WO2024108596A1

WO2024108596A1 - Grinding unit deflection control apparatus, system and method, and rail grinding wagon

Info

Publication number: WO2024108596A1
Application number: PCT/CN2022/134489
Authority: WO
Inventors: 杨全; 郭平; 张东方; 余高翔; 何伟; 吴磊; 谢尚; 曾海林
Original assignee: 株洲时代电子技术有限公司
Priority date: 2022-11-25
Filing date: 2022-11-25
Publication date: 2024-05-30

Abstract

Provided is a grinding unit deflection control apparatus, comprising a deflection control unit (14), which controls the deflection of a grinding unit (100) in a parking state of a grinding wagon, and completes the calibration of a deflection angle; a data acquisition unit (21), which collects, during a calibration process, actual deflection angle values of a plurality of groups of grinding units and actuating mechanism stroke feedback values corresponding to the actual deflection angle values; and a data fitting unit (22), which uses a set function to perform fitting to obtain parameters of the function according to a plurality of groups of data combinations of the actual deflection angle values of the grinding units and the corresponding actuating mechanism stroke feedback values, and transmitting the parameters of the function to the deflection control unit. The deflection control unit performs deflection control on the grinding units in an operation state of the grinding vehicle by using the set function and the parameters, which are transmitted by the data fitting unit. By means of the apparatus, the technical problem of the deflection angle control precision of an existing grinding deflection control method being low due to an error easily occurring caused by machining and assembling, structural elastic deformation, etc., of grinding units can be solved. Further provided are a grinding unit deflection control method, a grinding unit deflection control system comprising the control apparatus, and a rail grinding wagon comprising the control apparatus or the control system.

Description

A grinding unit deflection control device, system, method and rail grinding vehicle

Technical Field

The present application relates to the field of rail engineering machinery, and in particular to a grinding unit deflection control device, system, method and rail grinding vehicle.

Background technique

With the continuous increase in railway transportation volume and load, various damages and defects are prone to occur on the surface and inside of rails, such as corrugation, cracks, peeling, crushing, pitting and fat edges. If not repaired in time, these defects will accelerate the deterioration, resulting in high rail replacement costs. Rail grinding is the main means to eliminate rail diseases and repair rail profiles. The use of rail grinding technology for line maintenance has become a consensus of track maintenance at home and abroad. Its application is becoming more and more popular, and it has also created great benefits for the railway system.

The rail grinding vehicle is a device used to grind the surface of the rails of the line to eliminate the surface defects of the rails (rust, fatigue cracks, unevenness, corrugation, fat edges, deformation, etc.). A plurality of grinding trolleys are arranged at the bottom of the grinding vehicle, and the grinding trolleys perform continuous grinding operations on the rails under the traction of the whole vehicle. A grinding unit 100 is arranged inside each grinding trolley, and the grinding unit 100 is the core mechanism of the rail grinding vehicle. As shown in Figure 1, the grinding unit 100 is composed of a rotatable deflection mechanism 2 (also called a cradle), a grinding motor 1, a grinding wheel (also called a grinding head 3), a grinding downward pressure cylinder (i.e., a downward pressure drive mechanism 7), a guide rod (i.e., a downward pressure guide column 4), a guide sleeve (i.e., a downward pressure guide sleeve 5) and an adjustment mechanism. The upper parts of the two groups of downward pressure guide columns 4 are connected by a connecting frame 6, and the lower part of the downward pressure guide column 4 is fixedly connected to the deflection mechanism 2. One end of the downward pressure driving mechanism 7 is connected to the connecting frame 6, and the other end is connected to the outer surface of the grinding motor 1 through the connecting arm plate 10. The grinding motor 1 is directly connected to the grinding head 3 and drives it to rotate at high speed. At the same time, the grinding motor 1 is installed on the downward pressure guide sleeve 5. The downward pressure driving mechanism 7 is controlled to drive the downward pressure guide sleeve 5 to move axially along the downward pressure guide column 4 to realize the downward pressure grinding operation of the grinding motor 1, and the adjustment mechanism is used to ensure the position, quality and efficiency of the grinding and avoid obstacles to ensure safety. With the continuous improvement of the railway operation speed, especially the rapid development of high-speed railways, the operating accuracy requirements of the rail grinding vehicle are getting higher and higher. The core of the operating accuracy lies in the deflection control and downward pressure control of the grinding unit 100. In particular, the precise adjustment and control of the deflection angle of the grinding unit is a key factor in determining the grinding quality, which directly affects the profile accuracy of the rail after grinding, and the guarantee of its control accuracy has always been a technical problem.

The contact between the grinding head 3 and the rail 200 is a linear contact. Each grinding wheel forms a bright band (elongated plane) on the rail 200. Multiple grinding heads 3 form multiple bright bands through different angle distributions, thereby covering the entire rail surface of the rail 200. The deflection mechanism 2 is provided with a rotating shaft, which can generate the required deflection angle toward the inside and outside of the rail under the drive of the deflection drive mechanism 8. The deflection angle range of the existing national railway grinding vehicle grinding unit 100 is generally -25° to +70°, and there are two main forms of angle deflection: one is a one-stage deflection of the deflection cylinder (i.e., the deflection drive mechanism 8), and the other is a two-stage deflection of the swing cylinder (i.e., the swing drive mechanism 9) + the deflection electric cylinder (i.e., the deflection drive mechanism 8). The deflection cylinder and the deflection electric cylinder are equipped with a stroke sensor, and the deflection angle of the grinding head 3 is determined by the change in length. The deflection structure of the grinding unit 100 using a deflection cylinder deflection method is shown in FIG3 , while the deflection structure of the grinding unit 100 using a swing cylinder + deflection electric cylinder two-stage deflection method is shown in FIG4 .

As shown in FIG5 , the rotation point of the deflection mechanism 2 (i.e., the cradle) is point O, the installation point of the deflection cylinder (i.e., the deflection drive mechanism 8) on the frame is point B, the installation point of the deflection cylinder on the deflection mechanism 2 is point A, the line segment length b of OB is a fixed value, the line segment length a of OA is a fixed value, and the line segment length L of AB changes as the deflection cylinder is extended or retracted. The deflection angle α of the grinding motor 1 is the angle between the vertical line of gravity of the grinding motor and the rotation axis, the outer deflection angle of the grinding motor is "-", and the inner deflection angle of the grinding motor is "+"; when α=0°, the length of the deflection cylinder or the deflection electric cylinder is L ₀ (at this time ∠AOB=θ ₀ ).

According to the above cosine theorem:

Available:

therefore:

Among them, the minimum length of the deflection cylinder after contraction is L _min , and the feedback voltage is V _min ; the maximum length of the deflection cylinder after extension is L _max , and the feedback voltage is V _max ; V _target is the deflection cylinder feedback voltage corresponding to the target length L _target .

However, in actual use, it was found that there was a large error between the deflection angle of the grinding unit measured by the existing control method and the theoretical angle, as shown in Figure 2 (the ordinate in the figure represents the deflection angle, in degrees; the abscissa represents the stroke voltage, in V). The maximum error reached 2°, and the errors of different grinding units on the same grinding vehicle were also different, with poor consistency, and could not meet the ±0.5° deflection angle error range requirement of the "TB/T3520-2018 Railway Large-Scale Maintenance Machinery Rail Grinding Vehicle" standard.

In summary, the technical problems existing in the existing grinding unit deflection control method are mainly:

(1) The deflection control accuracy of the grinding unit is poor, which seriously affects the grinding quality. The main reasons for this problem are: First, the processing error. After actual processing and assembly, there is a certain error in the positions of the three points A, O, and B, resulting in deviations between the dimensions of a, b, and _L0 and the theory. This deviation cannot be measured on site and will have a greater impact on the accuracy of the deflection angle. Second, the elastic deformation of the grinding unit frame structure. At different deflection angles, the deformation caused by gravity on the grinding unit is different, resulting in different angular deformations of the grinding unit under different deflection angles. Third, the clearance of each deflection axis is affected, mainly the internal clearance of the rotating bearing, the clearance between the bearing and the pin shaft, and the clearance in the cylinder. Fourth, the accuracy and linearity error of the feedback voltage signal of the deflection cylinder stroke sensor. Since the above four reasons are difficult to eliminate, the error control of the deflection angle becomes a technical problem, and it is difficult to further improve its deflection accuracy.

(2) The grinding deflection angle calibration efficiency is low and the manual error is large. The main reason for this problem is that in order to improve the calibration accuracy of the deflection angle, calibration is often carried out through multi-point calibration and segmented correction, but the workload is relatively large. At the same time, the inclinometer used in the existing calibration method is a single-axis inclinometer, which must be placed on the rotating surface by manual observation and experience in order to accurately test the inclination angle. The calibration is greatly affected by human operation, the efficiency is low and the accuracy is difficult to guarantee.

(3) The high temperature and internal high pressure during the grinding unit operation cause the hydraulic lock of the deflection cylinder to get stuck. The main reason for this problem is that during the grinding operation, the grinding wheel rotates at high speed on the rail, grinding the top surface of the rail, generating high-temperature sparks, causing the temperature inside the grinding trolley to rise sharply, thereby increasing the temperature of the deflection cylinder and the internal hydraulic oil. The hydraulic oil sealed by the hydraulic lock inside the cylinder expands at high temperatures, causing the hydraulic pressure inside the cylinder to increase significantly, making the hydraulic lock unable to open or getting stuck. At the same time, it also causes frequent oil leaks in the hydraulic cylinder, hydraulic lock and oil pipe.

(4) The grinding unit has large deflection vibrations. When the grinding motor is controlled to deflect at an angle, the deflection cylinder often vibrates violently, causing the deflection cradle to be unable to stop smoothly at the desired angle, and the desired grinding effect cannot be achieved. In particular, when the cradle is deflected to a larger angle, and when the cradle is deflected and stopped in place, large vibrations will be generated. As the deflection angle continues to increase, the amplitude increases, the vibration frequency increases, and the violent vibrations damage the hydraulic system and the cradle mechanism. The main reason for this problem is that the existing grinding unit deflection control method does not achieve acceleration and deceleration control, and does not consider the impact of the deflection angle on the output force.

In the prior art, the following technical solutions are mainly related to this application:

Prior art 1 is a Chinese invention application filed by the applicant on February 22, 2017 and published on June 20, 2017, with publication number CN106873639A. The invention application discloses a rail grinding deflection angle control method, and the rail grinding deflection angle control system includes a deflection motor, a downward pressure guide post, a grinding motor, a deflection cradle, a telescopic cylinder, a cradle and a control unit. The control unit obtains the error angle between the feedback angle of the current grinding motor and the target angle preset by the host computer in real time, and continuously adjusts the deflection motor action according to the error angle, so that the grinding motor deflects to the preset target angle, and finally makes the grinding motor perform grinding operations according to the preset target angle. The invention can solve the technical problem that the grinding angle of the existing rail grinding deflection angle control method is easy to change during the grinding process, resulting in uneven light bands and non-standard grinding rail profiles.

Prior art 1 corrects the deflection angle based on certain conditions (timing, temperature change reaching a certain value, pressure change reaching a certain value), and corrects the deflection angle in real time by continuously adjusting the deflection motor action to avoid changes in the deflection angle during the grinding process, thereby reducing the requirements for system action sensitivity and response speed due to frequent corrections. However, it solves the technical problem that the target angle of grinding cannot be maintained, and does not involve the control of the deflection angle of the grinding unit. At the same time, although the invention application can dynamically maintain the position of the cylinder to a certain extent to solve the problem of high-temperature oil expansion and leakage in the cylinder, in fact, the angle is difficult to dynamically control, which not only requires high precision of each component, but also easily leads to instability of the grinding light band.

Prior art 2 is a Chinese invention application applied for by Wuhan University, China Railway Fourth Survey and Design Institute Group Co., Ltd., and Shenyang Aotofu Technology Co., Ltd. on December 31, 2021, and published on April 26, 2022, with publication number CN114395953A. This invention application discloses a portable high-pressure water jet rail grinding incident angle calibration method and system, which uses an accelerometer and a gyroscope to collect raw acceleration data and angular velocity data, and combines the sensitivities of the two sensors to obtain three-axis acceleration data and three-axis angular velocity data, and then obtains the inertial force vector of the accelerometer by definition, and obtains the first set of angle data between the vector and each axis. In order to reduce the influence of mechanical vibration and noise during the grinding operation, the three-axis angular velocity data obtained by the gyroscope, which is less affected by external vibration, is used as the second set of angle data. The two sets of data are subjected to a first-order complementary algorithm to obtain precise values, that is, different weights are assigned to the two sets of data for correction, and finally the incident angle is determined, and the disadvantages of the two sensors are complemented, solving the problem of errors caused by mechanical vibration and noise during the calibration of the incident angle of water jet rail grinding.

Prior art 2 uses the complementary performance of two new sensors (accelerometer and gyroscope) to calibrate and control the grinding angle. After calibration, the grinding angle remains fixed, and the deflection angle of each water jet cannot be controlled during the grinding operation. It solves the problem of the influence of mechanical vibration on the traditional inclinometer, which is a technical problem of calibrating the sensor used, but does not involve the technical problem of calibrating the deflection angle of the grinding unit.

Summary of the invention

In order to solve the above technical problems, the present application provides a grinding unit deflection control device, system, method and rail grinding vehicle to solve the technical problem that the existing grinding unit deflection control method is prone to errors due to reasons such as grinding unit processing and assembly and structural elastic deformation, which in turn leads to low deflection angle control accuracy.

In order to achieve the above technical objectives, the embodiment of the present application specifically provides a technical implementation solution of a grinding unit deflection control device, and the grinding unit deflection control device includes:

The deflection control unit controls the deflection of the grinding unit when the grinding vehicle is parked, and completes the deflection angle calibration;

The data acquisition unit collects multiple sets of actual deflection angle values of the grinding unit and corresponding actuator stroke feedback values during the calibration process;

The data fitting unit adopts a set function fitting to obtain the function parameters according to the combination of multiple groups of data of the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value, and transmits the function parameters to the deflection control unit;

The deflection control unit uses the set function and the parameters transmitted by the data fitting unit to control the deflection of the grinding unit when the grinding vehicle is in operation.

Furthermore, the set function includes but is not limited to any one of an exponential function, a Fourier series, a sine function, and a polynomial function.

Furthermore, the device also includes an automatic calibration control unit, which is connected to the deflection control unit, the data acquisition unit and the data fitting unit respectively. The automatic calibration control unit is used to realize the deflection angle calibration control of the grinding unit by the deflection control unit by setting the sequence number of the grinding unit to be deflected, the deflection angle interval, the deflection angle range and the deflection voltage range in the deflection angle calibration state. In the grinding vehicle operation state, the data acquisition unit and the data fitting unit do not work, and the deflection control unit realizes the control of the grinding unit operation deflection action.

The embodiment of the present application further specifically provides a technical implementation solution for a rail grinding vehicle, including: the grinding unit deflection control device as described above.

The present application also specifically provides a technical implementation scheme for a grinding unit deflection control system, the grinding unit deflection control system includes: a controller, a control element, an actuator, a deflection mechanism, a stroke sensor, and the deflection control device as described above. During the grinding operation, the controller sends a control instruction to the control element according to the deviation between the set angle value and the feedback angle value, the control element controls the actuator to move, and then the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and the deflection control unit converts the voltage or current value of the stroke sensor into a feedback angle value according to the set function and parameters and outputs it to the controller, so that the deflection mechanism accurately deflects to the set angle value.

Furthermore, the set function is fitted using the following two exponential functions:

α＝f(V)＝a*exp(b*V)+c*exp(d*V)

Among them, a, b, c, d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the grinding unit deflection, and V is the voltage value of the stroke sensor.

The embodiment of the present application also specifically provides another technical implementation scheme of the grinding unit deflection control system, the grinding unit deflection control system includes: a controller, a control element, an actuator, a deflection mechanism, a stroke sensor, and the deflection control device as described above. During the grinding operation, the deflection control unit converts the set angle value into a target voltage or current value according to the set function and parameters, and the controller sends a control instruction to the control element according to the deviation between the target voltage or current value and the feedback value, and the control element controls the actuator to act, and then the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and outputs the stroke voltage or current feedback value to the controller, so that the deflection mechanism accurately deflects to the set angle value.

Furthermore, the set function is fitted using the following Fourier series first expansion function:

V＝f(α)＝a ₀ +a ₁ *cos(α*ω)+b ₁ *sin(α*ω)

Wherein, a ₀ , a ₁ , b ₁ , and ω are parameters in the Fourier series, V is the target voltage value of the stroke sensor, and α is the set angle value of the grinding unit deflection.

Furthermore, in the deflection angle calibration state, when the data acquisition unit collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, the grinding head of the grinding unit is pressed down onto the rail surface according to the average downward force of the normal grinding operation state.

Furthermore, in the deflection angle calibration state, the deflection control unit first controls the deflection of the grinding unit according to the theoretical parameters of the fitting function, and deflects the grinding unit to the set maximum angle. Then, it deflects toward the other side according to the set angle interval. When the deflection angle is in place, it automatically stops and presses the grinding head down to the rail surface of the rail according to the average downward force during normal operation. The data acquisition unit automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value. This operation is repeated until the grinding unit deflects to the maximum set angle on the other side and stops. The grinding head is pressed down to the rail surface of the rail according to the average downward force during normal operation. The data acquisition unit automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value to complete the data collection of all calibration points. All collected data are input into the data fitting unit for fitting to obtain new function fitting parameters, and the parameters are output to the deflection control unit to replace the original control parameters to complete the control parameter calibration.

Furthermore, the deflection control unit controls the deflection of the grinding unit with the replaced control parameters in the parking state of the grinding vehicle, tests the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit, and determines whether there is an error greater than the set angle error value. If the deflection control unit determines that the error is greater than the set angle error value, the tolerance control range of the target angle, voltage or current value is reduced, or the data fitting unit re-fits the function according to the actual deflection angle value of the grinding unit and the actuator stroke feedback value.

Furthermore, the system also includes a deflection angle calibration subsystem, which includes an inclination sensor installed on the deflection mechanism, the downward pressure guide column or the guide sleeve when the grinding vehicle is parked. When the grinding vehicle is parked, the grinding unit deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle, and at the same time, the actual deflection angle value of the grinding unit is obtained through the inclination sensor, and the corresponding actuator stroke feedback value is obtained through the stroke sensor.

Furthermore, the inclination sensor is fixed on the mounting plane of the deflection mechanism through a magnetic base.

Furthermore, the inclination sensor is fixed on a mounting base, and the mounting base is further fixed to the outer side surface of the downward pressure guide column or guide sleeve through a magnetic base.

Furthermore, the inclination sensor can realize dual-axis acquisition, and the deflection control unit calculates the inclination angle α of the grinding unit in the X direction based on the dual-axis acquisition data of the inclination sensor according to the following formula:

Wherein, x' and y' are the dual-axis sensor signal output values of the inclination sensor, and sin ^-1 is the inverse sine function.

Furthermore, the tilt sensor has a wireless node, and the deflection angle calibration subsystem also includes a wireless gateway. The wireless gateway receives the tilt data of the tilt sensor as the actual deflection angle value of the grinding unit, and outputs it to the deflection control unit through the network port.

Furthermore, when the grinding head performs continuous grinding operations at a set angle, a number of micro-deflection actions of a set amplitude are applied at set intervals based on the set angle value to achieve angle inching fine-tuning and high-temperature overpressure flow relief inside the actuator.

Furthermore, the control element includes a proportional reversing valve and a hydraulic lock, and the actuator adopts a hydraulic cylinder. The two oil outlets of the hydraulic lock are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlets of the proportional reversing valve. The controller controls the pressure or flow of the proportional reversing valve to accelerate and decelerate, thereby realizing the movement speed control of the hydraulic cylinder. In the acceleration stage of the actuator startup, the opening of the proportional reversing valve is controlled from small to large. In the deceleration stage when the set angle value is about to be reached, the opening of the proportional reversing valve is controlled from large to small. In the angle inching fine-tuning stage, the opening of the proportional reversing valve is set according to the inclination angle of the grinding unit.

The embodiment of the present application further specifically provides a technical implementation solution for a rail grinding vehicle, including: the grinding unit deflection control system as described above.

The embodiment of the present application further specifically provides a technical implementation scheme of a grinding unit deflection control method, and the grinding unit deflection control method comprises the following steps:

S11) controlling the grinding unit to deflect when the grinding vehicle is parked, and collecting multiple sets of actual deflection angle values of the grinding unit and corresponding actuator stroke feedback values during the deflection process;

S12) using the set function fitting, obtaining the function parameters according to the multiple data combinations of the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value, and returning the new parameters obtained by fitting;

S13) replacing the function parameters of the grinding unit deflection control with the new parameters obtained by fitting;

S16) In the grinding vehicle operation state, the grinding unit is deflected and controlled according to the set function and the new parameters obtained by fitting.

Furthermore, between step S13) and step S16) the following steps are included:

S14) using the replaced control parameters to control the deflection of the grinding unit when the grinding vehicle is parked, testing the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit, and determining whether there is an error greater than a set angle error value;

S15) If the error is greater than the set angle error value, the tolerance control range of the target angle, voltage or current value is reduced, or the function is refitted according to the actual deflection angle value of the grinding unit and the actuator stroke feedback value.

Further, the step S16) includes the following steps:

The controller sends a control instruction to the control element according to the deviation between the set angle value and the feedback angle value, and the control element controls the actuator to move, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and the deflection control unit converts the voltage or current value of the stroke sensor into a feedback angle value according to the set function and parameters and outputs it to the controller, so that the deflection mechanism accurately deflects to the set angle value.

α＝f(V)＝a*exp(b*V)+c*exp(d*V)

Further, the step S16) includes the following steps:

The deflection control unit converts the set angle value into a target voltage or current value according to the set function and parameters. The controller sends a control instruction to the control element according to the deviation between the target voltage or current value and the feedback value. The control element controls the actuator to act, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and outputs the stroke voltage or current feedback value to the controller, so that the deflection mechanism accurately deflects to the set angle value.

V＝f(α)＝a ₀ +a ₁ *cos(α*ω)+b ₁ *sin(α*ω)

Further, the step S11) includes:

In the deflection angle calibration state, during the process of collecting the actual deflection angle value of the grinding unit and the actuator stroke feedback value, the grinding head of the grinding unit is pressed down onto the rail surface according to the average downward force of the normal grinding operation state.

Furthermore, in the step S11), in the deflection angle calibration state, the deflection angle calibration control of the grinding unit is realized by setting the grinding unit serial number, deflection angle interval, deflection angle range and deflection voltage range to be deflected. In the step S16), in the grinding vehicle operation state, the deflection control unit realizes the control of the grinding unit operation deflection action.

Furthermore, in the step S11), under the deflection angle calibration state, the deflection control unit first controls the deflection of the grinding unit according to the theoretical parameters of the fitting function, and deflects the grinding unit to the set maximum angle. Then, it deflects toward the other side according to the set angle interval. When the deflection angle is in place, it automatically stops and presses the grinding head down to the rail surface of the rail according to the average downward force during normal operation, and automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value. Repeat this step until the grinding unit deflects to the maximum set angle on the other side, stops, presses the grinding head down to the rail surface of the rail according to the average downward force during normal operation, and automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and completes the data collection of all calibration points. By executing the step S12), all the collected data are fitted to obtain new function fitting parameters, and by executing the step S13), the parameters are output to the deflection control unit to replace the original control parameters, and the control parameter calibration is completed.

Furthermore, before step S11), the method further includes step S10):

S10) When the grinding vehicle is parked, the inclination sensor is installed on the deflection mechanism, the downward pressure guide column or the guide sleeve.

Repeat the above steps S10) to S15) to calibrate other groups of grinding units.

The step S11) further comprises:

When the grinding vehicle is parked, the grinding unit deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle, and at the same time obtains the actual deflection angle value of the grinding unit through the inclination sensor, and obtains the corresponding actuator stroke feedback value through the stroke sensor.

Further, the step S10) includes:

Fixing the inclination sensor on the mounting plane of the deflection mechanism through a magnetic base;

Or the inclination sensor is fixed on a mounting seat, and then the mounting seat is fixed to the outer side surface of the downward pressure guide column or guide sleeve through a magnetic base.

Further, the step S11) includes:

The inclination sensor is used to collect biaxial data. The deflection control unit collects biaxial data based on the inclination sensor and calculates the inclination angle α of the grinding unit in the X direction according to the following formula:

Further, the step S11) includes:

The inclination data of the inclination sensor is received through the wireless gateway as the actual deflection angle value of the grinding unit, and is output to the deflection control unit through the network port.

Further, the step S16) includes:

When the grinding head performs continuous grinding operation at a set angle, a micro-deflection action of a set amplitude is applied several times at a set interval based on the set angle value to achieve angle inching fine adjustment and high-temperature overpressure flow relief inside the actuator.

Furthermore, the control element includes a proportional reversing valve and a hydraulic lock, and the actuator adopts a hydraulic cylinder. The two oil outlets of the hydraulic lock are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlet of the proportional reversing valve. The step S16) includes:

During the grinding operation, the controller controls the pressure or flow of the proportional reversing valve to accelerate and decelerate, thereby realizing the movement speed control of the hydraulic cylinder. In the acceleration phase when the actuator is started, the opening of the proportional reversing valve is controlled from small to large. In the deceleration phase when the set angle value is about to be reached, the opening of the proportional reversing valve is controlled from large to small. In the angle inching fine-tuning phase, the opening of the proportional reversing valve is set according to the tilt angle of the grinding unit.

By implementing the technical solutions of the grinding unit deflection control device, system, method and rail grinding vehicle provided by the present application, the following beneficial effects are achieved:

(1) The grinding unit deflection control device, system, method and rail grinding vehicle of the present application can effectively avoid errors easily caused by reasons such as grinding unit processing and assembly and structural elastic deformation by collecting actual feedback data of the grinding unit deflection angle and actuator stroke and performing function fitting, thereby improving the control accuracy of the grinding unit deflection angle;

(2) The grinding unit deflection control device, system, method and rail grinding vehicle of the present application can improve the calibration efficiency and reduce the manual calibration error by performing fixed-point segmented calibration on the grinding unit deflection angle. At the same time, the dual-axis data collection of the inclination sensor can further simplify the operation and improve the calibration efficiency and accuracy.

(3) The grinding unit deflection control device, system, method and rail grinding vehicle of the present application can achieve deflection cylinder pressure relief by using the grinding unit deflection angle inching fine adjustment, thereby ensuring that the deflection angle accuracy remains unchanged during the grinding operation and avoiding the deflection cylinder from getting stuck, leaking oil and other phenomena;

(4) The grinding unit deflection control device, system, method and rail grinding vehicle of the present application can reduce the vibration during the deflection process by controlling the acceleration and deceleration of the grinding unit deflection process and at the same time controlling the output force by associating the angle, thereby reducing the damage of the deflection vibration to the deflection mechanism structure, the deflection electric cylinder or the deflection oil cylinder;

(5) In the grinding unit deflection control device, system, method and rail grinding vehicle of the present application, during the grinding unit deflection angle calibration process, the grinding head is pressed down onto the rail surface according to the average downward force during normal operation, and the influence of the elastic deformation of the grinding unit structure is taken into account. The static calibration is changed to semi-dynamic calibration, thereby further improving the control accuracy of the deflection angle.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following briefly introduces the drawings required for use in the embodiments or the prior art descriptions. Obviously, the drawings described below are only some embodiments of the present application, and for ordinary technicians in this field, other embodiments can be obtained based on these drawings without creative work.

FIG1 is a schematic structural diagram of a grinding unit used in the present application;

FIG2 is a schematic diagram showing a comparison between the deviation between the actual measured angle and the theoretical angle of the deflection unit using the existing deflection control method;

FIG3 is a schematic structural diagram of a deflection mechanism of a grinding unit in the prior art;

FIG4 is a schematic structural diagram of a deflection mechanism of another grinding unit in the prior art;

FIG5 is a schematic diagram of the deflection process of the grinding unit in the prior art;

FIG6 is a block diagram of the deflection angle control principle of a specific embodiment of the grinding unit deflection control device of the present application;

7 is a block diagram of the deflection angle control principle of another specific embodiment of the grinding unit deflection control device of the present application;

FIG8 is a principle block diagram of a specific embodiment of the grinding unit deflection control system of the present application;

FIG9 is a block diagram of the system structure of a specific embodiment of the grinding unit deflection control system of the present application;

FIG10 is a block diagram of the system structure of another specific embodiment of the grinding unit deflection control system of the present application;

11 is a schematic diagram of the installation structure of the angle calibration device of two specific embodiments of the grinding unit deflection control system of the present application;

FIG12 is a schematic structural diagram of an angle calibration device of a specific embodiment of the grinding unit deflection control system of the present application;

13 is a schematic structural diagram of an angle calibration device of another specific embodiment of the grinding unit deflection control system of the present application;

FIG14 is a schematic diagram of the principle of the installation structure of a specific embodiment of the grinding unit deflection control system of the present application;

15 is a schematic diagram of the connection structure of an automatic calibration control unit of a specific embodiment of the grinding unit deflection control system of the present application;

FIG16 is a schematic diagram of the placement structure of the inclination sensor in a specific embodiment of the grinding unit deflection control system of the present application;

FIG17 is a schematic diagram of the placement structure of the inclination sensor in a specific embodiment of the grinding unit deflection control system of the present application from another perspective;

FIG18 is a schematic diagram of the calculation principle of the inclination angle of the grinding unit in the X direction in a specific embodiment of the grinding unit deflection control system of the present application;

FIG19 is a schematic diagram of a deflection angle micro-control waveform of a specific embodiment of the grinding unit deflection control system of the present application;

FIG20 is a schematic diagram of the structure of a deflection deceleration control mechanism of a specific embodiment of the grinding unit deflection control system of the present application;

FIG21 is a flowchart of a specific embodiment of the grinding unit deflection control method of the present application;

FIG22 is a flowchart of a function fitting process of a specific embodiment of the grinding unit deflection control method of the present application;

FIG23 is a schematic diagram of an interface for collecting measured data in a specific embodiment of the grinding unit deflection control method of the present application;

FIG. 24 is a schematic diagram of an interface for performing curve fitting based on measured data in a specific embodiment of the grinding unit deflection control method of the present application.

Detailed ways

For the purpose of reference and clarity, the technical terms, abbreviations or abbreviations used below are recorded as follows:

Function fitting: also known as curve fitting, refers to a data processing method that uses a continuous curve to approximately describe or compare the functional relationship between coordinates represented by a discrete point group on a plane. Fitting is to connect a series of points on a plane with a smooth curve. Because this curve has countless possibilities, there are various fitting methods. The fitted curve can generally be represented by a function, and there are different fitting names depending on the function. This is the fitting function.

sum of sin: Short for sinusoidal approximation.

PID controller: Proportion Integration Differentiation, the abbreviation of proportional-integral-differential controller.

PI controller: Proportion Integration, short for proportional-integral controller.

PD controller: Proportion Differentiation, short for proportional-differential controller.

In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

As shown in Figures 1 to 24, specific embodiments of the grinding unit deflection control device, system, method and rail grinding vehicle of the present application are given. The present application is further described below in conjunction with the drawings and specific embodiments.

Example 1

As shown in FIGS. 9 and 10 , an embodiment of the grinding unit deflection control device of the present application specifically includes:

The deflection control unit 14 controls the deflection of the grinding unit 100 when the grinding vehicle is parked, and completes the deflection angle calibration;

The data acquisition unit 21 collects multiple sets of actual deflection angle values of the grinding unit and corresponding actuator stroke feedback values during the calibration process;

The data fitting unit 22 uses a set function fitting to obtain function parameters according to a combination of multiple data sets of the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value, and transmits the function parameters to the deflection control unit 14;

The deflection control unit 14 controls the deflection of the grinding unit 100 using the set function and the parameters transmitted by the data fitting unit 22 when the grinding vehicle is in operation.

The set function includes but is not limited to any one of an exponential function, a Fourier series, a sine function, and a polynomial function. The output mode of the actuator stroke feedback value includes but is not limited to any one of various types such as voltage, resistance, current, incremental pulse, and absolute pulse.

In order to fully solve the technical problem that the existing method for calculating the deflection target angle of the grinding unit is prone to errors due to the processing and assembly of the grinding unit and the elastic deformation of the structure, thereby resulting in low deflection angle control accuracy, the deflection control device 20 described in Example 1 of the present application specifically adopts an exponential function fitting algorithm based on measured data. For example, the set function can be further fitted using the following exponential function:

α＝f(V)＝a*exp(b*V)+c*exp(d*V)+······

Among them, a, b, c, d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the grinding unit 100 deflection, the output mode of the actuator stroke feedback value adopts a voltage type, V is the voltage value of the stroke sensor 15, and ... represents an exponential function with more terms. By measuring the data relationship between the grinding unit deflection angle and the deflection cylinder feedback voltage, the exponential function parameters such as a, b, c, d are obtained.

Of course, the set function may also use but is not limited to the following algorithm.

Fourier series fitting:

α＝f(V)＝a ₀ +a ₁ *cos(V*ω)+b ₁ *sin(V*ω)+······

Among them, a ₀ , a ₁ , b ₁ , ω are parameters in the algorithm function, V is the voltage value of the stroke sensor 15 , α is the feedback angle value of the deflection of the grinding unit 100 , and ······· represent higher-order Fourier series expansion terms.

Sine approximation fit sum of sin:

α＝f(V)＝a ₁ *sin(b ₁ *V+c ₁ )+a ₂ *sin(b ₂ *V+c ₂ )+······

Among them, a ₁ , a ₂ , b ₁ , b ₂ , c ₁ , c ₂ are parameters in the algorithm function, V is the voltage value of the stroke sensor 15 , α is the feedback angle value of the deflection of the grinding unit 100 , and ······· represent sinusoidal functions with more terms.

The input variable of the above algorithm function is the voltage value V, and the output variable is the angle value α, which is applied to the deflection control forward algorithm shown in Figure 6. Correspondingly, the deflection control reverse algorithm shown in Figure 7 can also be used, in which case the input variable is the angle value α and the output variable is the voltage value V. For example, taking Fourier series fitting as an example, the corresponding function becomes:

V＝f(α)＝a ₀ +a ₁ *cos(α*ω)+b ₁ *sin(α*ω)+······

Wherein, a ₀ , a ₁ , b ₁ , ω are parameters in the algorithm function, V is the target voltage value of the stroke sensor 15, α is the set angle value of the deflection of the grinding unit 100, and ... represents a higher-order Fourier series expansion term. When other algorithm functions are used to implement the deflection control reverse algorithm, similar changes are also used to interchange the positions of the voltage variable V and the angle variable α.

The specific process of function (curve) fitting is: the data fitting unit 22 performs fitting based on the actual deflection angle value of the grinding unit and the multiple data combinations of the corresponding actuator stroke feedback value, and then returns the parameters obtained by fitting. The data fitting unit 22 performs fitting based on the data combinations of different actual deflection angle values of the grinding unit and the corresponding actuator stroke feedback values, obtains the fitting parameters with the smallest comprehensive error, and replaces the control parameters of the deflection control unit 14 with the fitting parameters. As a typical specific embodiment, the two columns of data combination of the actual deflection angle value α of the grinding unit and the actuator stroke feedback value V are fitted in the data fitting unit 22 according to the fitting algorithm, and then the parameters obtained by fitting are returned. Before fitting, multiple groups of data are required, such as: collecting 10 to 20 groups of data, or more groups of data, the more data combinations, the more accurate the fitting results. The fitting process is to comprehensively consider all the position points to obtain the parameters a, b, c, d with the smallest comprehensive error (taking the fitting of two exponential functions as an example). The parameters in the deflection control algorithm of the grinding unit 100 are kept and replaced with the new parameters after fitting. In order to improve the accuracy of fitting, it is best to collect multiple sets of data as evenly as possible within the entire angle range. The starting and ending points of angle collection can be selected near the maximum angle or the minimum angle. For example, in the inner 70° deflection angle range, the innermost 65° can be taken as the last data collection point.

Theoretically, the higher the number of the algorithm function for fitting (the more terms), the higher the fitting accuracy. However, considering that the higher the number of terms (the more terms), the more parameters there are, the more calculations are required, which is also true for other algorithms. Therefore, after actual structural error verification, taking into account the error range requirement of the fitting accuracy meeting the deflection angle of ±0.5° and the speed of algorithm calculation, it is a better solution to use two exponential functions and Fourier series expansion functions to respectively realize the function fitting in the deflection control forward algorithm (as shown in Figure 9) and the reverse algorithm (as shown in Figure 10).

As shown in FIG. 15 , the deflection control device 20 further includes an automatic calibration control unit 24, which is connected to the deflection control unit 14, the data acquisition unit 21 and the data fitting unit 22 respectively. The automatic calibration control unit 24 is used to realize the deflection angle calibration control of the grinding unit 100 by the deflection control unit 14 by setting the grinding unit serial number, deflection angle interval, deflection angle range and deflection voltage range required for deflection in the deflection angle calibration state. In the grinding vehicle operation state, the data acquisition unit 21 and the data fitting unit 22 do not work, and the deflection control unit 14 realizes the control of the operation deflection action of the grinding unit 100.

The grinding unit deflection control device described in Example 1 adopts an automatic calibration and automatic fitting method, and realizes data collection by controlling the continuous deflection of the grinding unit 100, and then automatically analyzes and calculates the data. Based on the set functional relationship, the curve fitting is performed on the actual detected stroke sensor voltage and the calibration inclination angle (obtained by the inclination sensor 17) data to obtain the optimal control parameters, and the original control parameters are corrected to correct the deviation caused by the processing and assembly errors and structural elastic deformation of the grinding unit 100, which can effectively ensure the grinding unit deflection control accuracy and the grinding deflection angle calibration efficiency. After actual measurement, the grinding unit deflection control device can achieve a control accuracy of ±0.2°~±0.3° for the grinding motor deflection angle by adopting the technical solution described in Example 1, which can well meet the railway standard for the control accuracy of the grinding motor deflection angle of ±0.5°.

Example 2

The angle deflection control principle of the grinding unit 100 is as follows: during the grinding process, in order to ensure that the deflection mechanism 2 (also known as the grinding unit frame, cradle, cradle, etc.) can accurately deflect to the set target angle value, the controller 11, the control element 12, the actuator 13 (in this embodiment, more specifically, the deflection drive mechanism 8, the deflection drive mechanism 8 can further use a deflection oil cylinder or a deflection electric cylinder) and the stroke sensor 15 (cylinder or electric cylinder stroke sensor) need to cooperate with each other. Among them, the controller 11 is the core of the entire deflection control system 300 and is the issuer of the control command. After receiving the command, the actuator 13 acts according to a certain rule to deflect the deflection mechanism 2. During the deflection process, the stroke sensor 15 in the deflection oil cylinder or the deflection electric cylinder detects the displacement of the oil cylinder or the electric cylinder in real time. As shown in Figures 6 and 9, in this embodiment, the deflection control unit 14 adopts a deflection control forward algorithm. The control algorithm converts the voltage or current signal of the stroke sensor 15 into a feedback angle value of the deflection mechanism 2 and outputs it to the controller 11, thereby forming a closed-loop control system to achieve precise control of the deflection angle of the grinding unit 100.

As shown in Figures 6 and 9, an embodiment of the grinding unit deflection control system of the present application specifically includes: a controller 11, a control element 12, an actuator 13, a deflection mechanism 2, a stroke sensor 15, and a deflection control device 20 as described in Example 1. During the grinding operation, the controller 11 sends a control instruction to the control element 12 according to the deviation between the set angle value (also called the target angle value) and the feedback angle value, and the control element 12 controls the actuator 13 to act, and then the actuator 13 drives the deflection mechanism 2 to perform the deflection operation. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time, and the deflection control unit 14 converts the voltage or current value of the stroke sensor 15 into a feedback angle value according to the set function and parameters and outputs it to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value. Among them, the controller 11 can specifically adopt a PID controller, a PI controller, a PD controller, etc.

In order to fully solve the technical problem that the existing grinding unit deflection angle control method is prone to errors due to grinding unit processing and assembly and structural elastic deformation, thereby resulting in low deflection angle control accuracy, this embodiment specifically adopts an exponential function fitting with better comprehensive measured fitting effect to implement the deflection control forward algorithm. For example, the set function can be further fitted using the following two exponential functions:

α＝f(V)＝a*exp(b*V)+c*exp(d*V)

Wherein, a, b, c, d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the deflection of the grinding unit 100 , and V is the voltage value of the stroke sensor 15 .

Of course, in addition to using two-term exponential functions, the function set by the above deflection control forward algorithm can also use exponential functions with more terms or other algorithm functions for fitting.

In the deflection angle calibration state, the data acquisition unit 22 collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value (such as the deflection cylinder feedback voltage in this embodiment), and the grinding head 3 of the grinding unit 100 is pressed down onto the rail surface of the rail 200 according to the average downward force of the normal grinding operation state (the downward force during the grinding process is not a fixed value, but changes in real time. Because there are ripples on the surface of the rail 200, the grinding unit 100 will vibrate, resulting in the need to adjust the downward force in real time to stabilize the grinding power. The average downward force refers to taking an average value on the basis of the dynamically fluctuating downward force for static downward pressure, and then measuring the calibration angle) to solve the influence of processing and manufacturing gaps and structural elastic deformation in traditional methods.

In the deflection angle calibration state (at this time, the grinding vehicle is in the parking state), the deflection control unit 14 first controls the deflection of the grinding unit 100 according to the theoretical parameters of the fitting function, and deflects the grinding unit 100 to the set maximum angle. Then, according to the set angle interval (the deflection angle calibration can also be performed by setting a time interval, and the angle interval control method is easier to implement and meet the requirements of control accuracy), it deflects toward the other side. When the deflection angle is in place, it automatically stops and presses the grinding head 3 down to the rail surface of the rail 200 according to the average downward force during normal operation. The data acquisition unit 21 automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value. Repeat this operation until the grinding unit 100 deflects to the maximum setting angle on the other side and stops. The grinding head 3 is pressed down to the rail surface of the rail 200 according to the average downward force during normal operation. The data acquisition unit 21 automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and completes the data collection of all calibration points. All collected data are input into the data fitting unit 22 for fitting to obtain new function fitting parameters, and the parameters are output to the deflection control unit 14 to replace the original control parameters, thereby completing the control parameter calibration.

The deflection control unit 14 uses the replaced control parameters to control the deflection of the grinding unit 100 when the grinding vehicle is parked, tests the error between the theoretical deflection angle value (calculated according to the set fitting function and the replaced control parameters) and the actual deflection angle value of the grinding unit 100, and determines whether there is an error greater than the set angle error value. If the deflection control unit 14 determines that the error is greater than the set angle error value, the tolerance control range of the target angle, voltage or current value is reduced, or the data fitting unit 22 re-fits the function according to the actual deflection angle value of the grinding unit and the actuator stroke feedback value.

The deflection control system 300 also includes a deflection angle calibration subsystem, which includes an inclination sensor 17 installed on the deflection mechanism 2, the downward guide column 4 or the downward guide sleeve 5 when the grinding vehicle is parked. After the deflection angle calibration is completed, the inclination sensor 17 needs to be removed from the installation position before normal grinding operation. When the grinding vehicle is parked, the grinding unit 100 deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle, and at the same time, the actual deflection angle value α of the grinding unit is obtained through the inclination sensor 17, and the corresponding actuator stroke feedback voltage value V is obtained through the stroke sensor 15.

The deflection angle control of the grinding unit during the deflection angle calibration process can be implemented in a variety of ways, for example: the actuator 13 (which can be a deflection oil cylinder or a deflection electric cylinder) records data every time it is extended to a certain length until it is fully extended, and can be controlled by the stroke of the oil cylinder; it can also be converted into the deflection angle of the grinding unit 100, and data can be recorded every set angle; it can also be recorded every set time; the grinding unit 100 can also be continuously deflected, and sufficient data can be automatically recorded during the deflection process. The deflection control process of the grinding unit during the data collection process can be specifically implemented, but not limited to: deflection → pause → press down → collect; or press down → continuous deflection and collection; or press down → deflection → pause → collect, etc.

As shown in FIG. 11, it is only a schematic diagram of the installation positions of the inclination sensor 17 on the deflection mechanism 2 and the downward pressure guide column 4 (or the downward pressure guide sleeve 5), and it is not that two inclination sensors 17 are installed on the deflection mechanism 2 and the downward pressure guide column 4 (or the downward pressure guide sleeve 5) at the same time. As shown in FIG. 12 and FIG. 14, the inclination sensor 17 is adsorbed and fixed on the installation plane of the deflection mechanism 2 by the magnetic base 16. Or the inclination sensor 17 can be fixed on the mounting seat 23, and the mounting seat 23 is adsorbed and fixed on the outer side of the downward pressure guide column 4 or the downward pressure guide sleeve 5 by the magnetic base 16, as shown in FIG. 13. At the same time, the inclination sensor 17 has a wireless node, and the deflection angle calibration subsystem also includes a wireless gateway 18, as shown in FIG. 8. The wireless gateway 18 receives the inclination data of the inclination sensor 17 as the actual deflection angle value of the grinding unit, and outputs it to the deflection control unit 14 through the network port. The deflection control unit 14 is a part of the grinding operation control system 19.

The deflection angle calibration subsystem of the grinding unit 100 is mainly used to improve the control accuracy and calibration efficiency of the grinding operation (deflection) angle, and automatically controls the grinding unit 100 to perform intermittent deflection actions, and collects the deflection cylinder voltage signal and the deflection angle signal of the inclination sensor at different angles. The deflection control system 300 described in this embodiment can realize functions such as wireless collection, automatic calibration, parameter fitting and result verification.

As shown in FIG. 17 , β refers to the operation error generated during the manual placement process. Due to the existence of β, X' and X are not in the same direction. In this embodiment, the inclination sensor 17 can realize dual-axis data acquisition, and the influence of the installation positioning error on the measurement of the inclination angle can be corrected by calculation. As shown in FIG. 16 to FIG. 18 , the deflection control unit 14 is based on the dual-axis data collected by the inclination sensor 17, and further calculates the inclination angle α of the grinding unit 100 in the X direction according to the following formula:

Wherein, x' and y' are the output values of the dual-axis sensing signal of the tilt sensor 17, and sin ^-1 is the inverse sine function. In FIG16 , H is the horizontal direction.

The deflection angle calibration subsystem has a wireless data acquisition function. The calibration inclination sensor 17 uses a wireless sensor, which can realize long-distance wireless data transmission without wiring and is easy to use. At the same time, the inclination sensor 17 has a magnetic base 16, which can be quickly and automatically fixed on the deflection mechanism 2 (i.e., the grinding unit frame) to be measured, making it more convenient to use.

When the grinding head 3 performs continuous grinding at a set angle, a micro-deflection action of a set amplitude is applied several times at a set interval based on the set angle value to achieve angle inching fine adjustment (i.e., continuous multiple small amplitude pulsating adjustment) and high temperature overpressure discharge inside the actuator, as shown in Figure 19. As shown in Figure 20, the control element 12 further includes a proportional reversing valve 121 and a hydraulic lock 122, and the actuator 13 adopts a hydraulic cylinder. The two oil outlets of the hydraulic lock 122 are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlet of the proportional reversing valve 121.

As a typical specific embodiment of the present application, during the grinding operation, if the grinding deflection angle is set to 35°, two small deflection actions with an amplitude of ±0.5° are performed every 60 seconds. This action can reduce the hydraulic pressure inside the deflection cylinder (i.e., the deflection drive mechanism 8) that increases due to temperature rise, and discharge a certain amount of hydraulic oil, thereby avoiding the continuous increase in the hydraulic pressure inside the deflection cylinder, and further avoiding the problems of the hydraulic lock 122 being unable to open, stuck, and leaking. Among them, the set grinding deflection angle of 35° can also be all possible grinding angles used during the operation of the grinding unit 100. The angle can be any angle between -35° (negative value represents deflection to the outside) and 70° (positive value represents deflection to the inside), and can even be in the range of -45° to 75° for some models. In addition, the small action of deflecting ±0.5° can also be ±1° or ±2°, which is generally a smaller angle, so as not to have a greater impact on the angle of rail grinding. As for the grinding angle deflection interval of 60s, it can be adjusted every 5 minutes, 10 minutes, or even 20 minutes.

As shown in the dotted box in Figure 20, the hydraulic lock 122 is essentially composed of two hydraulically controlled one-way valves. The hydraulically controlled one-way valves can lock the circuit so that the oil in the circuit cannot flow, so as to ensure that the hydraulic cylinder (i.e., the actuator 13) can maintain its position and remain stationary even when there is a certain load from the outside. The function of the hydraulic lock 122 is interlocking, that is, when the proportional reversing valve 121 in Figure 20 is in the middle position, the left and right cylinders of the hydraulic cylinder are in a stationary state under the action of the two hydraulically controlled one-way valves. However, when the proportional reversing valve 121 is in the right position, oil enters port B, and at this time, the right hydraulically controlled one-way valve enters oil, and at the same time, the oil circuit is controlled to open the left hydraulically controlled one-way valve to drain oil. The same applies when the proportional reversing valve 121 is in the left position.

In this embodiment, the proportional reversing valve 121 specifically adopts a three-position reversing valve, which has three oil-passing positions, namely, the left position, the middle position and the right position. At the same time, the proportional reversing valve 121 has four interfaces for connecting oil pipes, namely, P, T, A, and B ports. The left position refers to when the valve core is in the left position, the right position refers to when the valve core is in the right position, the middle position refers to the position when the hydraulic actuator stops, and the left position and the right position are the positions when the hydraulic actuator is working. The middle position is also the normal position of the hydraulic valve. In the middle position, the function shown by the four oil ports P, T, A, and B is the middle position function. Under the action of the proportional solenoid, the proportional reversing valve 121 can not only change the position of the valve core, but also the stroke of the change can change continuously or proportionally, which can control the movement direction of the oil cylinder and the movement speed of the oil cylinder. Among them, the P port is connected to the pressure oil, the T port is connected to the oil tank, and the A and B ports are connected to the oil inlet or return port of the hydraulic lock 122.

In order to solve the problem of deflection vibration of the grinding unit 100, the controller 11 is used to control the pressure or flow of the proportional reversing valve 121 by acceleration and deceleration to realize the movement speed control of the hydraulic cylinder. In the acceleration stage when the actuator 13 is started, the opening of the proportional reversing valve 121 is controlled from small to large. In the deceleration stage when the set angle value is about to be reached, the opening of the proportional reversing valve 121 is controlled from large to small. In this way, the violent vibration of the grinding unit during deflection can be avoided to the greatest extent, and the damage to the grinding hydraulic system (i.e., the proportional reversing valve 121 and the hydraulic lock 122) and the deflection mechanism 2 (i.e., the cradle) is greatly reduced. In the angle inching fine-tuning stage, the opening of the proportional reversing valve 121 is set according to the tilt angle of the grinding unit 100. The pressure of the P port of the proportional reversing valve 121 is generally 10MPa, that is, the maximum pressure output of the proportional reversing valve 121 is generally 10Mpa, and the minimum pressure output is 0. However, considering the influence of gravity when the grinding unit 100 is deflected at a large angle, the minimum output pressure should be greater than the pressure caused by the gravity load of the grinding unit 100, and the gravity load pressure is related to the deflection angle. For example, when the grinding unit 100 is at a position of about 0°, the minimum output pressure can be a pressure slightly greater than 0. When the deflection angle is about 60° to 70°, the minimum pressure needs to be about 7MPa to offset the tipping tendency caused by the gravity of the grinding unit 100.

It should be noted that in this embodiment, only the grinding unit 100 with a one-stage deflection structure of a deflection oil cylinder (i.e., the deflection drive mechanism 8) is used as an example for description. When the grinding unit 100 with a two-stage deflection structure of a swing oil cylinder (i.e., the swing drive mechanism 9) + a deflection electric cylinder (i.e., the deflection drive mechanism 8) is used as the actuator 13, a segmented calibration method can be adopted, that is, the swing drive mechanism 9 is first controlled to move so that the grinding unit 100 deflects to a set angle, and on this basis, the deflection drive mechanism 8 is then controlled to move so that the grinding unit 100 deflects to a calibrated angle. For example, the swing drive mechanism 9 is first controlled to move so that the grinding unit 100 deflects to 0°, assuming that the inner side is calibrated from 70° to 0° when the deflection drive mechanism 8 is extended, and the outer side is calibrated from 0° to 35° when the deflection drive mechanism 8 is retracted, and the calibration is divided into two sections, and the specific calibration separation angle can be 0°, or any other angle between -35° and 70°.

The deflection control system 300 described in this embodiment has the functions of automatic calibration, automatic fitting and result self-checking, which can effectively ensure the deflection control accuracy of the grinding unit and the calibration efficiency of the grinding deflection angle. The grinding operation computer (i.e., the grinding operation control system 19) is provided with calibration control software, which realizes data collection by controlling the continuous deflection of the grinding unit 100, and then automatically analyzes and calculates the data to obtain the optimal control parameters, and corrects the original control parameters. This embodiment is based on the correspondence between the internal stroke sensor data of the deflection cylinder and the deflection angle, and performs curve fitting on the relationship between the actually detected stroke sensor voltage and the calibrated inclination angle (obtained by the inclination sensor 17), so as to correct the deviation caused by the processing and assembly errors and structural elastic deformation of the grinding unit 100.

Example 3

As shown in Figures 7 and 10, another embodiment of the grinding unit deflection control system of the present application specifically includes: a controller 11, a control element 12, an actuator 13 (in this embodiment, more specifically, a deflection drive mechanism 8, and the deflection drive mechanism 8 can further adopt a deflection oil cylinder or a deflection electric cylinder), a deflection mechanism 2, a stroke sensor 15, and a deflection control device 20 as described in Example 1. During the grinding operation, the deflection control unit 14 converts the set angle value into a target voltage or current value according to the set function and parameters, and the controller 11 sends a control instruction to the control element 12 according to the deviation between the target voltage or current value and the feedback value, and the control element 12 controls the actuator 13 to act, and then the actuator 13 drives the deflection mechanism 2 to perform the deflection action. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time, and outputs the stroke voltage or current feedback value to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value. As shown in Figures 7 and 10, in this embodiment, the deflection control unit 14 adopts a deflection control reverse algorithm, which converts the set angle value of the deflection mechanism 2 into a target voltage or current signal of the stroke sensor 15 and outputs it to the controller 11, thereby forming a closed-loop control system to achieve precise control of the deflection angle of the grinding unit 100.

This embodiment adopts the Fourier series fitting with better comprehensive measured fitting effect to realize the deflection control reverse algorithm. For example, the set function can be further fitted by the following Fourier series first expansion function:

V＝f(α)＝a ₀ +a ₁ *cos(α*ω)+b ₁ *sin(α*ω)

Wherein, a ₀ , a ₁ , b ₁ , and ω are parameters in the Fourier series, V is a target voltage value of the stroke sensor 15 , and α is a set angle value of the deflection of the grinding unit 100 .

Of course, in addition to using the first-order Fourier series expansion function, the function set by the above-mentioned deflection control reverse algorithm can also be fitted using the Fourier series with a higher expansion order or other algorithm functions.

The difference between Example 3 and Example 2 is that the deflection control unit 14 specifically adopts the deflection control inverse algorithm, so the specific structure of the deflection control system 300 is different (as shown in Figures 9 and 10). The more detailed technical solutions of the remaining parts can be specifically referred to the relevant description in Example 2, which will not be repeated here.

Example 4

As shown in FIG. 21 , an embodiment of the grinding unit deflection control method of the present application specifically includes the following steps:

S13) replacing the function parameters of the deflection control of the grinding unit 100 with the new parameters obtained by fitting;

S16) In the grinding vehicle operation state, the grinding unit 100 is deflected and controlled according to the set function and the new parameters obtained by fitting.

Further included between step S13) and step S16):

S14) using the replaced control parameters to control the deflection of the grinding unit 100 when the grinding vehicle is parked, testing the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit 100, and determining whether there is an error greater than a set angle error value;

Before step S11), the method further includes step S10):

S10) When the grinding vehicle is parked, the inclination sensor 17 is installed on the deflection mechanism 2, the downward pressure guide column 4 or the downward pressure guide sleeve 5.

Repeat the above steps S10) to S15) to calibrate other multiple groups of grinding units 100.

Among them, the program flow of the function fitting process specifically includes four steps: data collection, data processing, parameter fitting and inspection and correction, as shown in Figure 22. The data processing flow mainly includes processing or eliminating abnormal collected data, converting data units, and processing continuously collected data to comprehensively obtain representative data. The set function includes but is not limited to any one of an exponential function, Fourier series, sine function, and polynomial function.

The above steps S14) to S15) use the new algorithm parameters to test the error between the theoretical calculation angle and the actual detection angle of the grinding unit 100, and determine whether there is a phenomenon that the deflection angle error is greater than ±0.5°. If the angle error exceeds ±0.5° when the grinding unit deflection angle is large, it can be considered to reduce the tolerance area of the control target voltage or current, or to re-correct the curve fitting parameters of this section. For example: set the target angle value of the deflection of the grinding unit 100 to 30°, and calculate the deviation between the feedback angle value and the set (target) angle value while controlling the deflection of the grinding motor 1. If the deviation is less than the tolerance of 0.5°, it means that the grinding motor 1 is deflected in place and the deflection action can be terminated. If there is an angle error exceeding ±0.5°, in order to improve the control accuracy, the tolerance can be modified from 0.5° to 0.3°, that is, the control will be terminated when the feedback angle is within the range of 29.7° to 30.3°.

When the deflection control unit 14 adopts the deflection control forward algorithm, step S16) further includes the following steps:

The controller 11 sends a control instruction to the control element 12 according to the deviation between the set angle value and the feedback angle value, and the control element 12 controls the actuator 13 (in this embodiment, more specifically, the deflection drive mechanism 8, which can further use a deflection oil cylinder or a deflection electric cylinder) to act, and then the actuator 13 drives the deflection mechanism 2 to perform the deflection action. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time, and the deflection control unit 14 converts the voltage or current value of the stroke sensor 15 into a feedback angle value according to the set function and parameters and outputs it to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value.

The set function can be further fitted using the following two exponential functions:

α＝f(V)＝a*exp(b*V)+c*exp(d*V)

When the deflection control unit 14 adopts the deflection control reverse algorithm, step S16) further includes the following steps:

The deflection control unit 14 converts the set angle value into a target voltage or current value according to the set function and parameters. The controller 11 sends a control instruction to the control element 12 according to the deviation between the target voltage or current value and the feedback value. The control element 12 controls the actuator 13 to act, and then the actuator 13 drives the deflection mechanism 2 to perform the deflection action. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time, and outputs the stroke voltage or current feedback value to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value.

The set function can be further fitted using the following Fourier series first expansion function:

V＝f(α)＝a ₀ +a ₁ *cos(α*ω)+b ₁ *sin(α*ω)

As shown in FIG23, it is a schematic diagram of the interface for collecting measured data of the grinding unit deflection control method, and as shown in FIG24, it is a schematic diagram of the interface for curve fitting based on the above-mentioned measured data. In the figure, the ordinate represents the stroke voltage (in V), and the abscissa represents the deflection angle (in °). Among them, the measured curve is the actual curve, which reflects the relationship between the actual deflection angle of the grinding unit and the stroke sensor voltage. The theoretical curve refers to the relationship curve corresponding to the design size when the deflection control system 300 is designed, without considering the errors caused by factors such as processing and manufacturing errors and gravity deformation.

Step S11) further comprises:

In the deflection angle calibration state, during the process of collecting the actual deflection angle value of the grinding unit and the actuator stroke feedback value, the grinding head 3 of the grinding unit 100 is pressed down onto the rail surface of the rail 200 according to the average downward force of the normal grinding operation state. At the same time, before performing the deflection angle (automatic) calibration, enter the deflection automatic calibration program on the display and set the relevant parameters: select the grinding unit serial number, deflection angle interval, deflection angle range and deflection voltage range that need to be deflected. When executing the automatic calibration program, in the deflection angle calibration state, the deflection angle calibration control of the grinding unit 100 is realized by setting the grinding unit serial number, deflection angle interval, deflection angle range and deflection voltage range that need to be deflected. In step S16), in the grinding vehicle operation state, the deflection control unit 14 realizes the control of the operation deflection action of the grinding unit 100.

In step S11), under the deflection angle calibration state, the deflection control unit 14 first controls the deflection of the grinding unit 100 according to the theoretical parameters of the fitting function, and deflects the grinding unit 100 to the set maximum angle. Then deflect toward the other side according to the set angle interval, and automatically stop when the deflection angle is in place, and press the grinding head 2 to the rail surface of the rail 200 according to the average downward force during normal operation, and automatically collect the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and repeat this step until the grinding unit 100 deflects to the maximum setting angle on the other side, and stops, and presses the grinding head 3 to the rail surface of the rail 200 according to the average downward force during normal operation, and automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and completes the data collection of all calibration points. By executing step S12), all collected data are fitted to obtain new function fitting parameters, and by executing step S13), the parameters are output to the deflection control unit 14 to replace the original control parameters, and the control parameter calibration is completed. At this time, the theoretical parameters of the fitting function are completely in accordance with the design size of the grinding unit 100, and according to the angle and voltage data corresponding to the triangular relationship of A, O, and B (i.e., a, b, L ₀ ), the parameters of the algorithm function, i.e., the theoretical function parameters, are fitted. In this case, the influence of factors such as processing structure error and deformation is not considered. The fitting curve is fitted according to the actual measured curve without considering the theoretical curve. Before the measured curve is obtained, the theoretical curve can be fitted to obtain preliminary parameters a, b, c, d (taking the fitting of two exponential functions as an example). With the preliminary parameters a, b, c, d, the corresponding control algorithm of the deflection control unit 14 can roughly control the grinding unit to perform deflection action and angle calibration, and then fit and correct the parameters a, b, c, d through the measured curve.

Step S11) further comprises:

When the grinding vehicle is parked, the grinding unit 100 deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle, and at the same time obtains the actual deflection angle value of the grinding unit through the inclination sensor 17, and obtains the corresponding actuator stroke feedback value through the stroke sensor 15. The number of calibration points can be changed by changing the deflection time interval setting or setting the angle interval according to the theoretical algorithm function reference. The calibration range of the grinding motor 1 can be changed by changing the deflection angle range, and the accuracy of small-range angle calibration can be improved. The settings of parameters such as time interval and deflection angle can meet a variety of customized calibration requirements to better meet the different application requirements of the work site.

In the deflection angle calibration process of step S11), the inclination data of the inclination sensor 17 is further received through the wireless gateway 18 as the actual deflection angle value of the grinding unit, and output to the deflection control unit 14 through the network port. At the same time, in order to correct the influence of the installation positioning error on the inclination measurement, and thus improve the control accuracy of the deflection angle of the grinding unit, step S11) further includes:

The tilt sensor 17 performs biaxial data collection. The deflection control unit 14 calculates the tilt angle α of the grinding unit 100 in the X direction based on the biaxial data collected by the tilt sensor 17 according to the following formula:

Among them, x' and y' are the dual-axis sensor signal output values of the inclination sensor 17, and sin ^-1 is the inverse sine function. As shown in Figures 16 and 17, it is a schematic diagram of the installation of the dual-axis inclination sensor, H is the horizontal direction, and the influence of the installation positioning error on the inclination measurement can be corrected by combining the inclination vectors in the two directions as shown in Figure 18.

In step S10), the inclination sensor 17 is further fixed on the mounting plane of the deflection mechanism 2 through the magnetic base 16; or the inclination sensor 17 is fixed on the mounting seat 23, and then the mounting seat 23 is fixed to the outer side of the downward pressure guide column 4 or the downward pressure guide sleeve 5 through the magnetic base 16.

Since the number of grinding units of the grinding vehicle is large, the calibration work needs to be carried out one by one for each grinding unit 100, so the inclination sensor 17 needs to be frequently transferred between each grinding unit 100, the operation and installation workload is large, and it is necessary to reserve an installation interface, or even to fix it by hand. In order to solve this technical problem, the inclination sensor 17 shown in Figures 16 and 17 is provided with a magnetic base 16, which can be quickly and automatically fixed on the grinding unit frame (i.e., the deflection mechanism 2) to be measured through the magnetic base 16, and the operation is very convenient. The magnetic base 16 has two structural forms: one is a calibration installation method based on a certain plane on the grinding unit frame, and the other is a calibration installation method based on the downward pressure guide column 4 or the downward pressure guide sleeve 5. Among them, the mounting surface of the first magnetic base 16 is a plane positioning structure, and the mounting surface of the second magnetic base 16 has a V-groove positioning structure.

During the grinding operation, the grinding head 3 rotates at high speed on the rail 200, grinding the top surface of the rail 200, generating high-temperature sparks, which can easily cause the temperature inside the grinding cart to rise sharply, thereby causing the temperature of the deflection cylinder (i.e., the deflection drive mechanism 8) and the internal hydraulic oil to rise. The hydraulic oil sealed by the hydraulic lock inside the cylinder expands at high temperatures, which will cause the hydraulic pressure inside the cylinder to increase significantly, making the hydraulic lock 122 unable to open or stuck. At the same time, the hydraulic cylinder, hydraulic lock 122 and oil pipe will frequently leak oil. In order to solve this technical problem, the present embodiment adopts micro-control measures, that is, when the grinding head 3 performs continuous grinding operations at a set angle, a small deflection action is performed at a certain interval. As a further improvement of this embodiment, step S16) also includes:

When the grinding head 3 performs continuous grinding at a set angle, a plurality of micro-deflection actions of a set amplitude are applied at set intervals based on the set angle value to achieve angle inching fine adjustment and high-temperature overpressure discharge inside the deflection cylinder.

The control element 12 further includes a proportional reversing valve 121 and a hydraulic lock 122, and the actuator 13 further uses a hydraulic cylinder. The two oil outlets of the hydraulic lock 122 are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlet of the proportional reversing valve 121. In order to solve the technical problem of the deflection vibration of the grinding unit, as a further improvement of this embodiment, step S16) also includes:

During the grinding operation, the controller 11 controls the pressure or flow of the proportional reversing valve 121 to accelerate and decelerate, thereby controlling the movement speed of the hydraulic cylinder. In the acceleration phase when the actuator 13 is activated, the opening of the proportional reversing valve 121 is controlled from small to large. In the deceleration phase when the set angle value is about to be reached, the opening of the proportional reversing valve 121 is controlled from large to small. In the angle inching fine-tuning phase, the opening of the proportional reversing valve 121 is set according to the tilt angle of the grinding unit 100.

In the above-mentioned embodiments 2-4 of the present application, the grinding unit 100 with a one-stage deflection structure of a deflection oil cylinder (i.e., a deflection drive mechanism 8) is introduced as an example. When the actuator 13 adopts a grinding unit 100 with a two-stage deflection of a swing oil cylinder (i.e., a swing drive mechanism 9) + a deflection electric cylinder (i.e., a deflection drive mechanism 8), a segmented calibration method can be adopted, that is, firstly controlling the swing drive mechanism 9 to move the grinding unit 100 to a set angle, and then on this basis, segmented control of the deflection drive mechanism 8 to move the grinding unit 100 to a calibrated angle. In addition, the deflection control device, system and method described in the embodiments of the present application can be applied to a multi-stage deflection structure, and the deflection oil cylinder involved in the deflection control system 300 can also be replaced by a deflection electric cylinder (electric push rod). The proportional speed control valve 121 in the deflection speed control structure can also be a hydraulic valve with a certain speed control function, such as a throttle valve and a servo valve. Although the deflection control forward algorithm in the deflection control algorithm is explained by exponential function fitting as an example, and the deflection control reverse algorithm is explained by Fourier series fitting as an example, other fitting function forms based on measured data can also be used. The deflection angle calibration subsystem adopts an automatic angle calibration method based on measured data, which can be wireless data transmission or wired data transmission.

According to the test results of actual applications, whether using exponential function, Fourier series, sine function or polynomial function fitting, the fitting accuracy can be controlled within the error range of ±0.2° to ±0.3°. After further increasing the number of function fitting times, it can even reach within ±0.2°, which well meets the ±0.5° deflection angle error range requirement of the grinding unit.

Example 5

An embodiment of a rail grinding vehicle of the present application specifically comprises: a grinding unit deflection control device 20 as described in Embodiment 1, wherein the deflection control device 20 is installed on the rail grinding vehicle as a part of a grinding operation control system 19.

Example 6

Another embodiment of the rail grinding vehicle of the present application specifically includes: the grinding unit deflection control system 300 as described in Embodiment 2 or Embodiment 3.

In the description of this application, it should be noted that when an element is referred to as being "fixed on" or "set on" another element, it can be directly on the other element or indirectly set on the other element; when an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.

It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, "multiple" and "several" mean two or more, unless otherwise clearly and specifically defined.

Professionals may further realize that the units and steps of each example described in the embodiments disclosed in the specific embodiments of the present application can be implemented by electronic hardware, computer software or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in the above description according to the function. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professionals and technicians can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this application.

The method or algorithm described in conjunction with the embodiments disclosed herein can be directly implemented using a software module executed by hardware or a processor, or a combination of the two. The software module can be placed in a random access memory (RAM), a memory, a read-only memory (ROM), an electrically programmable ROM, an electrically erasable programmable ROM, various programmable logic devices, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. The processor executing the software module can be a central processing unit (CPU), an embedded processor, a microcontroller (MCU), a digital signal processor (DSP), a single chip microcomputer, a system on a chip (SOC), a programmable logic device, and any other form of device with control and processing functions known in the art.

It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the conditions under which this application can be implemented. Therefore, they have no substantive technical significance. Any structural modification, change in proportional relationship or adjustment of size should still fall within the scope of the technical content disclosed in this application without affecting the effects and purposes that can be achieved by this application.

By implementing the technical solutions of the grinding unit deflection control device, system, method and rail grinding vehicle described in the specific embodiments of the present application, the following technical effects can be achieved:

(1) The grinding unit deflection control device, system, method and rail grinding vehicle described in the specific embodiments of the present application can effectively avoid errors easily caused by reasons such as grinding unit processing and assembly and structural elastic deformation by collecting actual feedback data of the grinding unit deflection angle and actuator stroke and performing function fitting, thereby improving the control accuracy of the grinding unit deflection angle;

(2) The grinding unit deflection control device, system, method and rail grinding vehicle described in the specific embodiments of the present application can improve the calibration efficiency and reduce the manual calibration error by performing fixed-point segmented calibration on the grinding unit deflection angle. At the same time, the dual-axis data collection of the inclination sensor can further simplify the operation and improve the calibration efficiency and accuracy.

(3) The grinding unit deflection control device, system, method and rail grinding vehicle described in the specific embodiments of the present application can ensure that the deflection angle accuracy remains unchanged during the grinding operation and avoid the deflection cylinder from getting stuck, leaking oil and other phenomena by using the grinding unit deflection angle jog fine adjustment to achieve deflection cylinder pressure relief;

(4) The grinding unit deflection control device, system, method and rail grinding vehicle described in the specific embodiments of the present application can reduce the vibration during the deflection process by controlling the acceleration and deceleration of the grinding unit deflection process and at the same time associating the angle to control the output force, thereby reducing the damage of the deflection vibration to the deflection mechanism structure, the deflection electric cylinder or the deflection oil cylinder;

(5) The grinding unit deflection control device, system, method and rail grinding vehicle described in the specific embodiments of the present application, during the grinding unit deflection angle calibration process, the grinding head is pressed down onto the rail surface according to the average downward force during normal operation, and the influence of the elastic deformation of the grinding unit structure is taken into account. The static calibration is changed to semi-dynamic calibration, thereby further improving the control accuracy of the deflection angle.

The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

The above is only a preferred embodiment of the present application, and does not constitute any formal limitation to the present application. Although the present application has been disclosed as above with a preferred embodiment, it is not intended to limit the present application. Any technician familiar with the art can use the above disclosed methods and technical contents to make many possible changes and modifications to the technical solution of the present application, or modify it into an equivalent embodiment of equivalent changes, without departing from the spirit and technical solution of the present application. Therefore, any simple modification, equivalent replacement, equivalent change and modification made to the above embodiments according to the technical essence of the present application, which does not depart from the content of the technical solution of the present application, still falls within the scope of protection of the technical solution of the present application.

Claims

A grinding unit deflection control device, characterized by comprising:

The deflection control unit controls the deflection of the grinding unit when the grinding vehicle is parked, and completes the deflection angle calibration;

The data acquisition unit collects multiple sets of actual deflection angle values of the grinding unit and corresponding actuator stroke feedback values during the calibration process;

The data fitting unit adopts a set function fitting to obtain the function parameters according to the combination of multiple groups of data of the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value, and transmits the function parameters to the deflection control unit;

The deflection control unit uses the set function and the parameters transmitted by the data fitting unit to control the deflection of the grinding unit when the grinding vehicle is in operation.
The grinding unit deflection control device according to claim 1 is characterized in that: the set function includes but is not limited to any one of an exponential function, a Fourier series, a sine function, and a polynomial function.
The grinding unit deflection control device according to claim 2 is characterized in that: the device also includes an automatic calibration control unit, which is respectively connected to the deflection control unit, the data acquisition unit and the data fitting unit; the automatic calibration control unit is used to, in the deflection angle calibration state, realize the deflection angle calibration control of the grinding unit by the deflection control unit by setting the serial number of the grinding unit to be deflected, the deflection angle interval, the deflection angle range and the deflection voltage range; when the grinding vehicle is in operation, the data acquisition unit and the data fitting unit do not work, and the deflection control unit realizes the control of the grinding unit operation deflection action.
A grinding unit deflection control system, characterized in that it comprises: a controller, a control element, an actuator, a deflection mechanism, a stroke sensor, and a deflection control device as described in any one of claims 1 to 3; during the grinding operation, the controller sends a control instruction to the control element according to the deviation between the set angle value and the feedback angle value, and the control element controls the actuator to act, and then the actuator drives the deflection mechanism to perform the deflection action; during the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and the deflection control unit converts the voltage or current value of the stroke sensor into a feedback angle value according to the set function and parameters and outputs it to the controller, so that the deflection mechanism accurately deflects to the set angle value.
The grinding unit deflection control system according to claim 4, characterized in that the set function is fitted using the following two exponential functions:

α＝f(V)＝a*exp(b*V)+c*exp(d*V)

Among them, a, b, c, d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the grinding unit deflection, and V is the voltage value of the stroke sensor.
A grinding unit deflection control system, characterized in that it includes: a controller, a control element, an actuator, a deflection mechanism, a stroke sensor, and a deflection control device as described in any one of claims 1 to 3; during the grinding operation, the deflection control unit converts the set angle value into a target voltage or current value according to the set function and parameters, the controller sends a control instruction to the control element according to the deviation between the target voltage or current value and the feedback value, the control element controls the actuator to act, and then the actuator drives the deflection mechanism to perform the deflection action; during the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and outputs the stroke voltage or current feedback value to the controller, so that the deflection mechanism accurately deflects to the set angle value.
The grinding unit deflection control system according to claim 6, characterized in that the set function is fitted using the following Fourier series first expansion function:

V＝f(α)＝a 0 +a 1 *cos(α*ω)+b 1 *sin(α*ω)

Wherein, a 0 , a 1 , b 1 , and ω are parameters in the Fourier series, V is the target voltage value of the stroke sensor, and α is the set angle value of the grinding unit deflection.
The grinding unit deflection control system according to any one of claims 4 to 7 is characterized in that: in the deflection angle calibration state, when the data acquisition unit collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, the grinding head of the grinding unit is pressed down onto the rail surface according to the average downward force of the normal grinding operation state.
The grinding unit deflection control system according to claim 8 is characterized in that: in the deflection angle calibration state, the deflection control unit first controls the grinding unit deflection according to the theoretical parameters of the fitting function, and deflects the grinding unit to the set maximum angle; then deflects toward the other side according to the set angle interval, and automatically stops when the deflection angle is in place and presses the grinding head down to the rail surface of the rail according to the average downward force during normal operation, and the data acquisition unit automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and repeats this operation until the grinding unit deflects to the maximum set angle on the other side and stops, and the grinding head is pressed down to the rail surface of the rail according to the average downward force during normal operation, and the data acquisition unit automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value to complete the data collection of all calibration points; all collected data are input into the data fitting unit for fitting to obtain new function fitting parameters, and the parameters are output to the deflection control unit to replace the original control parameters to complete the control parameter calibration.
The grinding unit deflection control system according to claim 9 is characterized in that: the deflection control unit uses the replaced control parameters to control the deflection of the grinding unit when the grinding vehicle is parked, tests the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit, and determines whether there is an error greater than the set angle error value; if the deflection control unit determines that the error is greater than the set angle error value, the tolerance control range of the target angle, voltage or current value is reduced, or the data fitting unit re-performs function fitting according to the actual deflection angle value of the grinding unit and the actuator stroke feedback value.
The grinding unit deflection control system according to claim 4, 5, 6, 7, 9 or 10 is characterized in that: the system also includes a deflection angle calibration subsystem, and the deflection angle calibration subsystem includes an inclination sensor installed on the deflection mechanism, the downward pressure guide column or the guide sleeve when the grinding vehicle is parked; when the grinding vehicle is parked, the grinding unit deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle, and at the same time obtains the actual deflection angle value of the grinding unit through the inclination sensor, and obtains the corresponding actuator stroke feedback value through the stroke sensor.
The grinding unit deflection control system according to claim 11 is characterized in that the inclination sensor is fixed on the mounting plane of the deflection mechanism through a magnetic base.
The grinding unit deflection control system according to claim 11 is characterized in that the inclination sensor is fixed on a mounting seat, and the mounting seat is further fixed to the outer side surface of the downward pressure guide column or guide sleeve through a magnetic base.
The grinding unit deflection control system according to claim 12 or 13 is characterized in that the inclination sensor can realize dual-axis acquisition, and the deflection control unit calculates the inclination angle α of the grinding unit in the X direction based on the dual-axis acquisition data of the inclination sensor according to the following formula:

Wherein, x' and y' are the dual-axis sensor signal output values of the inclination sensor, and sin -1 is the inverse sine function.
According to the grinding unit deflection control system of claim 14, it is characterized in that: the inclination sensor has a wireless node, and the deflection angle calibration subsystem also includes a wireless gateway; the wireless gateway receives the inclination data of the inclination sensor as the actual deflection angle value of the grinding unit, and outputs it to the deflection control unit through the network port.
The grinding unit deflection control system according to claim 4, 5, 6, 7, 9, 10, 12, 13 or 15 is characterized in that: when the grinding head performs continuous grinding operation at a set angle, a number of micro-deflection actions of a set amplitude are applied at set intervals on the basis of the set angle value to achieve angle inching fine-tuning and high-temperature overpressure flow relief inside the actuator.
The grinding unit deflection control system according to claim 4, 5, 6, 7, 9, 10, 12, 13 or 15 is characterized in that: the control element includes a proportional reversing valve and a hydraulic lock, and the actuator adopts a hydraulic cylinder; the two oil outlets of the hydraulic lock are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlets of the proportional reversing valve; the pressure or flow of the proportional reversing valve is accelerated and decelerated by the controller to realize the movement speed control of the hydraulic cylinder; in the acceleration stage of the actuator startup, the opening of the proportional reversing valve is controlled from small to large; in the deceleration stage when the set angle value is about to be reached, the opening of the proportional reversing valve is controlled from large to small; in the angle inching fine-tuning stage, the opening of the proportional reversing valve is set according to the inclination angle of the grinding unit.
A grinding unit deflection control method, characterized in that it comprises the following steps:

S11) controlling the grinding unit to deflect when the grinding vehicle is parked, and collecting multiple sets of actual deflection angle values of the grinding unit and corresponding actuator stroke feedback values during the deflection process;

S12) using the set function fitting, obtaining the function parameters according to the multiple data combinations of the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value, and returning the new parameters obtained by fitting;

S13) replacing the function parameters of the grinding unit deflection control with the new parameters obtained by fitting;

S16) In the grinding vehicle operation state, the grinding unit is deflected and controlled according to the set function and the new parameters obtained by fitting.
The grinding unit deflection control method according to claim 18 is characterized in that the method further comprises between step S13) and step S16):

S14) using the replaced control parameters to control the deflection of the grinding unit when the grinding vehicle is parked, testing the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit, and determining whether there is an error greater than a set angle error value;

S15) If the error is greater than the set angle error value, the tolerance control range of the target angle, voltage or current value is reduced, or the function is refitted according to the actual deflection angle value of the grinding unit and the actuator stroke feedback value.
The grinding unit deflection control method according to claim 18 or 19 is characterized in that: the set function includes but is not limited to any one of an exponential function, a Fourier series, a sine function, and a polynomial function.
The grinding unit deflection control method according to claim 20 is characterized in that the step S16) further comprises the following steps:

The controller sends a control instruction to the control element according to the deviation between the set angle value and the feedback angle value, and the control element controls the action of the actuator, which then drives the deflection mechanism to perform the deflection action; during the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and the deflection control unit converts the voltage or current value of the stroke sensor into a feedback angle value according to the set function and parameters and outputs it to the controller, so that the deflection mechanism can accurately deflect to the set angle value.
The grinding unit deflection control method according to claim 21 is characterized in that the set function is fitted using the following two exponential functions:

α＝f(V)＝a*exp(b*V)+c*exp(d*V)

Among them, a, b, c, d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the grinding unit deflection, and V is the voltage value of the stroke sensor.
The grinding unit deflection control method according to claim 20 is characterized in that the step S16) further comprises the following steps:

The deflection control unit converts the set angle value into a target voltage or current value according to the set function and parameters. The controller sends a control instruction to the control element according to the deviation between the target voltage or current value and the feedback value. The control element controls the action of the actuator, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time, and outputs the stroke voltage or current feedback value to the controller, so that the deflection mechanism accurately deflects to the set angle value.
The grinding unit deflection control device according to claim 23 is characterized in that the set function is fitted using the following Fourier series first expansion function:

V＝f(α)＝a 0 +a 1 *cos(α*ω)+b 1 *sin(α*ω)

Wherein, a 0 , a 1 , b 1 , and ω are parameters in the Fourier series, V is the target voltage value of the stroke sensor, and α is the set angle value of the grinding unit deflection.
The grinding unit deflection control method according to claim 21, 22, 23 or 24, characterized in that the step S11) further comprises:

In the deflection angle calibration state, during the process of collecting the actual deflection angle value of the grinding unit and the actuator stroke feedback value, the grinding head of the grinding unit is pressed down onto the rail surface according to the average downward force of the normal grinding operation state.
The grinding unit deflection control method according to claim 25 is characterized in that: in the step S11), in the deflection angle calibration state, the deflection angle calibration control of the grinding unit is realized by setting the grinding unit serial number, deflection angle interval, deflection angle range and deflection voltage range to be deflected; in the step S16), in the grinding vehicle operation state, the deflection control unit realizes the control of the grinding unit operation deflection action.
The grinding unit deflection control method according to claim 26 is characterized in that: in the step S11), in the deflection angle calibration state, the deflection control unit first performs the grinding unit deflection control according to the theoretical parameters of the fitting function, and deflects the grinding unit to the set maximum angle; then deflects toward the other side according to the set angle interval, and automatically stops when the deflection angle is in place, and presses the grinding head down to the rail surface of the rail according to the average downward force during normal operation, and automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and repeats this step until the grinding unit deflects to the maximum set angle on the other side, stops, presses the grinding head down to the rail surface of the rail according to the average downward force during normal operation, and automatically collects the actual deflection angle value of the grinding unit and the actuator stroke feedback value, and completes the data collection of all calibration points; by executing the step S12), all the collected data are fitted to obtain new function fitting parameters, and by executing the step S13), the parameters are output to the deflection control unit to replace the original control parameters, and the control parameter calibration is completed.
The grinding unit deflection control method according to claim 18, 19, 21, 22, 23, 24, 26 or 27, characterized in that before step S11), it also includes step S10):

S10) When the grinding vehicle is parked, the inclination sensor is installed on the deflection mechanism, the downward pressure guide column or the guide sleeve;

Repeat the above steps S10) to S15) to calibrate other groups of grinding units;

The step S11) further comprises:

When the grinding vehicle is parked, the grinding unit deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle, and at the same time obtains the actual deflection angle value of the grinding unit through the inclination sensor, and obtains the corresponding actuator stroke feedback value through the stroke sensor.
The grinding unit deflection control method according to claim 28, characterized in that the step S10) further comprises:

Fixing the inclination sensor on the mounting plane of the deflection mechanism through a magnetic base;

Or the inclination sensor is fixed on a mounting seat, and then the mounting seat is fixed to the outer side surface of the downward pressure guide column or guide sleeve through a magnetic base.
The grinding unit deflection control method according to claim 29, characterized in that the step S11) further comprises:

The inclination sensor is used to collect biaxial data. The deflection control unit collects biaxial data based on the inclination sensor and calculates the inclination angle α of the grinding unit in the X direction according to the following formula:

Wherein, x' and y' are the dual-axis sensor signal output values of the inclination sensor, and sin -1 is the inverse sine function.
The grinding unit deflection control method according to claim 30, characterized in that the step S11) further comprises:

The inclination data of the inclination sensor is received through the wireless gateway as the actual deflection angle value of the grinding unit, and is output to the deflection control unit through the network port.
The grinding unit deflection control method according to claim 18, 19, 21, 22, 23, 24, 26, 27, 29, 30 or 31, characterized in that the step S16) further comprises:

When the grinding head performs continuous grinding operation at a set angle, a micro-deflection action of a set amplitude is applied several times at a set interval based on the set angle value to achieve angle inching fine adjustment and high-temperature overpressure flow relief inside the actuator.
The grinding unit deflection control method according to claim 18, 19, 21, 22, 23, 24, 26, 27, 29, 30 or 31 is characterized in that the control element includes a proportional reversing valve and a hydraulic lock, and the actuator adopts a hydraulic cylinder; the two oil outlets of the hydraulic lock are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlet of the proportional reversing valve; the step S16) further includes:

During the grinding operation, the pressure or flow of the proportional reversing valve is accelerated and decelerated by the controller to realize the movement speed control of the hydraulic cylinder; in the acceleration stage when the actuator is started, the opening of the proportional reversing valve is controlled from small to large; in the deceleration stage when the set angle value is about to be reached, the opening of the proportional reversing valve is controlled from large to small; in the angle inching fine-tuning stage, the opening of the proportional reversing valve is set according to the inclination angle of the grinding unit.
A rail grinding vehicle, characterized in that it comprises: a grinding unit deflection control device as described in any one of claims 1 to 3.
A rail grinding vehicle, characterized by comprising: a grinding unit deflection control system according to any one of claims 4 to 17.