CN115679758A - Water jet and grinding wheel composite efficient steel rail grinding system and method - Google Patents
Water jet and grinding wheel composite efficient steel rail grinding system and method Download PDFInfo
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- CN115679758A CN115679758A CN202211394253.2A CN202211394253A CN115679758A CN 115679758 A CN115679758 A CN 115679758A CN 202211394253 A CN202211394253 A CN 202211394253A CN 115679758 A CN115679758 A CN 115679758A
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- 238000000227 grinding Methods 0.000 title claims abstract description 355
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 125
- 239000010959 steel Substances 0.000 title claims abstract description 125
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 106
- 239000002131 composite material Substances 0.000 title claims abstract description 18
- 238000000034 method Methods 0.000 title claims abstract description 12
- 238000005498 polishing Methods 0.000 claims abstract description 134
- 238000001514 detection method Methods 0.000 claims abstract description 26
- 238000004140 cleaning Methods 0.000 claims abstract description 18
- 239000002245 particle Substances 0.000 claims abstract description 11
- 239000003595 mist Substances 0.000 claims abstract description 8
- 201000010099 disease Diseases 0.000 claims description 45
- 208000037265 diseases, disorders, signs and symptoms Diseases 0.000 claims description 45
- 230000036544 posture Effects 0.000 claims description 26
- 230000007547 defect Effects 0.000 claims description 22
- 229910001651 emery Inorganic materials 0.000 claims description 22
- 238000000889 atomisation Methods 0.000 claims description 21
- 238000004891 communication Methods 0.000 claims description 12
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- 238000000429 assembly Methods 0.000 claims description 9
- 239000000428 dust Substances 0.000 claims description 9
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- 230000008569 process Effects 0.000 claims description 3
- 150000001875 compounds Chemical class 0.000 claims 1
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- 238000005507 spraying Methods 0.000 abstract description 2
- 238000005516 engineering process Methods 0.000 description 7
- 241000607479 Yersinia pestis Species 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 2
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- 238000004519 manufacturing process Methods 0.000 description 2
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- 238000010902 jet-milling Methods 0.000 description 1
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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
Technical Field
The invention belongs to the technical field of rail grinding, and particularly relates to a water jet and grinding wheel composite efficient rail grinding system and method.
Background
The steel rail is one of important bearing parts of rail transit, and disease characteristics such as corrugation, peeling, fish scale lines and the like are difficult to avoid due to the periodic load action of wheels in the service process. If the steel rail cannot be polished and repaired in time, huge noise and vibration are caused when the polishing trolley runs, and the running safety and comfort of the polishing trolley are reduced.
In order to prevent the phenomena of crack propagation, failure and the like after the steel rail is fatigued and worn, the steel rail needs to be polished and repaired in time. The common steel rail repairing technology mainly comprises two technologies of grinding wheel polishing and high-pressure water jet polishing. The grinding wheel is mature in the prior art, the grinding precision is high, and the following technical problems exist: the grinding and cutting amount is small, the operation efficiency is low, the steel rail is deformed by high heat generated, sparks splash during operation, a large amount of dust is generated, and the environment and the health of operators are affected. The high-pressure water jet polishing does not generate sparks and is pollution-free in the operation process, heat generated by polishing of the steel rail can be taken away by water flow, and thermal deformation of the rail surface of the steel rail is avoided.
Therefore, in the current stage, two polishing technical advantages of grinding wheel polishing and high-pressure water jet polishing are combined, polishing equipment with the defects of the grinding wheel polishing and the high-pressure water jet polishing is abandoned, and high-speed and high-precision polishing is carried out on the steel rail.
Disclosure of Invention
Aiming at the defects that the steel rail polishing equipment in the prior art is low in precision or low in operation efficiency and easily influences the environment, the invention provides the water jet and grinding wheel composite high-efficiency steel rail polishing system, which combines the advantages of two polishing technologies of grinding wheel polishing and high-pressure water jet polishing, abandons the polishing equipment with the defects of the grinding wheel polishing and the high-pressure water jet polishing, and performs high-speed high-precision polishing on the steel rail.
In order to achieve the purpose, the invention provides a water jet and grinding wheel composite high-efficiency steel rail grinding system, which comprises: the rail-travelling grinding wagon comprises a frame, wherein the bottom of the frame is provided with a support frame, wheels and side wheels; the water jet polishing units are symmetrically arranged on two sides of the frame and comprise nozzles 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 is fitted by adjusting the postures of the nozzles; the cleaning unit is positioned at the rear side of the water jet polishing unit and blows high-pressure air to blow off abrasive particles attached to the rail surface of the steel rail; the grinding wheel polishing unit is positioned at the rear side of the cleaning unit and comprises a grinding wheel and a grinding wheel adjusting assembly; the wheel adjusting assemblies are provided with a plurality of groups, and the ground surface capable of covering the rail surface of the steel rail is fitted by adjusting the postures of the grinding wheels; the atomization generating unit is positioned at the rear side of the grinding wheel polishing unit and generates water mist to cool the polished rail surface; the detection unit and the control unit are arranged on the grinding wagon, and the detection unit sends the acquired rail surface image of the steel rail and the vehicle speed information to the control unit; the control unit 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 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 is controlled to adjust the posture of a corresponding grinding wheel, grinding operation is carried out by taking the position with 5% of the total grinding quantity increased on the basis of the residual grinding quantity as a grinding starting point, and single-time accurate grinding is carried out on the residual grinding quantity to finish repairing operation.
Further, the detection unit includes an industrial camera and a wheel speed sensor, wherein: the industrial cameras are respectively and symmetrically fixed on two sides of the front end of the bottom of the frame and positioned right above the steel rail, and the industrial cameras transmit acquired image information of the rail surface of the steel rail to the control unit; the wheel speed sensor is arranged on the wheel, and the speed and the travel distance of the grinding vehicle can be accurately calculated by detecting the rotating speed of the wheel and according to the fixed circumference of the wheel.
Further, the device comprises a control unit 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 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 vehicle speed and the travel distance of the grinding wagon, and outputting steel rail defect position data; processing the total grinding quantity data of the steel rail disease positions and the steel rail disease position positioning data through a control module, and outputting a grinding control instruction; the driving module drives the corresponding functional unit to work, so that the water jet is controlled to polish the rail surface of the steel rail; through the control panel module, can input relevant information such as the ratio parameter of polishing, realize polishing the accurate of rail disease department.
Further, the nozzle adjusting assembly comprises a nozzle fixing clamp, a lifting frame, a nozzle angle adjusting motor and a first hydraulic cylinder; wherein: the bottom of the first hydraulic cylinder is fixed at the bottom of the frame 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; the nozzle angle adjusting motor is fixedly arranged on the side edge of the lifting frame, and a motor shaft of the nozzle angle adjusting motor penetrates through the lifting frame to be fixedly connected with the nozzle fixing clamp; and the nozzle fixing clamp is provided with a nozzle.
Furthermore, the water jet polishing unit further comprises a first distance meter arranged on the lifting frame and a first angle sensor arranged on the nozzle fixing clamp, and the first distance meter and the first angle sensor are respectively used for detecting the lifting height and the rotating angle of the nozzle and sending detection information to the control unit so as to generate current posture information of the nozzle.
Furthermore, the cleaning unit comprises an air outlet bell mouth, an air outlet pipe and a high-pressure air generating assembly; the air outlet bell mouth is positioned above the steel rail and is connected with a high-pressure air generation assembly pipeline arranged at the top of the frame through an air outlet pipe, and high-pressure air generated by the high-pressure air generation assembly is discharged.
Further, the emery wheel regulating assembly includes second pneumatic cylinder, lifter, emery wheel rotating electrical machines, angle adjusting rod and emery wheel angle accommodate motor, wherein: the second hydraulic cylinder is fixedly arranged on the frame, and one end of a piston rod of the second hydraulic cylinder is fixedly connected with the top of the lifting rod; the bottom of the lifting rod is provided with a rotating groove along the rod body, a pin shaft is rotatably arranged in the rotating groove, an angle adjusting rod is fixedly arranged on the pin shaft, and the angle adjusting rod can circumferentially swing by taking the pin shaft as an axis under the limit of the rotating groove; the grinding wheel angle adjusting motor is fixedly arranged on the outer side of the lifting rod, and a motor shaft of the grinding wheel angle adjusting motor is fixedly connected with one end of the pin shaft and can drive the pin shaft to rotate; the grinding wheel rotating motor is fixedly connected with the bottom of the lower angle adjusting rod, and a motor shaft of the grinding wheel rotating motor is fixedly connected with a grinding wheel.
Furthermore, the grinding wheel polishing unit further comprises a second distance meter on the lifting rod and a second angle sensor arranged on the angle adjusting rod, and the second distance meter and the second angle sensor are respectively used for detecting the lifting height and the rotating angle of the grinding wheel and sending detection information to the control unit so as to generate current attitude information of the grinding wheel.
Furthermore, the atomization generating unit comprises an atomization nozzle, an atomization generator, a water flow pipeline and a water tank; the atomization generator and the water tank are fixedly arranged at the top of the frame and are connected through a water flow pipeline; the atomizing spray head is positioned right above the steel rail and is connected with the output end of the atomizing generator through a pipeline.
According to another aspect of the invention, the invention also provides a water jet and grinding wheel composite high-efficiency rail grinding method, which comprises the following steps:
s100: setting grinding proportioning parameters, and distributing the grinding amount proportioning of a water jet grinding unit and a grinding wheel grinding unit, wherein the grinding amount of the grinding wheel grinding unit is adjusted up to 5% of the total grinding amount on the basis of the residual grinding amount;
s200: the grinding wagon drives into a grinding area on the steel rail, and the image information and the vehicle speed of the rail surface of the steel rail collected by the detection unit are detected;
s300: the control unit carries out 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 reaches a diseased part, the control unit controls the corresponding nozzle to adjust the posture, polishes the diseased part, and stops polishing operation when reaching the specified grinding amount;
s500: the cleaning unit blows high-pressure air to blow off the abrasive particles on the rail surface of the steel rail;
s600: after the grinding wheel polishing unit reaches a disease position, the control unit controls the corresponding grinding wheel 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 sprays water mist to cool the ground rail surface of the steel rail, and extinguishes sparks generated by grinding a grinding wheel, so as to wet generated dust and prevent diffusion;
s800: and finishing the polishing operation of the polishing area and recovering the polishing vehicle.
In general, compared with the prior art, the above technical solution contemplated by the present invention can achieve the following beneficial effects:
1. according to the water jet and grinding wheel composite efficient steel rail grinding system, the position of a steel rail defect is subjected to primary grinding through the water jet grinding unit, the grinding amount is controlled within the range of 90% -95% of the total grinding amount, and excessive grinding caused by immature water jet grinding technology and low grinding precision can be effectively avoided; through being equipped with the emery wheel unit of polishing, its initial point of polishing establishes to increase 5% total grinding volume department on the basis of surplus grinding volume, can avoid because of the water jet precision of polishing not enough with the face of polishing bump, reduce the emery wheel propulsion distance of polishing simultaneously, single operation can accomplish the operation of polishing that can be to the surplus grinding volume of disease department, thereby improved the efficiency of polishing, need not like traditional emery wheel polishing repetition 5-6 times and just can accomplish the restoration to rail disease and pest department, avoid the emery wheel to polish the time overlength and cause thermal deformation to disease and pest department.
2. According to the water jet and grinding wheel combined efficient steel rail grinding system, the high-pressure air generated by the cleaning unit is exhausted to clean the top end of the steel rail, so that abrasive particles attached to the rail surface of the steel rail can be easily blown off, and the grinding precision of a subsequent grinding wheel grinding unit and the damage to the grinding surface of the grinding wheel are avoided.
3. According to the water jet and grinding wheel composite efficient steel rail grinding system, the atomized water generating unit is arranged to spray water mist to cool the ground steel rail end face to avoid thermal deformation, meanwhile, sparks generated by grinding of the grinding wheel are extinguished, generated dust is wetted, and the influence of grinding of the grinding wheel on the surrounding environment of the steel rail is avoided.
4. According to the water jet and grinding wheel combined efficient steel rail grinding system, the surface machining depth of a steel rail reaches 0.1-3mm, grinding and repairing of the steel rail can be completed through single operation, the operation efficiency is very high, the precision of the section profile of the steel rail can reach +/-0.2 mm, the longitudinal smoothing precision reaches 0.01mm, the roughness Ra is less than or equal to 6.3 microns, and the grinding precision is high.
Drawings
FIG. 1 is a schematic structural diagram of a connector of a water jet and grinding wheel composite high-efficiency steel rail grinding system in an embodiment of the invention;
fig. 2 is a schematic view of a part of the structure of the grinding wheel grinding unit in the embodiment of the invention.
Fig. 3 is a schematic flow step diagram of a water jet and grinding wheel combined efficient rail grinding method in the embodiment of the invention.
In all the figures, the same reference numerals denote the same features, in particular:
1, grinding a vehicle; the method comprises the following steps: 11-frame, 12-wheel assembly, 121-support frame, 122-wheel, 13-side wheel;
2-a water jet milling unit comprising: 21-nozzle, 22-nozzle fixing clamp, 23-lifting frame, 24-nozzle angle adjusting motor, 25-first hydraulic cylinder and 26-abrasive water jet supply assembly;
3-a sweeping unit comprising: 31-an air outlet bell mouth, 32-an air outlet pipe and 33-a high-pressure air generating assembly;
4-a grinding wheel grinding unit comprising: 41-grinding wheel, 42-second hydraulic cylinder, 43-protective cover, 44-lifting rod, 441-rotating groove, 45-grinding wheel rotating motor, 46-angle adjusting rod and 47-grinding wheel angle adjusting motor;
5-an atomization generating unit comprising: 51-an atomizing spray head, 52-an atomizing generator, 53-a water flow pipeline and 54-a water tank;
6-a control unit;
7-a detection unit comprising: 71-an industrial camera;
8-steel rail.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
As shown in fig. 1-2, an embodiment of the invention provides a water jet and grinding wheel composite high-efficiency rail grinding system, which comprises a grinding wagon 1, a water jet grinding unit 2, a cleaning unit 3, a grinding wheel grinding unit 4, an atomization generating unit 5, a control unit 6 and a detection unit 7, wherein the water jet grinding unit 2, the cleaning unit 3, the grinding wheel grinding unit 4, the atomization generating unit 5, the control unit 6 and the detection unit 7 are arranged on the grinding wagon 1, the control unit 6 receives rail surface image information of a rail collected by the detection unit 7, obtains total grinding quantity data and positioning data of rail defects through an image processing algorithm, generates a grinding control instruction, after the grinding wagon 1 runs to an area to be ground, the water jet grinding unit 2 adjusts a nozzle 21 to adjust a posture to perform primary grinding on the positions of the defects on the rail 8 according to the grinding control instruction, stops grinding when the grinding quantity is 5% -10%, and avoids excessive grinding caused by poor precision; the cleaning unit 3 is subsequently followed, and high-pressure air is blown out to blow off abrasive particles attached to the steel rail 8, so that the influence on subsequent polishing precision is avoided; grinding wheel polishing unit 4 includes the emery wheel 41 that the multiunit gesture is different, the polishing point fit of a plurality of emery wheels 41 forms the surface of polishing that covers whole rail 8, go on to disease department position after to carry out the operation of polishing once only to surplus grinding output accurately, when improving the precision of polishing, long when having reduced emery wheel and polished, 1 surperficial thermal deformation of rail has been avoided, the mars has been reduced simultaneously, the large amount of production of dust, 5 blowout water smoke of atomizing unit are cooled down to the rail terminal surface of polishing. According to the polishing system, the water jet polishing unit 2 is used for primarily polishing the damaged part, a certain residual grinding amount is reserved, excessive polishing is avoided, the residual grinding amount can be repaired through single-time accurate polishing of the subsequent grinding wheel polishing unit 4, the defects of two polishing technologies are eliminated while the advantages of the two polishing technologies are combined, and high-speed and high-precision polishing of the steel rail is realized.
As shown in fig. 1, the sander 1 includes a frame 11, a wheel assembly 12, and side wheels 13. Wherein the frame 1 can be used for carrying and fixing other functional units, and the bottom part can move on the steel rail 8 through being fixedly connected with the wheel assembly 12. The wheel assemblies 12 are provided with a plurality of groups, symmetrically and fixedly arranged on two sides of the bottom of the frame 11, and comprise supporting frames 121 and wheels 122, the wheels 122 can walk on the steel rails 8, two ends of the wheels rotate through rotating shafts and are arranged at the bottoms of the supporting frames 121, and the tops of the supporting frames 121 are fixedly connected with the bottom of the frame 11. The side wheels 13 are attached to the side faces of the railheads and can roll along the side faces of the railheads to limit the advancing direction of the wheels 122, so that the grinding wagon 1 is prevented from tipping over when the wheels 122 are separated from the railways, and the tops of the wheels are connected with the bottoms of the supporting frames 121 through connecting rods.
The water jet polishing unit 2 comprises a nozzle 21, a nozzle adjusting assembly and an abrasive water jet supply assembly 26. The nozzle adjusting assemblies are symmetrically arranged on two sides of the bottom of the frame 11 and positioned above the steel rail 8, and the postures of the nozzles 21 are adjusted through the nozzle adjusting assemblies, so that polishing points of the nozzles 21 are fitted to form a polishing surface capable of covering the rail surface of the steel rail 8, and the polishing efficiency can be improved; 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; the bottom of the first hydraulic cylinder 25 is fixed at the bottom of the frame 11 through a bolt, one end of a piston rod of the first hydraulic cylinder is fixedly connected with the top of the lifting frame 23, and the first hydraulic cylinder is driven by a plug rod to adjust the height of the lifting frame 23 in the vertical direction. The fixed crane 23 side of locating of nozzle angle accommodate motor 24, its motor shaft pass crane 23 and nozzle fixation clamp 22 fixed connection, and through the motor shaft rotation, the adjustable injection angle of locating nozzle 21 on the nozzle fixation clamp 22. The abrasive water jet supply assembly 26 is fixed to the top of the carriage 11 and provides a mixture of high pressure water and abrasive material and is piped to the nozzle 21 to form a high pressure abrasive water jet for grinding the rail 8. In the embodiment of the present invention, the water jet polishing unit 2 further includes a first distance meter disposed on the lifting frame 23 and a first angle sensor disposed on the nozzle fixing clip 22, and the first distance meter and the first angle sensor are respectively configured to detect a lifting height and a rotation angle of the nozzle 21 and send detection information to the control unit 6, so as to generate current posture information of the nozzle 21.
Further, the nozzle angle adjusting motor 24, the first hydraulic cylinder 25, the first distance meter and the first angle sensor are in communication connection with the control unit 7 respectively, the first distance meter and the first angle sensor send detected information to the control unit 7 respectively, the control unit 7 generates a nozzle posture adjusting control instruction according to information of a region to be polished and a current posture of the nozzle 21, the nozzle angle adjusting motor 24 is controlled to adjust a spraying angle of the nozzle 21, the first hydraulic cylinder 25 is controlled to adjust a lifting height of the nozzle, so that posture adjustment of the plurality of groups of nozzles 901 is completed, and the region to be polished is precisely polished.
The grinding wheel polishing unit 4 is located on the rear side of the cleaning unit 3, polishes the residual grinding quantity of the position where the defect is located on the steel rail 8, improves polishing efficiency and polishing precision, and comprises a grinding wheel 41, a grinding wheel adjusting assembly and a protective cover 43. The grinding wheel adjusting assemblies are provided with multiple groups, and the grinding wheels 41 are adjusted through the multiple groups of grinding wheel adjusting assemblies, so that grinding points of the grinding wheels 41 fit a grinding surface capable of covering the rail surface of the steel rail 8, and the grinding efficiency is improved. The grinding wheel adjusting component 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, the second hydraulic cylinder 42 is fixedly arranged on the frame 11, one end of a piston rod of the second hydraulic cylinder is fixedly connected with the top of the lifting rod 44, and the lifting rod 44 can be driven to carry out lifting operation in the vertical direction; the bottom of the lifting rod 44 is provided with a rotating groove 411 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 limit 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 the 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, so that the grinding wheel 41 can be driven to rotate at a high speed to polish the rail surface of the steel rail 8. In the embodiment of the present invention, the grinding wheel polishing unit 4 further includes a second distance meter on the lifting rod 44 and a second angle sensor on the angle adjusting rod 46, which are respectively used for detecting the lifting height and the rotating angle of the grinding wheel 41, so as to generate the current posture information of the grinding wheel 41. The protective cover 43 is arranged above the grinding wheel 41, and can prevent sparks and dust generated by grinding from splashing and diffusing upwards to influence the surrounding environment.
Further, the second hydraulic cylinder 42, the grinding wheel rotating motor 45, the grinding wheel angle adjusting motor 47, the second distance meter and the second angle sensor are respectively in communication connection with the control unit 7, the second distance meter and the second angle sensor respectively send detected information to the control unit 7, the control unit 7 generates a grinding wheel polishing control instruction according to information of a region to be polished and the current posture of the grinding wheel 41, the grinding wheel rotating motor 45 is controlled to adjust the injection angle of the grinding wheel 41, the second hydraulic cylinder 42 is controlled to adjust the lifting height of the grinding wheel 41, the rotating speed of the grinding wheel rotating motor 45 is controlled to adjust the polishing force of the grinding wheel 41, so that the posture adjustment of multiple groups of grinding wheels 41 is completed, and the region to be polished is precisely polished.
The atomization generating unit 5 is located at the rear side of the grinding wheel polishing unit 4 and comprises an atomization nozzle 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 located right above the track and is connected with the output end of the atomizing generator 52 through a pipeline. Atomizing generator 52 and the communication connection of control unit 7, when emery wheel unit 4 of polishing was polished the rail, open the atomizing function in step, its input is leading-in with the water that rivers pipeline 53 led out from water tank 54, carry to atomizer 51 from the output after atomizing, and by atomizer 51 blowout, cool down rail 8, avoid thermal deformation, the mars that produces of polishing 41 with emery wheel simultaneously is put out, the dust of production waters wet, avoid the emery wheel to polish and produce the influence to rail surrounding environment.
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 driving module, and a control panel module; through the communication module, the control unit 6 is in communication connection with all the functional units, so that detection information is received; the image processing module carries out disease feature identification on the received image information through an image processing algorithm to obtain 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 travel distance of the grinding wagon 1 and outputting steel rail defect position data; processing the total grinding quantity data of the steel rail disease positions and the steel rail disease position positioning data through a control module, and outputting a grinding control instruction; the driving module drives the corresponding functional units to work, so that 8 rail surfaces of the steel rail are polished; through the control panel module, can input relevant information such as the proportion parameter of polishing, realize polishing 8 rail surfaces of rail accurately.
The detection unit 7 comprises an industrial camera 71 and wheel speed sensors, two groups of industrial cameras 71 are arranged and are respectively and symmetrically fixedly arranged on two sides of the front end of the bottom of the frame 11 and located right above the steel rail, the industrial cameras can acquire rail surface images of the steel rail 8 and transmit acquired information to the control unit 6, disease characteristic identification is carried out on the received rail surface images of the steel rail through an image processing algorithm to obtain steel rail disease characteristic data, the total grinding amount of the steel rail disease is calculated, and therefore a grinding control instruction is generated. The wheel speed sensor is arranged on a wheel 122, the speed and the advancing 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, the control unit 6 is provided with a positioning module, the position of a disease position on a steel rail 1 can be positioned according to the fixed distance between an industrial camera 71, a water jet grinding unit 2 and a grinding wheel grinding unit 4 which are arranged on the grinding wagon 1, and the grinding operation is carried out when the water jet grinding unit 2 and the grinding wheel grinding unit 4 are sequentially controlled to reach the disease position.
When the water jet and grinding wheel composite efficient steel rail grinding system works, grinding proportioning parameters are input through a control panel, wherein the grinding amount of a water jet grinding unit 2 can be set to be 90% -95% of the total grinding amount (namely the grinding depth reaches 90% -95% of the total depth to be ground at a disease place), the actual grinding amount of a grinding wheel grinding unit 4 is the total grinding amount increased by 5% on the residual grinding amount, and if the grinding amount of the water jet grinding unit 2 is set to be 90%, the grinding wheel grinding unit 4 starts grinding at the position where the total grinding amount is 85%, namely the residual grinding amount is ground at the position 85% of the total grinding depth as a starting point; after the grinding parameter ratio is set, traction force can be provided by a tractor to walk on the steel rail 8, after the steel rail enters a grinding area, an industrial camera 71 collects rail surface images of the steel rail, a wheel speed sensor measures the speed of the grinding vehicle 1, a control unit 6 generates a grinding control instruction according to detection information, and when the water jet grinding unit 2 reaches the position where a defect is located, a nozzle 21 is controlled to adjust the posture to carry out primary grinding; after the water jet polishing unit 2 finishes polishing work with a set grinding amount, the cleaning unit 3 blows high-pressure air through the air outlet bell mouth 31 to blow off abrasive particles on the rail surface of the steel rail 8; when the grinding wheel polishing unit 4 moves to a disease position, the control unit 6 adjusts the postures of the corresponding grinding wheels, and pushes the corresponding grinding wheels 41 to the position where 5% of the total grinding amount is added on the basis of the residual grinding amount for polishing, so that the polishing work of the residual grinding amount of the disease position is completed; meanwhile, the atomization generating unit 6 sprays water mist to cool the ground end face of the steel rail, so that thermal deformation of the ground end face of the steel rail is prevented, sparks generated by grinding the grinding wheel 41 are extinguished, generated dust is wetted to prevent diffusion, and influence on the surrounding environment is reduced.
According to the water jet and grinding wheel combined efficient steel rail grinding system, the position of the steel rail 8 defect is subjected to primary grinding through the water jet grinding unit 2, the grinding amount is controlled within the range of 90% -95% of the total grinding amount, and excessive grinding caused by immature water jet grinding technology and low grinding accuracy can be effectively avoided; through being equipped with emery wheel unit 4 of polishing, its initial point of polishing is established to increase 5% total grinding volume department on the basis of surplus grinding volume, can avoid because of the water jet precision of polishing is not enough with the face of polishing bump, reduce 41 advancing distance that polish of emery wheel simultaneously, single operation can accomplish the operation of polishing that can remain the grinding volume to disease department, thereby improved the efficiency of polishing, need not like traditional emery wheel polishing repetition 5-6 times can accomplish the restoration to rail disease department, avoid the emery wheel to cause thermal deformation to disease department polishing time overlength.
According to the polishing system, the surface processing depth of the steel rail 8 reaches 0.1-3mm, polishing repair of the steel rail can be completed through single operation, the operation efficiency is very high, the precision of the section profile of the steel rail can reach +/-0.2 mm, the longitudinal smooth precision reaches 0.01mm, the roughness Ra is less than or equal to 6.3 microns, and the polishing precision is high.
As shown in fig. 3, the invention also provides a water jet and grinding wheel composite high-efficiency rail grinding method, which comprises 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 grinding wagon 1 drives into a grinding area on the steel rail 8, and the detection unit 7 acquires the image information of the rail surface of the steel rail and the vehicle speed;
s300: the control unit 6 performs defect feature identification on the received steel rail surface image through an image processing algorithm to obtain steel rail defect feature data, calculates the total grinding quantity of a defect part, positions the defect 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, polishes the diseased part, and stops polishing operation when reaching a specified grinding amount;
s500: the cleaning unit 3 blows high-pressure air to blow off the abrasive particles on the rail surface 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, pushes the posture to a designated polishing point and performs polishing operation on the residual grinding quantity;
s700: the atomization generating unit 6 sprays water mist to cool the polished end face of the steel rail, and extinguishes sparks generated by polishing the grinding wheel 41, so as to wet generated dust and prevent diffusion;
s800: and finishing the polishing operation of the polishing area and recovering the polishing vehicle 1.
It will be understood by those skilled in the art that the foregoing is only an exemplary embodiment of the present invention, and is not intended to limit the invention to the particular forms disclosed, since various modifications, substitutions and improvements within the spirit and scope of the invention are possible and within the scope of the appended claims.
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).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211394253.2A CN115679758A (en) | 2022-11-08 | 2022-11-08 | Water jet and grinding wheel composite efficient steel rail grinding system and method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211394253.2A CN115679758A (en) | 2022-11-08 | 2022-11-08 | Water jet and grinding wheel composite efficient steel rail grinding system and method |
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| CN115679758A true CN115679758A (en) | 2023-02-03 |
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| CN202211394253.2A Pending CN115679758A (en) | 2022-11-08 | 2022-11-08 | Water jet and grinding wheel composite efficient steel rail grinding system and method |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117536035A (en) * | 2023-11-10 | 2024-02-09 | 中铁物总运维科技有限公司 | Fixed five-axis linkage rail profile intelligent polishing equipment |
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2022
- 2022-11-08 CN CN202211394253.2A patent/CN115679758A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117536035A (en) * | 2023-11-10 | 2024-02-09 | 中铁物总运维科技有限公司 | Fixed five-axis linkage rail profile intelligent polishing equipment |
| CN117536035B (en) * | 2023-11-10 | 2024-06-11 | 中铁物总运维科技有限公司 | Fixed five-axis linkage rail profile intelligent polishing equipment |
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