Automatic control system and method for forging die of special-shaped steel rail

Abstract

Provided is an automatic control system and method for a special-shaped rail forging die, which has an automatic control system for a special-shaped rail forging die; the automatic control system for a special-shaped rail forging die includes an automatic control system for a compound extrusion die; the working step beat of the automatic control system for a compound extrusion die is interlocked with the working step beat signal of the press control system; the press establishes a die closing working step formula according to the height position of the compound extrusion die, the working position operation serial number of the compound extrusion die, and the pressure values of different working steps of the compound extrusion die; multiple die closing working step formulas are integrated to form an automatic compound extrusion process; the automatic control system for a compound extrusion die and the press control system complete the multi-step die closing operation forging production of the special-shaped rail according to the automatic compound extrusion process. The present invention realizes automatic production and has the potential for popularization; it is of great significance for improving the application level of equipment and promoting the progress of turnout processing technology.

Description

Technical Field

[0001] The present invention belongs to the technical field of metal pressing and forging of steel rails, and particularly relates to an automatic control system and method for an abnormal-shaped steel rail forging die. Background Art

[0002] The forging of abnormal-shaped steel rails refers to the forging process of forging the cross-section type of a certain length at the end of the steel rail into the blank of another type of steel rail cross-section, also known as the forging of the heel end of the steel rail.

[0003] From the perspectives of economy, technology, and practicability, the compound extrusion process based on the compound extrusion die of our company has great practical application value, and also meets the product characteristics of short supply cycle, small batch, and many types of our company's export turnout business. Moreover, reducing the cost of steel rail forging is the primary cost control method for our company to maintain stable quality for a long time, and it has played an important role in achieving continuous profitability of the enterprise for many years.

[0004] However, under the existing technology, in the manual mode of multi-person cooperation based on the compound extrusion die, different operators and different operation methods have a great impact on the forming of workpieces, and the quality fluctuates greatly. To stabilize the product quality, on the one hand, improve production efficiency, and on the other hand, further improve the domestic automation process level of the heel end, combining Chinese and Western technologies; the press equipment and the feeding system basically follow the application principle of multi-station. In order to further retain the core of the die design and forging process in the production of steel rail forging, therefore, an automatic upgrade and transformation is carried out on the compound extrusion die operation in the existing multi-person cooperation manual mode, and the following improved technical solutions are proposed. Summary of the Invention

[0005] The technical problem solved by the present invention: Provide an automatic control system and method for an abnormal-shaped steel rail forging die, which uses a compound extrusion die to achieve automatic production, and solves the technical problems of poor quality consistency and low production efficiency in the manual mode of multi-person cooperation of the compound extrusion die in our country.

[0006] The technical solution adopted by the present invention: An automatic control method for an abnormal-shaped steel rail forging die, which has an automatic control system for an abnormal-shaped steel rail forging die; the automatic control system for the abnormal-shaped steel rail forging die includes an automatic control system for a compound extrusion die; the working step rhythm of the automatic control system for the compound extrusion die is interlocked with the working step rhythm signal of the press control system; the automatic control system for the compound extrusion die has a compound extrusion die; the press control system has a press; the press establishes a die closing working step formula according to the height position of the compound extrusion die, the working step operation number of the compound extrusion die, and the pressure value of different working steps of the compound extrusion die; multiple die closing working step formulas are integrated to form an automatic compound extrusion process; the automatic control system for the compound extrusion die and the press control system complete the multi-step die closing operation forging production of the abnormal-shaped steel rail according to the automatic compound extrusion process.

[0007] It also includes an automatic control system for a special-shaped rail forging die used in the automatic control method of the special-shaped rail forging die. The automatic control system for the special-shaped rail forging die has a compound extrusion die automatic control system; the compound extrusion die automatic control system has a compound extrusion die, and the compound extrusion die is composed of a rail head die, a rail web pre-forging die, a rail web final-forging die, a rail bottom rolling die, and a rail bottom shaping die; among them, the rail head die is located at the bottom; the rail web pre-forging die and the rail web final-forging die are both paired dies, and the paired rail web pre-forging die and rail web final-forging die are both arranged on both sides above the rail head die, and at the same time, the paired rail web pre-forging die and rail web final-forging die are horizontally equidistant at the front and rear two workstations; the rail bottom rolling die and the rail bottom shaping die are respectively located directly above the rail head die for mold closing; and the rail bottom rolling die and the rail bottom shaping die are also horizontally equidistant and respectively arranged at the front and rear two workstations; the rail web pre-forging die, the rail web final-forging die, the rail bottom rolling die, and the rail bottom shaping die form a die change system.

[0008] In the above technical solution, further: the compound extrusion die has a die platform, one end of the die platform is a platform front extension section and the other end is a platform rear extension section; between the platform front extension section and the platform rear extension section is the blanking station or the shaping station of the compound extrusion die; among them, the compound extrusion die has a die change rack; one side of the die change rack installs the rail web pre-forging die, and the other side of the die change rack installs the rail web final-forging die; the blanking process operation when the compound extrusion die moves to the blanking station accounts for more than 90% of the total process operation of the automatic compound extrusion process; the compound extrusion die only performs one shaping process operation at the shaping station per heat; when the compound extrusion die moves to the blanking station or the shaping station; the working die center of the compound extrusion die coincides with the center of the press.

[0009] In the above technical solution, further: the mold closing process formula includes the mold position parameter information, the mold type parameter information, the mold switching speed parameter information, and the mold power parameter information of the compound extrusion die at the blanking station and the shaping station.

[0010] In the above technical solution, further: the compound extrusion die includes an upper die rack, the front end of the upper die rack is suspended and installed with the rail bottom shaping die, and the rear end of the upper die rack is suspended and installed with the rail bottom rolling die; the rail bottom shaping die is driven by a two-way cylinder to realize the axial suspended slide rail die change operation of the rail bottom shaping die relative to the upper die rack; the rail bottom rolling die is driven by a servo cylinder body to realize the axial long and short stroke, high-precision, high-frequency, multi-step, multi-station suspended slide rail die change operation of the rail bottom rolling die relative to the upper die rack.

[0011] In the above technical solution, further: The rail bottom rolling die is connected to the push rod by a thread. The push rod is used to manually operate the axial sliding displacement of the rail bottom rolling die relative to the upper die holder. A scale is provided on the push rod. A T-shaped chute is made at the bottom of the upper die holder. The rail bottom shaping die and the rail bottom rolling die are slidably adapted to the T-shaped chute. The T-shaped chute is used to prevent the relative dislocation of the rail bottom shaping die and the rail bottom rolling die with respect to the upper die holder. The axial end of the push rod has an axial free movement degree of freedom. An axial guiding sleeve is provided on one side of the upper die holder. The middle part of the push rod is slidably frictionally adapted to the axial guiding sleeve. The axial guiding sleeve and the axial free movement degree of freedom are used to prevent the thread connection from being stuck due to the reciprocating deformation of the push rod.

[0012] In the above technical solution, further: The rail web pre-forging die and the rail web final forging die are respectively provided with two general action points, namely point 1 and point 2. The rail bottom shaping die is provided with two general action points, namely point 3 and point 4. The rail bottom rolling die is provided with six special working points, namely point 5, point 6, point 7, point 8, point 9, and point 10, and four reserved action points, namely point 11, point 12, point 13, and point 14. The upper position of the press is provided with a single-stroke general action point, namely point 15. The lower position of the press is provided with a single-stroke general action point, namely point 16. The press is also provided with a single-stroke pressurizing general action point, namely point 17.

[0013] In the above technical solution, further: The rail web pre-forging die and the rail web final forging die adjust the actual position of the die by adjusting the die installation screw. The rail bottom rolling die adjusts the actual position of the die by adjusting parameters. The single-stroke general action points of the press set the upward, downward, and downward pressure parameters of each cycle according to different working steps, different die changes, different workstations, different die closing serial numbers, and different pressures.

[0014] In the above technical solution, further: The servo cylinder body has a cylinder body installation guiding protective cover.

[0015] In the above technical solution, further: A pusher is provided at the outer end of the push rod. A die connection part is provided at the inner end of the push rod. The inner side of the push rod is connected to the compound extrusion die through the die connection part.

[0016] Advantages of the present invention compared with the prior art:

[0017] 1. The present invention can realize the automated continuous production of the process technology level of the loose block type compound extrusion die, making a major breakthrough in the long-term multi-person collaborative application mode. Based on the accumulation of technical experience of the company's loose block type compound extrusion die, it can apply forging production with higher level, higher efficiency, and higher reliability.

[0018] 2. The composite extrusion production process of the present invention based on the loose block type composite extrusion die can fundamentally stabilize the product quality and improve the production efficiency compared with manual operation; it creates a quantitative space for the material forming and process in terms of temperature, time, pressure, speed, connection movement, position, and integration, greatly enhancing the process control of the forging process. At the same time, it also significantly improves the on-site labor environment and operation intensity of personnel.

[0019] 3. The present invention can quantify the equipment speed, pressure, and movement, providing convenience for the future equipment performance maintenance and daily use management, greatly optimizing the usage frequency and intensity of the rated performance of the equipment, and having great application value in reducing equipment part wear, reducing maintenance frequency, reducing fatigue, etc.

[0020] 4. The loose block type composite extrusion die of the present invention has low cost, mature technology, and high flexible die closing characteristics, and is economical, practical, and easy to implement in procurement and daily production; it can break through the passive form of the "only four-station" theory of the automated die control process in the rail forging field and achieve automated continuous production of two stations; it can smoothly ensure the automated improvement of the enterprise's equipment process level, reasonable control of production costs, stable and continuous mature processes, achieving multiple benefits with half the effort.

[0021] 5. The present invention has a reasonable structure, is simple and practical, has strong versatility, is convenient for installation and maintenance, is easy for design and construction, is applicable to the production of railway turnouts, and can be widely applied to the field of heel forging of rail parts; it has broad promotion and application potential in the turnout industry and related multi-platform fields of presses, and is the form of equipment development that the industry has been longing for for many years; it has a positive leading and exemplary effect and is of great significance for improving the application level of industry equipment and promoting the progress of turnout processing technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a three-dimensional view of the use state of the composite extrusion die and the press of the present invention;

[0023] Figure 2 is a three-dimensional view of the composite extrusion die of the present invention;

[0024] Figure 3 is a longitudinal sectional structure schematic diagram of the die closing state of the composite extrusion die of the present invention;

[0025] Figure 4 is a use state diagram of the billet making station of the composite extrusion die of the present invention;

[0026] Figure 5 is a use state diagram of the sizing station of the composite extrusion die of the present invention;

[0027] Figure 6 is Figure 4 Figure 5 a schematic diagram of the installation structure of the intermediate rail web pre-forging die and the rail web final-forging die on the die changing rack;

[0028] Figure 7 Front elevation view of one side of the web die

[0029] Figure 8 Front elevation view of the other side of the web die

[0030] Figure 9 For Figure 7 Figure 8 One length sectional view of the adjustable mounting screw of the middle web die

[0031] Figure 10 For Figure 7 Figure 8 Another length sectional view of the adjustable mounting screw of the middle web die

[0032] Figure 11 Longitudinal sectional view of the rail base die with a threaded push rod

[0033] Figure 12 Schematic diagram of an application embodiment of the five-station and five-time rolling stop position of the rail base rolling die

[0034] Figure 13 Stroke curve, pressure curve and working station curve diagram of the composite extrusion die of the present invention

[0035] Figure 14 Partial perspective view of the push rod connecting the composite extrusion die of the present invention

[0036] Figure 15 Perspective view of the push rod connecting the rail base rolling die of the present invention

[0037] Figure 16 Bottom perspective view of the composite extrusion die of the present invention

[0038] Figure 17 Perspective view of the cylinder mounting guide protective cover of the servo cylinder body of the present invention

[0039] In the figure: 1 - composite extrusion die, 2 - press; 11 - rail head die, 12 - web pre-forging die, 13 - web final-forging die, 14 - rail base rolling die, 15 - rail base shaping die; 101 - die platform, 102 - front extension section of the platform, 103 - rear extension section of the platform, 104 - blanking station, 105 - shaping station, 106 - die change rack, 3 - upper die holder, 4 - double-acting cylinder, 5 - servo cylinder body, 6 - thread, 7 - push rod, 301 - T-shaped sliding groove, 701 - axial free degree of the live opening, 8 - axial guide sleeve, 9 - screw, 501 - cylinder mounting guide protective cover, 702 - pusher; 703 - die connection part; 901 - three-hole connecting rod, 902 - retaining ring, 601 - rail base die connecting plate, 602 - rail base die mounting screw. Detailed implementation manners

[0040] The following will combine the accompanying drawings in the embodiments of the present invention Figure 1-17 to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0041] (As Figure 1 shown) The automatic control method for the special-shaped rail forging die has an automatic control system for the special-shaped rail forging die; the automatic control system for the special-shaped rail forging die includes an automatic control system for the composite extrusion die; the working step rhythm of the automatic control system for the composite extrusion die is interlocked with the working step rhythm signal of the press control system.

[0042] It should be noted that: the signal in the signal interlock refers to the position, operation of the mechanical structure movement and position signal of each module monomer in the composite extrusion die 1 and the press pressure execution mechanism; the signal interlock is to enable information connection between each module monomer and the press pressure mechanism, so as to cooperate to complete the process actions. The meaning of interlock is set logically to avoid equipment operation interference caused by misoperation and misaction, and to avoid potential safety operation hazards in case of human or accidental situations, that is, an execution logic of two-choice is set artificially, so that a considerable part of the execution actions cannot be synchronized by multiple machines, so as to achieve a definite execution control logic command, thereby effectively avoiding misaction.

[0043] (Combined with Figure 2 ) It also includes an automatic control system for the special-shaped rail forging die used in the automatic control method for the special-shaped rail forging die. The automatic control system for the special-shaped rail forging die includes an automatic control system for the composite extrusion die; the automatic control system for the composite extrusion die has a composite extrusion die 1, and the automatic control system for the composite extrusion die also has a composite extrusion die controller; the press control system has a press 2, and the press control system also has a press controller.

[0044] The controllers referred to here are all programmable logic controllers (PLCs). The composite extrusion die automatic control system and the press control system are connected as a whole. Specifically: transmitters (devices that send electrical signals) can be set at each node position of the composite extrusion die 1 and the press 2. The transmitters can be servo motors, cylinders, proximity switches, and photoelectric switches. There are also transmitters of position signal reporting points set by the servo system. Each transmitter at the reporting point is related to the mechanics and electrical aspects of the entire system. The purpose is to achieve logical control of precise steps and to achieve synchronous, coordinated, and continuous forging operations with the composite extrusion die 1 as the core and the press 2 as the auxiliary.

[0045] The press 2 establishes a mold closing step formula according to the height position of the composite extrusion die 1, the work station operation sequence number of the composite extrusion die 1, and the pressure values ​​of different steps of the composite extrusion die 1; multiple mold closing step formulas are integrated to form an automatic composite extrusion process; the composite extrusion die automatic control system and the press control system complete the multi-step mold closing operation forging production of special-shaped rails according to the automatic composite extrusion process.

[0046] Specifically, see Table 1: Mold closing step formula table

[0047]

[0048] It should be noted that in Table 1, such as mold 1-1, refers to the name of a mold combination, which is composed of multiple molds and molded. The other mold numbers are similar. Different molds have different functions and parameters. Since the rail needs to be heated for two times, for the convenience of management, some of the same mold combinations are defined according to different times to avoid confusion.

[0049] In Table 1: The corresponding combinations of molds for stations 1-1 to 2-7 have been given in Table 4: Rail waist mold change and station formula table described later, which has the same meaning. The serial number of the station is a numbering method for the logical arrangement of process actions. 1-X represents the station action of the first heating of the rail part, and X represents the number of stations after the first heating; 2-Y is the same. The station shown in this article is a forging step of the mold, and can also be qualitatively understood as a forging station. The difference between different stations lies in the different combinations of molds, different working positions of the molds, and different clamping parameters of the press.

[0050] Table 2: Rail bottom rolling die blank making point parameter setting scheme: (combined with Figure 12 )

[0051]

[0052] See Table 2 and the attached manual. Figure 2 , Figure 12. The rail bottom rolling die 14 and the rail bottom shaping die 15 share a T-shaped sliding groove 301 described later. They enter the T-shaped sliding groove 301 in different directions. The rail bottom rolling die 14 is installed in the raw material direction of the press 2 and enters the working position from the back to the front; the rail bottom shaping die 15 is installed in front of the press 2 and enters the working position from the front to the back.

[0053] The point position parameters of the rail bottom rolling die 14 in Table 2 should be understood as (in combination with Figure 12 ): The rail bottom rolling plate moves to the 230 position for the first rolling, to the 341 position for the second rolling, to the 452 position for the third rolling, and so on. The horizontal movement of the rail bottom rolling die 14 can also be achieved by pushing and pulling with the manual push rod 7. Since the rail bottom shaping die 15 is heavy, the form of manual pushing and pulling is not required.

[0054] Table 3: Point position parameters and action recipe scheme table for the rail bottom rolling die blanking:

[0055]

[0056]

[0057] It should be noted in Table 3 that whether the action sequence is 12345 or 54321 are all specific process steps. Its action sequence is related to the principle of metal plastic forming in process development. No matter which action sequence of the process steps, it is actually a blanking process step, and its rationality is for the purpose of blanking.

[0058] Table 4: Die change and station recipe table for the rail waist die:

[0059]

[0060]

[0061] In Table 4, the effect of restoring the station lies in the zero position of the die, that is, at the end of one heat operation. To avoid omission and facilitate program simplification, the die is processed to restore to the zero position.

[0062] The present invention can achieve the automated continuous production of the process technology level of the split die composite extrusion die, making a major breakthrough in the long-term multi-person collaborative application mode; on the basis of meeting the company's accumulation of split die composite extrusion die technology experience, it can apply production with higher level, higher efficiency, and higher reliability.

[0063] (As Figure 2 , Figure 3 shown) In the above embodiment, further: The composite extrusion die 1 is composed of a rail head die 11, a rail waist pre-forging die 12, a rail waist final-forging die 13, a rail bottom rolling die 14, and a rail bottom shaping die 15.

[0064] Among them, the rail head die 11 is located at the bottommost part of the die platform 101 of the composite extrusion die 1; the rail web pre-forging die 12 and the rail web final-forging die 13 are both paired dies, and the paired rail web pre-forging die 12 and the rail web final-forging die 13 are both located on both sides above the rail head die 11. At the same time, the paired rail web pre-forging die 12 and the rail web final-forging die 13 are horizontally arranged at the same height at the front and rear two workstations of the die platform 101; the rail bottom rolling die 14 and the rail bottom shaping die 15 are respectively located directly above the rail head die 11 for die closing; and the rail bottom rolling die 14 and the rail bottom shaping die 15 are horizontally and suspendedly installed with the die changing rack 3 as the support; the rail bottom rolling die 14 and the rail bottom shaping die 15 are also horizontally arranged at the same height at the front and rear two workstations of the die changing rack 3 respectively.

[0065] Among them, the rail web pre-forging die 12, the rail web final-forging die 13, the rail bottom rolling die 14, and the rail bottom shaping die 15 form a die changing system, which is the main improvement point of the present invention. The die changing system is used to realize the position, type, die changing speed and action of the dies required for different workstations, and form a die closing process formula. Multiple die closing process formulas are integrated to complete the multi-step die changing operation of the composite extrusion process.

[0066] It should be noted that: the die changing structure of the rail web pre-forging die 12 and the rail web final-forging die 13 is a guide type die changing device, referring to the Chinese patent with the patent number ZL201420260003.4.

[0067] Based on the composite extrusion production process of the loose block type composite extrusion die, the present invention can fundamentally stabilize the product quality and improve the production efficiency compared with manual operation; it creates a quantitative space for the material forming and process from aspects such as temperature, time, pressure, speed, connection action, position and integration, greatly improving the process control of the forging process, and at the same time also significantly improving the on-site labor environment and operation intensity of personnel.

[0068] (Such as Figure 4 、 Figure 5 、 Figure 6 shown) In the above embodiments, further: the composite extrusion die 1 has a die platform 101, one end of the die platform 101 is a platform front extension section 102 and the other end is a platform rear extension section 103.

[0069] Between the platform front extension section 102 and the platform rear extension section 103 is the blank making station 104 or the shaping station 105 of the composite extrusion die 1; among them, the composite extrusion die 1 has a die changing rack 106; one side of the die changing rack 106 is installed with the rail web pre-forging die 12, and the other side of the die changing rack 106 is installed with the rail web final-forging die 13.

[0070] When in use: when the rail web pre-forging die 12 of the die changing rack 106 moves to Figure 4When performing the pre-forging operation at the blank-making station 104 as shown. When the web forging die 13 of the die-changing frame 106 moves to Figure 5 the sizing station 105 as shown, the final forging operation is performed. Whether it is pre-forging or final forging, the working die center of the compound extrusion die 1 always coincides with the center of the press 2.

[0071] Among them, the blank-making process operation when the compound extrusion die 1 moves to the blank-making station 104 accounts for more than 90% of the total process operations of the automatic compound extrusion process; the compound extrusion die 1 only performs one sizing process operation on the sizing station 105 per heat; when the compound extrusion die 1 moves to the blank-making station 104 or the sizing station 105; it is respectively used to perform the blank-making action or the sizing action.

[0072] In the above embodiment, further: The die-closing process formula includes die position parameter information, die type parameter information, die switching speed parameter information, and die power parameter information of the compound extrusion die 1 at the blank-making station 104 and the sizing station 105.

[0073] The present invention can quantify the equipment speed, pressure, and actions, providing convenience for future equipment performance maintenance and daily use management, greatly optimizing the usage frequency and intensity of the equipment's rated performance, and having great application value in reducing equipment part wear, reducing maintenance frequency, reducing fatigue, etc.

[0074] (As Figure 2 shown) In the above embodiment, further: The compound extrusion die 1 includes an upper die holder 3. The front end of the upper die holder 3 is suspended and installed with a web sizing die 15, and the rear end of the upper die holder 3 is suspended and installed with a web rolling die 14; the web sizing die 15 is driven by a two-way cylinder 4 to realize the axial suspended slide die-changing operation of the web sizing die 15 relative to the upper die holder 3; similarly: the web rolling die 14 is driven by a servo cylinder body 5 (as Figure 14 shown) to realize the axial long and short stroke high-precision, high-frequency, multi-process, multi-station suspended slide die-changing operation of the web rolling die 14 relative to the upper die holder 3.

[0075] In the above embodiment, further: The servo cylinder body 5 has a cylinder body installation guide protective cover 501 (as Figure 17 shown), which can effectively play a protective role.

[0076] (As Figure 11 shown) In the above embodiment, further: The web rolling die 14 is connected to the push rod 7 by a thread 6 (combined with Figure 15 , Figure 16 ), and the threaded connection is convenient for assembly and debugging. Figure 11 In, the web die connecting plate 601 is fixedly installed with web-type dies such as the web rolling die 14 through web die installation screws 602.

[0077] The push rod 7 is used to manually operate the axial sliding displacement of the rail bottom rolling die 14 relative to the upper die holder 3. When the automatic mode cannot be executed, it can be timely switched to the manual mode to continue forging.

[0078] Furthermore: The push rod 7 is provided with scales. The scales on the push rod 7 are used to master the position accuracy during manual operation to ensure the consistency of the product forging quality when different personnel operate.

[0079] (Such as Figure 15 ) A T-shaped sliding groove 301 is made at the bottom of the upper die holder 3; the rail bottom shaping die 15 and the rail bottom rolling die 14 are slidably adapted to the T-shaped sliding groove 301 to provide stable linear guidance. The T-shaped sliding groove 301 is used to prevent the relative misalignment of the rail bottom shaping die 15 and the rail bottom rolling die 14 with the upper die holder 3.

[0080] The shaft end of the push rod 7 has an axial live-joint freedom 701; an axial guiding sleeve 8 is provided on one side of the upper die holder 3; the middle part of the push rod 7 is slidably frictionally adapted to the axial guiding sleeve 8; the axial guiding sleeve 8 and the axial live-joint freedom 701 are used to prevent the screw connection from failing and jamming due to the reciprocating deformation of the push rod 7 and to provide stable linear guidance for the linear position of the push rod 7.

[0081] In the above embodiment, furthermore: A push handle 702 is provided at the outer end of the push rod 7; a die connection part 703 is provided at the inner end of the push rod 7; the inner side of the push rod 7 is connected to the rail bottom rolling die 14 in the composite extrusion die 1 through the die connection part 703. The die connection part 703 is a vertical plate structure and is reliably connected to the die through multi-point fastening of the vertical plate structure. Thus, manual rolling operation can be carried out.

[0082] (Such as Figure 7 , Figure 8 , Figure 9 ) In the above embodiment, furthermore: The rail web pre-forging die 12 and the rail web finish-forging die 13 adjust the actual position of the die by adjusting the die installation screw 9.

[0083] Specifically: Screws 9 are respectively provided at both ends of the rail web pre-forging die 12 and the rail web finish-forging die 13. The length of the screw 9 can be replaced and adjusted. By replacing the length of the screw 9, the position transformation adjustment of the rail web pre-forging die 12 and the rail web finish-forging die 13 with different sizes can be realized. The outer end of the screw 9 is connected to a three-hole connecting rod 901, and a retaining ring 902 is used for blocking and fixing. The die connection is realized by using the three-hole connecting rod 901 and the retaining ring 902, which is fixed reliably and avoids loosening.

[0084] (See Figure 9 , Figure 10)It should be noted that: The pre-forging die 12 and the finish-forging die 13 of the rail web adjust the actual position of the die by adjusting the die installation screw 9. The screw 9 follows the existing annular retaining ring form, and the rod body length of the screw 9 is divided into four grade lengths. Cooperating with the M24*70 and M24*100 hexagon head screws and the existing M24*120 hexagon socket head cap screws for the rail head die, it can realize stepless adjustment of the die handle-die spacing from 60 mm to 320 mm, and the adjustment flexibility is far better than the original form.

[0085] The bottom-rolling die 14 of the rail adjusts the actual position of the die by adjusting parameters; the single-stroke general action points of the press 2 set the up, down, and down pressure parameters for each cycle according to different working steps, different die changes, different workstations, different die-closing serial numbers, and different pressure settings.

[0086] In the above embodiments, further: The pre-forging die 12 and the finish-forging die 13 of the rail web are respectively provided with two general action points, namely No. 1 and No. 2. The bottom-sizing die 15 is provided with two general action points, namely No. 3 and No. 4; the bottom-rolling die 14 is provided with six special working points, namely No. 5, No. 6, No. 7, No. 8, No. 9, and No. 10, and four reserved action points, namely No. 11, No. 12, No. 13, and No. 14; the up position of the press 2 is provided with a single-stroke general action point, namely No. 15; the down position of the press 2 is provided with a single-stroke general action point, namely No. 16; the press 2 is also provided with a single-stroke pressurizing general action point, namely No. 17.

[0087] It should be noted that: Regarding the action points and working points, the main differences in the action points and working points of different dies lie in the working combination form and the die position during work. Its specific position is determined according to the actual forging process and the specific die. When necessary, different heating furnace bodies and rail materials also need to be fine-tuned. For specific point information, please refer to Table 1: Die-closing Working Step Recipe Table; and Table 3: Bottom-rolling Die Blank-making Point Parameter and Action Recipe Scheme Table.

[0088] It can be seen that the rhythm of the main actions of the basic process of the die-closing recipe, and the site settings clarify the connection method of each recipe and the action signal-sending nodes. The combination of the action rhythm, site, connection method, and action signal-sending nodes realizes the complete logic of the automatic control of the special-shaped rail forging die with actions, parameters, positions, and coordination among the die-closing operations of numerous presses, die station switching, and forging working step forming, and realizes synchronous, coordinated, and continuous automated production with die control as the core and press operation as an auxiliary.

[0089] Table 5: Signal Point Setting Information Table

[0090]

[0091]

[0092] It should be noted that in Table 5, taking Point 16 and Point 17 as examples: Point 16 and Point 17 actually represent the lower limit position when the press descends from the initial height and the maximum limit pressure during the descending process, which can achieve the dimensional control of the mold. In the table, 1-1 in 16-1-1 corresponds to the closing die 1-1. In principle, for different closing dies, the upward movement, downward movement, and pressure of the press are different, so as to optimize the configuration parameters of the process and adjust flexibly. In the table, H1 represents the closing die height value. F2 represents the pressure value. 15-1-1(H1-1) corresponds to the action name of the press upward movement for die change 1-1 at Point 15.

[0093] The loose block type composite extrusion die of the present invention has low cost, mature technology, and has the characteristic of highly flexible die closing. It is economical and practical for procurement and daily production and is easy to implement; it can break through the passive form of the "only four-station" theory in the field of automatic die control technology in the rail forging field and realize the automatic continuous production of two stations; it can smoothly ensure the automatic improvement of the enterprise's equipment process level, reasonable control of production costs, continuous stability of mature processes, achieving multiple benefits with half the effort.

[0094] In summary, the structure of the present invention is reasonable, simple and practical, has strong versatility, is convenient for installation and maintenance, is easy for design and construction, is applicable to the production of steel railway switches, and can be widely applied to the field of rail piece heel forging; it has broad promotion and application potential in the switch industry and related multi-platform fields of presses, and is the form of equipment development that the industry has been longing for for many years; it has a positive leading and exemplary effect and is of great significance for improving the application level of industry equipment and promoting the progress of switch processing technology.

[0095] Each embodiment in this specification is described in a related manner. For the same or similar parts among the embodiments, reference can be made to each other. Each embodiment focuses on the differences from other embodiments.

[0096] The above description is only a preferred embodiment of the present invention and is not intended to limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention are included in the protection scope of the present invention.

Claims

1. An automatic control method for a special-shaped rail forging die, characterized in that: It has an automatic control system for the forging die of special-shaped steel rails; the automatic control system for the forging die of special-shaped steel rails includes an automatic control system for the compound extrusion die; the working step rhythm of the automatic control system for the compound extrusion die is interlocked with the working step rhythm signal of the press control system; the automatic control system for the compound extrusion die has a compound extrusion die (1); the press control system has a press (2); the press (2) establishes a die-closing working step formula according to the height position of the compound extrusion die (1), the working position serial number of the compound extrusion die (1), and the pressure values of different working steps of the compound extrusion die (1); multiple die-closing working step formulas are integrated to form an automatic compound extrusion process; the automatic control system for the compound extrusion die and the press control system complete the multi-step die-closing operation forging production of special-shaped steel rails according to the automatic compound extrusion process. The compound extrusion die (1) includes an upper die holder (3), and a rail bottom shaping die (15) is suspended and installed at the front end of the upper die holder (3), and a rail bottom rolling die (14) is suspended and installed at the rear end of the upper die holder (3); the rail bottom shaping die (15) is driven by a two-way cylinder (4) to realize the axial suspended slide die-changing operation of the rail bottom shaping die (15) relative to the upper die holder (3); the rail bottom rolling die (14) is driven by a servo cylinder block (5) to realize the axial long and short stroke high-precision, high-frequency, multi-step, multi-station suspended slide die-changing operation of the rail bottom rolling die (14) relative to the upper die holder (3). The compound extrusion die (1) has a die platform (101), one end of the die platform (101) is a platform front extension section (102) and the other end is a platform rear extension section (103); between the platform front extension section (102) and the platform rear extension section (103) is the blanking station (104) or the shaping station (105) of the compound extrusion die (1); among them, the compound extrusion die (1) has a die-changing rack (106); a rail waist pre-forging die (12) is installed on one side of the die-changing rack (106), and a rail waist final-forging die (13) is installed on the other side of the die-changing rack (106).

2. The automatic control method for the special-shaped steel rail forging die according to claim 1, wherein: When the compound extrusion die (1) moves to the blanking station (104), the blanking working step operation accounts for more than 90% of the total working step operation of the automatic compound extrusion process; the compound extrusion die (1) only performs one shaping working step operation at the shaping station (105) per heat; when the compound extrusion die (1) moves to the blanking station (104) or the shaping station (105); the working die center of the compound extrusion die (1) coincides with the center of the press (2).

3. The automatic control method for the special-shaped steel rail forging die according to claim 1, wherein: The die-closing working step formula includes die position parameter information, die type parameter information, die switching speed parameter information, and die power parameter information of the compound extrusion die (1) at the blanking station (104) and the shaping station (105).

4. The automatic control method for the special-shaped steel rail forging die according to claim 1, wherein: The rail bottom rolling die (14) is connected to the push rod (7) by a thread (6). The push rod (7) is used to manually operate the axial sliding displacement of the rail bottom rolling die (14) relative to the upper die holder (3). A scale is provided on the push rod (7). A T-shaped sliding groove (301) is formed at the bottom of the upper die holder (3). The rail bottom shaping die (15) and the rail bottom rolling die (14) are slidably adapted to the T-shaped sliding groove (301). The axial end of the push rod (7) has an axial free end degree of freedom (701). An axial guiding sleeve (8) is provided on one side of the upper die holder (3). The middle part of the push rod (7) is slidably frictionally adapted to the axial guiding sleeve (8).

5. The automatic control method for the special-shaped rail forging die according to claim 1, characterized in that: The servo cylinder block (5) has a cylinder block installation guiding protective cover (501).

6. The automatic control method for the special-shaped steel rail forging die according to claim 4, characterized in that: A push handle (702) is provided at the outer end of the push rod (7). A die connecting part (703) is provided at the inner end of the push rod (7). The inner side of the push rod (7) is connected to the composite extrusion die (1) through the die connecting part (703).

7. The automatic control system for the special-shaped rail forging die used in the automatic control method of the special-shaped rail forging die according to claim 1, characterized in that: The automatic control system of the special-shaped rail forging die has a composite extrusion die (1). The composite extrusion die (1) is composed of a rail head die (11), a rail web pre-forging die (12), a rail web final-forging die (13), a rail bottom rolling die (14), and a rail bottom shaping die (15). Among them, the rail head die (11) is located at the bottommost. The rail web pre-forging die (12) and the rail web final-forging die (13) are both paired dies, and the paired rail web pre-forging die (12) and rail web final-forging die (13) are both arranged on both sides above the rail head die (11). At the same time, the paired rail web pre-forging die (12) and rail web final-forging die (13) are horizontally at the same height at the front and rear two workstations. The rail bottom rolling die (14) and the rail bottom shaping die (15) are respectively located directly above the rail head die (11) for mold closing. And the rail bottom rolling die (14) and the rail bottom shaping die (15) are also horizontally at the same height and are respectively arranged at the front and rear two workstations. The rail web pre-forging die (12), the rail web final-forging die (13), the rail bottom rolling die (14), and the rail bottom shaping die (15) form a die change system.

8. The automatic control system for the special-shaped rail forging die according to claim 7, characterized in that: The rail web pre-forging die (12) and the rail web final-forging die (13) are respectively provided with two general action points, namely point 1 and point 2. The rail bottom shaping die (15) is provided with two general action points, namely point 3 and point 4. The rail bottom rolling die (14) is provided with six special working points, namely point 5, point 6, point 7, point 8, point 9, and point 10, and four reserved action points, namely point 11, point 12, point 13, and point 14. At the upward position of the press (2), there is a single-stroke general action point, namely point 15. At the downward position of the press (2), there is a single-stroke general action point, namely point 16. The press (2) is also provided with a single-stroke pressurizing general action point, namely point 17.

9. The automatic control system of the special-shaped steel rail forging die according to claim 7, wherein: The rail web pre-forging die (12) and the rail web final-forging die (13) adjust the actual position of the die by adjusting the die installation screw (9).

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