Rail pair mechanism and rail pairing method

Abstract

The present application provides a kind of rail alignment mechanism, which includes rail profile scanning component (1), rail torsion adjustment mechanism (2), rail transverse adjustment mechanism (3), rail vertical adjustment mechanism (4). The whole rail alignment mechanism is installed between rail clamping mechanism (5) and top forging mechanism (6) of welding rail equipment. After the rail clamping mechanism clamps the rail (7), the alignment mechanism starts to adjust the position of the rail, which avoids the disturbance error caused by clamping the rail after the alignment is completed. The rail alignment relies on sensor positioning. In this way, different rail alignment rules can be used (such as rail center alignment (8), rail bottom edge alignment (9), rail top surface alignment (10), rail right working edge alignment (11) and rail left working edge alignment (12)). Without changing the structure of the welding machine or the structure of the rail clamping mold, the rail is not aligned by the rail clamping mold. The rail clamping mold has no accuracy requirement, thereby prolonging its service life.

Description

TECHNICAL FIELD

[0001] The present application relates to a rail alignment mechanism and belongs to the technical field of engineering equipment. BACKGROUND

[0002] The rail clamping force of the currently widely used rail welding equipment is as high as 300 tons. The alignment principle of the rails is to use this feature to design the clamping dies with high precision. Under the action of the clamping force, the two rails are tightly attached to the dies, and the alignment of the rails is completed by relying on the precision of the dies. Due to this feature, the existing rail welding equipment does not have a rail position adjustment function and can only perform rail center alignment. When the positioning dies are worn, the rigidity of the welding machine body is reduced, the profiles of the two rails are inconsistent, new and old rails are welded, and the rail alignment reference becomes the working edge, the rail top surface, and the rail bottom surface. The rail alignment process of the traditional rail welding equipment becomes very complex, and methods such as replacing the dies, adding shims between the rails and the dies, etc. are used for adjustment. The process is repeated until it is qualified.

[0003] The utility model patent with publication number CN 201473841 U discloses a rail alignment welding machine that aligns the rails according to the working edge. This welding machine only has a rail transverse adjustment function and lacks rail vertical and transverse twisting functions. It aligns the rails by relying on the notch on the box. Since there is no measurement system and the rail adjustment system is single, it can only perform rail working edge alignment. It lacks rail center and rail bottom edge alignment functions and cannot perform alignment of new and old rails. The use function is limited. SUMMARY

[0004] The present application provides a rail alignment mechanism, which includes a rail profile scanning assembly and a rail attitude adjustment mechanism. The rail profile scanning assembly is connected to and communicates with the rail attitude adjustment mechanism to control the action of the rail attitude adjustment mechanism according to the scanning results of the rail profile scanning assembly, so as to realize the selected rail alignment rules according to the rail position and profile data scanned by the rail profile scanning assembly (1), such as rail center alignment (8), rail bottom edge alignment (9), rail top surface alignment (10), rail right working edge alignment (11), or rail left working edge alignment (12).

[0005] The rail alignment mechanism of the present application does not need to change the structure of the welding machine or the structure of the welding rail clamping dies. At the same time, it does not need to align the rails with the clamping dies. Therefore, there is no precision requirement for the clamping dies, thereby prolonging the service life of the clamping dies.

[0006] The rail profile scanning assembly preferably comprises a scanning control system, which comprises at least three laser scanning sensors respectively arranged on the top of the rail and on both sides of the rail, and the scanning sensors are connected to a scanning sensor moving device which moves in the direction parallel to the rail within the range of ±500 mm at the rail joint to scan the position and profile of the two sections of the rail to be welded. The straightness and misalignment of the rail are calculated according to the scanning results. The rail position adjustment value is output to the adjustment mechanism according to the selected alignment standard. At the same time, it is judged whether the rail alignment meets the requirements.

[0007] More preferably, the scanning control system comprises a 3D scanning control system which is connected to and controls the rail posture adjustment mechanism.

[0008] The 3D scanning control system uses a laser profile sensor as a working element, which is arranged at the joint of the two rails and moves in the direction of the rail.

[0009] Preferably, the rail posture adjustment mechanism is arranged between the rail clamping mechanism and the upsetting mechanism.

[0010] More preferably, the rail posture adjustment mechanism is fixed on the upsetting mechanism (such as the upsetting cylinder rod and the frame of the upsetting mechanism), and the rail clamping mechanism of the welding machine is placed on the rail posture adjustment mechanism; the rail posture adjustment mechanism drags the rail clamping mechanism and the rail to move together to finally realize the rail adjustment function.

[0011] Preferably, the rail posture adjustment mechanism comprises rail transverse adjustment, transverse torsion and vertical adjustment functions.

[0012] Preferably, the rail posture adjustment mechanism comprises a rail torsion adjustment mechanism (2), a rail transverse adjustment mechanism (3) and a rail vertical adjustment mechanism (4).

[0013] Preferably, the rail profile scanning assembly (1) comprises three laser profile scanning sensors (101) fixed on the scanning sensor moving device (102).

[0014] The laser profile scanning sensors (101) are respectively arranged on the top surface of the rail and on both sides of the rail. The scanning sensor moving device (102) is fixed on the outer box body (402). The scanning sensor moving device (102) drives the laser scanning sensor (101) to move and scan in the direction parallel to the rail (7) to collect the position and profile data of the two sections of the rail. At the same time, it can stop at the joint of the two rails to monitor the rail alignment result in real time. The result is fed back to the rail posture adjustment mechanism until the rail alignment meets the requirements.

[0015] The rail torsion adjustment mechanism (2) comprises a rotating shaft (201), a torsion guide frame (202), a rail clamping mechanism (5) of the rail welding equipment connected with the rotating shaft (201) and the torsion guide frame (202), and a fixed end of a torsion adjustment device (203) installed on the torsion guide frame (202), wherein the movable end of the torsion adjustment device (203) pushes the rail clamping mechanism (5) to realize end rotation adjustment of the rail clamping mechanism (5), and then the rail clamping mechanism drives the rail (7) to realize torsion adjustment of the rail.

[0016] The rail transverse adjustment mechanism (3) comprises a transverse guide frame (301) and a transverse adjustment device (302). The torsion guide frame (202) is embedded in a guide sliding groove (303) of the transverse guide frame (301). The transverse adjustment device (302) is installed between the torsion guide frame (202) and the transverse guide frame (301). The transverse adjustment device drives the torsion guide frame (202) to move transversely to realize transverse adjustment of the rail (7).

[0017] The rail vertical adjustment mechanism (4) comprises an outer box body (401) and a vertical adjustment device (402). The transverse guide frame (301) is placed in the outer box body (401) as a whole, and the end of the transverse guide frame (301) is embedded in a guide sliding groove (403) of the outer box body (401). Two groups of vertical adjustment devices are arranged at the two ends of the transverse guide frame (301) to lift the transverse guide frame (301) to realize vertical adjustment of the rail.

[0018] The second aspect of the present application provides a rail alignment method, which comprises,

[0019] Step S1: the scanning sensor moving device of the rail profile scanning assembly moves in the direction parallel to the rail within the range of ±500 mm at the rail joint to scan the positions and profiles of the two sections of rails to be welded.

[0020] Step S2: the straightness and the misalignment size of the rails are calculated according to the scanning results.

[0021] Step S3: the rail position adjustment value is output to the rail position adjustment mechanism according to the selected alignment standard.

[0022] Step S4: whether the rail alignment meets the requirements is judged, and the alignment state between the two sections of rails is adjusted by the rail position adjustment mechanism.

[0023] Preferably, a 3D scanning measurement and control system is adopted, and a laser profile sensor is used as a working element and is arranged at the joint of the two rails to move and scan the positions and profiles of the two sections of rails to be welded.

[0024] More preferably, the rail posture obtained by scanning is input to a control system as a control input quantity. According to the internal control strategy of the control system, a rail position adjustment target value is calculated and transmitted to the adjustment mechanism to complete the rail alignment adjustment work.

[0025] Preferably, the rail-alignment method described in the second aspect of the present invention adopts the rail-alignment mechanism described in the first aspect of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the assembly of a rail alignment machine according to a preferred embodiment of the rail alignment mechanism of the present invention;

[0027] Figure 2 for Figure 1 A side view of a schematic structural diagram of a rail profile scanning assembly according to the illustrated embodiment;

[0028] Figure 3 for Figure 2 A front view of a preferred embodiment of the rail profile scanning assembly is shown;

[0029] Figure 4 for Figure 2 A schematic diagram of the three-dimensional structure of the rail profile scanning assembly of the illustrated embodiment;

[0030] Figure 5 for Figure 1 Schematic diagram of rail posture adjustment assembly of the illustrated embodiment;

[0031] Figure 6 for Figure 1 Schematic diagram of the rail torsion adjustment mechanism of the illustrated embodiment;

[0032] Figure 7 for Figure 1 Schematic diagram of the rail transverse adjustment mechanism of the illustrated embodiment;

[0033] Figure 8 for Figure 1 A schematic diagram of a rail vertical adjustment mechanism according to the illustrated embodiment;

[0034] Figure 9 This is a schematic diagram of rail center alignment;

[0035] Figure 10 for Figure 9 Schematic diagram of the relative positions of the two sections of rails to be butted together;

[0036] Figure 11 for Figure 9 Schematic diagram of rail top surface alignment in the illustrated embodiment;

[0037] Figure 12 for Figure 9 Schematic diagram of rail bottom edge alignment in the illustrated embodiment;

[0038] Figure 13 for Figure 9 Schematic diagram of alignment of the right working edge of the rail in the embodiment shown;

[0039] Figure 14 for Figure 9 Schematic diagram of alignment of the left working edge of the rail in the embodiment shown;

[0040] 1. Rail profile scanning assembly 2. Rail torsion adjustment mechanism 3. Rail lateral adjustment mechanism

[0041] 4 Rail vertical adjustment mechanism 5 Rail clamping mechanism 6 Upsetting mechanism 7 Rail

[0042] 101 three laser profile scanning sensors 102 fixed on the scanning sensor moving device

[0043] 201 rotating shaft 202 torsion guide frame 203 torsion adjustment cylinder

[0044] 301 lateral guide frame 302 lateral adjustment cylinder 303 lateral guide chute

[0045] 401 outer box body 402 vertical adjustment cylinder 403 vertical guide slide. DETAILED DESCRIPTION

[0046] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings of preferred embodiments of the rail-to-rail mechanism of the present invention.

[0047] Example 1.1: Figure 1 The figure shows a preferred embodiment of the rail alignment mechanism of the present invention, which includes a rail profile scanning component (1), a rail torsion adjustment mechanism (2), a rail lateral adjustment mechanism (3), and a rail vertical adjustment mechanism (4); the rail torsion adjustment mechanism (2), the rail lateral adjustment mechanism (3), and the rail vertical adjustment mechanism (4) are installed in an outer box body 401, and the rail alignment mechanism is installed between the rail clamping mechanism (5) and the upsetting mechanism (6) of the rail welding equipment. When the rail clamping mechanism (5) clamps the rail (7), the rail alignment mechanism starts to adjust the rail position, so as to avoid the disturbance error caused by clamping the rail after the alignment is completed.

[0048] Figure 2 - Figure 4The rail profile scanning assembly (1) is shown, three laser profile scanning sensors (101) are fixed on the scanning sensor moving device (102). The scanning sensor moving device 102 includes a vertical opening downward U-shaped frame, which is connected to the longitudinal side wall of the outer box body 402 of the rail vertical adjustment mechanism 4 through the moving rod. The laser profile scanning sensor (101) is respectively placed at the lower center of the top surface of the U-shaped frame and the lower bottom surface of the two ends of the U-shaped frame, so as to scan and monitor the profile data of the top surface of the rail and the two side edges of the rail. The scanning sensor moving device (102) drives the laser scanning sensor (101) installed on the U-shaped frame to move along the direction parallel to the rail under the extension of the moving rod, and scans and collects the position data and profile data of the two rails to be connected. The laser profile scanning sensor (101) can be stopped at the joint of the two rails under the drive of the scanning sensor moving device 102, real-time monitor the result of the rail alignment, and feed back the result to the rail posture adjustment mechanism. Until the rail alignment meets the requirements.

[0049] Figure 6 The structure diagram of the preferred embodiment of the rail torsion adjustment mechanism (2) is shown. In this embodiment, the rail torsion adjustment mechanism 2 includes a torsion guide frame (202), which is a horizontally arranged rectangular or square frame. The height of the torsion guide frame 202 is 3-4 times the thickness of the frame. The center of the longitudinal two ends of the torsion guide frame 202 includes a through hole, and a rotating shaft 201 is embedded in the through hole. The rail clamping mechanism of the welding equipment is inserted into the shaft sleeve of the torsion guide frame (202) through the rotating shaft (201). The first mounting seat is arranged on the transverse two end surfaces of the torsion guide frame 202. The torsion adjustment oil cylinder (203) is linked to the first mounting seat. The piston rod end of the torsion adjustment oil cylinder (203) is connected to the rail clamping mechanism 5, and the rail clamping mechanism (5) is driven to rotate relative to the outer box body 401 by the extension and retraction of the piston rod of the torsion adjustment oil cylinder 203, so that the rail clamping mechanism (5) drives the rail (7) to realize the torsion adjustment of the rail.

[0050] Figure 7 The structure diagram of the rail transverse adjustment mechanism (3) is shown. It includes a transverse guide frame (301) and a transverse adjustment oil cylinder (302). The transverse guide frame 301 is a single frame mounted on the outer side of the transverse two ends of the torsion guide frame 202. The transverse guide frame 301 includes a transverse guide sliding groove 303, and the torsion guide frame (202) is embedded in the transverse guide sliding groove (303) of the transverse guide frame (301). The torsion guide frame (202) can only slide transversely in the transverse guide sliding groove (303) of the transverse guide frame (301). The transverse adjustment oil cylinder 302 is fixed on the torsion guide frame (202), and the piston rod of the transverse adjustment oil cylinder 302 is fixed on the transverse guide frame (301). The transverse adjustment oil cylinder 302 drives the transverse movement of the torsion guide frame (202) by the extension and retraction of the piston rod to realize the transverse adjustment of the rail (7).

[0051] Figure 8 The structure diagram of the vertical adjustment mechanism (4) of the steel rail, which comprises an outer box 401 and a vertical adjustment oil cylinder (402). The transverse guide frame (301) is placed in the outer box 401 as a whole, and the end of the transverse guide frame (301) is embedded in the vertical guide slot (403) of the outer box (401). The vertical guide slot 403 is a boss with a groove integrally formed in the outer box 401. The transverse guide frame (301) can only move up and down in the vertical guide slot (403) on the outer box (401). Two groups of vertical adjustment oil cylinders 402 are arranged at the two ends of the transverse guide frame (301) for lifting the transverse guide frame (301) to achieve the vertical adjustment of the steel rail (7). The cylinder barrel of the vertical adjustment oil cylinder 402 is connected to the third mounting seat on the top of the longitudinal end face of the outer box 401, and the piston end of the vertical adjustment oil cylinder 402 is connected to the top surface of the transverse guide frame 301.

[0052] As shown in Figure 1 , Figure 5 and Figure 6 , the rail clamping mechanism 5 in the embodiment is a one-piece structure, and the top thereof comprises a longitudinal beam, four groups of transverse beams integrally formed on both sides of the longitudinal beam, and rail clamping block mounting grooves at the bottom of the transverse beams at the longitudinal front and rear ends, wherein the rail clamping blocks are arranged in the rail clamping block mounting grooves to clamp the rail waist. The four groups of transverse beams form three groups of guide grooves on both sides of the longitudinal beam. The middle guide groove of the three groups of guide grooves accommodates the piston end of the torsion adjustment oil cylinder 203 connected to the torsion frame 202. The piston end of the torsion adjustment oil cylinder 203 is connected to the steel rail 7 after penetrating through the middle guide groove.

[0053] During operation, the rail clamping mechanism (5) of the rail welding equipment is arranged in the torsion guide frame 202 of the rail torsion adjustment mechanism 2, and the rail vertical adjustment mechanism 4, the rail transverse adjustment mechanism 3 embedded therein, and the rail torsion adjustment mechanism 2 are integrally arranged between the top forging mechanisms (6). The top forging mechanisms 6 penetrate through the mounting holes in the longitudinal side walls of the two outer boxes 401, and the two outer boxes 401 and the rail vertical adjustment mechanism 4, the rail transverse adjustment mechanism 3 embedded therein, and the rail torsion adjustment mechanism 2 arranged therein are arranged between the two steel rails to be connected. The rails of the two outer boxes 401 are adjusted in position by the rail vertical adjustment mechanism 4, the rail transverse adjustment mechanism 3 embedded therein, and the rail torsion adjustment mechanism 2 arranged in the outer box 401, so as to achieve the purpose of rail connection. When the rail clamping mechanisms (5) in the two outer boxes 401 clamp the two steel rails (7) to be connected as shown in Figure 9 , Figure 10 , the rail profile scanning assembly 1 arranged on the outer box 401 of the rail connection mechanism starts to work and adjusts the position of the steel rail after the laser profile scanning sensor 101 and the scanning sensor moving device 102 start to work.

[0054] The positive effects of the rail alignment mechanism described in the above embodiments are that the positions of the two sections of rail to be welded can be automatically adjusted according to the rail position and profile results scanned by the scanning system to meet the selected rail alignment rules, i.e. the rail center alignment (8) as shown in Figure 9 , the rail top surface alignment (9) as shown in Figure 11 , the rail bottom edge alignment (10) as shown in Figure 12 , the rail right working edge alignment (11) as shown in Figure 13 , or the rail left working edge alignment (12) as shown in Figure 14 . This can improve the efficiency and quality of rail welding and reduce the workload of later rail polishing.

[0055] The rail profile scanning assembly uses three groups of profile sensors to scan the posture and position data of the two sections of rail to be welded in real time, and to monitor the rail alignment results in real time. This can realize rail alignment automation and improve the flatness of the rail welding head to meet the quality requirements of rail welding.

[0056] The adjustment mechanism is installed between the rail clamping mechanism and the top forging mechanism of the rail welding equipment. The rail alignment mechanism starts to adjust the position of the rail only after the rail clamping mechanism clamps the rail, so as to avoid the disturbance error caused by clamping the rail after the alignment is completed. The rail transverse torsion, transverse and vertical adjustment mechanisms adjust the rail to the required position to meet different alignment standards (rail center alignment (8), rail bottom edge alignment (9), rail top surface alignment (10), rail right working edge alignment (11) and rail left working edge alignment (12)).

[0057] Embodiment 1.2: A rail alignment mechanism, which is the same as that in Embodiment 1.1, except that the torsion adjustment oil cylinder 203, the transverse adjustment oil cylinder 302 and the vertical adjustment oil cylinder 402 are replaced by power output devices such as speed reduction motors or stepping motors or lead screws.

[0058] Embodiment 1.3: A rail alignment mechanism, which is the same as that in Embodiment 1.1, except that the transverse guide sliding groove 303, the vertical guide sliding groove 403 and the guide groove of the rail clamping mechanism 5 are replaced by wire rails or optical shafts.

[0059] The rail alignment mechanism described above can automatically adjust the posture of the two sections of rail to be welded to meet the selected rail alignment standards. It is used in rail welding equipment to realize the function of automatic rail alignment, thereby improving the efficiency and quality of rail welding, the adaptability of existing welding machines and reducing the workload of later rail polishing.

[0060] Embodiment 2.1: A rail-to-rail method, which comprises placing a laser profile scanning sensor (101) on the top surface of the rail and on both sides of the rail, respectively. The scanning sensor moving device (102) is fixed on the outer box (402); the scanning sensor moving device (102) drives the laser scanning sensor (101) to move in parallel with the direction of the rail (7) to scan and collect the position and profile data of the two rails. At the same time, it can stop at the joint of the two rails to monitor the rail alignment result in real time. The laser profile scanning sensor (101) feeds back the result to the rail posture adjustment mechanism, which compares with the adjustment rules to obtain the required adjustment amount, and adjusts in the vertical or horizontal direction or twists horizontally until the rail alignment meets the requirements.

Claims

1. A method of rail alignment for performing work on a rail using a rail alignment apparatus, the rail alignment apparatus comprising a rail profile scanning assembly (1) and a rail attitude adjustment mechanism, characterised in that: The rail profile scanning assembly (1) is connected with and communicates with the rail posture adjusting mechanism, so as to control the rail posture adjusting mechanism to act according to the scanning result of the rail profile scanning assembly, so as to realize the alignment of two sections of rails to be welded (7) according to the position and profile data of the rails (7) scanned by the rail profile scanning assembly (1) and according to the rail center alignment (8), the rail bottom edge alignment (9), the rail top surface alignment (10), the rail right working edge alignment (11) or the rail left working edge alignment (12). The rail profile scanning assembly (1) comprises three laser profile scanning sensors (101) fixed on a scanning sensor moving device (102). The rail posture adjusting mechanism comprises a rail torsion adjusting mechanism (2), a rail transverse adjusting mechanism (3) and a rail vertical adjusting mechanism (4). The rail torsion adjusting mechanism (2) comprises a rotating shaft (201) and a torsion guide frame (202). A rail clamping mechanism (5) of a rail welding device is connected with the rotating shaft (201) and the torsion guide frame (202). A fixed end of a torsion adjusting device (203) is arranged on the torsion guide frame (202). A movable end of the torsion adjusting device (203) pushes the rail clamping mechanism (5) to realize the rotating adjustment of the end of the rail clamping mechanism (5), so that the rail clamping mechanism drives the rail (7) to realize the torsion adjustment of the rail. The rail transverse adjusting mechanism (3) comprises a transverse guide frame (301) and a transverse adjusting device (302). The torsion guide frame (202) is embedded in a guide sliding groove of the transverse guide frame (301). The transverse adjusting device (302) is arranged between the torsion guide frame (202) and the transverse guide frame (301). The transverse adjusting device drives the torsion guide frame (202) to move transversely to realize the transverse adjustment of the rail (7). The rail vertical adjusting mechanism (4) comprises an outer box body (401) and a vertical adjusting device (402). The transverse guide frame (301) is arranged in the outer box body (401). The end of the transverse guide frame (301) is embedded in a guide sliding groove of the outer box body (401). Two groups of vertical adjusting devices are arranged at the two ends of the transverse guide frame (301) to lift the transverse guide frame (301) to realize the vertical adjustment of the rail. The rail alignment method comprises the following steps: Step S1: The scanning sensor moving device of the rail profile scanning assembly moves in the direction parallel to the rail within the range of ±500 mm at the rail joint to scan the position and profile of the two sections of rails to be welded. Step S2: The straightness and the misalignment size of the rail are calculated according to the scanning result. Step S3: The rail position adjustment value is output to the rail position adjusting mechanism according to the selected alignment standard. Step S4: It is judged whether the rail alignment meets the requirements, and the alignment state between the two sections of rails is adjusted by the rail position adjusting mechanism.

2. The rail pairing method of claim 1, wherein: The rail profile scanning assembly (1) comprises a scanning control system, which comprises at least three laser profile scanning sensors (101) arranged at the top of the rail and the two sides of the rail respectively. The scanning sensors are connected to the scanning sensor moving device.

3. The rail pairing method of claim 2, wherein: The scanning control system comprises a 3D scanning control system, which is connected with and controls the rail posture adjusting mechanism.

4. The rail pairing method of claim 3, wherein: The 3D scanning measurement and control system uses a laser profile sensor as a working element, which is placed at the joint of two rails and moves along the rail direction to scan.

5. The rail pairing method defined in claim 1 or 2 or 4, characterised in that: The rail posture adjusting mechanism is fixed on the top forging mechanism, and the rail clamping mechanism of the welding machine is placed on the rail posture adjusting mechanism; the rail posture adjusting mechanism drags the rail clamping mechanism and the rail to move together, so that the rail adjusting function is finally realized.

6. The rail aligning method as claimed in claim 5, wherein: The rail posture adjusting mechanism is arranged between the rail clamping mechanism and the top forging mechanism.

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