WO2019153537A1 - 一种适用于钢轨在线铣磨作业的定位装置 - Google Patents

一种适用于钢轨在线铣磨作业的定位装置 Download PDF

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Publication number
WO2019153537A1
WO2019153537A1 PCT/CN2018/084991 CN2018084991W WO2019153537A1 WO 2019153537 A1 WO2019153537 A1 WO 2019153537A1 CN 2018084991 W CN2018084991 W CN 2018084991W WO 2019153537 A1 WO2019153537 A1 WO 2019153537A1
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WIPO (PCT)
Prior art keywords
rail
positioning device
line
milling
support base
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PCT/CN2018/084991
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English (en)
French (fr)
Inventor
曹佐权
韩双平
蔡昌胜
吴鹏坤
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中国铁建高新装备股份有限公司
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Publication of WO2019153537A1 publication Critical patent/WO2019153537A1/zh

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    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/12—Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B31/00—Working rails, sleepers, baseplates, or the like, in or on the line; Machines, tools, or auxiliary devices specially designed therefor
    • E01B31/02—Working rail or other metal track components on the spot
    • E01B31/12—Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails
    • E01B31/17—Removing metal from rails, rail joints, or baseplates, e.g. for deburring welds, reconditioning worn rails by grinding
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B2203/00—Devices for working the railway-superstructure
    • E01B2203/01—Devices for working the railway-superstructure with track
    • E01B2203/012—Devices for working the railway-superstructure with track present, i.e. in its normal position
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
    • E01B2203/00—Devices for working the railway-superstructure
    • E01B2203/14—Way of locomotion or support
    • E01B2203/141—Way of locomotion or support on the track to be treated

Definitions

  • the invention relates to a positioning device suitable for online milling operation of a rail, and belongs to the technical field of railway machinery design and manufacture.
  • the rail milling machine is used for on-line milling of the rail during the working operation, which can eliminate the rail disease such as wave grinding, crack, fat edge and peeling, and effectively extend the service life of the rail.
  • the milling unit needs to be accurately positioned on the rail during the operation and accurately follows the rail sliding in real time. Therefore, the milling unit of the rail milling machine needs to be equipped with a positioning device.
  • the existing milling unit is equipped with a positioning device that uses a wear block as a contact member to slide on the top surface of the rail, and an eddy current sensor is used as a lateral displacement measuring sensor, and the end of the detecting rod is driven by a spring mechanism to be in close contact with the rail.
  • a positioning device that uses a wear block as a contact member to slide on the top surface of the rail
  • an eddy current sensor is used as a lateral displacement measuring sensor, and the end of the detecting rod is driven by a spring mechanism to be in close contact with the rail.
  • the wear block will scratch the surface of the rail, and cause the milling unit to vibrate and reduce the servo feed precision, and the wear block It is easy to wear and needs to be replaced regularly, which increases the maintenance cost.
  • the eddy current sensor has a small measuring range and low measurement accuracy.
  • the rail joint and the wrong tooth in the rail will make the detecting rod instantaneously move beyond the eddy current sensor.
  • the measuring range causes frequent and urgent lifting of the milling unit.
  • the lateral displacement of the milling unit is related to the measured value of the eddy current sensor, the lateral tracking of the milling unit is prone to errors, which directly affects the lateral direction after the operation. Contour accuracy; in addition, if the milling and grinding unit is lifted at the position with the rail edge, the rod will be scratched by the fat. All of the above problems will greatly reduce the reliability and accuracy of the milling and grinding unit.
  • Chinese Patent Application No. 201610870842.1 discloses an adaptive following device for lateral positioning of a rail milling device, comprising a base, a lever positioning device, a lever resetting device, a lever adjusting device and an inductive device;
  • the lever positioning device includes a lever and a positioning alloy block, the lever resetting device including a return spring and a reset top pin, the lever adjusting device including a cylinder, the sensing device including a linear displacement sensor and a sensor mount.
  • the adaptive following device solves the problem that the conventional lateral positioning device cannot be properly positioned due to the rail edge and serious collapse of the rail, and can adapt to the non-rail specifications and the different rail connections, under the condition of the rail fat edge and the collapsed serious line.
  • the device achieves precise positioning and digital feedback of milling and grinding, but still does not address the problem of scratching the surface of the rail following the base of the device, and the follower cannot effectively follow the peaks and troughs of the rail surface.
  • the positioning device can support the milling and grinding unit to quickly slide on the surface of the rail, and can not cause secondary damage to the top surface of the rail; on the other hand, the positioning device is descending. In the process of following and improving the work, it is necessary to overcome the harsh working conditions such as rail joints, wrong teeth and fat edges to meet the technical requirements of the milling unit operation.
  • the direction perpendicular to the rail i.e., parallel to the sleeper
  • the direction perpendicular to the top surface of the rail is vertical
  • the direction parallel to the rail is longitudinal
  • the technical problem to be solved by the invention is to provide a positioning device suitable for on-line milling operation of a steel rail, which can break through the technical problems of inaccurate positioning and scratching the surface of the rail of the existing milling device, and realize milling of the rail milling machine.
  • the unit is accurately positioned, accurately follows the rail sliding in real time, and improves the precision and reliability of the milling unit.
  • a positioning device suitable for on-line milling operation of a rail comprising a lower support seat connected to the upper support seat, the upper support seat being mounted with a vertical feed base, the vertical support
  • the feed base is equipped with a front support seat and a rear support base.
  • the rear support base is further connected with a detection rod.
  • the front support base is provided with a cylinder, a length gauge, a spring mechanism, a signal shaft, an overtravel induction switch and a work sensing switch.
  • the detecting rod is connected to the cylinder, the length gauge, the spring mechanism and the signal shaft.
  • the lower support base comprises a front end inner frame and a rear end inner frame, the seat body between the front end inner frame and the rear end inner frame is parallel to the top surface of the rail, and the upper end of the front end inner frame is connected to the upper support seat.
  • the front inner frame and the rear inner frame of the lower support base are respectively arranged with a set of rollers, the number of each set of rollers is at least one, and the center distance between the two sets of rollers is greater than 200 mm to ensure that the positioning device is pressed in the wave.
  • one of the rollers can contact the peak or the trough, and the middle of the lower support is arranged with a force sensor for detecting the pressure of the milling unit, the working surface of the force sensor and the upper support The bottom surface is in contact.
  • the front end of the detecting rod is connected to the moving end of the cylinder, the length gauge, the spring mechanism and the signal shaft, and the end of the detecting rod is fixed with a contact block.
  • a pressing block is mounted on the inner side of the rear support seat, and the detecting rod is connected by a pin shaft in the pressing block to mount the detecting rod on the positioning device suitable for the on-line milling operation of the rail, the pressing
  • the engagement of the pin shaft in the block with the detecting rod is a movable hinge, and the detecting rod can be rotated at a small angle around a pin shaft in the pressing block.
  • the upper support base can be rotated at a small angle around a central circular axis of the vertical feed base to meet the positioning device suitable for the on-line milling operation of the rail on the uphill or the lower side. Angle deflection requirements generated during ramping.
  • the cylinder is connected to the pneumatic solenoid valve through the air duct, and the cylinder is actuated by the power loss of the pneumatic solenoid valve to further drive the movement of the detecting rod.
  • the measuring rod of the length gauge is linearly moved with the detecting rod, and the displacement value of the contact block sliding along the inner side of the rail is further measured in real time, and transmitted to the numerical control system through the data line to indicate milling.
  • the unit moves laterally.
  • the spring mechanism employs a compression spring whose spring force is smaller than the cylinder driving force.
  • the signal axis moves laterally with the detecting rod, and when the overtravel sensing switch detects the signal axis, indicating that the following abnormality is detected, the numerical control system instructs the milling unit to perform an emergency lifting, and the working sensing switch When the signal axis is detected, it indicates that the positioning device suitable for the on-line milling operation of the rail is in normal following, and the numerical control system instructs the milling unit to continue normal operation.
  • the positioning device provided by the invention adopts the following methods to realize the function:
  • the pneumatic solenoid valve loses power, the cylinder piston rod retracts and pulls the detection rod inward, the spring mechanism compresses, the contact block is away from the inner side of the rail, and the positioning device descends and presses on the top surface of the rail.
  • the pneumatic solenoid valve is energized, the piston rod of the cylinder extends and pushes the detection rod outward, the spring mechanism is reset, and the contact block is closely attached to the inner side of the rail.
  • the numerical control system collects the measured value of the length gauge. Instructs the milling unit to move laterally in the corresponding direction until the measured value of the length gauge is within the set window value to complete accurate positioning.
  • the numerical control system collects the measured value of the length gauge in real time, if the measured value exceeds the positioning device on the standard straight line.
  • the relative displacement value between the calibration contact and the milling unit, ie the window value the numerical control system instructs the milling unit to move laterally in the corresponding direction until the measured value of the length gauge returns to the window value, realizing precise tracking of the rail in real time. .
  • Another aspect of the present invention provides a positioning and hedging method suitable for on-line milling operation of a rail, which comprises the following steps:
  • the milling unit is ready for positioning.
  • the control system controls the piston rod of the cylinder to retract and pull the detection rod to the inside.
  • the spring mechanism is compressed, and the contact block is away from the fat side of the inner side of the rail.
  • the positioning device suitable for the on-line milling operation of the rail is lowered. And pressed on the top surface of the rail.
  • the control system controls the piston rod of the cylinder to extend and pushes the detection rod outward.
  • the spring mechanism is reset, and the contact block is tightly attached to the inner side of the rail.
  • the numerical control system collects the length gauge. The measured value indicates that the milling unit moves laterally in the corresponding direction until the measured value of the length gauge is within the set window value, and the accurate positioning is completed;
  • the numerical control system collects the measured value of the length gauge in real time, and if the measured value exceeds the positioning device, it is calibrated on the standard straight line.
  • the relative displacement value between the contact and the milling unit, that is, the window value the numerical control system instructs the milling unit to move laterally in the corresponding direction until the measured value of the length gauge returns to the window value, so as to accurately follow the rail sliding in real time.
  • the signal shaft receives the displacement signal during the movement of the contact block to drive the detection rod, and the overtravel sensor detects the signal.
  • the shaft and thus the overtravel sensing switch, transmits a signal to the numerical control system.
  • the numerical control system considers that the alarm signal is received, the pneumatic electromagnetic valve is de-energized, the piston rod of the cylinder is retracted and the detecting rod is pulled inward, the spring mechanism is compressed, and the contact block is away from the inner side of the rail.
  • the milling unit is urgently lifted to complete the disposal of abnormal conditions.
  • the present invention has the following advantages and effects:
  • the length gauge is used as the lateral follower displacement measurement sensor.
  • the length gauge has a large measuring range and high measurement accuracy.
  • the response overtravel alarm distance can reach 25mm, which significantly improves the fault tolerance distance and simultaneously measures the displacement of the length gauge.
  • the window value set by the numerical control system the purpose of improving the positioning accuracy of the milling unit and accurately following the rail sliding is achieved.
  • the carbide block with reasonable size is used as the lateral follower contact block, which is close to the inner side of the rail during the milling operation, and improves the passage of the milling unit at the maximum joint and the wrong tooth of the rail.
  • Figure 1 is a schematic view showing the inner layout of the present invention
  • FIG. 2 is a schematic view showing the layout of the outer side of the present invention.
  • FIG. 3 is a schematic partial layout view of a support base and an upper support base according to the present invention.
  • FIG. 4 is a schematic view showing a partial layout of a detecting rod of the present invention.
  • Fig. 5 is a schematic view showing the partial layout of the support base before the present invention.
  • Embodiment 1.1 A positioning device suitable for on-line milling operation of a rail, as shown in FIGS. 1-5, includes a lower support base 14, which is connected to one end of the upper support base 15 via a pin shaft, The upper support base 15 is mounted with a vertical feed base 5, which is mounted with a front support base 11 and a rear support base 6, and the lower support base 14 includes a front end inner frame and a rear end inner frame.
  • the seat body between the frame and the inner frame of the rear end is parallel to the plane of the rail, and the base body of the front end inner frame and the rear inner frame is further provided with a force sensor 17, and the upper part of the front end inner frame is connected with the upper support base 15 and the lower support
  • the front end inner frame and the rear inner frame of the seat 14 are respectively arranged with a set of rollers, each set of rollers includes two rollers, and the center distance between the two sets of rollers is 300 mm, so as to ensure that the positioning device suitable for the on-line milling operation of the rail is pressed
  • the force sensor 17 is used to detect the downward pressure of the milling unit, and the upper working surface of the force sensor 17 is in contact with the bottom surface of the upper support 15.
  • the rear support base 6 is further connected to the detecting rod 2, and the detecting rod 2 is longitudinally disposed along the front supporting base 11, the vertical feeding base 5 and the rear supporting base 6, and the longitudinal length of the detecting rod 2 is larger than the front supporting base 11, and the vertical direction
  • the sum of the longitudinal lengths of the feed base 5 and the rear support base 6; the longitudinal section of the detection rod 2 is an elongated rod comprising four corners and three longitudinal sections, a vertical vertical section and a vertical inclined section .
  • the front support base 11 includes a lateral support connected to the vertical feed base 5 and a longitudinal top plate, a longitudinal outer back plate and a longitudinal inner back plate integrally formed with the lateral support.
  • the longitudinal top plate extends longitudinally forward from the upper surface of the lateral support, and the longitudinal outer back plate and the longitudinal inner back plate are also integrally formed with the lateral support and the longitudinal top plate, and the central axis of the longitudinal top plate Along the central axis of the lateral support, the longitudinal outer back plate, the longitudinal inner back plate and the central axis of the lateral support are also perpendicular; the longitudinal inner back plate is longer than the longitudinal top plate, The longitudinal outer backing plate is equal in length to the longitudinal top plate.
  • an overtravel sensing switch 10 As shown in FIG. 5, an overtravel sensing switch 10, a spring mechanism 12, and a signal shaft 13 are disposed in the direction of the outer side of the longitudinal outer back plate adjacent to the lateral support to away from the lateral support, and the overtravel sensing switch is disposed. 10 and the axis of the signal shaft 13 are in the same horizontal plane, the longitudinal outer back plate below the signal shaft 13 is connected to the working inductive switch 16, the central axis of the signal shaft 13 and the work sensing switch 16 are in the same vertical plane; the overtravel sensing switch 10 is perpendicular to the central axis of the work sensing switch 16.
  • the front end of the detecting rod 2 is connected to the movable end of the cylinder 3, the length gauge 4, the spring mechanism 12 and the signal shaft 13, and the cylinder 3 is located away from the vertical feed base 5, and the length gauge 4 is close to the vertical
  • the contact block 8 is fixed to the end of the detecting lever 2.
  • a pressing block 9 is mounted on the inner side of the rear support base 6, and the detecting rod 2 is connected by a pin shaft in the pressing block 9 to mount the detecting rod on the positioning device suitable for the on-line milling operation of the rail, the pressing block
  • the engagement of the pin shaft 9 with the detecting lever is a movable hinge, so that the detecting lever 2 can be rotated at a small angle around the pin 18 in the pressing block 9.
  • the upper support base 15 can be rotated at a small angle around the central circular axis of the vertical feed base 5 to meet the above-mentioned positioning device suitable for the on-line milling operation of the rail, which is generated during the ascending or descending slope. Angle deflection requirements.
  • the cylinder 3 is connected to the pneumatic solenoid valve through the air duct, and the cylinder is actuated by the pneumatic solenoid valve to further reduce the movement of the detecting rod 2.
  • the measuring rod of the length gauge 4 is moved linearly with the detecting rod 2, and the displacement value of the contact block 8 sliding along the inner side of the rail is further measured in real time, and transmitted to the numerical control system through the data line, instructing the milling unit to perform lateral movement.
  • the spring mechanism 12 employs a compression spring whose spring force is smaller than the driving force of the cylinder 3.
  • the signal axis 13 moves laterally with the detecting lever 2, and when the overtravel sensing switch 10 detects the signal axis 13, it indicates that the following abnormality is indicated, and the numerical control system instructs the milling unit to perform an emergency lifting.
  • the working sensing switch 16 detects the signal axis 13 It is indicated that the positioning device suitable for the on-line milling operation of the rail is in normal following, and the numerical control system instructs the milling unit to continue normal operation.
  • the contact block 8 is made of a cemented carbide block having a circular arc angle at both ends and a straight line segment in the middle.
  • Embodiment 1.2 A positioning device suitable for on-line milling operation of a rail, which is different from Embodiment 1.1, in that a front wheel inner frame and a rear end inner frame of the lower support base 14 are respectively arranged with a set of rollers, one of which is a set of rollers. The number is one and the other group has two wheels.
  • Embodiment 1.3 A positioning device suitable for on-line milling operation of a rail, similar to Embodiment 1.1, in that a hydraulic cylinder is used to drive the detection rod.
  • the pneumatic solenoid valve When the milling unit is ready for positioning, the pneumatic solenoid valve is de-energized, the piston rod of the cylinder 3 is retracted and the detection rod 2 is pulled inward, the spring mechanism 12 is compressed, and the contact block 8 is away from the fat side of the inner side of the rail 1, suitable for The positioning device of the rail on-line milling operation descends and presses on the top surface of the rail 1.
  • the pneumatic solenoid valve is energized, the piston rod of the cylinder 3 extends and pushes the detection rod 2 outward, and the spring mechanism 12 reset, the contact block 8 is closely attached to the inner side of the rail.
  • the numerical control system collects the measured value of the length gauge 4, instructing the milling unit to move laterally in the corresponding direction until the measured value of the length gauge 4 is within the set window value. Accurate positioning.
  • the contact block 8 When the milling unit is in rapid sliding, the contact block 8 is in close contact with the inner side of the rail.
  • the numerical control system collects the measured value of the length gauge 4 in real time, if the measured value exceeds the positioning device in the standard straight line.
  • the relative displacement value between the contact fast 8 and the milling unit, ie the window value the numerical control system instructs the milling unit to move laterally in the corresponding direction until the measured value of the length gauge 4 returns to the window value, realizing real time Accurately follow the rails to slide.
  • the signal shaft 13 receives the displacement signal during the movement of the contact block 8 to drive the detecting rod 2, and the overtravel
  • the inductive switch 10 detects the signal shaft 13, so that the overtravel sensing switch 10 transmits a signal to the numerical control system, the numerical control system receives an abnormal alarm, the pneumatic electromagnetic valve is de-energized, the piston rod of the cylinder 3 is retracted and the detecting rod 2 is pulled inward, and the spring The mechanism 12 is compressed, the contact block 8 is away from the inner side of the rail, and the milling unit is urgently lifted to complete the disposal of abnormal conditions.
  • Embodiment 2.1 A positioning method suitable for on-line milling operation of a rail, comprising the following steps:
  • the milling unit is ready for positioning.
  • the pneumatic solenoid valve is de-energized, the piston rod of the cylinder 3 is retracted and the detection rod 2 is pulled inward, the spring mechanism 12 is compressed, and the contact block 8 is away from the fat side of the inner side of the rail 1, and is suitable for the rail.
  • the positioning device of the online milling operation is lowered and pressed on the top surface of the rail 1.
  • the pneumatic solenoid valve is energized, the piston rod of the cylinder 3 is extended and the detection rod 2 is pushed outward, and the spring mechanism 12 Reset, the contact block 8 is closely attached to the inner side of the rail.
  • the numerical control system collects the measured value of the length gauge 4, indicating that the milling unit moves laterally in the corresponding direction until the measured value of the length gauge 4 is within the set window value, and the accuracy is completed.
  • the contact block 8 When the milling unit is in rapid sliding, the contact block 8 is in close contact with the inner side of the rail, and the numerical control system collects the measured value of the length gauge 4 in real time as the geometrical parameters of the line change, if the measured value exceeds the positioning device on the standard straight line
  • the numerical control system instructs the milling unit to move laterally in the corresponding direction until the measured value of the length gauge 4 returns to the window value, realizing accurate in real time.
  • the milling unit When the milling unit is in rapid gliding, if the contact block 8 encounters a serious rail joint disease or other abnormality, the signal shaft 13 receives the displacement signal during the movement of the contact block 8 to drive the detecting rod 2, and the overtravel sensing The switch 10 detects the signal shaft 13, so that the overtravel sensing switch 10 transmits a signal to the numerical control system, the numerical control system receives an abnormal alarm, the pneumatic electromagnetic valve is de-energized, the piston rod of the cylinder 3 is retracted and the detecting rod 2 is pulled inward, and the spring mechanism 12 compression, the contact block 8 is away from the inner side of the rail, and the milling unit is urgently lifted to complete the disposal of abnormal conditions.
  • Steps a and b are sequentially performed according to the rail condition, or steps a, c are sequentially performed or steps a, b, and c are sequentially performed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Machines For Laying And Maintaining Railways (AREA)
  • Automatic Control Of Machine Tools (AREA)

Abstract

一种适用于钢轨在线铣磨作业的定位装置，包括下支撑座(14)，该下支撑座(14)连接上支撑座(15)，该上支撑座(15)安装有垂向进给底座(5)，该垂向进给底座(5)安装有前支撑座(11)和后支撑座(6)，该后支撑座(6)还连接检测杆(2)，前支撑座(11)上布置有气缸(3)、长度计(4)、弹簧机构(12)、信号轴(13)、超程感应开关(10)及作业感应开关(16)，检测杆(2)与气缸(3)、长度计(4)、弹簧机构(12)及信号轴(13)连接。以及一种适用于钢轨在线铣磨作业的定位及避险方法。该定位装置采用多个滚轮作为定位装置在钢轨顶面的走行部，足以支撑起铣磨单元在钢轨表面快速滑行，避免定位装置擦伤钢轨表面及产生振动，能有效监测到钢轨顶面波峰及波谷的变化，并且滚轮磨耗慢，能降低定位装置的维护成本。

Description

一种适用于钢轨在线铣磨作业的定位装置 技术领域
本发明涉及一种适用于钢轨在线铣磨作业的定位装置，属于铁路机械设计及制造技术领域。
背景技术
应用钢轨铣磨车在工作运行中对钢轨进行在线铣磨作业，可消除波磨、裂纹、肥边和剥落等钢轨病害，有效延长钢轨使用寿命。作为钢轨铣磨车的核心部件，铣磨单元在作业过程中需要准确定位在钢轨上，实时精确跟随钢轨滑行，因此钢轨铣磨车的铣磨单元需要配备一种定位装置。
现有的铣磨单元所配备的定位装置，采用磨耗块作为接触部件压在钢轨顶面滑行，选用电涡流式传感器作为横向位移量测量传感器，用弹簧机构驱动检测杆的末端使其紧贴钢轨内侧。在实际作业中，由于钢轨表面存在波磨，铣磨单元通过定位装置压在钢轨顶面滑行中，磨耗块会擦伤钢轨表面，并引起铣磨单元振动而降低伺服进给精度，且磨耗块易损耗，需要定期更换，增加了维护成本；同时，电涡流式传感器的测量范围小、测量精度低，一方面，钢轨存在的轨缝及错牙会使检测杆瞬间移动距离超过电涡流式传感器的测量范围，引起铣磨单元频繁紧急提升，另一方面，因铣磨单元的横向位移量与电涡流式传感器的测量值关联，使铣磨单元横向跟随容易产生误差，直接影响作业后的横向轮廓精度；再者，若铣磨削单元在有钢轨肥边的位置处提升时，检测杆会被肥边刮坏。以上问题都会使铣磨削单元的可靠性及作业精度大大降低。
申请号为201610870842.1的中国发明专利申请公开了一种用于钢轨铣磨装置侧向定位的自适应跟随装置，其包括底座、杠杆定位装置、杠杆复位装置、杠杆调整装置以及感应装置；其中所述杠杆定位装置包括杠杆以及定位合金块，所述杠杆复位装置包括 复位弹簧以及复位顶销，所述杠杆调整装置包括气缸，所述感应装置包括直线位移传感器以及传感器固定座。该自适应跟随装置解决了传统侧向定位装置由于钢轨肥边、塌边严重时无法正常定位的问题，同时能够适应不钢轨规格以及不同钢轨连接，在钢轨肥边及塌陷严重线路的工况下也能实现钢轨铣磨作业时铣磨装置的精密侧向定位。该装置实现了铣削和磨削的精密定位和数字化反馈，但是仍然没有解决跟随装置底座擦伤钢轨表面等问题，且该跟随装置不能有效跟随钢轨表面波峰及波谷。
为此，需要设计一种新型的定位装置，一方面，该定位装置能够支撑起铣磨单元在钢轨表面快速滑行，且不能对钢轨顶面造成二次伤害；另一方面，该定位装置在下降、作业跟随及提升过程中，要能够克服钢轨接缝、错牙、肥边等恶劣工况，以满足铣磨单元作业的技术要求。
发明内容
本发明中设定：垂直于钢轨延伸(即平行于轨枕)的方向为横向，垂直于钢轨顶面的方向为垂向，平行于钢轨延伸的方向为纵向。
本发明所要解决的技术问题是提供一种适用于钢轨在线铣磨作业的定位装置，用以突破现有铣磨装置定位不精确及擦伤钢轨表面的技术难题，实现钢轨铣磨车的铣磨单元准确定位、实时精确跟随钢轨滑行，并提高铣磨单元的作业精度及可靠性。
本发明通过下列技术方案实现：一种适用于钢轨在线铣磨作业的定位装置，包括下支撑座，该下支撑座连接上支撑座，该上支撑座安装有垂向进给底座，该垂向进给底座安装有前支撑座和后支撑座，该后支撑座还连接检测杆，所述前支撑座上布置有气缸、长度计、弹簧机构、信号轴、超程感应开关及作业感应开关，所述检测杆与所述气缸、长度计、弹簧机构及信号轴连接。
优选的是，所述下支撑座包括前端内框和后端内框，该前端内框与后端内框之间的 座体平行于钢轨顶面，所述前端内框上部连接所述上支撑座。
优选的是，所述下支撑座的前端内框及后端内框各布置有一组滚轮，每组滚轮数量至少为一个，两组滚轮之间中心距离大于200mm，以确保定位装置压在有波磨的钢轨顶面时，其中一组滚轮能够接触到波峰或波谷，所述下支撑座的中部布置有用于检测铣磨单元下压力的力传感器，所述力传感器的工作面与上支撑座的底面接触。
优选的是，所述检测杆的前端与所述气缸、长度计、弹簧机构及信号轴的动端连接，所述检测杆的末端固定有接触块。
优选的是，所述后支撑座下方内侧安装有压块，该压块内通过销轴连接检测杆，以便将检测杆安装于所述适用于钢轨在线铣磨作业的定位装置上，所述压块内的销轴与所述检测杆的配合为活动铰接，所述检测杆可绕该压块内的销轴做小角度转动。
在上述任一方案中优选的是，所述上支撑座可绕垂向进给底座的中心圆轴做小角度转动，以满足所述适用于钢轨在线铣磨作业的定位装置在上坡或下坡滑行中产生的角度偏转要求。
在上述任一方案中优选的是，所述气缸通过风管连接至气动电磁阀，并通过气动电磁阀得失电控制气缸动作，进一步驱动检测杆移动。
在上述任一方案中优选的是，所述长度计的测量杆随检测杆做横向直线运动，进一步实时测量接触块随钢轨内侧滑行的位移值，并通过数据线传输至数控系统，指示铣磨单元进行横向移动。
在上述任一方案中优选的是，所述弹簧机构采用压缩弹簧，该压缩弹簧的弹簧力小于气缸驱动力。
在上述任一方案中优选的是，所述信号轴随检测杆横向移动，所述超程感应开关检测到信号轴时，表明跟随异常，数控系统指示铣磨单元紧急提升，所述作业感应开关检 测到信号轴时，表明所述适用于钢轨在线铣磨作业的定位装置处于正常跟随，数控系统指示铣磨单元继续正常作业。
本发明提供的定位装置采用如下方法实现功能：
(1)当铣磨单元准备定位时，气动电磁阀失电，气缸活塞杆缩回并向内拉检测杆，弹簧机构压缩，接触块远离钢轨内侧肥边，定位装置下降并压在钢轨顶面，力传感器检测到压力值正常后，气动电磁阀得电，气缸活塞杆伸出并向外推检测杆，弹簧机构复位，接触块紧贴钢轨内侧，此时数控系统采集长度计的测量值，指示铣磨单元向相应的方向横向移动，直到长度计的测量值在设定的窗口值内，完成准确定位。
(2)当铣磨单元在快速滑行中，接触块紧贴钢轨内侧，随着线路几何参数的变化，数控系统实时采集长度计的测量值，若该测量值超出定位装置在标准直线线路上进行标定的接触快与铣磨单元之间的相对位移值，即窗口值，数控系统指示铣磨单元向相应的方向横向移动，直到长度计的测量值回到窗口值内，实现实时精确跟随钢轨滑行。
(3)当铣磨单元在快速滑行中，若接触块遇到严重的钢轨接头病害或其他异常时，超程感应开关检测到信号轴，数控系统认为接收到报警信号，气动电磁阀失电，气缸活塞杆缩回并向内拉检测杆，弹簧机构压缩，接触块远离钢轨内侧肥边，铣磨单元紧急提升，完成异常工况的处置。
本发明另一方面提供一种适用于钢轨在线铣磨作业的定位及避险方法，其包括下列步骤：
a.铣磨单元准备定位，此时控制系统控制气缸的活塞杆缩回并向内侧拉检测杆，弹簧机构压缩，接触块远离钢轨内侧的肥边，适用于钢轨在线铣磨作业的定位装置下降并压在钢轨顶面，力传感器检测到压力值正常后，控制系统控制气缸的活塞杆伸出并向外推检测杆，弹簧机构复位，接触块紧贴钢轨内侧，此时数控系统采集长度计的测量值， 指示铣磨单元向相应的方向横向移动，直到长度计的测量值在设定的窗口值内，完成准确定位；
b.当铣磨单元在快速滑行中，接触块紧贴钢轨内侧，随着线路几何参数的变化，数控系统实时采集长度计的测量值，若该测量值超出定位装置在标准直线线路上进行标定的接触快与铣磨单元之间的相对位移值，即窗口值，数控系统指示铣磨单元向相应的方向横向移动，直到长度计的测量值回到窗口值内，实现实时精确跟随钢轨滑行。
c.当铣磨单元在快速滑行中，若接触块遇到严重的钢轨接头病害或其他异常时，信号轴在接触块带动检测杆的活动过程中接收到位移信号，超程感应开关检测到信号轴，从而超程感应开关传递信号至数控系统，数控系统认为接收到报警信号，气动电磁阀失电，气缸的活塞杆缩回并向内拉检测杆，弹簧机构压缩，接触块远离钢轨内侧肥边，铣磨单元紧急提升，完成异常工况的处置。
本发明与现有技术相比具有下列优点和效果：
(1)采用多个滚轮作为定位装置在钢轨顶面的走行部，足以支撑起铣磨单元在钢轨表面快速滑行，避免定位装置擦伤钢轨表面及产生振动，能有效监测到钢轨顶面波峰及波谷的变化，并且滚轮磨耗慢，能降低定位装置的维护成本。
(2)采用长度计作为横向跟随位移量测量传感器，长度计的测量范围大、测量精度高，其响应的超程报警距离可达25mm，显著提高了容错距离，同时将长度计的位移测量值与数控系统设置的窗口值进行比较，达到提高铣磨单元定位精度和实时精确跟随钢轨滑行的目的。
(3)采用气缸驱动接触块的移动，使其横向移动距离大于10mm，并通过程序连锁，在任何条件下，当铣磨单元下降或提升时，气缸都会将接触块驱动离开钢轨内侧面，避免在有肥边的钢轨位置处下降或提升时刮伤接触块，进一步破坏检测杆。
(4)采用外形尺寸合理的硬质合金块作为横向跟随接触块，铣磨作业中紧贴钢轨内侧，提高铣磨单元在钢轨最大接缝和错牙处的通过性。
附图说明
图1为本发明之内侧布局示意图；
图2为本发明之外侧布局示意图；
图3为本发明之下支撑座与上支撑座局部布局示意图；
图4为本发明之检测杆局部布局示意图；
图5为本发明之前支撑座局部布局示意图。
图1-图3中数字标记的含义是：
1钢轨 2检测杆 3气缸 4长度计 5垂向进给底座
6后支撑座 7滚轮 8接触块 9压块 10超程感应开关
11前支撑座 12弹簧机构 13信号轴 14下支撑座 15上支撑座
16作业感应开关 17力传感器 18销轴
具体实施方式
实施例1.1:一种适用于钢轨在线铣磨作业的定位装置，如图1-图5所示，其包括下支撑座14，该下支撑座14通过销轴与上支撑座15的一端连接，该上支撑座15安装有垂向进给底座5，该垂向进给底座5安装有前支撑座11和后支撑座6，下支撑座14包括前端内框和后端内框，该前端内框与后端内框之间的座体平行于钢轨平面，所述前端内框和后端内框的座体上还装有力传感器17，所述前端内框上部连接上支撑座15，下支撑座14的前端内框及后端内框各布置有一组滚轮，每组滚轮包括两个滚轮，两组滚轮之间中心距离为300mm，以确保适用于钢轨在线铣磨作业的定位装置压在有波磨的钢轨顶面时，其中一组滚轮能够接触到波峰或波谷，力传感器17用于检测铣磨单元的下压 力，力传感器17上部的工作面与上支撑座15的底面接触。
后支撑座6还连接检测杆2，该检测杆2沿前支撑座11、垂向进给底座5和后支撑座6纵向设置，且该检测杆2的纵向长度大于前支撑座11、垂向进给底座5和后支撑座6的纵向长度之和；该检测杆2的纵剖面是包括四个拐角和三段纵向水平段、一段垂向竖直段和一段垂向倾斜段的长形杆。
如图1-图2所示，前支撑座11包括与垂向进给底座5连接的横向支座和与该横向支座呈一体结构的纵向顶板、纵向外侧背板及纵向内侧背板，所述纵向顶板从所述横向支座上表面纵向向前延伸，所述纵向外侧背板和纵向内侧背板与所述横向支座和所述纵向顶板也呈一体结构，所述纵向顶板的中心轴线与所述横向支座的中心轴线垂直，所述纵向外侧背板、纵向内侧背板与所述横向支座的中心轴线也垂直；所述纵向内侧背板比所述纵向顶板的长度更长，所述纵向外侧背板与所述纵向顶板的长度相等。
如图5所示，所述纵向外侧背板下方设置外沿靠近所述横向支座至远离横向支座的方向依次布置有超程感应开关10、弹簧机构12和信号轴13，超程感应开关10和信号轴13的轴线在同一水平面内，该信号轴13下方的纵向外侧背板连接作业感应开关16，信号轴13和作业感应开关16的中心轴线在同一竖直面内；超程感应开关10与所述作业感应开关16的中心轴相互垂直。
检测杆2的前端与所述气缸3、长度计4、弹簧机构12及信号轴13的动端连接，气缸3在远离所述垂向进给底座5的位置，长度计4在靠近所述垂向进给底座5的位置，检测杆2的末端固定有接触块8。
所述后支撑座6下方内侧安装压块9，该压块9内通过销轴连接检测杆2，以便将检测杆安装于所述适用于钢轨在线铣磨作业的定位装置上，所述压块9内的销轴与所述检测杆的配合为活动铰接，从而使所述检测杆2可绕该压块9内的销轴18做小角度转 动。
本实施例中，上支撑座15可绕垂向进给底座5的中心圆轴做小角度转动，以满足所述适用于钢轨在线铣磨作业的定位装置在上坡或下坡滑行中产生的角度偏转要求。
气缸3通过风管连接至气动电磁阀，并通过气动电磁阀得失电控制气缸动作，进一步驱动检测杆2移动。
长度计4的测量杆随检测杆2做横向直线运动，进一步实时测量接触块8随钢轨内侧滑行的位移值，并通过数据线传输至数控系统，指示铣磨单元进行横向移动。
弹簧机构12采用压缩弹簧，该压缩弹簧的弹簧力小于气缸3的驱动力。
信号轴13随检测杆2横向移动，所述超程感应开关10检测到信号轴13时，表明跟随异常，数控系统指示铣磨单元紧急提升，所述作业感应开关16检测到信号轴13时，表明所述适用于钢轨在线铣磨作业的定位装置处于正常跟随，数控系统指示铣磨单元继续正常作业。
接触块8采用两端为圆弧角、中间为直线段的硬质合金块。
实施例1.2:一种适用于钢轨在线铣磨作业的定位装置，同实施例1.1，不同之处在于：下支撑座14的前端内框及后端内框各布置有一组滚轮，其中一组滚轮数量为一个，另一组滚轮数量为两个。
实施例1.3:一种适用于钢轨在线铣磨作业的定位装置，同实施例1.1，不同之处在于：采用液压油缸驱动检测杆。
上述实施例所述适用于钢轨在线铣磨作业的定位装置的工作原理是：
(1)当铣磨单元准备定位时，气动电磁阀失电，气缸3的活塞杆缩回并向内侧拉检测杆2，弹簧机构12压缩，接触块8远离钢轨1内侧的肥边，适用于钢轨在线铣磨作业的定位装置下降并压在钢轨1顶面，力传感器17检测到压力值正常后，气动电磁阀得 电，气缸3的活塞杆伸出并向外推检测杆2，弹簧机构12复位，接触块8紧贴钢轨内侧，此时数控系统采集长度计4的测量值，指示铣磨单元向相应的方向横向移动，直到长度计4的测量值在设定的窗口值内，完成准确定位。
(2)当铣磨单元在快速滑行中，接触块8紧贴钢轨内侧，随着线路几何参数的变化，数控系统实时采集长度计4的测量值，若该测量值超出定位装置在标准直线线路上进行标定的接触快8与铣磨单元之间的相对位移值，即窗口值，数控系统指示铣磨单元向相应的方向横向移动，直到长度计4的测量值回到窗口值内，实现实时精确跟随钢轨滑行。
(3)当铣磨单元在快速滑行中，若接触块8遇到严重的钢轨接头病害或其他异常时，信号轴13在接触块8带动检测杆2的活动过程中接收到位移信号，超程感应开关10检测到信号轴13，从而超程感应开关10传递信号至数控系统，数控系统接收到异常报警，气动电磁阀失电，气缸3的活塞杆缩回并向内拉检测杆2，弹簧机构12压缩，接触块8远离钢轨内侧肥边，铣磨单元紧急提升，完成异常工况的处置。
实施例2.1:一种适用于钢轨在线铣磨作业的定位方法，其包括下列步骤：
a.铣磨单元准备定位，此时令气动电磁阀失电，气缸3的活塞杆缩回并向内侧拉检测杆2，弹簧机构12压缩，接触块8远离钢轨1内侧的肥边，适用于钢轨在线铣磨作业的定位装置下降并压在钢轨1顶面，力传感器17检测到压力值正常后，气动电磁阀得电，气缸3的活塞杆伸出并向外推检测杆2，弹簧机构12复位，接触块8紧贴钢轨内侧，此时数控系统采集长度计4的测量值，指示铣磨单元向相应的方向横向移动，直到长度计4的测量值在设定的窗口值内，完成准确定位；
b.当铣磨单元在快速滑行中，接触块8紧贴钢轨内侧，随着线路几何参数的变化，数控系统实时采集长度计4的测量值，若该测量值超出定位装置在标准直线线路上进行标定的接触快8与铣磨单元之间的相对位移值，即窗口值，数控系统指示铣磨单元向相 应的方向横向移动，直到长度计4的测量值回到窗口值内，实现实时精确跟随钢轨滑行。
c.当铣磨单元在快速滑行中，若接触块8遇到严重的钢轨接头病害或其他异常时，信号轴13在接触块8带动检测杆2的活动过程中接收到位移信号，超程感应开关10检测到信号轴13，从而超程感应开关10传递信号至数控系统，数控系统接收到异常报警，气动电磁阀失电，气缸3的活塞杆缩回并向内拉检测杆2，弹簧机构12压缩，接触块8远离钢轨内侧肥边，铣磨单元紧急提升，完成异常工况的处置。
根据钢轨情况依次执行步骤a、b或依次执行步骤a、c或依次执行步骤a、b、c。

Claims (13)

  1. 一种适用于钢轨在线铣磨作业的定位装置，其特征在于：包括下支撑座(14)，该下支撑座(14)连接上支撑座(15)，该上支撑座(15)安装有垂向进给底座(5)，该垂向进给底座(5)安装有前支撑座(11)和后支撑座(6)，该后支撑座(6)还连接检测杆(2)，后支撑座(6)下方内侧安装有压块(9)，前支撑座(11)上布置有气缸(3)、长度计(4)、弹簧机构(12)、信号轴(13)、超程感应开关(10)及作业感应开关(16)，检测杆(2)与气缸(3)、长度计(4)、弹簧机构(12)及信号轴(13)连接，上支撑座(15)可绕垂向进给底座(5)的中心圆轴做小角度转动，以满足所述适用于钢轨在线铣磨作业的定位装置在上坡或下坡滑行中产生的角度偏转要求。
  2. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：下支撑座(14)包括前端内框和后端内框，该前端内框与后端内框之间的座体平行于钢轨平面，所述前端内框上部连接所述上支撑座(15)。
  3. 如权利要求2所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：下支撑座(14)的前端内框及后端内框各布置有一组滚轮，每组滚轮数量至少为一个，两组滚轮之间中心距离大于200mm，以确保定位装置压在有波磨的钢轨顶面时，其中一组滚轮能够接触到波峰或波谷。
  4. 如权利要求1-3中任一项所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：下支撑座(14)的中部布置有用于检测铣磨单元下压力的力传感器，所述力传感器的工作面与上支撑座(15)的底面接触。
  5. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：检测杆(2)的前端与所述气缸(3)、长度计(4)、弹簧机构(12)及信号轴(13)的动端连接。
  6. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：检测杆(2)的末端固定有接触块(8)。
  7. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：压块(9)内通过销轴(18)连接检测杆(2)，以便将检测杆安装于所述适用于钢轨在线铣磨作业的定位装置上。
  8. 如权利要求7所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：压块(9)内的销轴(18)与检测杆(2)的配合为活动连接，检测杆(2)可绕该压块内的销轴做小角度转动。
  9. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：气缸(3)通过风管连接至气动电磁阀，并通过气动电磁阀得失电控制气缸动作，进一步驱动检测杆(2)移动。
  10. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：长度计(4)的测量杆随检测杆(2)做横向直线运动，进一步实时测量接触块(8)随钢轨内侧滑行的位移值，并通过数据线传输至数控系统，指示铣磨单元进行横向移动。
  11. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：所述弹簧机构采用压缩弹簧，该压缩弹簧的弹簧力小于气缸驱动力。
  12. 如权利要求1所述的适用于钢轨在线铣磨作业的定位装置，其特征在于：信号轴(13)随检测杆(2)横向移动，所述超程感应开关(10)检测到信号轴(13)时，表明跟随异常，数控系统指示铣磨单元紧急提升，所述作业感应开关(16)检测到信号轴(13)时，表明所述适用于钢轨在线铣磨作业的定位装置处于正常跟随，数控系统指示铣磨单元继续正常作业。
  13. 一种适用于钢轨在线铣磨作业的定位及避险方法，其特征在于：包括下列步骤：
    a.铣磨单元准备定位，此时控制系统控制气缸(3)的活塞杆缩回并向内侧拉检测杆(2)，弹簧机构(12)压缩，接触块(8)远离钢轨(1)内侧的肥边，适用于钢轨在线铣磨作 业的定位装置下降并压在钢轨(1)顶面，力传感器(17)检测到压力值正常后，控制系统控制气缸(3)的活塞杆伸出并向外推检测杆(2)，弹簧机构(12)复位，接触块(8)紧贴钢轨内侧，此时数控系统采集长度计(4)的测量值，指示铣磨单元向相应的方向横向移动，直到长度计(4)的测量值在设定的窗口值内，完成准确定位；
    b.当铣磨单元在快速滑行中，接触块(8)紧贴钢轨内侧，随着线路几何参数的变化，数控系统实时采集长度计(4)的测量值，若该测量值超出定位装置在标准直线线路上进行标定的接触快(8)与铣磨单元之间的相对位移值，即窗口值，数控系统指示铣磨单元向相应的方向横向移动，直到长度计(4)的测量值回到窗口值内，实现实时精确跟随钢轨滑行；
    c.当铣磨单元在快速滑行中，若接触块(8)遇到严重的钢轨接头病害或其他异常时，信号轴(13)在接触块(8)带动检测杆(2)的活动过程中接收到位移信号，超程感应开关(10)检测到信号轴(13)，从而超程感应开关(10)传递信号至数控系统，数控系统认为接收到报警信号，气动电磁阀失电，气缸(3)的活塞杆缩回并向内拉检测杆(2)，弹簧机构(12)压缩，接触块(8)远离钢轨内侧肥边，铣磨单元紧急提升，完成异常工况的处置；
    依次执行步骤a、b或依次执行步骤a、c或依次执行步骤a、b、c。
PCT/CN2018/084991 2018-02-09 2018-04-28 一种适用于钢轨在线铣磨作业的定位装置 WO2019153537A1 (zh)

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