RU2802979C1 - Mobile rail welding system - Google Patents

Abstract

FIELD: mobile rail welding systems.

SUBSTANCE: body of the system is made in the form of a transportable container with a manipulator compartment and the main compartment. In the manipulator compartment, there is a machine for electric contact welding of rails and a manipulator for the machine. The manipulator has the ability to extend from the compartment and rotate in a horizontal plane. The manipulator compartment doors close the front and side sides. The roof hatch is can be lifted. In the main compartment there is a control cabinet for the system, a hydraulic drive station, a diesel generator set, a receiver, a compressor, auxiliary equipment and an induction heating unit with a control cabinet, a cooling station and a thermal module. The main compartment is equipped with doors for access to the compartment, doors and a removable hatch for servicing the diesel generator set, a removable hatch for servicing the hydraulic drive station and rear doors for servicing the compressor.

EFFECT: maintainability of the system is increased.

9 cl, 28 dwg

Description

TECHNICAL FIELD

[01] The invention relates to equipment for butt welding of rails, namely to a mobile rail welding complex that can be used for welding rail joints on the road.

BACKGROUND OF THE ART

[02] The RF patent RU2431010, 00.27.2011 for the invention describes a mobile modular rail welding complex (MRSC), containing an electric generator, a welding current source, a programmable electric arc welding machine, grinding and rail cutting machines, electrical cables, tools and a supply of consumables. The complex is made in the form of a module with dimensions and total weight that allow it to be installed in the back of a light-duty truck, in which a set of equipment is placed and secured. The welding current source, programmable electric arc welding machine, grinding and rail cutting machines are removable, remote, for carrying out the rail welding process. The equipment of the complex additionally includes: lighting devices, an umbrella or tent and a flaw detector, which allow welding to be carried out in the dark and in weather with precipitation, as well as to perform quality control of the welded joint.

[03] The disadvantages of the complex are:

- lack of auxiliary doors and hatches for operation and maintenance of the complex;

- lack of a jib crane for pulling out equipment;

- absence of emergency diesel generator set and emergency hydraulic drive station;

- lack of ventilation grilles to suck in outside air.

[04] The patent for the invention RU2272859, 03/27/2006 describes a track rail welding and heat treatment complex containing at least one frame, mounted on it, at least one control cabin, power plant, welding machine, manipulator for moving the welding machine machines with a power source, a cooling system for the welding machine, welding equipment, at least one heat-treating unit connected to a frequency converter and a compressor of the heat-treating unit and mounted with the possibility of vertical and transverse movement, a device for moving it. At least one heat-treating unit is mounted at such a distance from the welding machine that in the working position it is equal to the length of the rail being processed. The complex has traction and trailer parts, while the traction part of the complex uses a vehicle on a pneumatic track and with running wheels, and the trailer part of the complex is equipped with pneumatic wheels with the ability to move along roads and railways.

[05] The disadvantages of this complex are:

- lack of auxiliary doors and hatches for operation and maintenance of the complex;

- absence of a jib crane for pulling out auxiliary equipment (there is only a beam crane for pulling out the thermal module);

- lack of emergency hydraulic drive station.

- lack of ventilation grilles to suck in outside air;

[06] The closest analogue of the invention is a container-type mobile rail welding complex, described in US application US2002170884A1, 11/21/2002. The complex has a body in the form of a container, designed to be installed on the floor (ground), car chassis or railway platform and capable of opening doors or a roof. In this case, the container contains equipment, including a welding device with a welding head, a robot, a diesel generator set, an induction heating installation, a control cabinet, and a hydraulic drive station.

[07] The disadvantages of this complex are:

- lack of auxiliary doors and hatches for operation and maintenance of the complex;

- absence of emergency diesel generator set and emergency hydraulic drive station;

- lack of ventilation grilles to suck in outside air.

[08] The common disadvantages of analogues are the low ease of operation, maintenance and repair of the rail welding complex.

[09] The technical problem to which the claimed invention is aimed is the low level of reliability, durability and maintainability of mobile rail welding complexes.

[010] DISCLOSURE OF THE INVENTION

[011] The main technical results of the invention are increasing ease of operation during operation, maintenance and repair of the complex, increasing reliability and maintainability, expanding functionality and increasing the working area for welding joints. Additional technical results are the versatility and optimization of lifting and securing and unfastening the complex, the versatility of the transportation process for delivering and installing the complex to the work site; optimization and acceleration of the welding process, ensuring mechanization of the team’s manual labor, reducing the frequency of fluid changes in the UIN cooling station, increasing the durability of the complex.

[012] The specified technical result is achieved in the claimed invention due to the fact that the mobile rail welding complex includes a body in the form of a transportable container, having a manipulator compartment and a main compartment. The manipulator compartment contains a machine for electric contact welding of rails and a manipulator for the machine, made with the ability to extend from the manipulator compartment and rotate in a horizontal plane. The manipulator compartment is equipped with folding doors covering the end and sides of the manipulator compartment, as well as a rotating roof hatch. The main compartment houses the complex control cabinet, hydraulic drive station, diesel generator set (DGS), receiver, compressor, auxiliary equipment and induction heating unit (IHU), containing the IH control cabinet, cooling station and thermal module. The main compartment is equipped with doors for access to the main compartment, doors for servicing the diesel generator set, a removable hatch for servicing the diesel generator generator, a removable hatch for servicing the hydraulic drive station, and rear doors for servicing the compressor.

[013] In addition, the specified technical result is achieved in private embodiments of the invention due to the fact that

[014] - an emergency station is additionally located in the main compartment, including an emergency diesel generator set and an emergency hydraulic drive station;

[015] - a jib crane is additionally installed in the main compartment, made with the ability to extend the UIN thermal module and auxiliary equipment from the main compartment;

[016] - in the main compartment there are additionally removable slides for removal from the main compartment of the compressor;

[017] - the main compartment is additionally equipped with an auxiliary hatch for connecting the equipment complex to the network during operation and repair;

[018] - the main compartment is additionally equipped with ventilation grilles for the diesel generator set and a ventilation grill for the UIN cooling station;

[019] - the container has a frame with mounting fittings and is designed to be installed on the floor, ground, car chassis and railway platform,

[020] - the UIN control cabinet contains a frequency converter for resistance welding.

[021] - a press for testing welded rail joints is installed in the main compartment.

[022] In the claimed complex, the division of the container into two compartments, the arrangement of equipment in them, as well as the use of doors and hatches for various equipment elements in the compartments increases the convenience and reliability of operation, and improves the maintainability of the equipment. The use of ventilation grilles improves the cooling of equipment elements. The presence of additional equipment in the complex in the form of an emergency station, a jib crane, removable skids, etc., increases the fault tolerance and reliability of the complex, and also simplifies the work of the welding team. In general, the layout of the equipment and the design of the container optimizes the process of work, transportation and ensures the versatility of the complex.

[023] BRIEF DESCRIPTION OF DRAWINGS

[024] The invention is illustrated by figures, which show the following objects.

[025] Figure 1 shows a mobile rail welding complex in a transport position, main view.

[026] Figure 2 shows a mobile rail welding complex in a transport position, view A on the right.

[027] Figure 3 shows a mobile rail welding complex in a transport position, view B on the left.

[028] Figure 4 shows a mobile rail welding complex in a transport position, top view B (roof hatch and roof not shown).

[029] Figure 5 shows a mobile rail welding complex in a transport position, rear view D.

[030] Figure 6 shows a mobile rail welding complex in a transport position, view D at an angle of 45° on the right (the roof hatch and roof are not shown).

[031] Figure 7 shows a mobile rail welding complex in a transport position, view E at an angle of 45° on the left (roof hatch, roof and front doors are not shown).

[032] Figure 8 shows a mobile rail welding complex in working position, main view G.

[033] Figure 9 shows a mobile rail welding complex in working position, view 3 on the right.

[034] Figure 10 shows a mobile rail welding complex in working position, view And on the left.

[035] Figure 11 shows a mobile rail welding complex in working position, top view K (the roof is not shown).

[036] Fig. 12 shows a mobile rail welding complex in working position, rear view L.

[037] Fig. 13 shows a mobile rail welding complex in working position, view M at an angle of 45° on the right (the roof is not shown).

[038] Fig. 14 shows a mobile rail welding complex in working position, view H at an angle of 45° on the left (the roof is not shown).

[039] Fig. 15 shows a mobile rail welding complex in working position, view P at an angle of 45° on the left (the roof is not shown).

[040] Fig. 16 shows a mobile rail welding complex in working position, view P at an angle of 45° to the right (the roof is not shown).

[041] Figure 17 shows a mobile rail welding complex in a serviced position, main view C.

[042] Fig. 18 shows a mobile rail welding complex in a serviced position, view T on the right.

[043] Fig. 19 shows a mobile rail welding complex in a serviced position, view U on the left.

[044] Figure 20 shows a mobile rail welding complex in a serviced position, top view F (roof not shown).

[045] Figure 21 shows a mobile rail welding complex in a serviced position, rear view X.

[046] Fig. 22 shows a mobile rail welding complex in a serviced position, view H at an angle of 45° on the right (the roof is not shown).

[047] Fig. 23 shows a mobile rail welding complex in a serviced position, view W at an angle of 45° on the left (the roof is not shown).

[048] Fig. 24 shows a mobile rail welding complex in a serviced position, view E at an angle of 45° on the left (the roof is not shown).

[049] Fig. 25 shows a mobile rail welding complex in a serviced position, view S at an angle of 45° to the right (the roof is not shown).

[050] Fig. 26 shows a mobile rail welding complex in a serviced position, section T-T.

[051] Fig. 27 is an extended view of I.

[052] Fig. 28 shows a mobile rail welding complex in working position, top view (the roof is not shown).

[053] Structural elements are indicated in the figures by the following positions

1 - machine for electric contact welding of rails (Fig. 23);

2 - manipulator (Fig. 23);

3 - outer shell (hereinafter referred to as KUNG) (Fig. 23);

4 - frame (Fig. 23);

5 - control cabinet (Fig. 25);

6 - hydraulic drive station (Fig. 23);

7 - diesel generator set (hereinafter DGS) (Fig. 23):

7.1 - diesel generator set engine (Fig. 24);

7.2 - diesel generator set (Fig. 24);

8 - control cabinet of the induction heating installation (hereinafter referred to as the control cabinet UIN) (Fig. 23);

9 - cooling station of the induction heating installation (hereinafter referred to as the UIN cooling station) (Fig. 11);

10 - thermal module of an induction heating installation (hereinafter referred to as the thermal module UIN) (Fig. 11);

11 - jib crane (Fig. 23);

12 - receiver (Fig. 25);

13 - compressor (Figs. 23, 25);

14 - emergency diesel generator set - hydraulic drive station (hereinafter referred to as emergency station) (Fig. 25);

15 - removable slide (Fig. 25);

16 - roof hatch (Fig. 25);

17 - right manipulator compartment door (Fig. 25);

18 - left manipulator compartment door (Fig. 23);

19 - auxiliary hatch (Fig. 25);

20 - removable generator maintenance hatch (Fig. 12);

21 - right DGS service door (Fig. 23);

22 - left DGS service door (Fig. 25);

23 - rear right door (Fig. 22);

24 - rear left door (Fig. 23);

25 - right main compartment door (Fig. 22);

26 - left main compartment door (Fig. 22);

27 - removable hatch for servicing the hydraulic drive station (Fig. 7);

28 - KUNG roof (Fig. 26);

29 - fastening fitting (Fig. 27).

30 - rear ventilation grille of the diesel generator set (Fig. 16);

31 - side ventilation grille of the diesel generator set (Fig. 16);

32 - ventilation grille of the UIN cooling station (Fig. 16);

33 - manipulator compartment,

34 main compartment.

[054] CARRYING OUT THE INVENTION

[055] The mobile rail welding complex (hereinafter referred to as the complex) is made on the basis of a container that can be installed on the floor, ground, car chassis or railway platform. The specified container has a frame (4) with fastening fittings (29), and an outer shell (KUNG) (3) with walls and a roof (28). Such a container provides versatility and optimization of lifting and securing and unfastening the complex.

[056] The container is preferably made with the approximate dimensions of a 30-foot tall container: height h=2840 mm, length l=7880 mm, and width s=2490 mm. This makes it possible to transport the complex on a standard truck (truck) without obtaining special permits or an escort vehicle. Those. universality of the transportation process is achieved for delivery and installation of the complex to the work site.

[057] The container is transversely divided into two compartments - in the front part there is a manipulator compartment (33), and in the rear part there is a main compartment (34) (see Fig. 4).

[058] In the manipulator compartment (33) there is a machine for electric contact welding of rails (1), as well as a manipulator (2), which makes it possible to extend the electric contact welding machine (1) from the manipulator compartment (33) and is made with the ability to rotate in the horizontal plane at an angle (δ) up to 40° in each direction. This increases the working area for welding joints and increases the functionality of the complex;

[059] In this case, the manipulator compartment (33) has right (17) and left (18) doors, each of which consists of two folding hinged doors that cover the end and side parts of the manipulator compartment (33). Said doors (17) and (18) have the ability to open at an angle (β) of up to 270°. In addition, the manipulator compartment (33) on the roof (28) is equipped with a rotating hatch (16), capable of rising to an angle α=30°.

[060] In the main compartment (34) of the container there is a control cabinet (5) for the complex, a hydraulic drive station (6), a diesel generator set (DGS) (7) with an engine (7.1) and a generator (7.2), an induction heating unit (IH ), jib crane (11), receiver (12), compressor (13), removable skids (15), emergency station (14) and auxiliary equipment (not shown in figures).

[061] The induction heating unit (IH) includes a control cabinet (8) IH, a cooling station (9) IH and a thermal module (10) IH.

[062] The emergency station (14) has an emergency diesel generator set and an emergency hydraulic drive station. The emergency station (14) is used at any stage of the complex operation in case of failure of the diesel generator set (7) or the hydraulic drive station (6), or both units simultaneously. This increases the reliability and fault tolerance of the complex.

[063] Accessory equipment may include, for example, fine and rough grinders, cables and other devices.

[064] The jib crane (11) is located on the inner side wall of the KUNG and allows you to remove the thermal module (9) UIN (Fig. 11, 14) and other auxiliary equipment outwards and lower it down. With a mass of the thermal module (9) of 60 kg and other auxiliary equipment of 40-50 kg, this makes it possible to facilitate and significantly speed up the work of the complex team and, accordingly, speed up the welding time of the welded joint.

[065] The rear wall of the main compartment (34) contains the rear right (23) and rear left (24) doors and the rear ventilation grille (30) of the diesel generator set. At the same time, on the side walls of the main compartment (34) there are right (25) and left (26) doors of the main compartment, right (21) and left (22) doors for servicing the diesel generator set, a removable hatch (20) for generator maintenance, an auxiliary hatch (19 ), a removable hatch (27) for servicing the hydraulic drive station, a side ventilation grille (31) of the diesel generator set and a ventilation grille (32) for the UIN cooling station (Fig. 16);

[066] The rear right (23) and left (24) doors are designed for maintenance and repair of the compressor (13), which is rolled out on a removable slide (15) (Fig. 23, 25), as well as the internal part of the diesel generator set (7). This increases the maintainability of the complex.

[067] The right (25) and left (26) doors of the main compartment (34) provide crew access to the main compartment (34) and to the complex as a whole.

[068] The right (21) and left (22) doors for servicing the diesel generator set, as well as a removable hatch (20), allow for maintenance and repair of the diesel generator set (7) both as a whole and its individual parts - the engine (7.1) and the generator ( 7.2).

[069] Ventilation grilles (30), (31) and (32) for the cooling station UIN and DGU are installed in close proximity to the suction pipes and fans of the cooling station (9) UIN and DGU (7), which allows air to be sucked directly from the atmosphere , and not hot air from the complex itself. This leads to more efficient cooling of the liquid in the cooling station of the UIN and DGU and makes it possible to reduce the frequency of fluid replacement and increase the useful life of the DGU.

[070] The auxiliary hatch (19) allows you to connect auxiliary equipment during operation and repair to the complex network from the surface, which speeds up the welding of the welded joint and improves the mechanization of manual labor of the complex crew.

[071] Instead of the usual control cabinet (8) UIN, a frequency converter for resistance welding can be installed, which ensures a reduction in the fuel consumption of the diesel generator set and a smoother load on the diesel generator set when welding a welded joint. Thus, the efficiency of the complex and the durability of the diesel generator set will be achieved. A press for testing welded rail joints can be installed in the container, which makes it possible to test welded joints at the site of the complex without interrupting the crew for transportation and testing of welded joints, i.e. optimize the process.

[072] The complex operates as follows.

[073] In the basic state, the complex is in the transport position and all doors and hatches (16-27) are closed (see Fig. 1-7). In this position, the inside of the complex is protected both from external mechanical influences and from the effects of precipitation. The complex in the transport position is installed on a car, trawl or railway platform using a crane, which lifts the complex by fastening fittings (29) installed in the frame (4) (Fig. 27). Then the complex is secured to a car, trawl or railway platform using the same fastening fittings (29) (Fig. 27).

[074] Next, the complex is moved by road or rail to the place where the rail welding work is carried out.

[075] The team of the complex brings it into working position (Fig. 8-16) with the following operations:

[076] 1) Open the doors (17,18) of the manipulator compartment at an angle β=270°, fold them and secure them (Fig. 8-16, 28).

[077] 2) Open the roof hatch (16) at an angle α=30° (Fig. 8, 16), while the height clearance on the railway is not violated, this allows the manipulator (2) to be folded out with the electric contact machine (1) welding of rails without exceeding the overall dimensions of the complex in the transport position in height h = 2840 mm (Fig. 1).

[078] 3) Bring the machine (1) for electric contact welding of rails into the working position by unfolding and turning the manipulator (2). At the same time, thanks to the folded doors (17, 18) of the manipulator compartment, the manipulator has the ability to rotate at an angle δ=40° in each direction from the complex, which allows you to weld rails both on a standard railway track with a gauge of 1520 mm, and outside it at distance g=2517 mm from the center of the complex in each direction (Fig. 28).

[079] 4) Open the doors (25, 26) of the main compartment at an angle γ=180°, fold them and secure them (Fig. 8, 13, 14), which provides a wide working area in the j=2000 mm team for access to the complex .

[080] 5) In a wide working area, the team attaches the UIN thermal module (9) to the jib crane (11), located on the inner side wall of the KUNG. Next, turn the crane-jib (11) at an angle β=270°, take out and lower down (Fig. 11, 14) the thermal module (9) and other auxiliary equipment.

[081] 6) Open the auxiliary hatch (19) (Fig. 16), and connect the auxiliary equipment to the complex network.

[082] 7) Includes a diesel generator set (7), a control cabinet (5) of the complex and a control cabinet (8) of the UIN (Fig. 23, 25), while due to the ventilation grilles (29, 30, 31) cooling of the cooling station of the UIN is ensured and DGS with atmospheric air.

[083] 8) The team welds the joint using an electric contact welding machine (1), using a hydraulic drive station (6), a control cabinet (5) and a diesel generator set (7). Next, rough grinding of the welded joint is carried out with auxiliary equipment, heat treatment of the welded joint with a thermal module (10) UIN using a control cabinet (8) UIN, a cooling station (9) UIN and DGU (7), and finishing grinding of the welded joint with auxiliary equipment.

[084] 9) After completing the welding of the joint, the thermal module (9) UIN and auxiliary equipment with a jib crane (11) and the electric contact welding machine for rails (1) with a manipulator (2) are folded back into the KUNG (3), i.e. bringing the complex into transport position.

[085] In the event of failure of the diesel generator set (7) or the hydraulic drive station (6), or both units at the same time and the manipulator (2) being unable to operate because of this, the team uses the emergency station (14) (Fig. 25) to in order to complete the process of folding the electric contact welding of rails (1) with a manipulator (2) and further freeing up the work site. The emergency station (14) is used by the team at any stage of the complex operation in the event of failure of the diesel generator set (7) or the hydraulic drive station (6), or both units simultaneously.

[086] During work, daily, weekly, monthly and emergency repair services of the complex are performed. To do this, carry out the following operations.

[087] 1) Open the right door (17) of the manipulator compartment at an angle β=270° and the left door (18) of the manipulator compartment at γ=180° degrees, fold them and secure them (Fig. 20), open the roof hatch (16) by 30 degrees (Fig. 8, 16);

[088] 2) The electric contact welding machine (1) of rails is brought into working position by unfolding the manipulator (2);

[089] 3) Open the left door (25) of the main compartment (34) at an angle ε=90° and the right door (26) of the main compartment (34) at an angle γ=180°, fold them and secure them (Fig. 20- 25);

[090] 4) Take out and lower down the thermal module (9) UIN (Fig. 20) and other auxiliary equipment;

[091] 5) Open the auxiliary hatch (19) (Fig. 24) and connect the auxiliary equipment for repair to the complex network;

[092] 6) Open the left door (22) for servicing the diesel generator set at an angle γ=180° and the right door (21) for servicing the diesel generator set at an angle ε=90°, and also remove the removable hatch (20) (Fig. 12, 25), and for maintenance or repair of the diesel generator set or its parts;

[093] 7) Remove the removable hatch (27) (Fig. 7, 23) for maintenance and repair of the hydraulic drive station (6) (Fig. 25);

[094] 8) Install the removable skid (15) and roll out the compressor (13) (Fig. 23, 25) for maintenance and repair.

Claims (13)

1. Mobile rail welding complex, including a body in the form of a transportable container, having a manipulator compartment (33) and a main compartment (34), while - in the manipulator compartment (33) there is a machine for electric contact welding of rails (1) and a manipulator (2) for the machine (1), made with the ability to extend from the manipulator compartment (33) and rotate in the horizontal plane, - the manipulator compartment (33) is equipped with folding doors (17), (18) covering the end and sides of the manipulator compartment (33), as well as a roof lifting hatch (16), - in the main compartment (34) there is a control cabinet (5) for the complex, a hydraulic drive station (6), a diesel generator set (DGS) (7), a receiver (12), a compressor (13), auxiliary equipment and an induction heating unit (IH) ), containing a control cabinet (8) UIN, a cooling station (9) and a thermal module (10), - the main compartment is equipped with doors (25), (26) for access to the main compartment, doors (21), (22) for servicing the diesel generator set, a removable hatch (20) for servicing the generator of the diesel generator set, a removable hatch (27) for servicing the hydraulic drive station, rear doors (23), (24) for servicing the compressor. 2. The complex according to claim 1, in which in the main compartment (34) an emergency station (14) is additionally located, including an emergency diesel generator set and an emergency hydraulic drive station. 3. The complex according to claim 1, in which in the main compartment (34) an additional jib crane (11) is installed, which can be extended from the main compartment of the thermal module (9) of the UIN and auxiliary equipment. 4. The complex according to claim 1, in which the main compartment (34) additionally houses a removable slide (15) for removal from the main compartment of the compressor (13). 5. The complex according to claim 1, in which the main compartment (34) is additionally equipped with an auxiliary hatch (19) for connecting the equipment complex to the network during operation and repair. 6. The complex according to claim 1, in which the main compartment (34) is additionally equipped with ventilation grilles (30), (31) for the diesel generator set and a ventilation grille (32) for the UIN cooling station. 7. The complex according to claim 1, in which the container has a frame (4) with fastening fittings and is designed to be installed on the floor, ground, car chassis and railway platform. 8. The complex according to claim 1, in which the control cabinet UIN (8) contains a frequency converter for resistance welding. 9. The complex according to claim 1, in which a press for testing welded rail joints is installed in the main compartment (34).