RU86128U1 - INSTALLATION FOR AUTOMATIC ELECTRIC ARC SURFACE OF RAILWAY RAILWAY - Google Patents

Abstract

Installation for automatic electric arc surfacing of a rail track, mainly switch points and frame rails, containing an autonomous power unit made in the form of a single-phase and three-phase current source, a platform with a welding torch mounted with the possibility of relative longitudinal movement from the drive, which is made with longitudinal and transverse horizontal guides to allow longitudinal and transverse reciprocating movement a welding torch and automatic arc welding of a worn surface according to a predetermined program, and a control panel, characterized in that it is equipped with a mechanism for the automatic oscillatory movement of the welding torch in the longitudinal direction during its reciprocating movement to enable simultaneous surfacing of the frame rail and a pre-curved arrow point transfer by means of local fixation on a non-working edge of a wit of a control installation plaque the plates and fixed at the ends of the wit to provide tensile deformation of the wit in the longitudinal direction of the supporting force clamps, between which are located the thrust liners installed between the base of the wit and the shoe of the frame rail.

Description

The utility model relates to railway transport and can be used for restoration repair by automatic electric arc surfacing of a worn-out surface of a complex profile of crosspieces and frame rails of railroad track turnouts with subsequent mechanical processing.

Known mobile power plant containing a car van, on the chassis of which technological equipment for welding works is mounted (see, for example, the description of the invention to the USSR copyright certificate No. 249465, class F01N 3 / 02.1968).

The disadvantage of the installation is the limited scope due to the recruitment of only one type of equipment, as well as the need for additional qualified personnel for its maintenance.

There is also known a device for automatic electric arc surfacing of a rail track, comprising a carriage mounted on a support with the possibility of translating into working position and horizontal longitudinal movement along the rail track, on which a tool head with a fused burner is fixed, as well as a control unit equipped with an additional support on the rail the path and the control panel for automatic surfacing, while the additional support is mounted opposite the carriage, which is made possible limited limited lateral horizontal movement along the rail, and the mechanism for translating the carriage into working position is equipped with a means for fixing the tool head with a fused burner in the working position (see, for example, the description of the patent of the Russian Federation for utility model No. 44682, CL ЕВВ 31/17, B23P 9/04, published March 27, 2005).

However, such an installation is intended for reconstructing track repair does not provide simultaneous repair of turnouts and frame rails of a railway rail, which limits its technological capabilities.

The closest known for its technical essence and the achieved result is the installation selected as a prototype installation for automatic electric arc surfacing of railway rail parts, containing an autonomous power unit, made in the form of a single-phase and three-phase current source, a platform with a welding torch installed with the possibility of relative longitudinal and lateral movement from the drive, which is made with longitudinal horizontal guides to ensure the axis of the longitudinal and transverse reciprocating movement of the welding torch and automatic arc welding of the worn surface according to the specified program, and the control panel (see, for example, the description of the RF patent for utility model No. 79480, class B23P 6/00, publ. 10.01 .2009).

The disadvantage of the installation is the limited scope due to the possibility of restoring only railroad switches, increased specific energy consumption and inefficiency, which makes it unattractive.

The essence of the claimed utility model is expressed in the aggregate of essential features sufficient to achieve the technical result provided by the proposed utility model, which is expressed in expanding technical capabilities and increasing the efficiency of technological equipment.

The specified technical result is achieved by the fact that the installation for automatic electric arc surfacing of the rail track, containing an autonomous power unit, made in the form of a single-phase and three-phase current source, a platform with a welding torch installed with the possibility of relative longitudinal movement from the drive, which is made with longitudinal and transverse horizontal guides to allow longitudinal and transverse reciprocation to be surfaced torch and automatic arc welding of a worn surface according to a given program, and the control panel is equipped with a mechanism for automatic oscillatory movement of the welding torch in the longitudinal direction during its reciprocating movement to enable simultaneous surfacing of the frame rail and the previously curved switch tongue by means of local fixation on broken face of the wit of the control mounting plate and fixed at the ends of the wit and to provide the tensile deformation of the tongue in the longitudinal direction of the supporting force clamps, which are located between thrust bearings, mounted between the sole and shoe tongue stock rail.

Comparison of the claimed technical solution with the prototype made it possible to establish compliance with its criterion of "novelty", since it is not known from the prior art.

The proposed device is industrially applicable, since it can be implemented by existing technical means.

Thus, the proposed technical solution meets the established conditions of patentability of a utility model.

The other known technical solutions for a similar purpose with similar significant features by the applicant was not found.

Figure 1 presents the proposed installation, a plan view, figure 2 is the same, a top view, figure 3 is the same side view, figure 4 is a view A and view B in figure 2, 5 is a diagram of the restoration of the switch wag, figure 6 is a diagram of the restoration of the frame rail.

The installation for automatic electric arc surfacing of a rail track, mainly switch points and frame rails, comprises an autonomous power unit 1, made in the form of a single-phase and three-phase current source, a platform 2 with a welding torch 3, mounted with the possibility of relative longitudinal movement from the drive, which is made with longitudinal 4 and transverse 5 horizontal guides to enable longitudinal and transverse reciprocating movement fusion torch and the implementation of automatic electric arc deposition of a worn surface according to a predetermined program, and a control panel.

The installation is equipped with a mechanism 6 for the automatic oscillatory movement of the welding torch in the longitudinal direction when it is reciprocating to enable simultaneous surfacing of the frame rail and the previously bent wit of the railroad switch by locally attaching the wit 7 of the control mounting plate 8 in the form of a copper bus and fixed along the ends of the wit to provide tensile deformation of the wit in the longitudinal direction of the supporting force clamps in 9, between which persistent inserts 10 are installed, installed between the sole of the switch tongue and the shoe of the frame rail 11.

When restoring the wit and frame rail, a rail bracket 12 is used, designed to accommodate the welding torch with little wear.

Power unit 1 of high power (14 kW), which is an autonomous source of single-phase and three-phase current, which provides the generation of electric energy for power supply of all consumers, which allows surfacing of a worn surface with subsequent grinding of the restored rolling surface of the rail track.

A welding inverter of a direct current inverter type with an integrated or external wire feed mechanism with a welding torch is used as a welding source, providing a rated welding current of at least 220 A, at 100% PV, (PV is the on-time). A welding rectifier with an increased frequency of the welding current at the output ensures high stability of the welding arc, and due to the existence of feedback between the characteristics of the electric arc and the rectifier, the current and voltage on the arc are automatically maintained at a predetermined optimal value.

The surfacing machine for surfacing is a frame with a working body installed on it, providing movement along the guides of the surfacing torch 3 in the transverse and longitudinal directions according to a given program, an electronic control unit (not shown) built-in in the machine body, which is used for burner movements and surfacing modes, and a programmable device for movements welding torch, providing mechanical movement of the welding torch according to any given figure - the area of wear of the crosspiece - in any necessary after ovatelnosti which is determined, in turn, necessary for the metal tongue 7 and the stock rail track switch 11, surfacing technology individual rollers and rail - continuous welding.

An auxiliary processing (grinding), measuring and control tool is intended for metal processing before and after surfacing and flaw detection of metal before and after repair by surfacing.

The installation is as follows.

To perform work on automatic electric arc surfacing of wits and frame rails, it is necessary to perform the following steps:

To plug:

- power cable for the welding rectifier to the 380 V socket (3 phase) of the dashboard of the electric generator of the autonomous power unit 1;

- a distribution box of cable fittings to a 220 V outlet (3 phase) of the dashboard of an electric generator of an autonomous power unit 1;

- power cables of the rail grinding machine to the cable armature connectors;

- power cable of the angle grinder to the outlet of the electric generator 220 (1 phase);

- power cable of the feed mechanism to the welding rectifier;

- return wire of the welding current circuit from the welding rectifier to the wit (frame rail) or metal plate;

- the return wire of the welding current circuit is fixed with a screw clamp with a grip, so as to ensure reliable contact, eliminating the possibility of sparking.

- cable from the control unit to the surfacing machine;

- control cable from the machine to the welding rectifier;

- unpack and install the cassette with self-protective flux-cored flux-cored wire with a diameter of 1.6 mm and install it into the feeding mechanism, fix it with clamping nuts. By pressing the start-feed button, get the free end of the wire out of the mouthpiece of the torch. Using a ruler, adjust the required overhang of the welding wire after exiting the torch tip. The overhang of the welding wire should be 25-30 mm.

Start the engine of the power plant and transfer the load to the generator in accordance with the instruction manual.

With the appropriate toggle switches, turn on the power of the welding rectifier with the feed mechanism and the machine.

It is forbidden to select and test the surfacing modes directly on the wit and frame rail on existing tracks.

Self-shielding flux-cored wire is surfaced with direct current of reverse polarity (plus on the welding torch): current 140-160 A, voltage 24-26 V.

If during welding the electric arc burns unstably, and the slag is difficult to separate, the surfacing stops, and the wire cassette is calcined in the furnace at a temperature of 200 ° C for 3 hours, and then a second test is carried out in the same way. If the results of the retest are unsatisfactory, the wire is rejected and a complaint is made to the unsuitable lot.

Inspection of the turnout before surfacing and the measurement of the defective place on the wit and frame rail should be carried out by the master of the welding-surfacing column together with a representative of the distance along the job not lower than the road master.

Measurement and marking of the wit for surfacing is carried out using a track caliper, a metal ruler 1 m long in accordance with GOST 427-75 and a caliper with a depth gauge ШЦ-1 (0-125) in accordance with GOST 166-80 or a similar tool.

Before surfacing wit and frame rail, the following steps must be performed, namely:

- cleaned of dirt and wiped dry with wiping materials;

- removed surface defects with a grinding wheel;

- the length of the grinding area should be 4 mm longer than the length of the surfacing;

After grinding the defective place to pure metal, visual and color capillary inspection is carried out.

Color capillary flaw detection is carried out using red penetrating liquid and white developing paint (penetrant kit) according to GOST 18442-80, which allows to identify surface defects before and after surfacing.

In case of revealing surface cracks - they are polished.

After grinding the defective metal, the restoration area (surfacing length +100 mm in both directions) is heated by a multi-flame heating burner to a temperature of 30-40 ° C to remove water from the surface of the wit or frame rail, and the resulting rust in a protected place is removed by the grinding wheel, which is included in the kit Spare parts.

Grinding of defective metal is carried out with an abrasive tool, avoiding arson. The transition zone from the polished surface to the skating surface should be smooth.

Before performing surfacing, it is necessary to preliminarily bend the switch tongue for which, in the middle part of the weld zone, between the sole of the blade and the shoe of the frame rail, a metal thrust pad 10 with a height of 50 mm is inserted, and supporting force clamps 9 at the ends of the surfacing section, thereby creating tensile forces in witty turnout. On the non-working edge of the wit, an installation copper bus 8 is fixed with a length of 1300 mm to form the upper edge of the wit.

Before surfacing, a pre-heating with a multi-flame heating torch of a wit or head of a frame rail is made to a temperature of 400-450 ° C.

The heating temperature is measured by a digital small-sized thermometer or pyrometer by the contact method for the surfacing length plus 100 mm in both directions.

Using the remote control, the operator starts and stops the movement of the carriage, starts the surfacing process, assigns the direction of movement and the length of the movement, turns on the vibrations and selects the vibrations at the beginning and end of the surfacing, which allows surfacing the wit and frame rail in one pass.

Programming of the beginning of electric arc surfacing starts from the root side of the wit in its lower part, programming is carried out at four points, while the upper edge of the wit is formed on a copper plate, the welding machine allows surfacing of the wig in the longitudinal direction, while performing oscillatory movements.

The roller of the first section is surfaced on a horizontal shelf, obtained by inserting a wheel flange into the side surface of the wit, with its subsequent transition at an angle of 45 ° from bottom to top, ending surfacing on the upper edge of the wit head.

The surfacing of horizontal rollers begins and ends on the weld metal. After surfacing the roller, the slag is knocked down, the roller is brushed with a metal brush to a shine.

The remaining parts of the worn surface are restored similarly to the previous ones. With lateral wear of the frame rail in the front reach and the cover zone of the switch tongue, the worn surface is surfaced, for which tensile stress is created due to the bending of the frame rail 11.

Surfacing is carried out from the front departure of the frame rail to the zone of shelter wit, in automatic mode by oscillatory movements in the longitudinal direction.

In case of unforeseen circumstances, the operator can stop surfacing with the emergency shutdown button. To continue surfacing, it is necessary to heat the wit or frame rail to the required temperature.

The weld wits and frame rails are treated with an abrasive tool after they are naturally cooled to a temperature of 50 ° -70 ° C, avoiding arson.

Grind in the longitudinal direction of the wit or frame rail in accordance with the rail track profile template.

In the deposited metal there should be no fusion, cracks, slag inclusions, porosity. Places of detected defects are subject to grinding and surfacing.

The installation moves to the place of work, providing diagnostics, electric arc surfacing of the worn surface and subsequent machining of the restored working surface of the railway rail in the mode of technological windows without canceling the movement of trains and removing the rail track.

The claimed installation provides the expansion of functional technological capabilities by providing automatic electric arc surfacing of a worn surface of turnouts of complex configuration and the rolling surface of frame rails of a rail track.

A feature and advantage of the described installation is that it can be used as an autonomous mobile service center for emergency repair work for 2 hours with the possibility of access to hard-to-reach places in the mode of the technological window without closing the train movement.

Claims (1)

Installation for automatic electric arc surfacing of a rail track, mainly switch points and frame rails, containing an autonomous power unit made in the form of a single-phase and three-phase current source, a platform with a welding torch mounted with the possibility of relative longitudinal movement from the drive, which is made with longitudinal and transverse horizontal guides to allow longitudinal and transverse reciprocating movement a welding torch and automatic arc welding of a worn surface according to a predetermined program, and a control panel, characterized in that it is equipped with a mechanism for the automatic oscillatory movement of the welding torch in the longitudinal direction during its reciprocating movement to enable simultaneous surfacing of the frame rail and a pre-curved arrow point transfer by means of local fixation on a non-working edge of a wit of a control installation plate the plates and fixed at the ends of the wit to provide tensile deformation of the wit in the longitudinal direction of the supporting power clamps, between which are located the thrust liners installed between the sole of the wit and the shoe of the frame rail.