RU2792556C1 - Method for profile recovery on at least one rail - Google Patents

Abstract

FIELD: railways.

SUBSTANCE: invention relates to a method for restoring the profile of a rail (2) of a laid rail track during the movement of a processing vehicle along the rail track (1) in the section of its running surface (10) located on the rail head (5). At the same time, a processing node (14) is provided, having a first and a second processing unit. At the first stage of processing, the material is removed during the milling process. In this case, a waviness of the surface is formed, having crests (18) of waves and troughs (19) of waves. At the second stage of processing, the surface waviness is reduced by plastic deformation of the crests (18) of the waves by means of at least one deformation directed in the direction of the processed running surface (10) and force applied in a pulsating manner (21).

EFFECT: surface hardening is provided while smoothing its waviness, dustiness is eliminated and noise during processing is reduced.

20 cl, 5 dwg

Description

The invention relates to a method for restoring the profile of at least one rail in at least a section of its running surface located on the rail head.

When the profile of the track rails is reconstructed by means of a milling process with a multi-track milling cutter head, so-called milling waviness occurs in the individual cutter marks. In this case, we are talking about a periodic pattern of elevations and depressions alternating in the direction of movement, which, although almost invisible, must nevertheless be eliminated. This can be done, for example, by grinding or by sliding grinding stones. However, belt grinders or end mills can also be used for this. It has been found through measurements that these milling ripples, if not eliminated, have a significant effect on the noise level of railway vehicles running on rails. In particular, it has been found that the shape and arrangement and, under certain conditions, the period length of these undulations have a measurable effect on the noise properties of the track rails. According to EN 13231, waviness would be allowed within certain limits, but in practice, during technical operation, in particular at higher driving speeds, too high noise loads would occur.

The restoration of the profile of the rail head can be carried out either in such a way that the processing unit together with its processing units is stationary, and the rail being processed moves relative to it, or that the rails are already laid in the rail track formed from them on the ballast bed, and the processing vehicle having the processing node moves along the laid rail track, and processing is performed at the same time.

DE 29 20 889 A1 discloses a method for cold rolling structural elements with a rolling force not equal to zero, this rolling force pulsating with varying frequency and amplitude, with the deepest places of the rolling tool indentations obtained at the maximum value as if they had been produced by static load, follow each other at a distance that is not more than twice the width of the imprint.

EP 0 465 683 A1 discloses a method for machining the running surface of rails for rail vehicles against the formation of grooves, wherein the surface of the rails, at least in the region of the running surface, is subjected to hardening shot blasting at an Almen value that satisfies the formula A=BxZ ² +C, while hardening shot blasting is carried out at ambient temperature.

AT 391 285 B discloses a device for sealing and hardening parts of rails, with which repeated short-term impact forces are applied, while several hammer tools are supported in one common tool holder with the possibility of being driven by repeated short-term reciprocating impacts, and also provides support for fixing the processed part of the rail. This tool holder and/or this support is movably supported relative to each other in the longitudinal direction of the running surface of the rail part and can be reversibly driven, while the hammer tools are releasably connected into impact elements corresponding to the surface contour of the rail part in the surface areas to be machined.

AT 521 163 A4 of the present applicant describes a method and apparatus for processing the running surface of a rail using at least one moving along the rail and pressed at least against its running surface, a rotating, cutting shaping tool. In addition, at the same time, after processing with a cutting shaping tool, at least one rolling element adapted to the rail surface to be processed in order to even out the irregularities of the running surface of the rail, producing cold deformation of the running surface of the rail, rolls along the rail. This rolling element, which acts as a roll, rolls with its lateral surface along the running surface of the rail, constantly pressing, while the generatrix of the lateral surface rolling along the running surface around an axis corresponds to the cross section of the shaped, i.e., already restored, rail surface. This rolling element exerts a constantly high contact pressure on the rail during travel. As a result of this high contact pressure, with a correspondingly small area of contact with the rail, a compression occurs, causing the desired cold deformation. This method, in principle, has proven itself in practice, however, due to the applied high contact pressure, it could not be used with all types of processing machines. In this case, the possible contact pressure is essentially dependent on the dead weight of each processing machine.

In addition, also in EP 1 820 902 A1 of the present applicant, a method has been proposed for milling the heads of track rails laid on a bed by means of a mobile milling device. This milling device includes a rotary driven milling cutter head which is supported in a chassis including a milling cutter head drive. This milling cutter head is guided vertically and/or sideways by means of a guide means along the rail head to be machined, wherein the milling cutter head has several sets of cutter head blades arranged one behind the other in the direction of the perimeter of the milling cutter head. Each set of cutterhead blades reproduces the railhead profile to be machined from approximately circular individual arcs of varying radii. At the same time, it was necessary to avoid additional processing of the waviness formed during the milling process. However, in practical operation, this could be achieved very rarely and only under the most optimal conditions. However, very long processing times were most often required and thus also longer closures of the track to be worked or the track to be laid were associated with this. In order to shorten the processing times again, reworking of the running surface was once again necessary.

However, this most commonly used post-grinding step has some disadvantages. Sparks may occur during grinding, and this may cause a fire. It was also not easy to suck out the resulting grinding dust, which increased the environmental pollution to a certain extent. In addition, for the maintenance personnel of the processing vehicle, the dustiness was also an additional health risk. The grinding process leads to the formation of martensite in the technical material of the rail of the treated surface area, which increases the risk of destruction of the ground surface area.

The object of the present invention was to overcome the disadvantages of the prior art and to provide a method for re-profiling rails, with which reduced processing time can be achieved with little surface undulation.

This problem is solved using a method for restoring the profile according to the claims.

The method according to the invention serves to restore the profile of at least one rail of a track laid and formed by rails, wherein the processing is carried out at least in a section of its running surface located on the rail head. This includes the following steps:

- providing a processing vehicle, this processing vehicle being able to travel on a rail track;

- providing a processing unit, and this processing unit is located on the processing vehicle, and the processing of the processed walking surface is performed during the movement of the processing vehicle; this processing node includes

- at least one first processing unit, having at least one rotary-driven, cutting processing tool, while said at least one processing tool is made in the form of a milling wheel or a milling cutter head, having a plurality arranged one behind the other along the perimeter , as well as cutter head blades oriented along the profile of the rail head to be restored;

- at least one second processing unit;

- processing the rail head in the area of its running surface in the first stage of processing by means of said at least one cutting processing tool, while in the first stage of processing material is removed in the milling process, and during this removal of material in the direction of the longitudinal extent of the rail, surface waviness is formed, having crests of waves and troughs of waves, and in the subsequent second stage of processing by the second processing unit, this waviness of the surface is reduced and/or modified;

- at the same time, when the surface waviness decreases, at the second stage of processing, at least the crests of the waves are plastically deformed and aligned, and

- in this case, the plastic deformation of at least the crests of the waves is carried out by means of at least one deformation force directed in the direction of the machined running surface, and it is also provided,

- that said at least one deformation force is applied in a pulsating manner, while the rail material is slightly displaced, and that in the second processing step, the processing tool of the second processing unit is not constantly superimposed on the running surface to be processed.

In this technique, it is advantageous that in this way profile reconstruction is carried out with an economical and at the same time reduced processing time. Thus, after a short processing time, the rails are again available for installation and the associated technical operation. But, in addition, the dust content that usually occurs is also avoided in this way, and, despite this, the waviness of the running surface that occurs during the milling process is reduced. This, in turn, significantly reduces the noise that usually occurs during technical operation. As a result of plastic deformation of at least wave crests or elevations in the longitudinal profile of the running surface, the surface is hardened and consequently the subsequent service life is extended.

Since a processing vehicle is provided, and the processing unit is located on the processing vehicle, and the processing vehicle can travel on the laid and rail-shaped track, the processing of the running surface to be processed is performed while the processing vehicle is moving.

In this technique, it is advantageous that in this way profile reconstruction is carried out with an economical and at the same time reduced processing time, and the closure of the track to be processed is reduced. Thus, the track is again available for the intended technical operation after a short time. But in this way, in addition, it is also possible to avoid the usually occurring dustiness, and, despite this, the waviness of the running surface that is formed during the milling process is reduced. This, in turn, significantly reduces the noise that usually occurs during technical operation. As a result of the plastic deformation of at least wave crests or elevations in the longitudinal profile of the running surface, the surface is hardened and consequently the subsequent service life of the rail is extended.

In addition, said at least one deformation force is applied in a pulsating manner. The pulsating application of the deformation force has the advantage that the machining tool of the second machining unit does not constantly overlap the running surface to be machined. In this case, the machining tool continues to move at a lower feed force or, respectively, at a lower drive power.

A variant of the method is also preferred, in which at least one guiding means is provided for the relative direction of at least one of the processing units in height and/or sideways with respect to the rail head to be processed. Due to the presence of at least one guiding means, it is possible to adapt and guide at least one of the processing units to carry out the profile restoration process to the given geometric dimensions of the rail. Preferably, each of the processing units is assigned its own guiding means, whereby a higher guiding accuracy is possible, and therefore a more precise reconstruction of the profile of the rail head in the region of its running surface can be carried out.

Another technique is characterized in that said at least one deformation force is applied to the machined running surface in normal orientation. In this case, a uniform deformation of the at least deformable wave crests or, respectively, of the elevations can be carried out during the second processing step. In addition, evenness is possible, or, accordingly, deviation from a rectilinear nominal line or nominal plane can be minimized.

Also preferred is a method variant in which said at least one pulsatingly applied deformation force is selected from a range of force values, the lower limit of which is 20 N, in particular 150 N, and the upper limit of which is 80 kN, in particular 1.5 kN.

Depending on the chosen method and the chosen means of applying the pulsating strain force, for example, force ranges can be selected having a lower limit of 20 N and an upper limit of 50 N, or having a lower limit of 150 N and an upper limit of 1.5 N, or having lower limit 20 kN and upper limit 80 kN.

By setting a predetermined range of force values, the deformation measure of the rail surface can be adapted to the respective conditions after the milling process.

Another technique is characterized in that said at least one pulsating strain force is applied with increasing intensity. By increasing the intensity of the deformation force within certain predetermined limits during the alignment of the running surface of the rail, a variable adaptation to different conditions of use can be achieved.

In addition, a preferred technique is that said at least one pulsating deformation force is applied at a frequency selected from a frequency range whose lower limit is 100 Hertz (Hz), in particular 500 Hertz (Hz), and the upper limit the limit of which is 25 kilohertz (kHz), in particular 3 kilohertz (kHz).

Depending on the chosen method and the chosen means of applying the pulsating strain force, for example, frequency ranges can be selected having a lower limit of 100 Hertz (Hz) and an upper limit of 350 Hertz (Hz), or having a lower limit of 500 Hertz (Hz), and an upper limit of 3 kilohertz (kHz), or having a lower limit of 5 kilohertz (kHz) and an upper limit of 25 kilohertz (kHz).

In this way, within predetermined limits, the number of strokes can be better adapted to the undulation being processed.

Another preferred technique is characterized in that said at least one pulsating strain force is applied at a uniform frequency or at a variable frequency. In this case, it is always easier to prevent the superposition of oscillations.

Another preferred technique is characterized in that the second machining unit includes at least one deforming tool. Thus, by equipping the second machining unit with at least one deforming tool, the applied deformation force can be applied to the machined running surface of the rail head like a hammer movement.

One of the variants of the method is also preferable, in which at least one deforming tool has a working surface facing the running surface of the rail head being machined, and this working surface is made with a longitudinal extent that extends at least two, preferably at least three located in the direction of the longitudinal extent directly behind each other of the crest of the waves. Thus, due to the selected minimum length of the working surface during processing, an overlap of the working surface extending over several wave crests can be guaranteed. In this way, a better and more uniform alignment of the at least deformable wave crests can be achieved.

Another technique is characterized in that a plurality of deforming tools are provided, and these deforming tools are arranged in an offset distribution relative to each other over the profile cross section to be machined. This creates the possibility of processing in one working stroke of a larger section of the cross section of the profile at the second stage of processing.

Also preferred is a technique in which a plurality of deforming tools are provided, and each of these deforming tools is provided with a ball-segmented hammer head. Thus, by selecting a plurality of deforming tools, which are preferably in the form of pins or needles, a more individual alignment of at least the wave crests can be performed.

Another preferred technique is characterized in that the maximum deformation path of the plurality of deforming tools ends at least before the wave trough is reached. But this maximum deformation path of a plurality of deforming tools can also end at the wave trough. In addition, this maximum deformation path of the plurality of deforming tools can extend beyond the wave trough towards the rail foot into the rail head material. Thus, by setting and limiting the maximum deformation path of a plurality of deforming tools, the portion of the running surface to be machined in the second processing step can be accurately predetermined and set. In addition, the degree of deformation of the wave crests can also be better determined in advance.

Also preferable is one of the variants of the method, in which a pulsating deformation force is applied to the machined running surface by means of a shot blasting method and a plurality of shot blasting elements. In this case, the action of mechanical deformation can also be applied to at least the leveled wave crests or, respectively, elevations. During the movement of the shot blasting elements, which, for example, can be balls or the like, they have a certain measure of kinetic energy, which, when individual shot blasting elements hit the rail surface to be machined, is mostly converted into an applied deformation force.

Another technique is characterized in that the elements to be shot-blasted after the deformation process are collected by means of a collecting unit, in particular a suction device. This can ensure the reuse of already used elements for shot blasting for a new blasting process. But in addition to this, the formation of stratification and the possible environmental pollution associated with it in the region of the track is also largely minimized.

Another preferred technique is characterized in that the amplitude of the surface waviness is reduced in the normal direction to the longitudinal extent of the machined running surface to a certain amplitude value, which is selected from a range of amplitude values, the lower limit of which is 0.001 mm, in particular 0.004 mm, and the upper limit of which is 0 .01 mm, in particular 0.008 mm. In this case, in the second processing step, in spite of the previously carried out removal process by means of a wheel cutter, very low surface waviness can be achieved. This can greatly reduce the noise that occurs during the technical operation of railway vehicles. The amplitude values must be chosen and aligned within such limits that they lie below the periodic surface structure causing the acoustic emission.

Also preferred is one method in which the surface waviness is reduced and/or modified to an average roughness value Ra of less than 0.004 mm. A high degree of leveling and therefore very low surface undulations can also be achieved.

Another technique is characterized in that in the first processing step, the wave crests located in the direction of the longitudinal extent directly one after another are made from each other at a distance having a value selected from a range of distance values, the lower limit of which is 1.0 mm, in particular 1.8 mm, and the upper limit of which is 14 mm, in particular 10 mm. In this case, depending on the relevant machining parameters, such as, for example, the speed of the milling wheel, the number of milling blades distributed around the circumference of the milling wheel, as well as the relative speed between the milling wheel and the rail, can be set within predetermined limits and the surface waviness can be determined. .

Finally, a technique is preferred in which the processing vehicle's advancing speed during the re-profiling process has a speed value that is selected from a range of speed values whose lower limit is 3 m/min, in particular 5 m/min, and the upper limit which is 40 m/min., in particular 30 m/min. Thus, by selecting the relative speed between the rail and the machining unit, the evenness of the running surface achieved after the second machining step can be additionally influenced.

For a better understanding of the invention, it is explained in more detail in the following figures.

Shown, in each case in a highly simplified, schematic representation:

fig. 1: a rail track having some nominal rail profile, in cross section and an enlarged view;

fig. 2 is a plan view of a rail track with a processing vehicle on it, having a processing unit and its processing units;

fig. 3: the rail head after the first processing step and the deforming tool applying the plastic deformation force of the second processing unit, in side view;

fig. 4: another rail head after the first processing step and a plurality of plastic deformation force-applying deforming tools, in side view;

fig. 5: Another rail head after the first processing step and another possibility of applying the plastic deformation force by the ball shot blasting method, in side view.

First, it should be noted that in the differently described embodiments, the same parts are provided with the same reference symbols or, respectively, the same names of structural elements, while the explanations contained in the entire description can be transferred to the same parts having the same reference symbols or, respectively, the same names. structural elements. Also the position data selected in the description, such as, for example, top, bottom, side, etc., refer to the figure directly described as well as to the figure shown, and these position data can be transferred in meaning to a new position.

The term "in particular" is hereinafter understood to mean a possible more special implementation or a more detailed specification of any item or method step, but should not necessarily be its mandatory, preferred embodiment or mandatory methodology.

First, it should be mentioned that the profile recovery method described below can, on the one hand, be carried out with a permanently placed processing unit and, on the other hand, also with a mobile processing unit. The following describes the case in which a mobile processing unit is provided to move along the at least one processing rail.

In the fundamentally related FIGS. 1-5 show and describe the various possibilities and arrangements of the machining components that serve to reshape the rails.

In FIG. 1 shows a cross-section of a track 1 including at least one pair of rails 2, these rails being parallel to each other, spaced apart by a track gauge distance. The rails 2 are fastened at equal, preferably short distances, most often on sleepers 4 of concrete, steel, wood or plastic laid out transversely to the axis 3 of the track, the depiction of the fasteners being omitted here. The axis 3 of the path forms a center axis, in which case a center plane having a vertical orientation can also pass along it. The rails 2 of the track 1 form, as a track, together with the rail fastenings and the bed, the upper structure of the railway section. In principle, the rails 2 shown and described here form linear bearing and guiding elements in the railway industry and thus a predetermined path for rail vehicles located on them. It should be mentioned here that the cross section of the rails 2 can be made in a wide variety of ways, and this cross section has been chosen only as an example.

Each of the rails 2 includes, when viewed in its cross section, a rail neck 6 and a rail sole 7. In this case, the head 5 of the rail rests on the neck 6 of the rail, and the sole 7 of the rail, in turn, is fixed on the sleeper 4 or another support or, respectively, the base.

The part of the rail head 5 which can touch the wheels of the rail vehicle is in this connection referred to as the running surface 10. The ridges of the rail vehicle tread, which are not shown, are located respectively on the sides of the rails 2 facing each other, and these are also those sides facing the axle 3 path or, respectively, the middle of the path. The rail head 5 is laterally delimited by an inner side surface 8 and an opposite outer side surface 9. The section of the profile that extends, when viewed in cross section, between the side surfaces 8 and 9, can in the broadest sense be called the running surface 10 of the rail 2. Running surface 10 each rail 2 may consist of a tread surface 11 and a tread face 12. In this case, the tread surface 11 is located, passing on the upper side of the rail head 5, while the tread edge 12 forms a transition to the inner side surface 8, which faces the middle of the track or, respectively, the axis 3 of the track.

On the running surface 10 of the laid rails 2, damage occurs over time, such as, for example, corrosion, wear, cracks, defects in the tread surface, such as corrugations, waves, corrugations, chipping, changes in the transverse profile, such as flattening of the barrel-shaped tread surface, burrs, thickening or the like. These wear and/or damage phenomena, which are essentially limited to the outermost region of the running surface 10, can mostly be eliminated by re-profileing the rail 2. Most often, the worn or damaged material of the rail head 5 on the surface of the rail 2 is removed by cutting, and the machined head 5 of the rail, as far as possible, again approaches the nominal profile of the rail 2.

The method according to the invention concerns the profiling or re-profiling of the running surface 10, in particular its tread 11 and/or the tread 12, wherein the machining can also extend beyond the tread 12 along the inner side surface 8. It would also be possible to carry out machining, probably , also outside the rolling surface 11 on the outer side surface 9.

In FIG. 2 shows in a highly stylized and simplified way a track 1 formed from rails 2 in a plan view and supported on the rails 2 and the processing vehicle 13 guided along them together with its processing unit 14. The possible direction of processing and therefore the direction of advance of the processing vehicle 13 is indicated arrow, and here it is carried out from left to right. Only wheelsets 15 spaced apart in the direction of the longitudinal axis of the track have been designated, of which at least one of the wheelsets 15 can be in a drive connection with the drive means. The image of the support frame of the processing vehicle 13 has been omitted for better visibility, and only the outline of the processing vehicle 13 has been shown.

The processing unit 14 includes at least a first processing unit 16 having at least one rotary cutting processing tool 17. The first processing unit 16 can be supported, for example, by means of sliders, while for direction and relative rail 2 can be provided with their own guide means. Preferably, it is provided that for each of the two rails 2, their own first processing unit 16 can be assigned for processing. Said at least one first processing tool 17 in the present embodiment is made in the form of a milling wheel, as well as cutter head blades oriented along the restored profile of the rail head. These cutter head blades are not marked in detail and are only labeled in a simplified manner. The cutterhead blades are each composed of a set of cutterhead distributed around the perimeter, each set of cutterhead consisting of a plurality of cutterhead blades adapted to the profile of the rail head 5 in their orientation and direction. Due to the rotational movement of the milling wheel, each cutter head blade arranged one after the other in the perimeter direction of each set of cutter head produces its own machining mark. The illustration or more detailed designation of the different drive means for the first processing unit 16 and its processing tool 17 has been omitted for better visibility.

In FIG. 3 shows a side view of the rail 2, showing in a highly exaggerated way and not to scale the waviness of the surface of the track made by only one of the previously described blades of the cutterhead, which occurs during the removal process during the restoration of the profile. This surface waviness appears due to the relative movement between said at least one rail 2 and the processing unit 14. Thus, for example, the advance speed of the processing vehicle 13 or the advance speed of the rail 2 during the reprofiling process may have a speed value that is selected from the range speed values, the lower limit of which is 3 m/min., in particular 5 m/min., and the upper limit of which is 40 m/min., in particular 30 m/min.

The processing of the head 5 of the rail on the area of its running surface 10 in the first stage of processing is carried out by means of the specified at least one cutting processing tool 17, while in the first stage of processing, the removal of material is performed in the milling process. With this removal of material, which is carried out in the direction of the longitudinal extension of the rail 2, the previously described surface waviness is formed, having crests 18 of waves and troughs 19 of waves. These wave crests 18 may also be referred to as elevations, and these wave troughs 19 may also be referred to as depressions.

The waviness of the surface, which occurs as a result of the milling process during the first stage of processing, can be formed, for example, by crests 18 of waves located in the trace or, respectively, the milling trace, as well as one after the other in the direction of the longitudinal extension at a distance from each other having a value selected from a range of distance values, the lower limit of which is 1.0 mm, in particular 1.8 mm, and the upper limit of which is 14 mm, in particular 10 mm. Moreover, this distance value is dependent on the rotational speed of the milling wheel, the number of cutter head sets and the relative speed between the rail 2 and the cutting tool 17. The higher the speed difference and/or the lower the rotational speed of the milling wheel, the greater this distance value.

As is clear from the joint examination of FIG. 2 and FIG. 3, the processing unit 14 also includes at least one second processing unit 20 which is provided to reduce the previously described surface undulations. However, this would have to be carried out or, accordingly, carried out without additional removal of material in the area of the head 5 of the rail.

The reduction and associated alignment of at least the crests 18 of the waves must be carried out by means of plastic deformation. Due to plastic deformation, the material or, respectively, the technical material of the rail 2 is somewhat displaced, as a result of which the straightness of the running surface 10 improves. predominantly carried out in the direction of the longitudinal extent of the rail 2. Thus, the corresponding crests 18 of the waves are deformed, preferably by the applied force 21 of the deformation, respectively directly adjacent or, respectively, directly adjacent to them, the depressions 19 of the waves. This achieves an adaptation to the predominantly straight longitudinal course of the finished restored running surface 10 of the rail 2.

To perform plastic deformation requires the application of at least one directed in the direction of the processed running surface 10 force 21 deformation. This deformation force 21 can be applied by various means, such as, for example, a second or other machining tool. In this case, said at least one deformation force 21 must be applied in normal orientation to the machined running surface 10. In addition, it may be preferable if the force 21 deformation is applied in a pulsating manner. This can be done by means of electrical and/or pneumatic and/or hydraulic drive means which are well known in the art.

Pulsating application here means that the energy (impact energy) is not continuously transferred through the surface of the workpiece into the material. The deformation or cold deformation of the technical material of the rail is carried out due to the dissipation of energy when the impact energy hits the surface of the workpiece, which can be called the plastic scattering energy.

The at least one strain force 21 applied in a pulsating manner can also be applied with increasing intensity. In addition, also the application frequency of said at least one pulsatingly applied deformation force 21 can be uniform or variable frequency. In this case, the number of oscillations per second can be adapted to each application.

As already mentioned, the processing unit 14 together with the processing units 16, 20 can be positioned, being placed stationary, and the processed rail 2 during the processing steps makes a relative advance through the processing unit 14 with respect to the processing unit 14 in the direction of its longitudinal extent.

Preferably, however, the post-treatment and restoration of the profile is carried out on the track 1 laid in the ballast bed. In this case, the processing unit 14 is located on or supported by the processing vehicle 13. The processing vehicle 13 moves along the track 1 laid out and formed by the rails 2, while the processing of the running surface 10 being processed is carried out during the movement of the processing vehicle 13.

In order to achieve alignment between the rail 2 to be machined and at least one of the processing units 16, 20, as is well known, at least one guide means 22 can be provided for the relative direction of at least one of the processing units 16, 20 in height and/or to the side with respect to the processed head 5 of the rail. Preferably, each of the processing units 16, 20 can be assigned and connected to its own guide means 22.

So, as can also be seen from FIG. 3, the second machining unit 20 may include at least one deforming tool 23. Said at least one deforming tool 23 is shown in a position detached from the rail surface to be machined (running surface 10). Said at least one deforming tool 23 includes a working surface 24 facing the running surface 10 of the rail head 5 to be machined. at least three wave crests 18 located in the direction of the longitudinal extent directly one after the other. This is indicated respectively in FIG. 3 and the following FIG. 4. The longitudinal extent of the working surface 24 can also extend to a greater number of wave crests 18 located directly one behind the other.

In this case, the working surface 24 covers at least one wave cavity 19, and preferably at least two wave cavity 19, in the direction of the longitudinal extension of the rail 2. Thus, it is achieved that the working surface 24 also during the second processing step always comes into deforming contact along with at least two of the 18 wave crests. It should be mentioned that, for example, for each of the previously described marks from the individual blades of the cutter head, its own deforming tool 23 can be assigned. Several deforming tools 23 are then provided, and these deforming tools 23 are located, distributed with a shift relative to each other over the cross section to be machined profile.

With this somewhat larger and more voluminous at least one deforming tool 23, said at least one deformation force 21 applied in a pulsating manner can be selected from a range of force values, the lower limit of which is 20 kN, in particular 40 kN, and the upper limit which is 80 kN, in particular 60 kN.

Also, said at least one oscillatingly applied deformation force 21 can be applied at a frequency that is selected from a frequency range whose lower limit is 100 Hertz (Hz), in particular 150 Hertz (Hz), and whose upper limit is 350 Hertz ( Hz), in particular 300 Hertz (Hz).

In FIG. 4 shows another possibility of arranging and executing the second machining unit 20 on the rail 2 to be machined in a side view of the rail 2. Here again, the waviness of the surface of the track, which occurs during the removal process during the restoration of the profile, is made only by one of the previously described cutter head blades.

The second processing unit 20 includes, in this embodiment, a plurality of deforming tools 25. Each of the deforming tools 25 is in the form of a pin or in the form of a needle and can be respectively provided with a ball-shaped hammer head. The maximum deformation path of the plurality of deforming tools 25 must be chosen such that it ends at least before the wave trough 19 is reached. But this maximum deformation path can also be chosen so that it ends at the trough 19 of the wave. But regardless of this, it would also be possible for this deformation path to propagate beyond the wave cavity in the direction of the rail sole 7 into the material of the rail head 5 . It is also shown that the individual deforming tools 25 are not all simultaneously moved in the direction of the deformable running surface 10, but the deforming movement can be carried out in a pulsating manner and alternately by means of a plurality of deforming tools 25 made in the form of pins or needles. Therefore, the processing ends of the deforming tools 25 are shown in different from each other distance from the running surface 10.

In this example of application of the pulsating deformation force 21, it can be selected from a range of force values whose lower limit is 150 N, in particular 650 N, and whose upper limit is 1.5 kN, in particular 1.0 kN.

At the same time, said at least one oscillatingly applied deformation force 21 can be applied at a frequency that is selected from a frequency range whose lower limit is 500 Hertz (Hz), in particular 1 kilohertz (kHz), and whose upper limit is 3 kilohertz. (kHz), in particular 2 kilohertz (kHz).

In FIG. 5 also indicates that the deformation force 21 applied by the second machining unit 20 can be applied by the ball shot blasting method. In the ball shot blasting method, a plurality of individual balls 26 are ejected or moved at a predetermined speed against the running surface 10 to be machined, and a deformation force 21 is generated. In this processing step, the balls 26, after the deformation process, must again be collected by means of a collecting unit 27, in particular a suction device. In this case, the collected balls 26 can be reused. The supply of individual balls 26 is indicated schematically, while they move at a predetermined speed in the central supply channel 28, which is directed in the direction of the running surface 10 being processed. here outside around the supply channel 28, by means of a suction process. This image is selected schematically in a simplified way, while here it is also possible to have an oblique or angular orientation of the jet of balls on the running surface 10.

The previously described ball shot blasting method refers to specially designed shot blasting elements which are in the form of balls. It should also be pointed out at this point that the deformation force 21 applied by the second machining unit 20 can be applied not only by means of balls 26 but also by means of so-called shot blasting elements 29 made in any other way, also with pulsating power transmission. The spatial shape of the individual elements 29 for shot blasting may differ from the shape of the ball and any one can be chosen. For tapping and the associated plastic deformation, for example, a sandblasting process could also be used. As technical materials of the elements 29 for shot blasting, for example, metal, mineral or ceramic materials can be selected.

In this described application example of the pulsating deformation force 21, it can be selected from a range of force values, the lower limit of which is 20 N, in particular 30 N, and the upper limit of which is 50 N, in particular 40 N.

At the same time, said at least one oscillatingly applied deformation force 21 can be applied at a frequency that is selected from a frequency range whose lower limit is 5 kilohertz (kHz), in particular 10 kilohertz (kHz), and the upper limit of which is 25 kilohertz. (kHz), in particular 20 kilohertz (kHz).

With all the second stages of processing described earlier and performed by various means, the amplitude of the surface waviness should decrease in the normal direction to the longitudinal extent of the processed running surface 10 to a certain amplitude value, which is selected from the range of amplitude values, the lower limit of which is 0.001 mm, in particular 0.004 mm, and the upper limit of which is 0.01 mm, in particular 0.008 mm.

Due to plastic deformation, the waviness of the surface can also be reduced and/or modified to an average roughness value Ra of less than 0.004 mm. However, in this case, the hardening of the surface of at least the machined sections of the running surface 10 can also be achieved.

In addition, the plastic deformation process must be carried out below the recrystallization temperature of each rail technical material of the rail 2. In this way, thermal stresses and undesirable changes in the structure, at least in the surface area, can be prevented.

In all of the previously described profile restoration processes, the material is first mechanically removed at least in the region of the rail head 5 by means of at least one cutting processing tool 17, in particular a wheel cutter. Subsequently, and after this, another mechanical deformation of the material of the previously processed rail head 5 is carried out. At the second or subsequent stage of work, no further removal of the material is carried out, but only mechanical deformation and the smoothing of the surface waviness associated with it.

In the exemplary embodiments, possible embodiments are shown, and at this point it should be noted that the invention is not limited to its specifically depicted embodiments, but, moreover, different combinations of individual embodiments are also possible among themselves, and this possibility of variation, in accordance with the doctrine of technical use of a particular invention is available to a person skilled in the art.

The scope of protection is defined by the claims. However, the description and drawings must be involved in the interpretation of the claims. Individual features or combinations of features from the various embodiments shown and described may constitute independent inventive solutions. The problem underlying these independent inventive solutions is contained in the description.

All indications of ranges of values in this specification should be understood to simultaneously include any and all of their individual ranges, for example, the indication from 1 to 10 should be understood to include all individual ranges from the lower limit of 1 to upper limit 10, i.e. all individual ranges start with a lower limit of 1 or more and end with an upper limit of 10 or less, such as 1-1.7 or 3.2-8.1 or 5.5-10.

For the sake of order, in conclusion, it should be noted that for a better understanding of the design, the elements were partially depicted without respect to scale and / or in an enlarged and / or reduced form.

LIST OF REFERENCES

1 rail track

2 rail

3 Axis rail

4 Sleeper

5 Rail head

6 Rail neck

7 Rail sole

8 Inner side surface

9 Outer side surface

10 Running surface

11 Roll surface

12 Edge of rolling

13 Processing vehicle

14 Processing node

15 Wheel set

16 First processing unit

17 Machining tool

18 Wave crest

19 Wave trough

20 Second processing unit

21 Deformation force

22 Guide

23 Deforming tool

24 work surface

25 Deforming tool

26 ball

27 Collector

28 Feed channel

29 Shot blasting element

Claims (28)

1. A method for restoring the profile of at least one rail (2) of a rail track (1) laid and formed by rails (2), at least in a section of its running surface (10) located on the head (5) of the rail, including the following stages: - providing a processing vehicle (13), this processing vehicle (13) being movable on a rail track (1); - providing a processing unit (14), and this processing unit (14) is located on the processing vehicle (13), while the processing of the processed running surface (10) is performed during the movement of the processing vehicle (13); this processing unit (14) includes at least one first processing unit (16), having at least one cutting processing tool (17) driven in rotation, while said at least one processing tool (17) is made in the form of a milling wheel having a plurality of another along the perimeter, as well as cutter head blades oriented along the restored profile of the rail head; at least one second processing unit (20); - processing of the head (5) of the rail in the area of its running surface (10) at the first stage of processing by means of the specified at least one cutting processing tool (17), while at the first stage of processing the material is removed during the milling process, and at the same time the material is removed in the direction of the longitudinal extension of the rail (2), a surface waviness is formed having crests (18) of waves and troughs (19) of waves, and in the subsequent second stage of processing by means of a second processing unit, this surface waviness is reduced and/or modified; - at the same time, with a decrease in the surface waviness, at the second stage of processing, at least the crests (18) of the waves are plastically deformed and leveled, and - at the same time, plastic deformation of at least wave crests (18) is performed by means of at least one deformation force (21) directed in the direction of the machined running surface (10), characterized in that said at least one deformation force (21) is applied in a pulsating manner, while the material of the rail (2) is slightly displaced, and the second stage of processing is carried out without permanent imposition of the processing tool of the second processing unit (20) on the processed running surface (10). 2. The method according to claim 1, characterized in that at least one guiding means (22) is provided for the relative direction of at least one of the processing units (16, 20) in height and / or sideways with respect to the head being processed ( 5) rail. 3. Method according to claim 1 or 2, characterized in that said at least one deformation force (21) is applied to the running surface (10) to be machined in normal orientation. 4. Method according to any one of claims 1 to 3, characterized in that said at least one pulsatingly applied deformation force (21) is selected from a range of force values, the lower limit of which is 20 N, in particular 150 N, and the upper limit which is 80 kN, in particular 1.5 kN. 5. Method according to any one of claims 1 to 4, characterized in that said at least one applied pulsating strain force (21) is applied with increasing intensity. 6. Method according to any one of claims 1 to 5, characterized in that said at least one pulsatingly applied strain force (21) is applied at a frequency selected from a frequency range whose lower limit is 100 Hertz (Hz), in particular 500 Hz, and the upper limit of which is 25 kilohertz (kHz), in particular 3 kHz. 7. Method according to claim 6, characterized in that said at least one applied pulsating strain force (21) is applied with a uniform frequency or with a varying frequency. 8. Method according to any one of claims 1 to 7, characterized in that the second processing unit (20) includes at least one deforming tool (23). 9. The method according to claim 8, characterized in that said at least one deforming tool (23) has a working surface (24) facing the running surface (10) of the machined head (5) of the rail, and this working surface (24) is made with a longitudinal extension that extends over at least two, preferably at least three wave crests (18) located in the direction of the longitudinal extension directly one after the other. 10. The method according to claim 8 or 9, characterized in that several deforming tools (23) are provided, and these deforming tools (23) are arranged in an offset distribution relative to each other over the profile cross section to be machined. 11. A method according to any one of claims 1 to 7, characterized in that a plurality of deforming tools (25) are provided, and each of these deforming tools (25) is provided with a hammer head made in the form of a ball segment. 12. Method according to claim 11, characterized in that the maximum deformation path of the plurality of deforming tools (25) ends at least before the wave trough (19) is reached. 13. Method according to claim 11, characterized in that the maximum deformation path of the plurality of deforming tools (25) ends at the trough (19) of the wave. 14. The method according to claim 11, characterized in that the maximum deformation path of the plurality of deforming tools (25) extends beyond the trough (19) of the wave in the direction of the foot (7) of the rail into the material of the head (5) of the rail. 15. A method according to any one of claims 1 to 7, characterized in that a pulsating deformation force (21) is applied to the running surface (10) to be machined by means of a shot blasting method and a plurality of shot blasting elements (29). 16. The method according to claim 15, characterized in that the elements (29) for shot blasting after the deformation process are collected by means of a collecting unit (27), in particular a suction device. 17. The method according to any one of claims 1 to 16, characterized in that the amplitude of the surface waviness is reduced in the normal direction to the longitudinal extent of the processed running surface (10) to a certain amplitude value, which is selected from the range of amplitude values, the lower limit of which is 0.001 mm , in particular 0.004 mm, and the upper limit of which is 0.01 mm, in particular 0.008 mm. 18. Method according to any one of claims 1 to 17, characterized in that the surface waviness is reduced and/or modified to an average roughness value Ra of less than 0.004 mm. 19. The method according to any one of claims 1 to 18, characterized in that in the first stage of processing, the crests (18) of the waves located in the direction of the longitudinal extent directly one after another are performed from each other at a distance having a value selected from the range of values distance, the lower limit of which is 1.0 mm, in particular 1.8 mm, and the upper limit of which is 14 mm, in particular 10 mm. 20. The method according to any one of claims 1 to 19, characterized in that the advance speed of the processing vehicle (13) during the profile recovery process has a speed value selected from a range of speed values, the lower limit of which is 3 m/min, in particular 5 m/min, and the upper limit of which is 40 m/min, in particular 30 m/min.

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