CN111074702B - Abrasive belt type steel rail grinding operation control system and grinding control method thereof - Google Patents

Abrasive belt type steel rail grinding operation control system and grinding control method thereof Download PDF

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CN111074702B
CN111074702B CN201911408647.7A CN201911408647A CN111074702B CN 111074702 B CN111074702 B CN 111074702B CN 201911408647 A CN201911408647 A CN 201911408647A CN 111074702 B CN111074702 B CN 111074702B
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grinding
motor
abrasive belt
polishing
plc
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CN111074702A (en
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聂蒙
马震
李建勇
刘月明
樊文刚
曹建国
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Beijing Jiaotong University
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    • EFIXED CONSTRUCTIONS
    • E01CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01BPERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02Working rail or other metal track components on the spot
    • E01B31/12Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails
    • E01B31/17Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails by grinding
    • E01B31/175Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails by grinding using grinding belts

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
  • Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)

Abstract

The invention provides an abrasive belt type steel rail grinding operation control system and a grinding control method thereof. The system comprises: a sanding control device and a sanding implementing mechanism which are connected with each other; the grinding control device collects the rotating speed of the abrasive belt, the current signal of the grinding motor and the advancing speed of the grinding vehicle, generates a grinding motor control signal and a grinding force control signal according to the collected information and the target grinding requirement, and transmits the signals to the grinding implementation mechanism; the grinding implementation mechanism regulates and controls the rotation speed of the grinding motor according to the grinding motor control signal, regulates and controls the rotation speed of the abrasive belt, regulates and controls the grinding acting force of the abrasive belt on the steel rail according to the grinding force control signal, and achieves the purpose of removing materials on the surface of the steel rail. The system and the method provided by the embodiment of the invention can be used for mastering the grinding operation state in real time according to the operation signal feedback, forming a high-precision control closed loop by regulating and controlling the composite action of the rotating speed and the grinding acting force of the grinding motor, and realizing the whole process servo control of the abrasive belt type steel rail grinding operation.

Description

Abrasive belt type steel rail grinding operation control system and grinding control method thereof
Technical Field
The invention relates to the technical field of railway engineering machinery, in particular to an abrasive belt type steel rail grinding operation control system and a grinding control method thereof.
Background
With the rapid development of high-speed railways and the continuous improvement of railway transportation capacity in China, the problem of contact fatigue damage of steel rails is more and more serious. The rail grinding operation is an important means for maintaining the rail, and can effectively repair the rail profile and prolong the service life of the rail. Compared with the traditional steel rail grinding mode based on grinding wheel grinding, the steel rail grinding mode based on the abrasive belt has a series of advantages of being not easy to burn steel rails, high in operation efficiency, easy to recover abrasive dust and the like.
However, the application of belt grinding to rail grinding brings corresponding difficulties to the control system and the control mode. In the prior art, an abrasive belt grinding method applied to rail grinding comprises the following steps: and (4) performing experimental processing operation by adopting a pressure regulation and control mode. For example, the 201711214352.7 patent technology "a blade robot belt grinding force control method" and 201110231331.2 patent technology "a belt grinding device with programmable grinding force control" issued by the national intellectual property office. The adoption of the regulation and control of the grinding pressure can obtain better grinding effect under a stable processing environment.
The belt sanding method applied to rail sanding in the prior art has the following defects: the field operation environment of rail polishing makes the pressure regulation and control mode difficult to ensure the processing effect. This is because, on the one hand, the relative position of the belt unit and the rail is uncertain and does not have a relatively stable machining reference, and on the other hand, the machining positioning accuracy is difficult to guarantee due to the unstable running speed of the grinding carriage.
Disclosure of Invention
The embodiment of the invention provides an abrasive belt type steel rail grinding operation control system and a control method thereof, which are used for realizing the overall process servo control of abrasive belt type steel rail grinding operation.
In order to achieve the purpose, the invention adopts the following technical scheme.
An abrasive belt type rail grinding operation control system, comprising: a sanding control device and a sanding implementing mechanism which are connected with each other;
the grinding control device is used for acquiring the rotating speed of an abrasive belt, a current signal of a grinding motor and the advancing speed of a grinding vehicle, generating a grinding motor control signal and a grinding force control signal according to the acquired information and a target grinding requirement, and transmitting the grinding motor control signal and the grinding force control signal to a grinding implementation mechanism;
the polishing implementation mechanism; the abrasive belt control device is used for regulating and controlling the rotating speed of the grinding motor according to the grinding motor control signal, regulating and controlling the rotating speed of the abrasive belt, regulating and controlling the grinding acting force of the abrasive belt on the steel rail according to the grinding force control signal and realizing the removal of materials on the surface of the steel rail.
Preferably, the sanding control device comprises: the system comprises a touch screen module, a PLC (programmable logic controller), a signal conditioning module, an orthogonal encoder, a current transformer, an AD (analog-digital) interface module, a DA (digital-analog) interface module, a high-speed DI (direct current) interface module, a direct current motor driver and a stepping motor driver;
the orthogonal encoder is arranged in a driving wheel train of the grinding wagon and is connected to the PLC through a high-speed DI interface module; the current transformer is arranged in the driving motor and connected with the signal conditioning module, and the signal conditioning module is connected with the PLC through the AD interface module; a direct current motor driver for driving the grinding motor to rotate is connected to the PLC through a DA interface module; a stepping motor driver for driving the grinding force to load is connected to the PLC through a DA interface module; the touch screen module is connected with the PLC.
Preferably, the grinding implementation mechanism comprises a grinding motor, a tension wheel, a driving wheel, a contact wheel, an abrasive belt, a loading stepping motor, a transmission gear train and a lead screw guide rail, wherein the tension wheel, the driving wheel, the contact wheel and the abrasive belt form an abrasive belt gear train unit; and the loading stepping motor, the transmission gear train and the lead screw guide rail form a grinding force loading unit.
Preferably, the PLC controller is a polishing controller, the quadrature encoder is a speed sensor, the current transformer is a current transformer, the dc motor driver is a polishing motor driver, the stepping motor driver is a grinding force loading unit driver, and the signal conditioning module is a signal conditioning unit.
A grinding control method of an abrasive belt type steel rail grinding operation control system comprises the following steps:
s001, inputting a target polishing profile on an input interface of the touch screen module according to polishing requirements;
s002, the PLC compares the target polishing profile with the current profile of the target, and the target polishing amount is calculated;
s003, the PLC starts to monitor the current amount of the grinding motor and the advancing speed of the grinding wagon;
s004, the current transformer transmits the acquired current signal of the grinding motor to the signal conditioning module, the signal conditioning module filters, amplifies and modulates the current signal and transmits the current signal to the PLC through the AD interface module, the PLC obtains the current amount of the grinding motor according to the current signal, and the current grinding acting force of the abrasive belt is solved according to the current amount of the grinding motor;
the orthogonal encoder collects the advancing speed of the grinding wagon and transmits the advancing speed to the PLC through the high-speed DI interface;
s005, calculating the current polishing amount by the PLC through the mapping relation among the rotating speed of the abrasive belt, the advancing speed of the polishing vehicle, the grinding acting force and the polishing amount, and comparing the current polishing amount serving as a feedback amount with a target polishing amount to obtain a polishing error amount;
s006, generating a polishing motor control signal by the PLC according to the polishing error amount and the advancing speed of the polishing vehicle, transmitting the polishing motor control signal to a direct current motor driver through a DA interface, controlling the driving force output by the direct current motor driver by using the polishing motor control signal, and regulating the rotating speed of a polishing motor through the driving force so as to regulate the rotating speed of the abrasive belt;
the PLC generates a grinding force control signal according to the grinding error amount and the current grinding acting force of the abrasive belt, transmits the grinding force control signal to the stepping motor driver through the DA interface, controls the driving force output by the stepping motor driver by using the grinding force control signal, regulates and controls the grinding acting force loaded by the grinding force loading unit through the driving force, and the grinding acting force acts on the steel rail through the abrasive belt to realize the material removal on the surface of the steel rail;
and S007, repeating S003-S006 until the target polishing amount is reached.
Preferably, the formula for calculating the sanding amount a is as follows:
Figure GDA0003003854230000041
a is the grinding amount, vsThe rotational speed, v, of the abrasive beltwFor the running speed of the grinding wagon, FnFor the current grinding force of the belt, E*Is the elastic contact modulus, ε (N)0σ) is the belt characteristic function.
According to the technical scheme provided by the embodiment of the invention, the system and the method provided by the embodiment of the invention can master the grinding operation state in real time according to the operation signal feedback, and the grinding motor current is adopted to cooperate with the travelling speed of the grinding vehicle to regulate and control the actual grinding amount by regulating and controlling the composite action of the rotating speed and the grinding acting force of the grinding motor, so that a high-precision control closed loop is formed, and the whole process servo control of the grinding operation of the abrasive belt type steel rail is realized.
Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
Fig. 1 is an implementation schematic diagram of an abrasive belt type rail grinding operation control system provided by an embodiment of the invention;
FIG. 2 is a schematic diagram of an implementation of a sanding implement mechanism according to an embodiment of the present invention;
fig. 3 is a processing flow chart of a grinding control method of an abrasive belt type rail grinding operation control system according to an embodiment of the present invention.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
As used herein, the singular forms "a", "an", "the" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that when an element is referred to as being "connected" or "coupled" to another element, it can be directly connected or coupled to the other element or intervening elements may also be present. Further, "connected" or "coupled" as used herein may include wirelessly connected or coupled. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
It will be understood by those skilled in the art that, unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the prior art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
For the convenience of understanding the embodiments of the present invention, the following description will be further explained by taking several specific embodiments as examples in conjunction with the drawings, and the embodiments are not to be construed as limiting the embodiments of the present invention.
An implementation schematic diagram of an abrasive belt type steel rail grinding operation control system provided by an embodiment of the invention is shown in fig. 1, and the abrasive belt type steel rail grinding operation control system comprises a grinding control device and a grinding implementation mechanism which are connected with each other. The grinding control device comprises: the system comprises a touch screen module, a Programmable Logic Controller (PLC) Controller, a quadrature encoder, a current transformer, an analog-to-Digital (AD) Interface module, a Digital-to-analog (DA) Interface module, a high-speed Digital Interface (DI) Interface module, a signal conditioning module, a direct current motor driver and a stepping motor driver.
The grinding control device is used for acquiring the rotating speed of an abrasive belt, a current signal of a grinding motor and the advancing speed of a grinding vehicle, generating a grinding motor control signal and a grinding force control signal according to acquired information and a target grinding requirement, and transmitting the grinding motor control signal and the grinding force control signal to a grinding implementation mechanism.
The polishing implementation mechanism; the abrasive belt control device is used for regulating and controlling the rotating speed of the grinding motor according to the grinding motor control signal, regulating and controlling the rotating speed of the abrasive belt, regulating and controlling the grinding acting force of the abrasive belt on the steel rail according to the grinding force control signal and realizing the removal of materials on the surface of the steel rail.
The PLC controller is a polishing controller, the orthogonal encoder is a speed sensor, the current transformer is a current transformer, the AD interface module, the DA interface module and the high-speed DI interface module are interface modules, the direct current motor driver is a polishing motor driver, the stepping motor driver is a grinding force loading unit driver, and the signal conditioning module is a signal conditioning unit.
The orthogonal encoder is arranged in a driving wheel train of the grinding wagon and is connected to the PLC through a high-speed DI interface module; the current transformer is arranged in the driving motor and connected with the signal conditioning module, and a signal generated by the current transformer is amplified and filtered by the signal conditioning module and then transmitted to the PLC through the AD interface module; a direct current motor driver for driving the grinding motor to rotate is connected to the PLC through a DA interface module; a stepping motor driver for driving the grinding force to load is connected to the PLC through a DA interface module; the touch screen module is connected with the PLC.
An implementation schematic diagram of a polishing implementation mechanism provided by the embodiment of the invention is shown in fig. 2, and the polishing implementation mechanism comprises a polishing motor, a tension wheel, a driving wheel, a contact wheel, an abrasive belt, a loading stepping motor, a transmission gear train and a lead screw guide rail.
Wherein the tension wheel, the driving wheel, the contact wheel and the abrasive belt form a abrasive belt wheel train unit; the loading stepping motor, the transmission gear train and the lead screw guide rail form a grinding force loading unit.
Based on the above control system for the grinding operation of the abrasive belt type steel rail, the processing flow of the method for controlling grinding of the abrasive belt type steel rail provided by the embodiment of the invention is shown in fig. 3, and the method comprises the following processing steps:
s001, inputting a target polishing profile on an input interface of the touch screen module according to polishing requirements;
s002, the PLC compares the target polishing profile with the current profile of the target, and the target polishing amount is calculated;
s003, the PLC starts to monitor the current amount of the grinding motor and the advancing speed of the grinding wagon;
s004, the current transformer transmits the acquired current signal of the polishing motor to the signal conditioning module, the signal conditioning module adjusts the waveform, amplitude and frequency of the current signal, the current signal is filtered, amplified and modulated and then transmitted to the PLC through the AD interface, the PLC obtains the current amount of the polishing motor according to the current signal, and the current grinding acting force of the abrasive belt is solved according to the current amount of the polishing motor.
The orthogonal encoder collects the advancing speed of the grinding wagon, and transmits the advancing speed to the PLC through a high-speed DI (Digital Interface) Interface.
S005, the PLC calculates the current grinding amount a through the mapping relation among the rotating speed of the abrasive belt, the advancing speed of the grinding vehicle, the grinding acting force and the grinding amount, and the calculation formula is as follows:
Figure GDA0003003854230000071
a is the grinding amount, vsThe rotational speed, v, of the abrasive beltwFor the running speed of the grinding wagon, FnFor the current grinding force of the belt, E*Is the elastic contact modulus, ε (N)0σ) is the belt characteristic function.
Comparing the current polishing amount serving as a feedback amount with a target polishing amount to obtain a polishing error amount;
s006, a PLC controller generates a polishing motor control signal according to the polishing error amount and the advancing speed of the polishing vehicle, transmits the polishing motor control signal to a direct current motor driver through a DA interface, controls the driving force output by the direct current motor driver by using the polishing motor control signal, and regulates and controls the rotating speed of the polishing motor through the driving force;
the PLC generates a grinding force control signal according to the grinding error amount and the current grinding acting force of the abrasive belt, transmits the grinding force control signal to the stepping motor driver through the DA interface, controls the driving force output by the stepping motor driver by using the grinding force control signal, and regulates and controls the grinding acting force loaded by the grinding force loading unit through the driving force, wherein the grinding acting force is the abrasive belt acting on the steel rail, so that the material on the surface of the steel rail is removed. This part is the secondary closed loop of the system;
and S007, repeating S003-S006 until the target polishing amount is reached.
When the grinding vehicle changes due to the advancing speed and the grinding acting force, the PLC solves the current grinding amount in real time according to the mapping relation between the abrasive belt rotating speed, the advancing speed of the grinding vehicle, the grinding acting force and the grinding amount, and carries out quantitative regulation and control on the grinding process according to the operation requirement. The PLC controller can adjust and control the rotating speed and the grinding acting force of the grinding motor in time according to changes.
In conclusion, the system and the method provided by the embodiment of the invention can master the grinding operation state in real time according to the operation signal feedback, and can regulate and control the actual grinding amount by regulating and controlling the composite action of the rotating speed and the grinding acting force of the grinding motor and adopting the current of the grinding motor to be matched with the travelling speed of the grinding vehicle, so that a high-precision control closed loop is formed, the whole process servo control of the grinding operation of the abrasive belt type steel rail is realized, and the robustness of the system is greatly improved. The problems that the abrasive belt type steel rail grinding processing reference is uncertain and the removal amount of grinding materials is difficult to master in real time are solved, and the quantitative regulation and control of the grinding amount are effectively realized.
The invention solves the problem of out-of-control removal amount of grinding materials caused by the change of the advancing speed of the grinding wagon in the process of rail grinding, and can well eliminate the irregularity of the rail surface of the rail;
those of ordinary skill in the art will understand that: the figures are merely schematic representations of one embodiment, and the blocks or flow diagrams in the figures are not necessarily required to practice the present invention.
The embodiments in the present specification are described in a progressive manner, and the same and similar parts among the embodiments are referred to each other, and each embodiment focuses on the differences from the other embodiments. In particular, for apparatus or system embodiments, since they are substantially similar to method embodiments, they are described in relative terms, as long as they are described in partial descriptions of method embodiments. The above-described embodiments of the apparatus and system are merely illustrative, and the units described as separate parts may or may not be physically separate, and the parts displayed as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the modules may be selected according to actual needs to achieve the purpose of the solution of the present embodiment. One of ordinary skill in the art can understand and implement it without inventive effort.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims (4)

1. The utility model provides an abrasive belt rail operation control system that polishes which characterized in that includes: a sanding control device and a sanding implementing mechanism which are connected with each other;
the grinding control device is used for acquiring the rotating speed of an abrasive belt, a current signal of a grinding motor and the advancing speed of a grinding vehicle, generating a grinding motor control signal and a grinding force control signal according to the acquired information and a target grinding requirement, and transmitting the grinding motor control signal and the grinding force control signal to a grinding implementation mechanism;
the polishing implementation mechanism; the abrasive belt control device is used for regulating and controlling the rotating speed of the grinding motor according to the grinding motor control signal, regulating and controlling the rotating speed of the abrasive belt, regulating and controlling the grinding acting force of the abrasive belt on the steel rail according to the grinding force control signal and realizing the removal of materials on the surface of the steel rail;
the grinding control device comprises: the system comprises a touch screen module, a PLC (programmable logic controller), a signal conditioning module, an orthogonal encoder, a current transformer, an AD (analog-digital) interface module, a DA (digital-analog) interface module, a high-speed DI (direct current) interface module, a direct current motor driver and a stepping motor driver;
the orthogonal encoder is arranged in a driving wheel train of the grinding wagon and is connected to the PLC through a high-speed DI interface module; the current transformer is arranged in the driving motor and connected with the signal conditioning module, and the signal conditioning module is connected with the PLC through the AD interface module; a direct current motor driver for driving the grinding motor to rotate is connected to the PLC through a DA interface module; a stepping motor driver for driving the grinding force to load is connected to the PLC through a DA interface module; the touch screen module is connected with the PLC.
2. The system of claim 1, wherein the sanding implement mechanism comprises a sanding motor, a tension wheel, a drive wheel, a contact wheel, a sanding belt, a loading stepper motor, a drive train, and a lead screw rail, wherein the tension wheel, the drive wheel, the contact wheel, and the sanding belt comprise a sanding belt pulley system unit; and the loading stepping motor, the transmission gear train and the lead screw guide rail form a grinding force loading unit.
3. The system of claim 1, wherein the PLC controller is a grinding controller, the quadrature encoder is a speed sensor, the dc motor driver is a grinding motor driver, the stepper motor driver is a grinding force loading unit driver, and the signal conditioning module is a signal conditioning unit.
4. A grinding control method of an abrasive belt type rail grinding work control system according to any one of claims 1 to 3, comprising:
s001, inputting a target polishing profile on an input interface of the touch screen module according to polishing requirements;
s002, the PLC compares the target polishing profile with the current profile of the target, and the target polishing amount is calculated;
s003, the PLC starts to monitor the current amount of the grinding motor and the advancing speed of the grinding wagon;
s004, the current transformer transmits the acquired current signal of the grinding motor to the signal conditioning module, the signal conditioning module filters, amplifies and modulates the current signal and transmits the current signal to the PLC through the AD interface module, the PLC obtains the current amount of the grinding motor according to the current signal, and the current grinding acting force of the abrasive belt is solved according to the current amount of the grinding motor;
the orthogonal encoder collects the advancing speed of the grinding wagon and transmits the advancing speed to the PLC through the high-speed DI interface;
s005, calculating the current polishing amount by the PLC through the mapping relation among the rotating speed of the abrasive belt, the advancing speed of the polishing vehicle, the grinding acting force and the polishing amount, and comparing the current polishing amount serving as a feedback amount with a target polishing amount to obtain a polishing error amount;
s006, generating a polishing motor control signal by the PLC according to the polishing error amount and the advancing speed of the polishing vehicle, transmitting the polishing motor control signal to a direct current motor driver through a DA interface, controlling the driving force output by the direct current motor driver by using the polishing motor control signal, and regulating the rotating speed of a polishing motor through the driving force so as to regulate the rotating speed of the abrasive belt;
the PLC generates a grinding force control signal according to the grinding error amount and the current grinding acting force of the abrasive belt, transmits the grinding force control signal to the stepping motor driver through the DA interface, controls the driving force output by the stepping motor driver by using the grinding force control signal, regulates and controls the grinding acting force loaded by the grinding force loading unit through the driving force, and the grinding acting force acts on the steel rail through the abrasive belt to realize the material removal on the surface of the steel rail;
and S007, repeating S003-S006 until the target polishing amount is reached.
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CN114406876A (en) * 2022-01-25 2022-04-29 中国铁建高新装备股份有限公司 Steel rail polishing flexible feeding device and control method

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