CN115679758A - Water jet and grinding wheel composite efficient steel rail grinding system and method - Google Patents

Abstract

The invention discloses a water jet and grinding wheel composite high-efficiency steel rail grinding system and a method. The control unit receives the rail surface image information of the steel rail acquired by the detection unit, generates a polishing control instruction, controls the water jet polishing unit to perform primary polishing on the damaged part after the polishing vehicle runs to the region to be polished, and stops polishing when the total grinding amount is 5% -10%; high-pressure air blown out by the follow-up cleaning unit blows off abrasive particles attached to the steel rail; the grinding wheel polishing unit is used for accurately polishing the residual grinding quantity, and the atomizing unit is used for spraying water mist to cool the polished end face of the steel rail. According to the polishing system, the water jet polishing unit is used for primary polishing, a certain residual grinding amount is reserved, excessive polishing is avoided, and the residual grinding amount can be used for finishing repair operation through single accurate polishing of the grinding wheel polishing unit.

Description

A water jet, grinding wheel composite high-efficiency rail grinding system and method

technical field

The invention belongs to the technical field of rail grinding, and more specifically relates to a water jet and grinding wheel composite high-efficiency rail grinding system and method.

Background technique

As one of the important load-bearing components of rail transit, steel rails will inevitably have damage characteristics such as corrugation, peeling, and fish scales due to the periodic load from the wheels during service. If the steel rail cannot be polished and repaired in time, it will cause huge noise and vibration during the operation of the grinding vehicle, which will reduce the safety and comfort of the grinding vehicle.

In order to prevent the phenomenon of crack propagation and failure after rail fatigue and wear, it is necessary to grind and repair the rail in time. Commonly used rail repair technologies mainly include grinding wheel grinding and high-pressure water jet grinding. Among them, the grinding wheel grinding technology is relatively mature at this stage, and the grinding precision is high, but there are the following technical problems: the amount of grinding and cutting is small, the operation efficiency is low, the high heat generated deforms the rail, and sparks fly during operation, generating a large amount of dust, which affects the environment and operator health. However, high-pressure water jet grinding does not produce sparks and pollution during the operation process, and the water flow can take away the heat generated by grinding the rail to avoid thermal deformation of the rail surface. However, the current technology is not yet fully mature and relies on multiple sensor controls. The positioning accuracy is extremely high, and it is easily affected by the environment, resulting in a reduction in grinding accuracy, failing to meet the required grinding effect, and even excessive grinding, resulting in rail damage.

Therefore, at this stage, there is an urgent need for a grinding equipment that combines the advantages of grinding wheel grinding and high-pressure water jet grinding, and abandons the shortcomings of both, to perform high-speed and high-precision grinding on rails.

Contents of the invention

In view of the low precision of the existing rail grinding equipment, or the low operating efficiency and easy impact on the environment, the present invention provides a water jet and grinding wheel composite high-efficiency rail grinding system, which combines two grinding technologies of grinding wheel grinding and high-pressure water jet grinding Advantages, the grinding equipment that abandons the disadvantages of both, can perform high-speed and high-precision grinding on rails.

In order to achieve the above object, the present invention provides a water jet, grinding wheel composite high-efficiency rail grinding system, including: a grinding car for rail travel, including a frame, the bottom of which is provided with a support frame, wheels and side wheels; symmetrically arranged on both sides of the frame The water jet grinding unit on the side includes nozzles and nozzle adjustment components; the nozzle adjustment components are provided with multiple groups, and by adjusting the attitude of multiple nozzles, a grinding surface that can cover the rail surface is fitted; it is located on the rear side of the water jet grinding unit The cleaning unit, which blows out high-pressure air to blow off the abrasive particles attached to the rail surface; the grinding wheel grinding unit located on the rear side of the cleaning unit, including the grinding wheel and the grinding wheel adjustment assembly; The attitude of the grinding wheel is used to fit the grinding surface that can cover the rail surface; the atomization generating unit located at the rear of the grinding wheel grinding unit generates water mist to cool the polished rail surface; and the detection unit installed on the grinding car. and a control unit, the detection unit sends the collected rail surface image and vehicle speed information to the control unit; the control unit processes the detection information, obtains the total grinding amount data of the rail defect and the positioning data of the rail defect, and According to the preset grinding amount ratio parameters, the grinding control command is generated, and the water jet grinding unit is controlled to perform preliminary grinding on the rail defect. The grinding amount ranges from 90% to 95% of the total grinding amount, and the grinding wheel grinding unit is controlled. Adjust the posture of the corresponding grinding wheel, and start the grinding operation at the position where the total grinding amount is increased by 5% on the basis of the remaining grinding amount, and perform a single precise grinding on the remaining grinding amount to complete the repair operation.

Further, the detection unit includes an industrial camera and a wheel speed sensor, wherein: the industrial camera is provided with two groups, which are symmetrically fixed on both sides of the front end of the bottom of the frame respectively, and are located directly above the rail, and collect the rail surface The image information is sent to the control unit; the wheel speed sensor is installed on the wheel, by detecting the wheel speed, and according to the fixed circumference of the wheel, the speed and travel distance of the grinding car can be accurately calculated.

Further, it includes a control unit communication module, a positioning module, an image processing module, a control module, a drive module and a control panel module; through the communication module, the communication connection between the control unit and each functional unit is realized, thereby receiving detection information; the The image processing module identifies the disease characteristics of the received image information through the image processing algorithm, and obtains the total grinding amount data of the rail defect; the positioning module locates the position of the rail defect according to the detected vehicle speed and the distance traveled by the grinding car, Output the positioning data of the rail defect; through the control module, process the total grinding data of the rail defect and the positioning data of the rail defect position, and output the grinding control command; through the drive module, drive the corresponding functional unit to work, so as to realize the control of water The jet grinds the rail surface; through the control panel module, relevant information such as grinding ratio parameters can be input to achieve precise grinding of rail defects.

Further, the nozzle adjustment assembly includes a nozzle fixing clip, a lift frame, a nozzle angle adjustment motor, and a first hydraulic cylinder; wherein: the bottom of the first hydraulic cylinder is fixed to the bottom of the vehicle frame by bolts, and one end of the piston rod is connected to the lift frame The top is fixedly connected; the nozzle angle adjustment motor is fixedly arranged on the side of the lifting frame, and its motor shaft passes through the lifting frame and is fixedly connected with the nozzle fixing clip; the nozzle fixing clip is provided with a nozzle.

Further, the water jet polishing unit also includes a first rangefinder arranged on the lifting frame and a first angle sensor arranged on the nozzle fixing clip, which are respectively used to detect the lifting height and rotation angle of the nozzle, and detect The information is sent to the control unit to generate the current attitude information of the nozzle.

Further, the cleaning unit includes an air outlet bell mouth, an air outlet pipe and a high-pressure wind generating assembly; the air outlet bell mouth is located above the rail, and is connected to the high-pressure air generating assembly installed on the top of the frame through the air outlet pipe , to discharge the high-pressure wind generated by the high-pressure wind generating component.

Further, the grinding wheel adjustment assembly includes a second hydraulic cylinder, a lifting rod, a grinding wheel rotation motor, an angle adjustment rod and a grinding wheel angle adjustment motor, wherein: the second hydraulic cylinder is fixed on the vehicle frame, and one end of the piston rod is connected to the The top of the elevating rod is fixedly connected; the bottom of the elevating rod is provided with a rotating groove along the rod body, and a pin shaft is rotated in the rotating groove, and an angle adjustment rod is fixed on the pin shaft. The adjusting rod can swing around the pin shaft as the axis center; the grinding wheel angle adjusting motor is fixedly arranged on the outside of the lifting rod, and its motor shaft is fixedly connected with one end of the pin shaft, which can drive the pin shaft to rotate; the grinding wheel rotating motor is connected with the lower angle adjusting The bottom of the rod is fixedly connected, and its motor shaft is fixedly connected with the grinding wheel.

Further, the grinding wheel grinding unit also includes a second rangefinder on the lifting rod and a second angle sensor on the angle adjusting rod, which are used to detect the lifting height and rotation angle of the grinding wheel respectively, and send the detection information to The control unit thus generates the current attitude information of the grinding wheel.

Further, the atomization generation unit includes an atomization nozzle, an atomization generator, a water flow pipeline and a water tank; the atomization generator and the water tank are fixed on the top of the vehicle frame, and the two are connected by a water flow pipeline; The atomization nozzle is located directly above the rail, and is connected to the output end of the atomization generator through a pipeline.

According to another aspect of the present invention, there is also provided a water jet, grinding wheel composite high-efficiency rail grinding method, including the following steps:

S100: setting the grinding ratio parameter, assigning the ratio of the grinding amount of the water jet grinding unit to the grinding wheel grinding unit, the grinding amount of the grinding wheel grinding unit is increased by 5% of the total grinding amount on the basis of the remaining grinding amount;

S200: The grinding vehicle drives into the grinding area on the rail, and the rail surface image information and vehicle speed collected by the detection unit;

S300: The control unit performs defect feature recognition on the received rail surface image through an image processing algorithm to obtain rail defect feature data, calculates the grinding amount of the defect, and locates the defect, and then generates a grinding control command;

S400: After the water jet grinding unit reaches the diseased part, the control unit controls the corresponding nozzles to adjust the attitude, grind the diseased part, and stop the grinding operation when the specified grinding amount is reached;

S500: The cleaning unit blows out high-pressure air to blow off the abrasive particles on the rail surface;

S600: After the grinding wheel grinding unit reaches the diseased part, the control unit controls the corresponding grinding wheel to adjust its posture, pushes it to the designated grinding point, and performs grinding operations on the remaining grinding amount;

S700: The atomization generating unit sprays water mist to cool down the polished rail surface, extinguishes the sparks generated by the grinding wheel, and wets the generated dust to prevent it from spreading;

S800: Complete the grinding operation in the grinding area, and recover the grinding vehicle.

Generally speaking, compared with the prior art, the above technical solutions conceived by the present invention can achieve the following beneficial effects:

1. A water jet, grinding wheel composite high-efficiency rail grinding system of the present invention, through a water jet grinding unit, the position of the rail defect is initially polished, and the grinding amount is controlled within the range of 90%-95% of the total grinding amount It can effectively avoid excessive grinding caused by immature water jet grinding technology and low grinding precision; by setting the grinding wheel grinding unit, the starting point of grinding is set at the place where the total grinding amount is increased by 5% on the basis of the remaining grinding amount. It can avoid the collision with the grinding surface due to insufficient water jet grinding precision, and at the same time reduce the grinding distance of the grinding wheel, and can complete the grinding operation of the remaining grinding amount of the disease in a single operation, thereby improving the grinding efficiency, without grinding like traditional grinding wheels Repeat 5-6 times to complete the repair of the rail defect, to avoid thermal deformation caused by the grinding wheel grinding the disease for too long.

2. A high-efficiency water jet and grinding wheel composite rail grinding system of the present invention can clean the top of the rail through the high-pressure air generated by the cleaning unit, and can easily blow off the abrasive particles attached to the rail surface to avoid affecting the follow-up The grinding accuracy of the grinding wheel grinding unit and the damage caused to the grinding wheel grinding surface.

3. A water jet and grinding wheel composite high-efficiency rail grinding system of the present invention is equipped with an atomization generating unit to spray water mist to cool down the polished rail end face to avoid thermal deformation, and at the same time extinguish sparks generated by grinding wheel grinding, resulting in Wet the dust to avoid the influence of the grinding wheel on the surrounding environment of the rail.

4. A water jet and grinding wheel composite high-efficiency rail grinding system of the present invention can process the surface of the rail to a depth of 0.1-3mm, and can complete the grinding and repairing of the rail in a single operation, and the operation efficiency is very high. The precision can reach ±0.2mm, the longitudinal smoothness precision can reach 0.01mm, the roughness Ra≤6.3um, and the grinding precision is high.

Description of drawings

Fig. 1 is a structural schematic diagram of a connector of a water jet and grinding wheel composite high-efficiency rail grinding system in an embodiment of the present invention;

Fig. 2 is a partial structural schematic diagram of the grinding wheel grinding unit in the embodiment of the present invention.

Fig. 3 is a schematic flow chart of a water jet and grinding wheel composite high-efficiency rail grinding method in an embodiment of the present invention.

In all drawings, the same reference numerals represent the same technical features, specifically:

1-grinding car; including: 11-frame, 12-wheel assembly, 121-support frame, 122-wheel, 13-side wheel;

2-Water jet grinding unit, including: 21-nozzle, 22-nozzle fixing clip, 23-lift frame, 24-nozzle angle adjustment motor, 25-first hydraulic cylinder, 26-abrasive water jet supply assembly;

3-Cleaning unit, including: 31-air outlet bell mouth, 32-air outlet pipe, 33-high pressure air generating component;

4-Grinding wheel grinding unit, including: 41-grinding wheel, 42-second hydraulic cylinder, 43-protective cover, 44-lifting rod, 441-rotating groove, 45-grinding wheel rotating motor, 46-angle adjustment lever, 47-grinding wheel angle adjust the motor;

5-atomization generating unit, including: 51-atomization nozzle, 52-atomization generator, 53-water flow pipeline, 54-water tank;

6 - control unit;

7-detection unit, including: 71-industrial camera;

8- Rails.

Detailed ways

In order to make the object, technical solution and advantages of the present invention clearer, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present invention, not to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not constitute a conflict with each other.

As shown in Figure 1-2, the embodiment of the present invention provides a water jet, grinding wheel composite high-efficiency rail grinding system, including a grinding car 1, and a water jet grinding unit 2, a cleaning unit 3, and a grinding wheel arranged on the grinding car 1 Grinding unit 4, atomization generation unit 5, control unit 6 and detection unit 7, the control unit 6 receives the rail rail surface image information collected by the detection unit 7, and obtains the total grinding amount data of the rail defect and the rail surface through an image processing algorithm. Locate the data of the defect and generate a grinding control instruction. After the grinding vehicle 1 travels to the area to be polished, the water jet grinding unit 2 adjusts the nozzle 21 according to the grinding control instruction and adjusts the posture to perform preliminary grinding on the position of the defect on the rail 8. Stop grinding when the remaining 5%-10% of the amount is left to avoid excessive grinding due to poor precision; follow up with the cleaning unit 3, and blow out high-pressure air to blow off the abrasive particles attached to the rail 8, so as to avoid affecting the subsequent grinding accuracy; Grinding wheel grinding unit 4 It includes multiple groups of grinding wheels 41 with different postures. The grinding points of multiple grinding wheels 41 are fitted to form a grinding surface covering the entire surface of the rail 8. After traveling to the position of the diseased part, the remaining grinding amount is accurately completed at one time. Grinding operation , while improving the grinding accuracy, the grinding time of the grinding wheel is reduced, the thermal deformation of the surface of the rail 1 is avoided, and the generation of sparks and dust is reduced at the same time. The atomization unit 5 sprays water mist to cool the polished rail end face. In the grinding system of the present invention, the water jet grinding unit 2 is used to initially grind the diseased part, and a certain amount of remaining grinding is retained to avoid excessive grinding, and the remaining grinding amount can be repaired by a single precise grinding of the follow-up grinding wheel grinding unit 4 Operation, while combining the advantages of the two grinding technologies, the defects of the two grinding technologies are abandoned, and the high-speed and high-precision grinding of the rail is realized.

As shown in FIG. 1 , the grinding vehicle 1 includes a frame 11 , a wheel assembly 12 and side wheels 13 . Wherein, the vehicle frame 1 can be used for loading and fixing other functional units, and the bottom is fixedly connected with the wheel assembly 12 so that it can travel on the rail 8 . The wheel assembly 12 is provided with multiple groups, symmetrically fixed on both sides of the bottom of the vehicle frame 11, including a support frame 121 and a wheel 122. The wheel 122 can walk on the rail 8, and its two ends are rotated by a rotating shaft. The bottom of the frame 121, the top of the support frame 121 is fixedly connected with the bottom of the vehicle frame 11. Said side wheel 13 fits with the side of the rail head and can roll along the side of the rail head to limit the direction of travel of the wheel 122 to prevent the wheel 122 from deviating from the track and cause the grinding car 1 to tip over. Bottom connection.

The water jet polishing unit 2 includes a nozzle 21 , a nozzle adjustment assembly and an abrasive water jet supply assembly 26 . The nozzle adjustment assembly is provided with multiple groups, which are symmetrically arranged on both sides of the bottom of the vehicle frame 11 and above the rail 8. The postures of the multiple nozzles 21 are adjusted through multiple groups of nozzle adjustment assemblies, so that the grinding points of the multiple nozzles 21 can be fitted. Covering the grinding surface of the rail surface of the rail 8 can improve the grinding efficiency; the nozzle adjustment assembly includes a nozzle fixing clip 22, a lifting frame 23, a nozzle angle adjustment motor 24 and a first hydraulic cylinder 25; wherein, the first hydraulic cylinder 25 The bottom is fixed on the bottom of the vehicle frame 11 by bolts, and one end of its piston rod is fixedly connected with the top of the lifting frame 23, driven by the plug rod, the height of the vertical direction of the lifting frame 23 can be adjusted. The nozzle angle adjustment motor 24 is fixedly arranged on the side of the lifting frame 23, and its motor shaft passes through the lifting frame 23 and is fixedly connected with the nozzle fixing clip 22. By rotating the motor shaft, the nozzle 21 that is located on the nozzle fixing clip 22 can be adjusted. spray angle. The abrasive water jet supply assembly 26 is fixed on the top of the vehicle frame 11, which provides high-pressure water and abrasive mixture, and is transported to the nozzle 21 through a pipeline to form a high-pressure abrasive water jet to grind the rail 8. In the embodiment of the present invention, the water jet grinding unit 2 also includes a first rangefinder arranged on the lifting frame 23 and a first angle sensor arranged on the nozzle fixing clip 22, which are respectively used to detect the lifting height of the nozzle 21 and the rotation angle, and send the detection information to the control unit 6 to generate the current posture information of the nozzle 21.

Further, the nozzle angle adjustment motor 24, the first hydraulic cylinder 25, the first range finder and the first angle sensor are respectively connected to the control unit 7 in communication, and the first range finder and the first angle sensor respectively detect the The information is sent to the control unit 7, and the control unit 7 generates a nozzle attitude adjustment control command according to the information of the area to be polished and the current attitude of the nozzle 21, controls the nozzle angle adjustment motor 24 to adjust the spray angle of the nozzle 21, and controls the first hydraulic cylinder 25 to adjust the nozzle lift Height, so as to complete the attitude adjustment of multiple groups of nozzles 901, and perform precise grinding on the area to be polished.

The cleaning unit 3 is arranged on the vehicle frame 11 and is located at the rear side of the water jet polishing unit 2. After the water jet polishing unit 2 is polished, the remaining abrasive particles attached to the rail 8 are removed, which includes the air outlet bell mouth 31, Outlet pipe 32 and high-pressure wind generating assembly 33, described air outlet bell mouth 31 is positioned at the top of rail 8, and it is connected with high-pressure wind generating assembly 33 pipes that are located at the top of vehicle frame 11 through air outlet pipe 32, and high-pressure wind generating assembly The high-pressure air generated by 33 is discharged to clean the top of the rail 8, which can easily blow off the abrasive particles attached to the rail surface, so as to avoid affecting the grinding accuracy of the subsequent grinding wheel grinding unit 4 and causing damage to the grinding surface of the grinding wheel 41. After the cleaning unit 3 removes the abrasive particles, a small amount of water stains will remain on the rail 8, which can reduce the temperature when the subsequent grinding wheel grinding unit 4 is grinding, avoid thermal deformation of the rail surface, and help reduce the wear rate of the grinding wheel and Improve the smoothness of the rail surface after grinding.

The grinding wheel grinding unit 4 is located at the rear side of the cleaning unit 3, and grinds the remaining grinding amount at the position of the defect on the rail 8, and improves the grinding accuracy while improving the grinding efficiency. It includes a grinding wheel 41, a grinding wheel adjustment assembly and Shield 43. The grinding wheel adjustment assembly is provided with multiple groups, through which the multiple grinding wheels 41 are adjusted, so that the grinding points of the multiple grinding wheels 41 fit a grinding surface that can cover the rail surface of the rail 8, thereby improving the grinding efficiency. The grinding wheel adjustment assembly includes a second hydraulic cylinder 42, a lifting rod 44, a grinding wheel rotating motor 45, an angle adjustment rod 46 and a grinding wheel angle adjustment motor 47. The second hydraulic cylinder 42 is fixed on the vehicle frame 11, and its piston rod One end is fixedly connected with the lifting rod 44 top, which can drive the lifting rod 44 to carry out lifting operation in the vertical direction; An angle adjustment rod 46 is fixed on the pin shaft, and the angle adjustment rod 46 can swing around the pin shaft as the axis under the limitation of the rotation groove 411 . The grinding wheel angle adjustment motor 47 is fixedly arranged on the outside of the elevating rod 44, and its motor shaft is fixedly connected with one end of the pin shaft, which can drive the pin shaft to rotate. The grinding wheel rotating motor 45 is fixedly connected with the bottom of the lower angle adjusting rod 46, and its motor shaft is fixedly connected with the grinding wheel 41, which can drive the grinding wheel 41 to rotate at a high speed so that the 8 rail surfaces of the rails are polished. In the embodiment of the present invention, the grinding wheel grinding unit 4 also includes a second rangefinder on the lifting rod 44 and a second angle sensor on the angle adjusting rod 46, which are used to detect the lifting height and rotation angle of the grinding wheel 41 respectively. , so as to generate the current posture information of the grinding wheel 41. The protective cover 43 is arranged on the top of the grinding wheel 41, which can prevent sparks and dust generated by grinding from splashing upwards and spreading, affecting the surrounding environment.

Further, the second hydraulic cylinder 42, the grinding wheel rotating motor 45, the grinding wheel angle adjusting motor 47, the second rangefinder and the second angle sensor are respectively connected to the control unit 7 in communication, the second rangefinder and the second angle sensor The detected information is sent to the control unit 7 respectively, and the control unit 7 generates a grinding wheel grinding control instruction according to the information of the area to be polished and the current attitude of the grinding wheel 41, controls the grinding wheel rotating motor 45 to adjust the spray angle of the grinding wheel 41, and controls the second hydraulic cylinder 42 Adjust the lifting height of the grinding wheel 41, control the rotation speed of the grinding wheel rotating motor 45 to adjust the grinding force of the grinding wheel 41, thereby completing the attitude adjustment of multiple groups of grinding wheels 41, and accurately grinding the area to be polished.

The atomization generating unit 5 is located at the rear side of the grinding wheel grinding unit 4 and includes an atomizing nozzle 51 , an atomizing generator 52 , a water flow pipe 53 and a water tank 54 . The atomization generator 52 and the water tank 54 are fixedly arranged on the top of the vehicle frame 11, and are connected by a water flow pipe 53; The atomization generator 52 communicates with the control unit 7. When the grinding wheel grinding unit 4 grinds the rail, the atomization function is activated synchronously. Afterwards, it is transported to the atomizing nozzle 51 from the output end, and is ejected by the atomizing nozzle 51 to cool down the steel rail 8 to avoid thermal deformation. The surrounding environment of the rail has an impact.

In the embodiment of the present invention, the control unit 6 includes a communication module, a positioning module, an image processing module, a control module, a drive module and a control panel module; through the communication module, the communication connection between the control unit 6 and each functional unit is realized, thereby receiving Detection information; the image processing module will receive the image information through the image processing algorithm to carry out disease feature recognition, and obtain the total grinding amount data of the rail disease; The position of the rail defect is located, and the positioning data of the rail defect is output; through the control module, the total grinding amount data of the rail defect and the positioning data of the rail defect position are processed, and the grinding control command is output; through the drive module, the corresponding functional unit is driven Work, so as to realize the grinding of the rail 8 rail surface; through the control panel module, relevant information such as grinding ratio parameters can be input to realize precise grinding of the rail 8 rail surface.

The detection unit 7 includes an industrial camera 71 and a wheel speed sensor. The industrial camera 71 is provided with two groups, which are respectively symmetrically fixed on both sides of the front end of the bottom of the vehicle frame 11, and are located directly above the rail, which can collect images of the rail surface of the rail 8. , and transmit the collected information to the control unit 6, carry out disease feature recognition on the received rail surface image through an image processing algorithm to obtain rail defect feature data, calculate the total amount of grinding at the rail defect, and generate a grinding control command . Described wheel speed sensor is arranged on the wheel 122, by detecting the wheel speed, and according to the fixed circumference of wheel 122, can accurately obtain the speed of a vehicle and the travel distance of grinding car 1, control unit 6 is provided with positioning module, according to the grinding car The fixed distance between the industrial camera 71 provided on 1, the water jet grinding unit 2 and the grinding wheel grinding unit 4 can locate the position of the disease on the rail 1, and control the water jet grinding unit 2 and the grinding wheel grinding unit in sequence 4. Carry out grinding operations when reaching the diseased part.

When the water jet and grinding wheel composite high-efficiency rail grinding system of the present invention is working, the grinding ratio parameters are first input through the control panel, wherein the grinding amount of the water jet grinding unit 2 can be set to 90%-95% of the total grinding amount % (that is, the grinding depth reaches 90%-95% of the total depth at the diseased place), the actual grinding amount of the emery wheel grinding unit 4 is a total grinding amount that increases 5% on the remaining grinding amount, such as the water jet grinding unit The amount of grinding of 2 is set to 90%, then the emery wheel grinding unit 4 starts grinding at the place where the total grinding amount is 85%, that is, the remaining grinding amount is polished at the 85% of the total grinding depth; After the parameter ratio is set, the tractor can provide traction to walk on the rail 8. After entering the grinding area, the industrial camera 71 collects the rail surface image, and the wheel speed sensor measures the speed of the grinding vehicle 1. According to the detection information, the control unit 6. Generate a grinding control command. When the water jet grinding unit 2 reaches the location of the disease, control the nozzle 21 to adjust the attitude and perform preliminary grinding; The high-pressure air blows out from the port 31 to blow off the abrasive particles on the rail surface of the rail 8; when the grinding wheel grinding unit 4 advances to the diseased part, the control unit 6 adjusts the attitude of each corresponding grinding wheel, and pushes the corresponding grinding wheel 41 to the base of the remaining grinding amount. Grind at 5% of the total grinding amount to complete the grinding work of the remaining grinding amount at the diseased part; at the same time, the atomization generating unit 6 sprays water mist to cool down the polished rail end face to prevent thermal deformation and The sparks generated by the grinding wheel 41 are extinguished, the generated dust is wetted to prevent diffusion, and the impact on the surrounding environment is reduced.

A water jet and grinding wheel composite high-efficiency rail grinding system of the present invention is provided with a water jet grinding unit 2 to perform initial grinding on the position of the rail 8 where the defect is located, and the grinding amount is controlled within the range of 90%-95% of the total grinding amount It can effectively avoid excessive grinding caused by immature water jet grinding technology and low grinding precision; by setting the grinding wheel grinding unit 4, the starting point of grinding is set at the position where the total grinding amount is increased by 5% on the basis of the remaining grinding amount , can avoid collision with the grinding surface due to insufficient water jet grinding precision, and reduce the grinding distance of the grinding wheel 41 at the same time, and can complete the grinding operation of the remaining grinding amount of the disease in a single operation, thereby improving the grinding efficiency. The grinding wheel grinding is repeated 5-6 times to complete the repair of the rail defect, so as to avoid the thermal deformation caused by the grinding wheel grinding the diseased part for too long.

The grinding system of the present invention can process the surface of the rail 8 to a depth of 0.1-3mm, and can complete the grinding and repairing of the rail in a single operation. Reach 0.01mm, roughness Ra≤6.3um, high grinding precision.

As shown in Figure 3, the present invention also provides a water jet, grinding wheel composite high-efficiency rail grinding method, including the following steps:

S100: Set the grinding ratio parameter, assign the grinding amount ratio between the water jet grinding unit 2 and the grinding wheel grinding unit 4, and the grinding amount of the grinding wheel grinding unit 4 is increased by 5% on the basis of the remaining grinding amount. cutting amount;

S200: The grinding vehicle 1 drives into the grinding area on the rail 8, and the rail surface image information and vehicle speed collected by the detection unit 7;

S300: The control unit 6 performs disease feature recognition on the received rail surface image through an image processing algorithm to obtain rail disease feature data, calculates the total grinding amount of the diseased part, and locates the diseased part, and then generates a grinding control instruction;

S400: After the water jet polishing unit 2 reaches the diseased part, the control unit 6 controls the corresponding nozzle 21 to adjust the posture, and polish the diseased part, and stop the grinding operation when the specified grinding amount is reached;

S500: The cleaning unit 3 blows out high-pressure air to blow off the abrasive particles on the rail surface of the rail 8;

S600: After the grinding wheel grinding unit 4 reaches the diseased part, the control unit 6 controls the corresponding grinding wheel 41 to adjust its posture, pushes it to the designated grinding point, and performs grinding operation on the remaining grinding amount;

S700: the atomization generating unit 6 sprays water mist to cool down the polished rail end face, extinguishes sparks generated by grinding the grinding wheel 41, and wets the generated dust to prevent diffusion;

S800: Finish the grinding operation in the grinding area, and recover the grinding vehicle 1.

It is easy for those skilled in the art to understand that the above descriptions are only preferred embodiments of the present invention, and are not intended to limit the present invention. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present invention, etc., All should be included within the protection scope of the present invention.

Claims (10)

1. The utility model provides a water jet, compound high-efficient rail system of polishing of emery wheel which characterized in that includes:

the grinding wagon (1) moving along the steel rail (8) comprises a frame (11), wherein the bottom of the frame is provided with a support frame (121), wheels and side wheels (13);

the water jet polishing units (2) are symmetrically arranged on two sides of the frame (11) and comprise nozzles (21) and nozzle adjusting components; the nozzle adjusting assemblies are provided with a plurality of groups, and the polished surface capable of covering the rail surface of the steel rail (8) is fitted by adjusting the postures of the nozzles (21);

the cleaning unit (3) is positioned at the rear side of the water jet polishing unit (2) and blows high-pressure air to blow off abrasive particles attached to the rail surface of the steel rail (8);

the grinding wheel polishing unit (4) is positioned at the rear side of the cleaning unit (3) and comprises a grinding wheel (41) and a grinding wheel adjusting assembly; the wheel adjusting assemblies are provided with a plurality of groups, and the ground surfaces capable of covering the rail surface of the steel rail (8) are fitted by adjusting the postures of the grinding wheels (41);

the atomization generating unit (5) is positioned at the rear side of the grinding wheel polishing unit (4) and generates water mist to cool the polished rail surface;

the detection unit (7) and the control unit (6) are arranged on the grinding wagon (1), and the detection unit (7) sends the acquired rail surface image of the steel rail (8) and the vehicle speed information to the control unit (6); the control unit (6) processes the detection information to obtain total grinding quantity data of the steel rail disease positions and positioning data of the steel rail disease positions, grinding control instructions are generated according to preset grinding quantity proportioning parameters, the water jet grinding unit (2) is controlled to carry out primary grinding on the steel rail disease positions, the grinding quantity range of the water jet grinding unit is 90% -95% of the total grinding quantity, the grinding wheel grinding unit (4) is controlled to adjust the posture of the corresponding grinding wheel (41), 5% of the total grinding quantity positions are increased on the basis of the residual grinding quantity to carry out grinding operation as grinding starting points, and single-time accurate grinding is carried out on the residual grinding quantity to finish repairing operation.

2. The water jet and grinding wheel combined high-efficiency rail grinding system as claimed in claim 1, wherein the detection unit (7) comprises an industrial camera (71) and a wheel speed sensor, wherein:

the two groups of industrial cameras (71) are respectively and symmetrically fixed on two sides of the front end of the bottom of the frame (11) and positioned right above the steel rail, and are used for transmitting acquired rail surface image information of the steel rail (8) to the control unit (6);

the wheel speed sensor is arranged on the wheel (122), and the speed and the travel distance of the grinding wagon (1) can be accurately calculated by detecting the rotating speed of the wheel and fixing the perimeter of the wheel (122).

3. The water jet and grinding wheel composite high-efficiency steel rail grinding system as claimed in claim 2, wherein the system comprises a control unit (6) communication module, a positioning module, an image processing module, a control module, a driving module and a control panel module;

through the communication module, the communication connection between the control unit (6) and each functional unit is realized, so that the detection information is received;

the image processing module identifies the disease characteristics of the received image information through an image processing algorithm to obtain the total grinding quantity data of the steel rail disease positions;

the positioning module is used for positioning the position of the steel rail defect according to the detected speed and the advancing distance of the grinding wagon (1) and outputting steel rail defect position data;

processing the total grinding quantity data and the steel rail defect position locating data of the steel rail defect part through a control module, and outputting a grinding control instruction;

driving the corresponding functional unit to work according to the polishing control instruction through the driving module;

through the control panel module, relevant information such as grinding proportioning parameters can be input, and accurate grinding of the steel rail disease is achieved.

4. The water jet and grinding wheel composite high-efficiency steel rail grinding system as claimed in any one of claims 1 to 3, wherein the nozzle adjusting assembly comprises a nozzle fixing clamp (22), a lifting frame (23), a nozzle angle adjusting motor (24) and a first hydraulic cylinder (25); wherein:

the bottom of the first hydraulic cylinder (25) is fixed at the bottom of the frame (11) through a bolt, and one end of a piston rod of the first hydraulic cylinder is fixedly connected with the top of the lifting frame (23);

the nozzle angle adjusting motor (24) is fixedly arranged on the side edge of the lifting frame (23), and a motor shaft of the nozzle angle adjusting motor penetrates through the lifting frame (23) to be fixedly connected with the nozzle fixing clamp (22);

and a nozzle (21) is arranged on the nozzle fixing clamp (22).

5. The water jet and grinding wheel combined efficient steel rail grinding system as claimed in claim 4, wherein the water jet grinding unit (2) further comprises a first distance meter arranged on the lifting frame (23) and a first angle sensor arranged on the nozzle fixing clamp (22) and used for detecting the lifting height and the rotating angle of the nozzle (21) respectively and sending the detection information to the control unit (6) so as to generate the current posture information of the nozzle (21).

6. The water jet and grinding wheel composite high-efficiency steel rail grinding system as claimed in any one of claims 1 to 3, wherein the cleaning unit (3) comprises an air outlet bell mouth (31), an air outlet pipe (32) and a high-pressure air generating assembly (33); air-out horn mouth (31) are located rail (8) top, and it takes place subassembly (33) pipe connection through air-out pipe (32) and the high-pressure draught of locating frame (11) top, take place the high-pressure draught that subassembly (33) generated and discharge.

7. The water jet and grinding wheel combined high-efficiency steel rail grinding system according to any one of claims 1 to 3, wherein the grinding wheel adjusting assembly comprises a second hydraulic cylinder (42), a lifting rod (44), a grinding wheel rotating motor (45), an angle adjusting rod (46) and a grinding wheel angle adjusting motor (47), wherein:

the second hydraulic cylinder (42) is fixedly arranged on the frame (11), and one end of a piston rod of the second hydraulic cylinder is fixedly connected with the top of the lifting rod (44);

a rotating groove (411) is formed in the bottom of the lifting rod (44) along the rod body, a pin shaft is rotatably arranged in the rotating groove (411), an angle adjusting rod (46) is fixedly arranged on the pin shaft, and the angle adjusting rod (46) can circumferentially swing by taking the pin shaft as an axis under the limiting of the rotating groove (411);

the grinding wheel angle adjusting motor (47) is fixedly arranged on the outer side of the lifting rod (44), and a motor shaft of the grinding wheel angle adjusting motor is fixedly connected with one end of a pin shaft and can drive the pin shaft to rotate;

the grinding wheel rotating motor (45) is fixedly connected with the bottom of the lower angle adjusting rod (46), and a motor shaft of the grinding wheel rotating motor is fixedly connected with the grinding wheel (41).

8. The steel rail grinding system with the combination of the water jet and the grinding wheel as claimed in claim 7, wherein the grinding wheel grinding unit (4) further comprises a second distance meter on the lifting rod (44) and a second angle sensor on the angle adjusting rod (46) for detecting the lifting height and the rotating angle of the grinding wheel (41), respectively, and sending the detection information to the control unit (6) to generate the current attitude information of the grinding wheel (41).

9. The water jet and grinding wheel composite high-efficiency steel rail grinding system as claimed in any one of claims 1 to 3, wherein the atomization generating unit (5) comprises an atomization spray head (51), an atomization generator (52), a water flow pipeline (53) and a water tank (54); the atomization generator (52) and the water tank (54) are fixedly arranged at the top of the frame (11) and are connected through a water flow pipeline (53); the atomizing nozzle (51) is positioned right above the steel rail (8) and is connected with the output end of the atomizing generator (52) through a pipeline.

10. A water jet and grinding wheel composite efficient rail grinding method is characterized by comprising the following steps:

s100: setting grinding proportioning parameters, and distributing the grinding amount proportioning of the water jet grinding unit (2) and the grinding wheel grinding unit (4), wherein the grinding amount of the grinding wheel grinding unit (4) is adjusted up to 5% of the total grinding amount on the basis of the residual grinding amount;

s200: the rail surface image information and the vehicle speed of the steel rail collected by the detection unit (7) are detected when the grinding wagon (1) drives into a grinding area on the steel rail (8);

s300: the control unit (6) performs disease feature identification on the received steel rail surface image through an image processing algorithm to obtain steel rail disease feature data, calculates the grinding amount of a disease part, positions the disease part and further generates a grinding control instruction;

s400: after the water jet polishing unit (2) reaches a diseased part, the control unit (6) controls the corresponding nozzle (21) to adjust the posture, the diseased part is polished, and the polishing operation is stopped when a specified grinding amount is reached;

s500: the cleaning unit (3) blows high-pressure air to blow off the rail surface abrasive particles of the steel rail (8);

s600: after the grinding wheel polishing unit (4) reaches a disease, the control unit (6) controls the corresponding grinding wheel (41) to adjust the posture, the corresponding grinding wheel is pushed to a designated polishing point, and the polishing operation is carried out on the residual grinding quantity;

s700: the atomization generating unit (6) sprays water mist to cool the ground rail surface of the steel rail, and extinguishes sparks generated by grinding the grinding wheel (41) to wet generated dust so as to prevent diffusion;

s800: finishing the polishing operation of the polishing area and recovering the polishing vehicle (1).

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