqués en 7, qui est disposé dans la partie centrale de la presse, un dispositif de mesurage 8 des rails à traiter et des moyens de déplacement de rail 7 à travers la machine, dans un plan horizontal. Ces moyens ne sont pas représentés spécifiquement.This press which is designated in the figures by the general reference number 1, is mounted on a platform 2 capable of moving on rails 3 with the aid of axles 4. The press 1 essentially comprises a set 6 of press a straightening rail indicated at 7, which is disposed in the central part of the press, a measuring device 8 of the rails to be treated and rail moving means 7 through the machine, in a horizontal plane. These means are not specifically represented.

L'ensemble de pressage 6 comprend un dispositif de redressage du rail dans un plan vertical, qui comporte un vérin vertical supérieur 10 destiné à actionner un marteau 11 constituant l'outil de pressage et qui est verticalement mobile, un vérin vertical inférieur 12 disposé verticalement en-dessous du vérin supérieur 10 et du marteau 11, et, de part et d'autre des vérins, dans la direction longitudinale du rail, deux ablots mobiles supérieurs articulés 13 et 14 et deux ablots mobiles inférieurs 15, 16. Les ablots supérieurs et inférieurs sont disposés respectivement au-dessus et en-dessous du rail 7 et destinés à retenir le rail lors du redressage.The pressing assembly 6 comprises a device for straightening the rail in a vertical plane, which comprises an upper vertical jack 10 intended to actuate a hammer 11 constituting the pressing tool and which is vertically movable, a lower vertical jack 12 arranged vertically. below the upper cylinder 10 and the hammer 11, and on either side of the cylinders, in the longitudinal direction of the rail, two articulated upper movable ablots 13 and 14 and two movable ablots lower 15, 16. The upper and lower ablots are respectively disposed above and below the rail 7 and intended to retain the rail during straightening.

L'ensemble de pressage 6 comporte encore un dispositif de redressage horizontal du rail 7, qui comprend un organe 18 d'appui horizontal du rail, appelé main de fer situé au niveau des vérins verticaux 10 et 12 et auquel est associé un vérin hydraulique horizontal d'actionnement 19, et deux organes de main de fer 20, 21 de retenue horizontale du rail 7, chacun disposé au niveau des ablots mobiles inférieurs 15 et 16.The pressing assembly 6 further comprises a device for horizontal straightening of the rail 7, which comprises a member 18 for horizontal support of the rail, called the iron hand located at the vertical cylinders 10 and 12 and which is associated with a horizontal hydraulic jack actuator 19, and two iron hand members 20, 21 horizontally retaining the rail 7, each disposed at the level of the lower movable ablots 15 and 16.

Le dispositif 8 de mesurage de la rectitude des rails à redresser 7 comporte essentiellement un chariot de mesure 21 (figure 5) pourvu d'un capteur laser vertical 22, qui est disposé dans le plan vertical de symétrie du rail 7 pour mesurer la rectitude du rail dans son plan vertical et, de part et d'autre du champignon de rail 23, dans le même plan horizontal, deux capteurs laser 24, 25 destinés à mesurer la rectitude de rail dans son plan horizontal.The device 8 for measuring the straightness of the rails to be straightened 7 essentially comprises a measuring carriage 21 ( figure 5 ) provided with a vertical laser sensor 22, which is arranged in the vertical plane of symmetry of the rail 7 to measure the straightness of the rail in its vertical plane and, on either side of the rail head 23, in the same plane horizontal, two laser sensors 24, 25 for measuring the straightness of rail in its horizontal plane.

Le chariot de mesurage 21 est déplaçable le long d'un dispositif de guidage horizontal 26, qui est monté fixe sur la structure de la presse.The measuring carriage 21 is movable along a horizontal guiding device 26, which is fixedly mounted on the structure of the press.

Après la description de la structure générale de la presse de redressage 1 de rail 7, on décrira ci-après le déroulement du procédé de redressage d'un rail à l'aide de la presse 1. La description du procédé se limitera au redressage du rail dans le plan vertical. Bien entendu, après le redressage vertical, l'invention prévoit également, si cela s'avère nécessaire, un redressage dans le plan horizontal dont les différentes opérations et étapes correspondent à celles du redressage vertical qu'on décrira ci-après.After describing the general structure of the straightening press 1 of rail 7, the procedure of straightening a rail using the press 1 will be described below. The description of the process will be limited to the straightening of the rail in the vertical plane. Of course, after the vertical straightening, the invention also provides, if necessary, straightening in the horizontal plane, the different operations and steps correspond to those of the vertical straightening described below.

Ce procédé comporte une première phase de mesure de la rectitude d'une section du rail. La rectitude est mesurée par le chariot de mesure 21 en effectuant une acquisition continue des signaux par l'intermédiaire des capteurs laser 22, 24 et 25. L'acquisition des valeurs de mesure est effectuée automatiquement lors de la course du chariot sur la section de rail correspondant à la position de la presse le long de son dispositif de guidage horizontal 26, sous la commande d'un équipement informatique approprié, agissant selon un logiciel de mesurage, conformément à l'invention. Le dispositif de mesurage établit par calcul de moyenne algébrique sur un nombre prédéterminé d'échantillons l'allure de la section de rail considérée. Puis on procède à une mémorisation, par exemple à chaque millimètre. La position absolue du chariot est donnée par un codeur incrémental et une barrière laser fixée à la poutre de mesurage.This method comprises a first phase of measuring the straightness of a section of the rail. Straightness is measured by the measuring carriage 21 by continuously acquiring the signals via the laser sensors 22, 24 and 25. The measurement values are acquired automatically during the carriage stroke on the rail section corresponding to the position of the press along its horizontal guiding device 26, under the control of appropriate computer equipment, acting according to a measuring software, according to the invention. The measuring device establishes, by calculation of the algebraic average over a predetermined number of samples, the shape of the rail section considered. Then we proceed to a storage, for example every millimeter. The absolute position of the carriage is given by an incremental encoder and a laser barrier fixed to the measuring beam.

Le dispositif de mesurage représente l'allure de la section de rail considérée sur un écran de visualisation, sous forme d'une courbe CR, comme on le voit sur la figure 6. Cette courbe indique sur la longueur de la section, les écarts du rail, c'est-à-dire la déformée, de l'axe de référence R représentatif de l'écart zéro sur la longueur de la section.The measuring device represents the shape of the section of rail considered on a display screen, in the form of a curve CR, as seen on the figure 6 . This curve indicates the length of the section, the deviations of the rail, that is to say the deformation, of the reference axis R representative of the zero difference over the length of the section.

Or, la section de rail peut présenter des défauts locaux de rectitude tels que par exemple des endroits auxquels deux rails courts ont été soudés l'un à l'autre pour la réalisation d'un rail long. Ces défauts locaux se manifestent sous forme de variations brutales de la concavité de la courbe de rectitude CR comme on le voit par exemple à l'endroit S indiqué par une ligne en traits interrompus, qui pourrait être un cordon de soudure. Plus précisément, un défaut local est considéré comme présent lorsque deux variations successives et symétriques sont repérées dans une zone de faible longueur.However, the rail section may have local straightness defects such as for example places where two short rails have been welded to each other for the realization of a long rail. These local defects are manifest in the form of sudden variations in the concavity of the straightness curve CR, as seen for example at the location S indicated by a dashed line, which could be a weld bead. More precisely, a local fault is considered as present when two successive and symmetrical variations are located in a zone of short length.

Une deuxième phase du procédé selon l'invention réside dans la détection et l'élimination mathématique des défauts constatés par une analyse mathématique à partir des données de la mesure de rectitude.A second phase of the method according to the invention lies in the detection and the mathematical elimination of the defects found by a mathematical analysis from the data of the measure of straightness.

Chaque défaut repéré est éliminé en effectuant un remplacement de la zone concernée par un segment linéaire. Les données qualitatives de chaque défaut sont conservées pour avoir une traçabilité du rail. La figure 6 illustre l'élimination du défaut S de la manière qui vient d'être indiquée.Each defect identified is eliminated by performing a replacement of the area concerned by a segment linear. The qualitative data of each defect are kept for traceability of the rail. The figure 6 illustrates the elimination of the defect S in the manner just indicated.

Au cours d'une troisième phase, on procède à une extraction et à un filtrage des données de mesure de la rectitude. A cette fin, les données brutes de mesure sont filtrées pour éliminer des petites irrégularités de la courbe. Puis on effectue un lissage. Les données de mesure filtrées sont à cette fin extraites par échantillonnage selon des pas prédéterminés, par exemple tous les centimètres. Ainsi, sur une section de mesure d'une longueur de 3000 millimètres, on retient ainsi 300 pas.In a third phase, the measurement data of the straightness is extracted and filtered. For this purpose, the raw measurement data are filtered to eliminate small irregularities in the curve. Then smoothing is done. The filtered measurement data are for this purpose extracted by sampling according to predetermined steps, for example every centimeter. Thus, on a measurement section with a length of 3000 millimeters, 300 steps are thus retained.

Le filtrage et le lissage des données de mesure permettent de conserver la forme globale de la rectitude tout en évitant les variations locales faibles et moyennes. Le résultat est représenté sur la figure 7.Filtering and smoothing the measurement data helps to maintain the overall shape of straightness while avoiding low and medium local variations. The result is represented on the figure 7 .

Au cours d'une quatrième phase, on détermine les zones hors tolérances de la section de rail qui vient d'être soumise aux phases de mesurage, filtrage et lissage. A cette fin, on examine si la courbe CR représentative de la forme du rail sort d'un couloir de tolérances. Un couloir de tolérances est caractérisé par sa longueur et sa hauteur, qui sont choisies en fonction des qualités de rectitude souhaitées du rail.During a fourth phase, the out-of-tolerance zones of the rail section which has just been subjected to the measurement, filtering and smoothing phases are determined. For this purpose, it is examined whether the CR representative of the shape of the rail leaves a tolerance corridor. A tolerance corridor is characterized by its length and height, which are chosen according to the desired straightness qualities of the rail.

Comme le montrent les figures 8 et 9, la détermination des zones hors tolérances est effectuée en posant une règle virtuelle 28 d'une longueur et d'une hauteur prédéterminées qui représentent respectivement la longueur et la hauteur du couloir de tolérances précité et en déplaçant cette règle le long de la totalité de la courbe CR selon un pas de valeur constant, les deux extrémités 29, 30 de la règle se trouvant toujours sur la courbe de rectitude, comme on le voit sur la figure 8. Comme l'illustre la figure 9, on considère comme étant hors tolérances les parties de la courbe de rectitude et ainsi du rail qui dépassent le bord longitudinal supérieur 31 de la règle, comme la partie hachurée notée 32. A chaque position de la règle, on établit s'il y a des parties estimées hors tolérance et, dans l'affirmatif, on les mémorise.As shown by Figures 8 and 9 , the determination of the out-of-tolerance zones is carried out by placing a virtual rule 28 of predetermined length and height which respectively represent the length and the height of the aforementioned tolerance corridor and by moving this rule along the whole of the CR curve in a step of constant value, the two ends 29, 30 of the rule still being on the curve of straightness, as seen on the figure 8 . As illustrated by figure 9 , we consider as out of tolerance the parts of the straightness curve and and rail extending beyond the upper longitudinal edge 31 of the rule, such as the hatched portion noted 32. At each position of the rule, it is established whether there are estimated parts out of tolerance and, if so, is stored .

Dans le cas d'exemples, l'opération de détermination des zones hors tolérance, tels que décrit ci-dessus, a permis d'établir une zone hors tolérance HT, qui s'étend de l'endroit de début D à l'endroit de fin F. La détermination de cette zone hors tolérance a été décrite ci-dessus et illustrée en ne prenant en compte que les tolérances positives. Bien entendu, l'exécution de cette quatrième étape implique également la prise en compte des tolérances négatives. Dans le cas d'une règle virtuelle utilisée à cette fin, la ligne de base de la règle représentée, dont les points d'extrémité 29 et 30 glissent sur la courbe CR constituerait alors la ligne de référence zéro entre la ligne de tolérance positive et de la ligne de tolérance négative.In the case of examples, the operation of determining the out-of-tolerance zones, as described above, made it possible to establish an out of tolerance zone HT, which extends from the start location D to the location The determination of this zone out of tolerance has been described above and illustrated by taking into account only the positive tolerances. Of course, the execution of this fourth step also involves taking into account the negative tolerances. In the case of a virtual rule used for this purpose, the base line of the represented rule, whose end points 29 and 30 slide on the curve CR would then constitute the reference line zero between the positive tolerance line and of the negative tolerance line.

A la phase de détermination des zones hors tolérance succède une cinquième phase consacrée au calcul des ratios de déformation globale. Au cours de cette phase, on calcule sur toute la longueur de la section du rail mesurée des ratios de déformation. Pour simplifier la description de cette opération, on se réfère aux figures 10 et 11 qui présentent une forme de courbe A plus simple. Comme on le voit sur ces figures, on établit successivement, en progressant pas à pas sur la courbe de rectitude CR, pour chaque pas, des ratios de déformation pour les différents écarts e possibles entre une valeur d'écart minimale emin (figure 10) et une valeur d'écart maximale emax (figure 11) des deux ablots du dispositif de pressage considéré. Les positions des ablots gauche et droit sont indiquées sur les figures 10 et 11 par les points 29 et 30. Le petit cercle au milieu des deux ablots représente la position du point p d'application de la force de pressage.In the phase of determining the out-of-tolerance zones follows a fifth phase devoted to the calculation of the global strain ratios. During this phase, deformation ratios are calculated over the entire length of the section of the measured rail. To simplify the description of this operation, reference is made to Figures 10 and 11 which have a simpler form of curve A. As can be seen in these figures, it is established successively, by progressing step by step on the straightness curve CR, for each step, deformation ratios for the different possible e differences between a minimum difference value e min ( figure 10 ) and a maximum deviation value e max ( figure 11 ) of the two ablots of the pressing device considered. The positions of the left and right ablots are indicated on the Figures 10 and 11 by points 29 and 30. The small circle in the middle of the two ablots represents the position of the point of application of the pressing force.

Ainsi, dans chaque position p, on détermine le ratio pour chaque écartement e, centré sur p entre les valeurs d'écart maximal emax et minimale emin. Pour chaque position et chaque écart e, on établit l'aire algébrique entre la courbe de rectitude CR et la droite joignant les points d'appui sur la courbe selon l'équation : A p ⁢ e = A + − A −

Figure imgb0001
Thus, in each position p, the ratio is determined for each distance e, centered on p between the maximum deviation values e max and minimum e min . For each position and each difference e, we establish the algebraic area between the straightness curve CR and the line joining the points of support on the curve according to the equation: AT p ⁢ e = AT + - AT -
Figure imgb0001

Le ratio pour une position p et un écart e donné est déterminé selon l'expression : R p ⁢ e = A p ⁢ e e 2

Figure imgb0002
The ratio for a position p and a given gap e is determined according to the expression: R p ⁢ e = AT p ⁢ e e 2
Figure imgb0002

La valeur du ratio R est toujours positive et donne l'indication de la déformation sans précision du sens de déformation qui pourrait être un creux ou une bosse.The value of the ratio R is always positive and gives the indication of the deformation without precision of the direction of deformation which could be a hollow or a bump.

A titre d'exemple, en se reportant à la figure 11, dans la position P0, la droite reliant les deux points d'appui (tel que défini sur la figure 10) sur la courbe de rectitude délimite avec celle-ci à gauche une aire négative A- et à droite une aire positive A+ puisque ces deux aires se trouvent respectivement en-dessous et au-dessus de la droite.For example, referring to the figure 11 in the position P 0 , the line connecting the two points of support (as defined on the figure 10 ) on the straightness curve delimits with this one on the left a negative area A - and on the right a positive area A + since these two areas are respectively below and above the right.

Le résultat final de cette phase de calcul est inscrit dans un tableau tel que le Tableau I ci-dessous qui comporte pour chaque écart e(1), e(2)... e (m) et chaque position p(1), p(2)... p(n) la valeur de ratio R (p, e) correspondante. Tableau I R(p,e) e(1) e(2) ... e(m-1) e(m) p(1) p(2) ... p(n-1) p(n) The final result of this calculation phase is entered in a table such as Table I below which comprises for each difference e (1), e (2) ... e (m) and each position p (1), p (2) ... p (n) the corresponding ratio value R (p, e). Table I R (p, e) e (1) e (2) ... e (m-1) e (m) p (1) p (2) ... p (n-1) p (n)

La phase six qui suit concerne le choix de la zone à redresser, de la section de rail mesurée. Cette zone est sélectionnée suivant deux critères, à savoir le ratio R(p,e) maximal et le point d'application de l'effort à effectuer par l'outil de pressage, dans une zone hors tolérances établie au cours de la phase 4. Le ratio R(p,e) maximal ainsi que les points d'appui et la position p du marteau de pressage, c'est-à-dire du point d'application de l'effort de pressage, qui sont associés à cette valeur R maximale se déduisent directement du Tableau I. Bien entendu, la distance d'un ablot de l'outil pourrait être différente de la distance de l'outil de l'autre ablot et constituer donc une variable à traiter d'une façon analogue à l'écart susmentionné.The sixth phase that follows concerns the choice of the area to straighten, the measured rail section. This zone is selected according to two criteria, namely the ratio R (p, e) maximum and the point of application of the effort to be made by the pressing tool, in an out of tolerance zone established during phase 4 The maximum ratio R (p, e) as well as the points of support and the position p of the pressing hammer, that is to say the point of application of the pressing force, which are associated with this maximum value R are deduced directly from Table I. Of course, the distance of a tool ablot could be different from the distance of the tool of the other ablot and thus constitute a variable to be treated in a similar way away from the above.

Au cours de la septième phase, on détermine la déformation plastique à réaliser pour conférer à la zone hors tolérances de la section de rail mesurée la rectitude souhaitée. La valeur de déformation plastique d est calculée à partir des éléments déterminés lors de la sixième phase de sélection de la zone à redresser, modulée par les paramètres du couloir de tolérance et optionnellement, par le choix d'une forme de rectitude finale, c'est-à-dire selon l'équation suivante : d = Y ⁢ t ∗ e L ⁢ t − Y ⁢ g − Y ⁢ d 2 + H ⁢ t 2 ∗ C ⁢ f

Figure imgb0003
avec :

Yt =
ordonnée du milieu du couloir de tolérances
e =
écartement des points d'appui
Lt =
Longueur du couloir de tolérances
Yg =
ordonnée du point d'appui gauche
Yd =
ordonnée du point d'appui droit
Ht =
hauteur du couloir de tolérances
Cf =
coefficient de forme compris dans l'intervalle [-1 ; +1]
  1. -1 pour déplacer la déformation résultante vers le bas du couloir de tolérances
  2. +1 pour déplacer la déformation résultante vers le haut du couloir de tolérances.
During the seventh phase, the plastic deformation to be performed is determined to give the area outside the tolerances of the measured rail section the desired straightness. The plastic deformation value d is calculated from the elements determined during the sixth phase of selection of the zone to be straightened, modulated by the parameters of the tolerance corridor and optionally, by the choice of a form of final straightness, c ' that is to say according to the following equation: d = Y ⁢ t * e The ⁢ t - Y ⁢ boy Wut - Y ⁢ d 2 + H ⁢ t 2 * VS ⁢ f
Figure imgb0003
 with:
Yt =
ordinate from the middle of the tolerance corridor
e =
spacing of the points of support
Lt =
Tolerance corridor length
Yg =
ordinate of the left fulcrum
Yd =
ordinate of the right fulcrum
Ht =
height of the tolerance corridor
Cf =
shape coefficient in the range [-1; +1]
  1. -1 to move the resultant deformation down the tolerance corridor
  2. +1 to move the resultant deformation up the tolerance path.

Le coefficient de forme est utilisé pour moduler l'état final de rectitude afin d'obtenir une forme optimale pour le traitement éventuel après redressage. Ainsi le rail pourrait être volontairement "bombé" afin d'optimiser la qualité d'une opération de meulage ultérieur.The form factor is used to modulate the final state of straightness in order to obtain an optimal shape for the possible treatment after straightening. Thus the rail could be voluntarily "curved" to optimize the quality of a subsequent grinding operation.

Après la détermination de la déformation plastique à réaliser, on procède, au cours d'une huitième phase, au redressage de la zone hors tolérances de la section de rail mesurée. Le processus du redressage est un cycle constitué par une succession d'une pluralité d'étapes de travail, à savoir une étape de sortie de l'outil de pressage, d'approche à vide du rail, de mise en contact de l'outil avec le rail et d'une partie de cycle caractérisée par la répétition d'une séquence de trois étapes de travail successives, que sont le chargement du rail et/ou un contrôle simultané de la déformée résiduelle en travaillant dans la zone de déformation élastique, le chargement à vitesse constante en zone de déformation plastique du rail, puis le déchargement.After the determination of the plastic deformation to be carried out, during the eighth phase, the area outside the tolerances of the measured rail section is straightened. The straightening process is a cycle consisting of a succession of a plurality of work steps, namely an exit step of the pressing tool, the approach of the rail to the vacuum, the contacting of the tool with the rail and a cycle part characterized by the repetition of a sequence of three successive work steps, that is the loading of the rail and / or a simultaneous control of the residual deformation while working in the zone of elastic deformation, loading at constant speed in plastic deformation zone of the rail, then unloading.

En se référant à la figure 12, on décrira ci-après plus en détail les différentes étapes du cycle de redressage, qui viennent d'être énoncées. Cette figure 12 illustre la relation entre la pression hydraulique P générant l'effort de pressage indiquée sur l'ordonnée et le déplacement X de l'outil indiquée sur l'abscisse, dans différentes situations de travail.Referring to the figure 12 The various stages of the straightening cycle, which have just been described, will be described in greater detail below. This figure 12 illustrates the relation between the hydraulic pressure P generating the pressing force indicated on the ordinate and the displacement X of the tool indicated on the abscissa, in different work situations.

La figure 12 illustre tout d'abord les trois premières étapes du cycle de redressage, à savoir les étapes de sortie de l'outil de pressage et du déplacement à vide, toutes les deux indiquées par la référence a, et l'étape de mise en contact de l'outil avec le rail, indiquée par la référence b. On constate que, pendant les deux premières étapes, sortie de l'outil de pressage puis déplacement à vide, la pression P peut-être assimilée à une constante. L'étape de sortie a pour but de s'affranchir des perturbations des signaux de pression et de position, liées à l'utilisation de certains composants et à garantir la stabilité des informations de contrôle. Dans le cas où la stabilité des signaux ne serait pas validée, le cycle de redressage est interrompu. L'étape de mise en contact b est caractérisée par une concavité spécifique de la courbe de pression/déplacement.The figure 12 firstly illustrates the first three steps of the straightening cycle, namely the steps of exit of the pressing tool and the no-load movement, both indicated by the reference a, and the step of contacting the the tool with the rail, indicated by the reference b. It is found that, during the first two steps, exit of the pressing tool then empty displacement, the pressure P can be assimilated to a constant. The purpose of the output step is to overcome the disturbances of the pressure and position signals related to the use of certain components and to guarantee the stability of the control information. In the event that the stability of the signals is not validated, the straightening cycle is interrupted. The contacting step b is characterized by a specific concavity of the pressure / displacement curve.

La figure 12 illustre aussi l'étape de chargement du rail par l'outil dans la zone de déformation élastique c du rail, qui est caractérisée par le fait que la courbe est sensiblement rectiligne et fait suite à la zone b.The figure 12 also illustrates the step of loading the rail by the tool in the elastic deformation zone c of the rail, which is characterized in that the curve is substantially rectilinear and follows the zone b.

Comme on le voit sur la figure 12, la zone de déformation plastique notée f qui suit se caractérise par le fait que la courbe pression/déplacement présente une allure convexe, c'est-à-dire la courbe dévie de la courbe assimilable à une droite définissant la zone élastique c. Comme on le comprendra plus loin, l'estimation de la déformée plastique est définie et calculée à partir de l'écart horizontal entre la position sur l'abscisse qui indique le début de la zone plastique f et la position réelle sur la courbe. L'étape de chargement s'achève à l'obtention de la déformation souhaitée d établie lors de la 7ième phase.As we see on the figure 12 the following plastic deformation zone denoted by f is characterized by the fact that the pressure / displacement curve has a convex shape, that is to say the curve deviates from the curve assimilable to a line defining the elastic zone c. As will be understood later, the estimate of the plastic deformation is defined and calculated from the horizontal difference between the position on the abscissa which indicates the start of the plastic zone f and the actual position on the curve. The loading step is completed to obtain the desired deformation established during the 7 th phase.

La zone de retour élastique g correspondant à l'étape de déchargement consiste en un retour contrôlé de l'outil de pressage en assurant que l'outil soit toujours en contact avec le rail. La figure 12 illustre enfin, l'étape de contrôle de la déformée résiduelle par rechargement élastique. Ce chargement se fait selon une courbe assimilable à une droite h qui présente la même pente que la partie élastique initiale c. La distance horizontale des deux parties droites c et h représente la déformation plastique du rail que l'outil a réalisé. Par conséquent, pour obtenir la déformation souhaitée d, il fallait donc aller sur la portion de courbe f jusqu'à la pression Pmax.The elastic return zone g corresponding to the unloading step consists of a controlled return of the pressing tool ensuring that the tool is always in contact with the rail. The figure 12 illustrates finally, the step of controlling the residual deformation by elastic reloading. This loading is done according to a curve comparable to a line h which presents the same slope as the initial elastic part c. The horizontal distance of the two straight portions c and h represents the plastic deformation of the rail that the tool has made. Therefore, to obtain the desired deformation d, it was therefore necessary to go on the curve portion f up to the pressure P max .

Après la description du déroulement de la phase de pressage, on comprend que le contrôle de la déformée résiduelle n'est réalisé qu'à partir d'une deuxième séquence de chargement, après la première séquence de déformation plastique. S'il s'avère que la déformation souhaitée n'est pas encore totalement réalisée lors de la première étape de chargement, l'invention prévoit que l'étape de contrôle de la déformée se poursuive en une nouvelle étape de chargement.After the description of the course of the pressing phase, it is understood that the control of the residual deformation is performed only from a second loading sequence, after the first plastic deformation sequence. If it turns out that the desired deformation is not yet fully realized during the first loading step, the invention provides that the deformation control step continues in a new loading step.

Durant toute cette succession d'étapes et de séquences énoncées ci-dessus, un logiciel approprié assure l'acquisition en continu de la pression de pressage et de la position de l'outil de pressage pour obtenir un ensemble de variables de calcul qui permettent de suivre la déformation du rail et de détecter la transition entre les phases selon l'équation : TDP x = 4 ∗ DP x − DP ⁢ x − 1 + 3 ∗ DP x − DP ⁢ x − 2 + 2 ∗ DP ⁢ x − 1 − DP ⁢ x − 3 + DP ⁢ x − 2 − DP ⁢ x − 3 15

Figure imgb0004
avec :

x :
position,
P(x) :
pression à la position x,
DP(i) :
delta-pression à la position i, Variation de pression avec la position précédente,
TDP(x) :
tendance delta-pression à la position x, Résultat d'un polynôme de calcul sur la variable précédente delta-pression.
Throughout this succession of steps and sequences set out above, appropriate software ensures the continuous acquisition of the pressing pressure and the position of the pressing tool to obtain a set of calculation variables that make it possible to follow the deformation of the rail and detect the transition between the phases according to the equation: TDP x = 4 * DP x - DP ⁢ x - 1 + 3 * DP x - DP ⁢ x - 2 + 2 * DP ⁢ x - 1 - DP ⁢ x - 3 + DP ⁢ x - 2 - DP ⁢ x - 3 15
Figure imgb0004
 with:
x:
position,
P (x):
pressure at position x,
DP (i):
delta pressure at position i, pressure change with the previous position,
TDP (x):
delta-pressure trend at position x, Result of a calculation polynomial on the previous delta-pressure variable.

Dans cette équation TDP(x), les termes DP(x) constituent la delta-pression mesurée à la position x, tandis que les termes DP(x-1), DP(x-2) et DP(x-3) constituent les valeurs mesurées aux trois positions précédentes. En établissant les différents éléments dont chacun constitue une mise en relation de deux valeurs DP établies à des positions différentes, et en multipliant chaque élément d'un facteur approprié, à savoir les facteurs respectivement 4, 3, 2, 1 et en choisissant comme diviseur la somme de ces facteurs, à savoir le nombre 15, on constate que dans la partie linéaire de la courbe, si la valeur delta DP prise entre deux positions adjacentes est égale par exemple à la valeur k, la tendance delta-pression TDP(x) est également égale à 15 et ne varie pas tant que l'on reste dans la partie linéaire de la courbe.In this equation TDP (x), the terms DP (x) constitute the delta-pressure measured at the position x, whereas the terms DP (x-1), DP (x-2) and DP (x-3) constitute the values measured at the three previous positions. By establishing the different elements each of which is a linking of two DP values established at different positions, and multiplying each element by an appropriate factor, namely the factors respectively 4, 3, 2, 1 and choosing as a divisor the sum of these factors, namely the number 15, it is found that in the linear part of the curve, if the delta value DP taken between two adjacent positions is equal to For example, at the value k, the delta-pressure trend TDP (x) is also equal to 15 and does not change as long as we remain in the linear part of the curve.

L'établissement de la tendance delta-pression TDPn(x) permet de constater la prise de contact de l'outil de pressage avec le rail dans la mesure où, à cet instant de temps, le seuil de n valeurs de delta-pression successives dépassant un écart minimal est atteint. Cette position correspond à la zone de montée en pression b. Le début de la zone élastique c est constaté lorsque la courbe pression/déplacement peut être assimilée à une droite, c'est-à-dire lorsque la tendance de la delta-pression reste constante. La courbe pression/déplacement entre dans la zone plastique lorsque cette courbe perd sa caractéristique linéaire et prend une convexité détectée par la décroissance sur n échantillons successifs de la valeur delta-pression.The establishment of the delta-pressure trend TDPn (x) makes it possible to note the engagement of the pressing tool with the rail since, at this instant of time, the threshold of n successive delta-pressure values exceeding a minimum difference is reached. This position corresponds to the pressure rise zone b. The beginning of the elastic zone c is observed when the pressure / displacement curve can be likened to a straight line, that is to say when the delta-pressure trend remains constant. The pressure / displacement curve enters the plastic zone when this curve loses its linear characteristic and takes a convexity detected by the decay on n successive samples of the delta-pressure value.

A partir des positions de début et fin de la zone élastique, le logiciel calcule la pente idéale correspondant à la zone élastique réelle. L'écart entre la droite représentative de la zone élastique et la courbe dans la zone plastique donnent la déformation plastique résiduelle. A tout instant, le début de la zone plastique peut être réajusté si la convexité de la courbe pression/déplacement est perdue. A chacun des réajustements de la zone plastique correspond un recalcul du coefficient directeur de la droite de caractéristique élastique, à savoir de la pente, et également de la déformation plastique résiduelle à atteindre.From the start and end positions of the elastic zone, the software calculates the ideal slope corresponding to the real elastic zone. The difference between the line representative of the elastic zone and the curve in the plastic zone gives the residual plastic deformation. At any time, the beginning of the plastic zone can be readjusted if the convexity of the pressure / displacement curve is lost. Each of the readjustments of the plastic zone corresponds to a recalculation of the directing coefficient of the straight line of elastic characteristic, namely of the slope, and also of the residual plastic deformation to be achieved.

Il est à noter que la déformation plastique résiduelle partielle est calculée avant le réajustement de la zone plastique puis mémorisée pour cumul. En d'autres termes, la déformation plastique résiduelle totale correspond à l'ensemble des déformations plastiques résiduelles partielles détectées durant le cycle complet de redressage. La déformation plastique résiduelle totale correspond à la somme des déformations plastiques résiduelles partielles détectées pendant le cycle.It should be noted that the partial residual plastic deformation is calculated before the readjustment of the plastic zone and then stored for cumulation. In in other words, the total residual plastic deformation corresponds to the set of partial residual plastic deformations detected during the complete straightening cycle. Total residual plastic deformation is the sum of the partial residual plastic deformations detected during the cycle.

Il ressort de la description de l'invention qui vient d'être faite, que le procédé selon l'invention, qui permet un déroulement automatique du processus de redressage, présente des avantages considérables par rapport à l'état de la technique. Tout d'abord, il n'y a plus nécessité de la présence d'un opérateur. D'autre part, la gestion automatique du cycle de pressage permet d'appliquer l'effort juste, nécessaire à la correction du défaut, et limite ainsi au minimum les contraintes internes auxquels le matériau du rail est exposé. La gestion automatique du cycle supprime en outre le risque d'erreurs humaines et réduit au minimum le temps du cycle de pressage.It follows from the description of the invention that has just been made that the method according to the invention, which allows an automatic process of the straightening process, has considerable advantages over the state of the art. First, there is no need for the presence of an operator. On the other hand, the automatic management of the pressing cycle makes it possible to apply the correct effort needed to correct the defect and thus minimizes the internal stresses to which the rail material is exposed. Automatic cycle management also eliminates the risk of human errors and minimizes the press cycle time.

L'invention repose sur l'acquisition et le traitement en temps réel du couple effort/déplacement mis en oeuvre par flexion élasto-plastique contrôlée. Le traitement de données permet l'identification et l'utilisation du comportement intrinsèque du matériau, indépendamment du produit traité, dans le but de détecter la transition entre le domaine élastique et le domaine plastique, caractérisé par une rupture de pente de la courbe effort/déplacement et ceci afin de prédire fidèlement la déformation plastique effective après libération. Outre la gestion des phases de pressage, le procédé permet de réaliser entre chaque phase de pressage la mesure et l'analyse des déformées du produit et détermine le positionnement optimal des points d'appui.The invention is based on the acquisition and the real-time processing of the effort / displacement torque implemented by controlled elasto-plastic flexion. The data processing allows the identification and use of the intrinsic behavior of the material, independently of the product being processed, in order to detect the transition between the elastic domain and the plastic domain, characterized by a slope break of the stress / strain curve. displacement and this in order to faithfully predict the effective plastic deformation after release. In addition to the management of the pressing phases, the method makes it possible to perform measurement and analysis of the product deformations between each pressing phase and determines the optimal positioning of the support points.

Bien entendu, l'invention n'est pas limitée au mode de réalisation de l'invention qui vient d'être décrit et est représenté aux figures.Of course, the invention is not limited to the embodiment of the invention which has just been described and is shown in the figures.

La presse et le procédé peuvent être modifiés de multiples manières, dans le cadre de l'invention. Ainsi, il n'est pas obligatoire d'utiliser pour un redressage dans un plan un outil de pressage et deux ablots. On pourrait aussi utiliser deux outils et un ablot ou encore une autre configuration d'outils et ablots d'appui.The press and the method can be modified in many ways within the scope of the invention. Thus, it is not mandatory to use for a straightening in one plane a pressing tool and two ablots. We could also use two tools and an ablot or another configuration of tools and ablots support.

Certes, l'invention est avantageusement utilisable pour la fabrication de rails, mais concerne, de façon générale, le redressage ou remise en forme de barres, tubes et profilés métalliques.Admittedly, the invention is advantageously used for the manufacture of rails, but relates, in general, the straightening or reshaping of bars, tubes and metal profiles.

Claims (12)

  1. A method for straightening rolled metal profiles, such as railroad tracks, by means of a press comprising a device for measuring the straightness of a profile to be straightened and for establishing the deflection of the profile, and a pressing assembly comprising at least one device for deforming the track through bending in a predetermined longitudinal plane of the profile, which comprises at least three members capable of contacting the profile, at least one of which is a tool for pressing the profile or a supporting member on the profile and the others of which are the supporting or pressing members, characterized in that the press (1) is made to acquire and process automatically in real time the data concerning the relation between the pressing forces applied by the pressing tool to the profile (7) and the displacement of the tool for this purpose and to apply the pressing force necessary for obtaining the deflection determined from such data, in order to perform the desired straightening of the profile, and that the characteristic curve of the pressing forces of the tool on the profile is established depending on the displacement of the tool in the domains of elastic and plastic deformation, and the stopping condition of the straightening process for making the desired residual deflection from this curve is validated.
  2. The method according to claim 1, characterized in that the stopping condition of the straightening process is determined when the pressing force reaches a value such that the horizontal deviation of the position on the x-axis, which indicates the beginning of the plastic zone (f), and the actual position on the curve is equal to the plastic deformation to be made (d).
  3. The method according to any of claims 1 or 2, characterized in that the straightness of the profile (7) to be straightened is measured, and after processing of the measurement data a straightness curve (CR) is established.
  4. The method according to claim 3, characterized in that out-of-tolerance areas of the profile to be straightened are determined as being situated outside a tolerance band of predetermined length and height, which is moved along the curve, with the end points representing zero tolerance sliding on the curve.
  5. The method according to claim 4, characterized in that the tolerance band is formed by a virtual ruler (28).
  6. The method according to any of claims 4 or 5, characterized in that before establishing the out-of-tolerance areas, an operation of detecting and eliminating defects from the straightness curve (CR) is performed by applying filtering and smoothing to the measured data composing this straightness curve.
  7. The method according to any of claims 4 to 6, characterized in that the ratios R(p,e) of the profile cross-section, measured by advancing step by step from one section end to the other, are established mathematically.
  8. The method according to claim 7, characterized in that a deformation ratio R(p,e) is established by sliding a straight line, the length of which corresponds to an actual clearance (e) of the two external contact members, by maintaining the ends of this straight line on the straightness curve (CR) and by keeping as a ratio the difference of the algebraic surfaces (A+) and (A-) between the curve and the straight line above and below said curve, divided by the square of clearance e.
  9. The method according to claim 8, characterized in that a value of the deformation ratio is established for each position of said straight line for all clearances (e) between a maximum clearance value (emax) and a minimum clearance value (emin).
  10. The method according to claim 9, characterized in that the distance between one external contact member and the contact member located between the external members can be a variable to be taken into account during straightening.
  11. The method according to any of claims 9 or 10, characterized in that the area to be straightened of the profile is chosen as being the area having a maximum deformation ratio, the point of pressing force application being included in an out-of-tolerance area.
  12. A press for straightening rolled profiles of the type comprising a device for measuring the straightness of the profile and establishing the deflection thereof, a pressing assembly comprising at least one device for deforming the profile through bending in a predetermined longitudinal plane thereof, characterized in that it comprises for implementing the method according to any of claims 1 to 11, a device for automatically acquiring and processing in real time the data regarding the profile to be straightened and calculating the straightening operation according to predetermined software.
EP05292194A 2004-10-22 2005-10-19 Method for straightening rolled metal sections Not-in-force EP1652593B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR0411316A FR2876925B1 (en) 2004-10-22 2004-10-22 PROCESS FOR LAMINATED METAL PROFILES

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EP1652593A1 EP1652593A1 (en) 2006-05-03
EP1652593B1 true EP1652593B1 (en) 2008-10-08

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AT (1) ATE410249T1 (en)
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CN105081016B (en) * 2015-08-12 2017-01-04 张家港市张运机械制造有限公司 Cage guide automatic flattening pipeline
CN112474897B (en) * 2020-12-14 2024-06-14 核工业理化工程研究院 Straightening device and straightening method for long tube type assembly
CN113319152B (en) * 2021-04-21 2022-10-28 邯郸钢铁集团有限责任公司 Method for realizing intelligent pressure straightening of steel rail
CN115647127B (en) * 2022-11-01 2024-04-19 山东纬速铝业有限公司 Straightening device for aluminum profile production and use method thereof

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US1796696A (en) * 1928-12-11 1931-03-17 Trimble Joseph Rail-reconditioning machine
US3295350A (en) * 1964-03-11 1967-01-03 Railway Automation Maintenance Continuous rail straightening press
US4077248A (en) * 1977-01-03 1978-03-07 Chemetron Corporation Rail straightening press
JPS57146422A (en) * 1981-03-06 1982-09-09 Toshiba Corp Automatic straightening device for shape steel
DE3927465A1 (en) * 1989-08-19 1991-02-21 Mae Maschinen U Apparatebau Go BREADING MACHINE FOR LONG-EXTENDED ALIGNMENT
DE3929397A1 (en) * 1989-09-05 1991-03-07 Mae Maschinen U Apparatebau Go AUTOMATIC BREADING MACHINE

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DE602005010178D1 (en) 2008-11-20
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FR2876925A1 (en) 2006-04-28
FR2876925B1 (en) 2008-05-30

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