JPH053485B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention provides a method and apparatus for repairing and correcting the rail shape according to the wear condition when wave-like wear etc. occur on the rail head of a railway road. It is related to.

[Prior Art] The surface of the rail head (upper surface and side surface) of a railway track has so-called wavy wear and deformation, which is a wave-like unevenness in the longitudinal direction of the rail, due to friction with the wheels of vehicles running on the rail. etc. occur. For example, wavy wear is wear on the rail top surface that has a nearly constant wavelength (30 to 2000 mm) in the longitudinal direction and a wave height of approximately 0.1 to 2 mm, and is most common on the inner track side of curves, acceleration and deceleration sections, etc. Occur. It is also said that the higher the speed of the vehicle, the more this occurs.

As such wave-like wear of the rail progresses,
Vibrations and shocks generated when vehicles pass are intense, leading to destruction of tracks and roadbeds and noise pollution. Therefore, when wave-like wear or the like occurs on the surface of the rail head, the shape of the rail head is corrected depending on the state of the wear.

Conventionally, the method of correcting the rail shape is to use a grindstone driven by a motor to remove the unevenness, especially the convex parts, caused by wave-like wear on the surface of the rail head, in other words, grinding. (correction by grinding) is common (for example, JP-A-60-95003; JP-A-60-95003;
No. 119801).

[Problems to be solved by the invention] However, in the case of wavy wear, etc., where the rail head is uneven, the height difference (wave height) of the unevenness is 0.1 to 2 mm.
In this case, it is difficult to completely remove the unevenness due to wear using the above-mentioned conventional correction method using only correction means, and moreover, the amount of one-time removal by the grindstone is usually only about 0.05 mm. For this reason, the larger the difference in height of the unevenness due to wear, the more the number of times of cutting increases, and the time required for correction work. There is also the problem that if corrections using only the cutting means are repeated, the outline of the rail head shape gradually becomes smaller.

In view of the above, the present invention is designed to easily form a rail into a predetermined shape without reducing the number of times of grinding and reducing the profile of the rail head in accordance with wear conditions such as severe wear and wavy wear. Can be corrected accurately. The present invention aims to provide an efficient rail shape correction method and device.

[Means for Solving the Problems] In the present invention, a thermal spray coating layer is formed on the surface of the rail head according to the wear condition using a metal thermal spraying method that allows extremely thin build-up, and then the grinding is carried out. By doing so, the above problem is solved.

That is, the rail shape correction method of the present invention is as follows:
An inspection device that measures wear conditions such as wave-like wear on the rail head, a repair device that sprays metal onto the rail head, a cooling device that cools the rail head, a grinding device that grinds the surface of the rail head, and Equipped with a measuring device to measure the shape of the rail head that has been ground down, a working vehicle that runs on the rail first measures the wear conditions such as wavy wear on the rail head that needs to be corrected. Metal is thermally sprayed on the top surface, shoulders, and sides of the rail head depending on the wear conditions, and the surface of the rail head is repaired with a thermal spray coating layer. At this time, the amount of thermal spraying is increased at deeper recesses on the surface of the rail head to make the thermal spray coating layer in the recesses thicker than at the convex portions, or by performing metal spraying only on the recessed portions. Repair the rail head surface so that it is almost flat. After cooling the top surface, shoulders, and side surfaces of the rail head repaired by this metal spraying, the top surface, shoulders, and measurement surface of the rail head are ground into a predetermined shape using a grinding device. Measure the shape of the rail head.

Furthermore, the device of the present invention used to carry out the above method is equipped with a work vehicle that can run on rails, and is movable up and down at the front of the work vehicle, and detects wear conditions such as wave-like wear on the rail head. a cooling device installed approximately in the center of the working vehicle to cool the top surface, shoulders and sides of the rail head; and a cooling device disposed between the measuring device and the cooling device, It is equipped to be movable up and down by the work vehicle, and according to the wear condition detected by the inspection device, metal is sprayed on the top surface, shoulders, and sides of the rail head to form a metal spray coating layer. A repair device to be repaired, and a top surface or shoulder portion of the rail head on which a metal spray coating layer is formed by the repair device, which is equipped on the work vehicle behind the cooling device so as to be able to adjust the inclination angle and the pressing force. A grinding device that grinds the side surface into a predetermined shape,
The present invention is characterized in that it comprises a measuring device that is vertically movably mounted on the working vehicle at a position rearward of the grinding device and measures the shape of the ground rail head.

[Effect]

According to the above-described method of the present invention, the wear condition such as wave-like wear on the rail head is measured, and at the same time, metal is continuously sprayed in an amount corresponding to the measured wear condition, and the rail head is After the surface is repaired with a thermal spray coating layer and the rail head repaired by metal spraying is cooled, the rail head surface is ground with a grinding device and the shape of the ground rail head is measured. do. By doing this, it is possible to make the rail shape approximately uniform over the entire length of the rail correction section, and with a very small amount of cutting, into a predetermined rail shape that corresponds to the standard contour. In order to correct the built-up part due to this, the outline of the head shape does not become smaller.

Moreover, the metal spraying allows for a very thin layer of build-up, without excessive build-up, and without creating any steps.The metal sprayed rail head is cooled before being ground. Therefore, the rail can be milled properly and efficiently without the risk of overheating, and the inspection of the wear condition, repair by metal spraying, cooling, milling, and measurement can be carried out continuously and efficiently. Furthermore, even if the thermal spray coating layer is extremely thin, it is reliably and firmly welded and integrated with the rail, and has sufficient strength.

Further, according to the above-described device of the present invention, since the inspection device, the repair device by metal spraying, the cooling device, the grinding device, and the measuring device are arranged in order from the front of the work vehicle, while the work vehicle is running, , We use an inspection device to measure the wear conditions such as wave-like wear on the rail head, and at the same time, continuously repair the rail head with metal spraying according to the wear condition, then cool the rail head, grind it, and make further corrections. Later shape measurements can be performed. Therefore, it is possible to carry out continuous and efficient operations from inspection of wear conditions such as wave-like wear, repair by metal spraying, cooling, machining, and measurement, and the amount of machining required is small. This means that the rail head can be corrected without having to repeatedly go back and forth across the work section.

[Example] Next, embodiments of the present invention will be described based on the drawings.

First, the apparatus shown in FIG. 1 used to carry out the method of the present invention will be explained. 1 indicates front and rear guide wheels 1.
The inspection device is equipped with a detector (not shown) between a and 1b for detecting wavy wear, etc. on the head surface of the rail 2, and 1c indicates an inspection unit incorporating the detector. This inspection device 1 is installed so that it can be raised and lowered by a hydraulic cylinder or the like on a working vehicle 3 that runs on rails 2 of a track, and is stored within the vehicle limits in the raised position during forwarding, and is only used during work. rail 2
It is provided so as to descend upward and travel together with the work vehicle 3 using front and rear guide wheels 1a, 1b.
The detector used in this measuring device 1 is as follows:
For example, non-contact sensors such as magnetic, capacitive, or optical sensors, or contact-type sensors such as potentiometers and differential transformers that convert the vertical displacement of the slide shaft that slides against the top surface of the rail into voltage or current. A sensor is used. By moving the inspection unit 1c equipped with this detector along the longitudinal direction of the rail, the state of wear such as wavy wear on the surface of the rail head is detected.

Reference numeral 4 denotes a repair device disposed behind the inspection device 1 and equipped on the working vehicle 3, and is equipped with a metal spraying means 5 for spraying metal onto the rail head. Based on the measured value, metal spraying is carried out in accordance with the wear condition via the control section, and the rail head is repaired with this sprayed metal layer. 5a shows the thermal spray nozzle part. This repair device 4 is installed so that it can be raised and lowered via a hydraulic cylinder or the like, and is lowered only during work to a position where the thermal spray nozzle portion 5a maintains a predetermined distance from the rail 2.
Let it run on top. In addition, spraying can be applied not only to the top surface of the two rail heads but also to the shoulders and sides.
moving the metal spraying means 5 left and right with the spray nozzle part 5a facing in a direction perpendicular to the rail head surface;
The structure is designed to be tiltable (dashed line in Figure 4). Further, this repair device 4 is connected to the inspection device 1 via a control unit 20 so that the amount of metal spraying increases as the depth of the recess increases, depending on the measured wear condition of the rail 2. controlled. FIG. 4 schematically shows the configuration for this control.

Note that, as the metal spraying means 5, well-known thermal spraying methods such as plasma spraying and flame spraying can be used, but plasma spraying is particularly preferable because it allows high melting point materials to be sprayed and the sprayed coating layer has a high degree of adhesion. . Further, the metal spraying material used by this repair device 4 is a metal of the same quality as the rail 2 or a metal material (including an alloy) having the same hardness and strength as the rail 2.

Reference numeral 7 denotes an air-cooled or water-cooled cooling device installed approximately at the center of the work vehicle 3 behind the repair device 4, and is provided to cool down the heat generated by the metal spraying, which reaches a considerably high temperature. .

Reference numeral 8 denotes a grinding device installed on the work vehicle 3 behind the cooling device 7, and includes a metal-sprayed rail 2.
This involves cutting the top surface, shoulders, and side surfaces of the head into a predetermined shape that corresponds to the reference contour of the rail. This grinding device 8 has a frame 11 having guide wheels 9 and 10 at the front and rear, and a plurality of grinding units 14 each having a grinding wheel 13 rotated by a motor 12 per rail 2 on one side, for example, three grinding units as shown in the figure. Each underframe 11 is arranged and mounted one by one, and is movable up and down by a hydraulic cylinder 15 for each underframe 11, so that when not working, it is in the raised position, and only when working, it is lowered onto the rail and travels with the working vehicle 3. It's summery.

Further, the grinding unit 14 is capable of adjusting the inclination angle and pressing force according to the contour of the rail head. For example, as shown in Japanese Patent Application Laid-Open No. 60-95003, which is cited as a conventional example,
By using a support means having a link structure and a hydraulic cylinder, the tilt angle and the pressing force can be adjusted according to signals from the control section 20, as shown in FIG. 4.

Reference numeral 16 denotes a measuring device for measuring the shape of the head of the rail 2 after it has been ground, and is used to check whether the correction has been carried out correctly with reference to the reference contour shape. It is installed at the rear of car 3.

A case will be described in which the method of the present invention is implemented using a correction device having the above configuration. First, while the work vehicle 3 is running, the wear condition such as wavy wear on the rail head that should be corrected is measured by the inspection device 1, and based on this measurement data, an appropriate metal spraying is calculated, and subsequent repairs are carried out. In the device 4, metal is thermally sprayed depending on the wear condition of the head of the rail 2. That is, the second
As shown in the enlarged view, the deeper the recess 17 caused by wear, the greater the amount of metal sprayed, and the sprayed coating layer 18 makes the entire head surface of the rail 2 somewhat flat. do. At this time, the thickness of the sprayed coating layer 18 is preferably set to a thickness that is approximately 0.05 to 0.1 mm thicker than the standard contour shape (X-X line) of the rail, for example, in relation to the amount of scraping due to later grinding. However, of course, the value may be outside the above range as long as the thermal spraying is enough to eliminate the difference in height of unevenness due to wear, and the concave portion 1 excluding the convex portion 19 may be
It is also possible to perform metal spraying only on the 7 locations.

Then, the rail head repaired by metal spraying as described above is successively installed in the subsequent cooling device 7.
After cooling, the rail head is further ground into a predetermined shape corresponding to the rail reference contour shape by a subsequent grinding device 8 as shown in Fig. 3, and the rail 2 head is coated with the above metal sprayed Since the coating layer 18 provides a flat state to some extent, the rail shape can be corrected to a predetermined shape without increasing the amount of grinding or the number of times of grinding.

[Effects of the Invention] As described above, according to the present invention, the surface of the rail head is coated by thermal spraying with a spray amount corresponding to the wear condition based on the measurement data of the wear condition such as wave-like wear on the rail head. The surface of the rail is repaired to a certain degree of flatness with a thermal spray coating layer, and then cooled down before the rail head surface is ground with a grinding device, which reduces the amount of grinding and the number of times the rail is overheated. The correction can be made very efficiently and accurately without any risk of damage, and the outline of the head shape will not become thinner even after repeated corrections. It is possible to automatically and continuously perform everything from wear inspection to repair using metal spraying, cooling, grinding, and measurement work. In addition, since the very thin metal spray coating layer is firmly welded and integrated with the rail and has sufficient strength, no problems will occur even when used after modification.

In particular, if the repairing device of the present invention is used, it is possible to efficiently carry out the entire process from inspection of wear conditions such as wave-like wear to repair by metal spraying, cooling, milling, and measurement in a continuous and integrated manner. Coupled with the fact that only a small amount is required, there is no need for the work vehicle to travel back and forth many times for scraping as in the past, making the implementation of the present invention more efficient.

[Brief explanation of drawings]

Fig. 1 is a side view showing an example of the correction device used in the present invention, Figs. 2 and 3 are enlarged sectional views showing the correction state, and Fig. 4 is the related configuration of the inspection device, repair device, grinding device, etc. FIG. 1...Inspection device, 2...Rail, 3...Work vehicle, 4...Repair device, 5...Metal spraying means, 7...
...Cooling device, 8...Grinding device, 14...Grinding unit, 16...Measuring device, 17...Recess, 18...
...sprayed metal layer, 19...convex portion.

Claims (1)

[Scope of Claims] 1. An inspection device that measures wear conditions such as wave-like wear on the rail head, a repair device that thermally sprays metal on the rail head, a cooling device that cools the rail head, and a rail head surface. Equipped with a grinding device to correct the shape of the head and a measuring device to measure the shape of the corrected head, a work vehicle running on the rail can inspect the wear condition such as wavy wear on the head of the rail to be corrected. , metal is thermally sprayed on the top surface, shoulders, and side surfaces of the rail head according to the measured wear condition, and the surface of the rail head is repaired with a thermally sprayed coating layer. After cooling the top surface, shoulders, and sides of the rail head, the top surface, shoulders, and sides of the rail head are ground into a predetermined shape using a grinding device, and the shape of the ground rail head is measured. Features a rail shape correction method. 2. A work vehicle capable of running on rails; an inspection device installed at the front of the work vehicle so as to be movable up and down to measure wear conditions such as wave-like wear on the rail head; and approximately at the center of the work vehicle. a cooling device that is installed in the section and cools the top surface, shoulders, and side surfaces of the rail head; and a cooling device that is installed between the inspection device and the cooling device and is installed in the work vehicle so as to be movable up and down, and that a repair device that repairs the top surface, shoulders, and side surfaces of the rail head by thermally spraying metal to form a metal thermal spray coating layer according to the wear condition detected by the device; a grinding device that is installed on a work vehicle so that the inclination angle and pressing force can be adjusted, and that grinds into a predetermined shape the top surface, shoulders, and side surfaces of the rail head on which a metal spray coating layer is formed by the repair device; . A rail shape correction device comprising: a measuring device that is vertically movably mounted on a working vehicle at a position rearward of the grinding device and measures the shape of a rail head that has been ground.