A method and device for preheating and heat preservation of rail forging movable block die

Abstract

Provided are a method and device for preheating and insulating a rail forging movable block die. The method uses a rail forging movable block die preheating and insulating device; the rail forging movable block die preheating and insulating device includes a movable preheating device and a fixed preheating device; before the end of the current rail forging shift and before the next shift connects the plate, the movable preheating device and the fixed preheating device are used to preheat the rail forging movable block die; the shift handover time, as well as part of the time before the end of the current shift and before the next shift connects the plate, are fully utilized to preheat the rail forging movable block die. The present invention solves the current technical problems of time-consuming preheating of rail forging movable block dies and low production efficiency; the die preheating operation time will be saved by more than 1.5 hours, effectively improving the die and end profiling operation time, and it is expected that the existing shift production data can be theoretically increased by more than 6-9 pieces / shift.

Description

Technical Field

[0001] The present invention particularly relates to a method and device for preheating and heat-insulating a rail forging movable block die. Background Art

[0002] At present, the Chinese patent application for the special-shaped rail forging die automatic control system and method disclosed by our unit and with publication number CN113664139A is taken as an example. The special-shaped rail forging die involved is a composite extrusion die (such as Figure 1 、 Figure 2 ) and consists of a rail head die, a rail waist pre-forging die, a rail waist final forging die, a rail bottom pressing plate die, and a rail bottom shaping plate die. The rail head die is located at the very bottom; the rail waist pre-forging die and rail waist final forging die form a two-station, equal-height pair of dies located on either side of the center above the rail head die. The rail bottom pressing plate die and rail bottom shaping plate die are located in two stations, equal-height above the rail waist die. A die-changing system is formed by combining the two stations. This two-station composite extrusion die enables efficient, continuous, and automated production of special-shaped rail forging.

[0003] Under the existing technology, the preheating of domestic two-station molds such as the above-mentioned one can only be done after the mold is installed on the press, and the mold is closed with the heated rail and then preheated by contact baking. A single set of molds needs to undergo three preheating processes: the first preheating for pre-forging and rail head mold, the second preheating for final forging, rail head mold and squeegee, and the third preheating for final forging, rail head mold and shaping plate; a single preheating process takes about 10-15 minutes, and the preheating time for a single set of molds is about 40 minutes or more. Preheating is required again when the mold temperature is below 200°C after taking over the morning shift, taking over the noon shift, and changing the mold. It can be seen that the existing preheating operation method is time-consuming, the process is difficult to control, and it seriously affects the efficiency of production operations. In this regard, the following improved technical solutions are proposed. Summary of the Invention

[0004] The technical problem solved by the present invention is to provide a method and device for preheating and insulating a rail forging movable block die, which adopts a movable preheating device and a fixed preheating device in a complementary manner and utilizes the preheating method during the time when the shift is changed to solve the current technical problems of time-consuming preheating of the rail forging movable block die and low production efficiency.

[0005] The technical solution adopted by the present invention is as follows: a method for preheating and insulating a rail forging movable block die, the method for preheating and insulating a rail forging movable block die uses a rail forging movable block die preheating and insulating device; the rail forging movable block die preheating and insulating device includes a movable preheating device and a fixed preheating device; before the end of the rail forging shift and before the next shift takes over the plate, the movable preheating device and the fixed preheating device are used to preheat the rail forging movable block die; the shift handover time and part of the time before the end of the current shift and before the next shift takes over the plate are fully utilized to preheat the rail forging movable block die.

[0006] In the above technical solution, further: if there is a mold change plan during normal production, the mold to be replaced will be placed in the fixed preheating device 1 hour in advance, and the fixed preheating device will preheat the mold according to the set time and temperature, and the mold will be replaced after preheating is completed; if there is no mold change plan during normal production, after the production of the last product is completed, if there is a mold change plan, the mold will be replaced and no preheating operation will be performed; after the production of the last product is completed, if there is no mold change plan, the movable preheating device will be hoisted into place according to the number of workstations; after selecting the mold preheating formula, the personnel will leave their posts and go off work; during the personnel change of posts, the movable preheating device will preheat the mold according to the set time and temperature; after the next shift arrives, the movable preheating device will complete preheating according to the set time; the production rail parts will be in place, hoisted out of the movable preheating device, and trial production of the rail parts in place will be carried out.

[0007] In the above technical solution, further: the movable preheating device is composed of an outer shell, a front end plate, a rear end plate, an insulation layer, a temperature measuring device, a handle, and a heating tube; the outer shell is an inverted U-shaped structure with an open bottom end; the lower cover of the inverted U-shaped outer shell in the length direction is adapted to the rail forging live block mold on the press without disassembly; the front end of the outer shell is provided with a front end plate; the rear end of the outer shell is provided with a rear end plate; the top end surface of the inner side of the outer shell is provided with an insulation layer; the temperature measuring device is installed on the top end of the outer shell; handles are provided on both sides of the top end of the outer shell; the inner side of the outer shell is provided with a plurality of heating tubes that are spaced parallel and evenly distributed along the length direction of the shell.

[0008] In the above technical solution, further: the end of the heating tube is detachably fastened to a plurality of heating tube mounting holes distributed in an array inside the front end plate or the rear end plate; the distribution shape of the heating tube unit composed of the multiple heating tube arrays surrounds the rail forging block mold, and the heating tubes are evenly distributed on the outside of the rail forging block mold.

[0009] In the above technical solution, further: the heating tube unit is composed of a mold non-working surface heating unit and a mold working surface heating unit; the mold non-working surface heating unit is arc-shaped, and symmetrically surrounds the left and right sides of the rail forging block mold with the left and right axes; the mold working surface heating unit is Y-shaped, and is arranged at the center position of the rail forging block mold, and its Y-shaped bifurcation surrounds and covers the top of the rail forging block mold, and is connected to the mold non-working surface heating unit.

[0010] In the above technical solution, further: the front end plate and the rear end plate are formed with positioning grooves that are adapted to engage with the ends of the rail forging block mold.

[0011] In the above technical solution, further: the heating tube is a stainless steel electric heating rod; the spacing between adjacent heating tubes and the distance between each heating tube and the rail forging block die are less than or equal to 20 mm.

[0012] In the above technical solution, further: the fixed preheating device includes a box-type heating furnace, a furnace charging and feeding car, and a multi-layer mold rack installed in combination with the furnace charging and feeding car; the multi-layer mold rack is detachably installed at the feeding front end of the furnace charging and feeding car; the furnace charging and feeding car pushes the multi-layer mold rack into the furnace cavity of the box-type heating furnace; the multi-layer mold rack neatly stacks the rail forging live block molds to be used.

[0013] In the above technical solution, further: the preheating and insulation device for the rail forging live block mold also includes a press control system; the press control system is electrically connected to the heating control unit, the temperature control unit, the time management unit, the power control unit and the network monitoring unit; the temperature control unit is used to set the preheating temperature; the time management unit is used to set the preheating time, the insulation time, the start time and the stop time; the network monitoring unit is used to monitor and manage the operation process of the preheating and insulation device for the rail forging live block mold.

[0014] A rail forging movable block die preheating and insulation device used in a rail forging movable block die preheating and insulation method, the rail forging movable block die preheating and insulation device comprising a movable preheating device and a fixed preheating device; the movable preheating device is adapted to cover the outer side of the rail forging movable block die that is not removed from a press and is used to preheat the rail forging movable block die; the fixed preheating device is used to send the idle rail forging movable block die into a box-type heating furnace for preheating.

[0015] In the above technical solution, further: the movable preheating device is composed of an outer shell, a front end plate, a rear end plate, an insulation layer, a temperature measuring device, a handle, and a heating tube; the outer shell is an inverted U-shaped structure with an open bottom end; the lower cover of the inverted U-shaped outer shell in the length direction is adapted to the rail forging live block mold on the press without disassembly; the front end of the outer shell is provided with a front end plate; the rear end of the outer shell is provided with a rear end plate; the top end surface of the inner side of the outer shell is provided with an insulation layer; the temperature measuring device is installed on the top end of the outer shell; handles are provided on both sides of the top end of the outer shell; the inner side of the outer shell is provided with a plurality of heating tubes that are spaced parallel and evenly distributed along the length direction of the shell.

[0016] In the above technical solution, further: the end of the heating tube is detachably fastened to a plurality of heating tube mounting holes distributed in an array on the inner side of the front end plate or the rear end plate; the distribution shape of the heating tube unit composed of the plurality of heating tube arrays surrounds the rail forging block mold and is evenly distributed on the outer side of the rail forging block mold.

[0017] In the above technical solution, further: the heating tube unit is composed of a mold non-working surface heating unit and a mold working surface heating unit; the mold non-working surface heating unit is arc-shaped, and symmetrically surrounds the left and right sides of the rail forging block mold with the left and right axes; the mold working surface heating unit is Y-shaped, and is arranged at the center position of the rail forging block mold, and its Y-shaped bifurcation surrounds and covers the top of the rail forging block mold, and is connected to the mold non-working surface heating unit.

[0018] In the above technical solution, further: the front end plate and the rear end plate are formed with positioning grooves that are adapted to engage with the ends of the rail forging block mold.

[0019] In the above technical solution, further: the heating tube is a stainless steel electric heating rod; the spacing between adjacent heating tubes and the distance between each heating tube and the rail forging block die are less than or equal to 20 mm.

[0020] In the above technical solution, further: the fixed preheating device includes a box-type heating furnace, a furnace charging and feeding car, and a multi-layer mold rack installed in combination with the furnace charging and feeding car; the multi-layer mold rack is detachably installed at the feeding front end of the furnace charging and feeding car; the furnace charging and feeding car pushes the multi-layer mold rack into the furnace cavity of the box-type heating furnace; the multi-layer mold rack neatly stacks the rail forging live block molds to be used.

[0021] The above technical solution further includes: a press control system; the press control system is electrically connected to a heating control unit, a temperature control unit, a time management unit, a power control unit and a network monitoring unit; the temperature control unit is used to set the preheating temperature; the time management unit is used to set the preheating time, the holding time, the start time and the stop time; the network monitoring unit is used to monitor and manage the operation process of the preheating and holding device of the rail forging block die.

[0022] The advantages of the present invention compared with the prior art are:

[0023] 1. The movable preheating device of the present invention is directly placed above the rail forging movable block die on the press, which is not disassembled, and covers the die to preheat it. It is used to preheat the pre-forging, final forging, pressing plate, and shaping plate installed on the press. Its operation mode does not move the die, and only requires the movable preheating device to be moved and installed. Multiple stations are preheated simultaneously to achieve the preheating and insulation effect of the entire set of dies, avoiding the need for disassembly and assembly of the dies, and improving preheating efficiency.

[0024] 2. The fixed preheating device of the present invention has a stationary furnace and a movable mold; it is mainly used to preheat the pre-forging, final forging, rail head molds, squeegee plates and shaping plates to be installed for production in advance before the assembly of the entire set of molds; it can realize the one-time furnace preheating of the entire set of molds to be used.

[0025] 3. The method of the present invention makes full use of the shift change time before and after get off work; as long as the installed mold needs to be preheated, the preheating temperature, preheating start and stop time, and insulation time are set in advance; for example: when leaving get off work, the next shift still needs to use the mold, the preheating start time should be 1-2 hours longer than the shift change time, and the stop time should be set after the next shift takes over, so as to fully connect the production operation time, especially using the shift change rest time to improve the preheating efficiency, shorten the waiting time, and achieve efficient production.

[0026] 4. The movable preheating device and the fixed preheating device of the present invention complement each other to achieve full coverage of the preheating methods of the press mold.

[0027] 5. The present invention can significantly shorten the current mold preheating operation time per shift to less than 30 minutes; the mold preheating operation time will be saved by more than 1.5 hours, effectively improving the operation time of the mold and end pressing, and it is expected that the current shift production data can be theoretically increased by more than 6-9 pieces.

[0028] 6. The heating tubes of the present invention adopt a contoured distribution design. By replacing the installation position of the end heating tubes on the end plate and adjusting the relative positions of the installation holes of each heating tube, the relative position of the heating unit and the mold can be adjusted to radiate heat to the mold surface to the greatest extent to achieve efficient mold preheating. The heating tubes serve as the only heat source for mold preheating. Stainless steel heat-resistant general-purpose electric heating rods are used. According to the space size of different mold parts, the heating units are composed of 2 or 3 tubes in a group, fully ensuring the functionality, continuity and controllability of the mold preheating function.

[0029] 7. The temperature control unit of the present invention is combined with a temperature measuring device to monitor the preheating working status in real time and realize power supply and power control according to the actual preheating effect; it realizes operations such as start-up, heat preservation, and power off, and realizes the parameter controllability, safety and manageability of the mold preheating process; the time management unit controls the preheating operation rhythm, time point, and time period to fully cooperate with the continuity and organization of the work on duty, and ensure the processability of the mold operation; the power control unit realizes the power start and stop operation of this device according to the time and temperature settings, realizing automated and intelligent management and control. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic longitudinal section diagram of a rail forging movable block die under the prior art;

[0031] Figure 2 Schematic diagram of the position of the four-step mold of the rail forging movable block mold under the existing technology;

[0032] Figure 3 A three-dimensional diagram of a movable preheating device suitable for a rolling board and a shaping board mold of the present invention;

[0033] Figure 4 A three-dimensional diagram of a movable preheating device suitable for rail waist pre-forging and final forging dies according to the present invention;

[0034] Figure 5 This is a schematic diagram of the use of the movable preheating device of the present invention on a rail forging movable block die in the prior art;

[0035] Figure 6 It is a longitudinal cross-sectional schematic diagram of the movable preheating device of the present invention;

[0036] Figure 7 Schematic diagram of the distribution of heating tubes in the movable preheating device of the present invention;

[0037] Figure 8 This is a profile distribution diagram of the heat radiation principle of the heating tube in the movable preheating device of the present invention;

[0038] Figure 9 This is a distribution diagram of the mold non-working surface heating unit and the mold working surface heating unit of the present invention;

[0039] Figure 10 A perspective view of a fixed preheating device according to the present invention;

[0040] Figure 11 This is a front view of a multi-layer mold storage rack for fixing a preheating device according to the present invention;

[0041] Figure 12 Flow chart of the method of the present invention;

[0042] Figure 13 This is a project display diagram of the network monitoring unit of the present invention;

[0043] Figure 14 This is the improved electrical control diagram based on the newly added Siemens 1212C PLC of the present invention;

[0044] Figure 15 This is a flow chart of the control principle of the present invention based on the existing press control system and combined with the newly added Siemens 1212C PLC;

[0045] Figure 16 This is a screenshot of the human-machine interface of the present invention based on the existing press control system;

[0046] Figure 17 This is a screenshot of the software running status of the present invention based on the existing press control system combined with the newly added Siemens 1212C PLC;

[0047] Figure 18 This is a screenshot of the human-machine interface for the newly added mold heating function of the present invention;

[0048] Figure 19Screenshots of the human-machine interface for mold preheating, delay time, heating time, total time, station parameters, and recipe selection;

[0049] Figures 20 to 28 The present invention is based on the existing press control system and combines the improved Siemens 1212C type PLC program to modify the ladder diagram.

[0050] In the figure: 1- movable preheating device; 2- fixed preheating device, 101- shell, 102- front end plate, 103- rear end plate, 104- insulation layer, 105- temperature measuring device, 106- handle, 107- heating tube, 108- positioning slot; 1-1 mold non-working surface heating unit, 1-2 mold working surface heating unit; 201- box-type heating furnace, 202- furnace loading and feeding car, 203- multi-layer mold storage rack. DETAILED DESCRIPTION

[0051] The following is a combination of the embodiments of the present invention Figure 1-28 The technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0052] A method for preheating and insulating a rail forging movable block die is disclosed. The method uses a rail forging movable block die preheating and insulating device. The rail forging movable block die preheating and insulating device comprises a movable preheating device 1 and a fixed preheating device 2.

[0053] The movable preheating device 1, with the mold stationary and the preheating device in motion, is used for online preheating and heat preservation operations at multiple workstations while the mold remains on the press. Specifically, as shown in the figure, the movable preheating device 1 is primarily used to preheat the pre-forging, final forging, press plate, and shaping plate molds already installed on the press.

[0054] The fixed preheating device 2 is used to preheat the mold before it is assembled. The principle is that the furnace remains stationary while the mold moves. A trolley transports the mold into the furnace for preheating. These two devices complement each other, providing comprehensive coverage for existing preheating methods for press molds.

[0055] A method for preheating and heat-insulating a rail forging movable block die is disclosed. A movable preheating device 1 and a fixed preheating device 2 are used to preheat the rail forging movable block die before the end of a rail forging shift and before the next shift connects the plate. The rail forging movable block die is preheated by fully utilizing the shift handover time and part of the time before the end of a shift and before the next shift connects the plate.

[0056] (like Figure 12As shown in the above embodiment, further: if there is a mold change plan in normal production, the mold to be replaced is placed in the fixed preheating device 2 one hour in advance, and the fixed preheating device 2 preheats the mold according to the set time and temperature, and the mold is replaced after preheating is completed; if there is no mold change plan in normal production, after the production of the last product is completed, if there is a mold change plan, the mold is replaced in place and no preheating operation is performed; after the production of the last product is completed, if there is no mold change plan, the movable preheating device 1 is hoisted into place according to the number of workstations; after selecting the mold preheating formula, the personnel leave their posts and go off work; during the personnel change of posts, the movable preheating device 1 preheats the mold according to the set time and temperature; after the next shift arrives, the movable preheating device 1 completes preheating according to the set time; the production rail is in place, hoisted away from the movable preheating device 1, and the trial production of the rail in place is carried out.

[0057] In the above embodiment, further, the movable preheating device 1 comprises a housing 101, a front end plate 102, a rear end plate 103, an insulation layer 104, a temperature measuring device 105, a handle 106, and a heating tube 107. The housing 101 is an inverted U-shaped structure with an open bottom end; the lower cover of the inverted U-shaped housing 101 along its length is adapted to fit the rail forging block die on a press machine without requiring disassembly; the front end of the housing 101 is provided with a front end plate 102; the rear end of the housing 101 is provided with a rear end plate 103; the top inner surface of the housing 101 is provided with an insulation layer 104; the top end of the housing 101 is mounted with a temperature measuring device 105; handles 106 are provided on both sides of the top end of the housing 101; and the inside of the housing 101 is provided with a plurality of heating tubes 107 spaced parallel and evenly distributed along the length of the housing 101.

[0058] In the above embodiment, further, the ends of the heating tubes 107 are removably fastened to a plurality of heating tube mounting holes arranged in an array on the inner side of the front plate 102 or the rear plate 103; the heating tube unit formed by the array of multiple heating tubes 107 is arranged in a contoured manner to surround the rail forging block die and is evenly distributed on the outer side of the rail forging block die. The heating tubes 107 of the present invention utilize a contoured distribution design. By changing the position of the heating tubes on the end plates of the device and adjusting the relative positions of the heating tube mounting holes, the relative positions of the heating tubes and the die can be adjusted to maximize heat radiation to the die surface, thereby achieving efficient die preheating.

[0059] by Figure 1 、 Figure 2Taking mold preheating as an example: there are two sets of movable preheating devices 1, used for preheating the rail waist loose block mold, the rail bottom rolling plate, and the shaping plate. The preheating operation principle of these modules is basically the same, the main difference being the use of different contoured heating tubes according to the different mold sizes. The contoured external dimensions of the heating tubes are designed according to the longitudinal cross-section of the mold. For backup, interchangeability, and versatility, the preheating principle of the pre-forging and final forging stations is exactly the same.

[0060] In order to achieve preheating better, more efficiently, more economically and practically: In the above embodiment, further: the heating tube unit is composed of a mold non-working surface heating unit 1-1 and a mold working surface heating unit 1-2. The mold non-working surface heating unit 1-1 is arc-shaped, and symmetrically surrounds the left and right sides of the rail forging block mold with the left and right axes; the mold working surface heating unit 1-2 is Y-shaped, and is arranged at the center of the rail forging block mold, and its Y-shaped bifurcation surrounds and covers the top of the rail forging block mold, and is connected to the mold non-working surface heating unit 1-1. The heating unit of the present invention serves as the only heat source for mold preheating. It adopts stainless steel heat-resistant universal heating rods. According to the space size of different mold parts, the heating unit is composed of 2 or 3 rods as a group to fully ensure the functionality, continuity and controllability of the mold preheating function.

[0061] In the above embodiment, further: the front end plate 102 and the rear end plate 103 are provided with positioning slots 108 adapted to engage with the ends of the rail forging movable block dies. The positioning slots are provided to avoid the dies and prevent interference and collision.

[0062] In the above embodiment, further: the heating tube 107 is a stainless steel electric heating rod; it is economical and durable, with a long service life, and the spacing between adjacent heating tubes 107 and the distance between each heating tube 107 and the rail forging block mold is less than or equal to 20 mm, thereby ensuring the preheating effect to the greatest extent.

[0063] It should be noted that the electrical hardware of the control system for the mobile preheating device 1 is based on the existing press production line control system, with only the preheating module software being developed and designed. The existing press production line control system utilizes a Siemens 1215C PLC (6ES7215-1AG40-0XB0).

[0064] As for the newly added preheating function, the supporting preheating module software is implemented by adding Siemens 1212C PLC (6ES7212-1BE40-0XB0) based on the existing Siemens 1215C PLC. For the specific implementation method, see Figure 14 , that is, the present invention is based on the improved electrical control diagram of the newly added Siemens 1212C PLC.

[0065] In the above embodiment, further: the rail forging live block die preheating and insulation device also includes a press control system; the press control system is electrically connected to a heating control unit, a temperature control unit, a time management unit, a power control unit and a network monitoring unit; the temperature control unit is used to set the preheating temperature; the time management unit is used to set the preheating time, the insulation time, the start time and the stop time; the network monitoring unit is used to monitor and manage the operation process of the rail forging live block die preheating and insulation device.

[0066] Specifically: (In conjunction with the instructions attached Figure 14 The present invention is based on the temperature control unit described in the electrical control diagram (improved by the newly added Siemens 1212C PLC). A thermocouple preheating chamber air temperature measurement point is set in the central area of ​​the mold preheating. The preheating working status is monitored in real time. According to the actual preheating effect, power supply and power control are implemented, and operations such as startup, heat preservation, and power off are realized to achieve parameter controllability, safety, and manageability of the mold preheating process. The time management unit controls the preheating operation rhythm, time point, and time period to fully cooperate with the continuity and organization of the work on duty and ensure the processability of the mold operation. The power control unit realizes the power start and stop operation of this device according to the time and temperature settings.

[0067] When used specifically: the mold preheating temperature setting range is ≥ 400°C, the workstations are mainly divided into pre-forging workstation, final forging workstation, shaping plate workstation and rolling plate workstation, and the time setting is set by year, month, day and 24-hour range (combined with Figure 13 The project display diagram of the network monitoring unit of the present invention) is used to fully consider the handover between the night shift and the next day shift. In addition, the movable preheating device 1 of this device can simultaneously realize the pre-forging, final forging, rail head mold, squeegee plate, and shaping plate preheating at one time. After each shift, before leaving work, the mobile preheating device can be directly placed on each mold station of the press as shown in the figure; set the preheating temperature, preheating time, insulation time, preheating start time (combined with Figure 15 This invention is based on the existing press control system and incorporates the control principle flow chart of the newly added Siemens 1212C PLC. The system automatically preheats the press during the morning shift, utilizing the time for unloading and placing rail parts, and during the afternoon and evening shifts when personnel are off duty, significantly improving production efficiency.

[0068] On this basis, firstly, the movable preheating device 1 of the present invention can preheat and keep warm the mold of the most recent planned operation and the mold to be welded and repaired in advance. In specific application: further, two or more sets of movable preheating devices 1 can be used to simultaneously maintain the temperature state of multi-station molds. (Combined with Figure 15The present invention is based on the existing press control system and combines the control principle flow chart of the newly added Siemens 1212C PLC. That is, for two or more sets of movable preheating devices 1, multiple sets of molds can be numbered as mold one, mold two, etc. When in use, put the heating device into mold one, or put the heating device into mold two, and then follow the Figure 15 As a necessary supplement and backup to the movable preheating device 1, the present invention also uses a fixed preheating device 2 as described below to preheat the unmounted mold in advance.

[0069] In the above embodiment, further: the fixed preheating device 2 includes a box-type heating furnace 201, a furnace charging and feeding vehicle 202, and a multi-layer mold storage rack 203 installed in combination with the furnace charging and feeding vehicle 202. The specific structure of the furnace charging and feeding vehicle 202 is as follows: Figure 10 As shown, the specific internal structure of the furnace charging and feeding trolley 202 can be found in the related patents applied for on the same day as this patent, and will not be described here in detail. The multi-layer mold rack 203 is detachably mounted at the feeding front end of the furnace charging and feeding trolley 202; the furnace charging and feeding trolley 202 pushes the multi-layer mold rack 203 into the furnace cavity of the box-type heating furnace 201; the multi-layer mold rack 203 neatly stacks the rail forging live block molds to be used. When in use: the fixed preheating device 2 uses the existing box-type heating furnace 201 in the workshop as the heat source for preheating, and the molds to be preheated are placed individually on the multi-layer mold rack 203 of the furnace charging and feeding trolley 202 as a whole set, and then sent into the furnace body to realize the overall preheating of the molds to be used. The multi-layer mold rack 203 is different from the preheating of the movable preheating device 1, and can realize the one-time furnace preheating of the entire set of molds at most.

[0070] It can be seen that the preheating device of the present invention can fully preheat the entire movable block mold. The preheating temperature error of each part and each mold is ±50°C. The single operation time of mold preheating is shortened to less than 60 minutes, of which the installation and preparation time for preheating should be less than 20 minutes; the overall preheating temperature of the mold is 200°C-300°C; the overall preheating time range of the mold is within 24 hours. Because the preheating operation can be started in an unattended state and has remote network control capabilities, the preheating operation can be effectively monitored and necessary management is carried out to fully ensure intelligent, safe, and reliable preheating operation.

[0071] A rail forging movable block mold preheating and heat preservation device used in the rail forging movable block mold preheating and heat preservation method, the rail forging movable block mold preheating and heat preservation device includes a movable preheating device 1 (such as Figure 5 As shown) and fixed preheating device 2 (as Figure 10 shown).

[0072] (like Figure 5(As shown) the movable preheating device 1 is adapted to cover the outside of the rail forging block die that is not disassembled on the press, and is used to preheat the rail forging block die; the fixed preheating device 2 is used to send the idle rail forging block die into the box-type heating furnace 201 for preheating.

[0073] The preheating device of the present invention will replace the current primitive heating rail baking heating method, and realize quantitative, controllable, flexible and intelligent mold preheating and insulation operations. The present invention can significantly shorten the current mold preheating operation time per shift to less than 30 minutes. The mold preheating operation time will be saved by more than 1.5 hours, which will effectively increase the operation time of the mold and end pressing. It is expected that the existing shift production data can be theoretically increased by more than 6-9 pieces. This invention will serve as a supplementary content in the later stage of the 5,000-ton automation upgrade in 2022, thereby further improving the efficiency of the 5,000-ton fully automated forging operation.

[0074] In the above embodiment, further: (as Figure 3 、 Figure 4 、 Figure 6 、 Figure 7 、 Figure 8 Figure 9 The movable preheating device 1 is composed of a shell 101, a front end plate 102, a rear end plate 103, an insulation layer 104, a temperature measuring device 105, a handle 106, and a heating tube 107.

[0075] The housing 101 is an inverted U-shaped structure with an open bottom end; the lower cover of the inverted U-shaped housing 101 in the longitudinal direction is adapted to the rail forging movable block mold on the press without having to be disassembled; the front end of the housing 101 is provided with a front end plate 102 (such as Figure 3 、 Figure 4 The rear end of the shell 101 is provided with a rear end plate 103; the inner top surface of the shell 101 is provided with an insulation layer 104 (as shown); Figure 6 The temperature measuring device 105 is installed on the top of the shell 101; handles 106 are provided on both sides of the top of the shell 101; the inner side of the shell 101 is provided with multiple heating tubes 107 spaced parallel and evenly distributed along the length direction of the shell 101.

[0076] In the above embodiment, further: the end of the heating tube 107 is detachably fastened to the plurality of heating tube mounting holes arrayed on the inner side of the front plate 102 or the rear plate 103 (eg Figure 7 The distribution shape of the heating tube unit composed of the plurality of heating tubes 107 arrays surrounds the rail forging live block mold and is evenly distributed outside the rail forging live block mold (combined with Figure 8 shown).

[0077] In the above embodiment, further: the heating tube unit is composed of a mold non-working surface heating unit 1-1 and a mold working surface heating unit 1-2 (such as Figure 9 As shown); the mold non-working surface heating unit 1-1 is arc-shaped and surrounds the left and right sides of the rail forging block mold symmetrically with the left and right axes; the mold working surface heating unit 1-2 is Y-shaped and is arranged at the center of the rail forging block mold, and its Y-shaped bifurcation surrounds and covers the top of the rail forging block mold and is connected to the mold non-working surface heating unit 1-1.

[0078] In the above embodiment, further: the front end plate 102 and the rear end plate 103 are provided with positioning slots 108 (such as Figure 7 shown).

[0079] In the above embodiment, further: the heating tube 107 is a stainless steel electric heating rod; the spacing between adjacent heating tubes 107 and the distance between each heating tube 107 and the rail forging block die are less than or equal to 20 mm.

[0080] (like Figure 10 As shown in the above embodiment, further: the fixed preheating device 2 includes a box-type heating furnace 201, a furnace charging and feeding trolley 202 and a multi-layer mold rack 203 installed in combination with the furnace charging and feeding trolley 202; the multi-layer mold rack 203 is detachably installed at the feeding front end of the furnace charging and feeding trolley 202; the furnace charging and feeding trolley 202 pushes the multi-layer mold rack 203 into the furnace cavity of the box-type heating furnace 201; the multi-layer mold rack 203 neatly stacks the rail forging live block dies to be used.

[0081] In the above embodiment, further: it also includes a press control system; the press control system is electrically connected to the heating control unit, the temperature control unit, the time management unit, the power control unit and the network monitoring unit.

[0082] The temperature control unit is used to set the preheating temperature; the time management unit is used to set the preheating time, the insulation time, the start time, and the stop time; the network monitoring unit is used to monitor and manage the operation process of the preheating and insulation device of the rail forging block mold.

[0083] The working principle of the present invention is as follows: Figure 2Taking the preheating of loose-block molds as an example, the preheating of molds already installed on the existing press remains intact, improving efficiency, convenience, speed, safety, and reliability. If preheating is required before the shift changes or before the end of a shift, the preheating temperature, preheating start / stop times, and hold time should be set in advance. For example, if the mold is still needed at the end of a shift, the preheating start time should be 1-2 hours longer than the shift change, and the preheating stop time should be set after the next shift change to ensure smooth production flow. For molds not already installed, the existing box-type heating furnace 201 is used to preheat the entire mold. The loading fixture of the existing box-type heating furnace 201 is modified to include a multi-layer mold rack 203, allowing for simultaneous loading and preheating of all the molds. The molds are lifted individually using existing magnetic lifters and placed on the multi-layer mold rack 203, arranged in layers to ensure uniform preheating. Since each mold weighs approximately one ton, preheating takes approximately 90-120 minutes. The multi-layer mold rack 203 is highly resistant to deformation and can be combined in multiple layers for repeated use. The mold loading operation is performed by the furnace loading trolley 202; after loading, the furnace mouth is fully sealed to reduce energy consumption. Since the existing furnace's operating temperature is controlled between 600°C and 1300°C, while the mold's actual preheating temperature range is 200°C to 300°C, only the electrical control section of the box-type heating furnace 201 needs to be modified. The workshop's day shift runs from 8:00 AM to 12:00 PM and from 1:30 PM to 5:30 PM, for a total of 8 hours; the night shift runs from 5:30 PM to 9:00 PM and from 9:30 PM to 1:00 AM, for a total of 7.5 hours. During normal mold production operations, both the day and night shifts require mold preheating. During mold pressure testing and commissioning, preheating and insulation are not only required for production, but also for welding repairs. Therefore, in order to ensure the compactness of the test operation, the installation of the mold is completed in the previous night shift, or carried out in the day shift on the day of the test and use; in order to fully save the mold installation and preheating preparation time, the mold preheating should have sufficient overlapping operation function, that is, make full use of the time of shift change to preheat the mold, so as to shorten the mold preparation and thus improve production efficiency.

[0084] In addition, see the implementation of the above functions. Figure 16 The present invention is based on the human-machine interface screenshot of the existing press control system and see Figure 17 The present invention is based on the existing press control system and combines the software running status screenshot of the newly added Siemens 1212C PLC. Figure 18 A screenshot of the human-machine interface of the present invention with the newly added mold heating function shows that the modified system has added a mold heating module compared to the original human-machine interface to achieve automatic control of mold heating. Figure 19The screenshot of the human-machine operation interface of the present invention for mold preheating, delay time, heating time, total time, workstation parameters and recipe selection can realize the selection and setting of mold preheating, delay time, heating time, total time, workstation parameters and recipe. Figures 20 to 28 , that is, the present invention is based on the existing press control system and combined with the improved Siemens 1212C PLC program modification ladder diagram. Among them, the program process of network 1 to network 4 is used to realize the system initialization and parameter loading function. The program process of network 5 to network 10 is mainly used to realize the function of the mold preheating system working according to time and temperature after the parameters are loaded. The program process of network 9 and network 10 is mainly used to realize that when the system working time or temperature reaches the set value, the system will automatically return to the steps corresponding to the aforementioned preset program 2 and preset program 3. For example, in program 10, when the temperature reaches the set value, the system returns to the step of program 3; for example, when the mold is preheated next time, you can directly click start, and the system will automatically run according to the original program process again, thereby realizing efficient automatic control production.

[0085] From the above description, it can be found that: the movable preheating device of the present invention is directly placed above the rail forging movable block die on the press that is not disassembled, and is covered over the die to preheat it; it is used for preheating the pre-forging, final forging, pressing plate and shaping plate installed on the press; its operation mode is that the die does not move, only the movable preheating device needs to be moved and installed, and multiple stations are preheated simultaneously to achieve the preheating and insulation effect of the entire set of dies; disassembly and assembly of the dies is avoided, and the preheating efficiency is improved.

[0086] The fixed preheating device of the present invention has a stationary furnace and a movable mold; it is mainly used for preheating a whole set of molds, including pre-forging, final forging, rail head molds, squeegee plates and shaping plates, which are to be installed for production and planned to be used, before assembly; and can realize one-time furnace preheating of a whole set of molds to be used.

[0087] The method of the present invention makes full use of the shift change time before taking over and leaving get off work; as long as the installed mold needs to be preheated, the preheating temperature, preheating start and stop time, and insulation time are set in advance; for example: when leaving get off work, the next shift still needs to use the mold, then the preheating start time should be 1-2 hours longer than the shift change time, and the stop time should be set after the next shift takes over, so as to fully connect the production operation time, especially using the shift change rest time to improve the preheating efficiency, shorten the waiting time, and achieve efficient production.

[0088] The movable preheating device and the fixed preheating device of the present invention complement each other to achieve full coverage of the preheating methods of the pressing mold.

[0089] The heating tubes of the present invention adopt a contoured distribution design. By replacing the installation position of the end heating tubes on the end plate and adjusting the relative positions of the installation holes of each heating tube, the relative position of the heating unit and the mold can be adjusted to radiate heat to the mold surface to the greatest extent to achieve efficient mold preheating. The heating tubes serve as the sole heat source for mold preheating and adopt stainless steel heat-resistant general-purpose electric heating rods. According to the space size of different mold parts, the heating units are composed of groups of 2 or 3 tubes, fully ensuring the functionality, continuity and controllability of the mold preheating function.

[0090] The temperature control unit of the present invention is combined with a temperature measuring device to monitor the preheating working status in real time and realize power supply and power control according to the actual preheating effect; it realizes operations such as startup, heat preservation, and power off, and realizes parameter controllability, safety and manageability of the mold preheating process; the time management unit controls the preheating operation rhythm, time point, and time period to fully cooperate with the continuity and organization of the current shift operation and ensure the processability of the mold operation; the power control unit realizes the power start and stop operation of this device according to the time and temperature settings, realizing automated and intelligent management and control.

[0091] Therefore, the movable preheating device 1 of the present invention can simultaneously achieve synchronous preheating of multiple workstations such as pre-forging, final forging, rail head mold, squeegee, and shaping plate at one time. After each shift and before leaving get off work, the movable preheating device 1 can be directly placed on each mold station of the press, and the preheating temperature, preheating time, insulation time, and preheating start time can be set. The system will automatically perform preheating operations during the morning shift rail unloading and material placement time, and the time when personnel are off duty at noon and at night. This greatly saves the contradiction between mold preheating and production operations, and greatly improves the press forging operation time when personnel are on duty. The movable preheating device 1 fully considers the operability, controllability, and time management of personnel. The fixed preheating device 2 of this device can perform preheating and insulation operations on the mold of the most recent planned operation and the mold to be welded and repaired in advance, and perform the temperature state maintenance operation of the mold synchronously with the mobile part. As a necessary supplement and backup for the movable preheating device 1, it can preheat the mold that has not been installed in advance, solving the problem of economical, efficient, practical and reliable preheating.

[0092] In summary, the present invention can significantly shorten the current mold preheating operation time per shift to less than 30 minutes. The mold preheating operation time will be saved by more than 1.5 hours, which effectively increases the operation time of the mold heel-end pressing, and is expected to theoretically increase the existing shift production data by more than 6-9 pieces. In addition, the device of the present invention has a reasonable structure, is simple and practical, has strong versatility, is easy to install and maintain, is convenient to design and construct, is suitable for the production of steel rail switches, and can be widely used in the field of rail heel-end forging. The present invention has the value of promotion and utilization, can improve the level of rail processing, and improve production efficiency.

[0093] It should be noted that the fixed preheating device in the "A method and device for preheating and insulating a rail forging live block die" provided by the present invention has the same structure and function as the "Multifunctional loading device for a heat treatment furnace" applied for by this unit on the same day.

[0094] Each embodiment in this specification is described in a related manner. The same or similar parts between the embodiments can be referred to each other. Each embodiment focuses on the differences from other embodiments.

[0095] The above description is only a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention are included in the scope of protection of the present invention.

Claims

1. A rail forging movable block die preheating and heat preservation device, characterized by: The invention comprises a movable preheating device (1) and a fixed preheating device (2); the movable preheating device (1) is adapted to be covered on the outside of a rail forging movable block die that is not disassembled on a press machine and is used to preheat the rail forging movable block die; the fixed preheating device (2) is used to send the idle rail forging movable block die into a box-type heating furnace (201) for preheating; The movable preheating device (1) is composed of a shell (101), a front end plate (102), a rear end plate (103), a heat-insulating layer (104), a temperature measuring device (105), a handle (106), and a heating tube (107); the shell (101) is an inverted U-shaped structure with an open bottom end; the lower cover of the inverted U-shaped shell (101) in the longitudinal direction is adapted to a rail forging movable block die on a press machine that does not need to be disassembled; the front end of the shell (101) is provided with a front end plate (102); the rear end of the shell (101) is provided with a rear end plate (103); the top end surface of the inner side of the shell (101) is provided with a heat-insulating layer (104); the top end of the shell (101) is installed with a temperature measuring device (105); handles (106) are provided on both sides of the top end of the shell (101); the inner side of the shell (101) is provided with a plurality of heating tubes (107) spaced and evenly distributed in parallel along the longitudinal direction of the shell (101); The fixed preheating device (2) comprises a box-type heating furnace (201), a furnace charging and feeding car (202), and a multi-layer mold storage rack (203) installed in combination with the furnace charging and feeding car (202); the multi-layer mold storage rack (203) is detachably installed at the feeding front end of the furnace charging and feeding car (202); the furnace charging and feeding car (202) pushes the multi-layer mold storage rack (203) into the furnace cavity of the box-type heating furnace (201); and the multi-layer mold storage rack (203) neatly stacks the rail forging movable block molds to be used.

2. The rail forging movable block die preheating and heat preservation device according to claim 1, characterized in that: The ends of the heating tubes (107) are detachably fastened to a plurality of heating tube mounting holes arrayed in the inner side of the front end plate (102) or the rear end plate (103) to form a whole; the distribution shape of the heating tube unit composed of the array of the plurality of heating tubes (107) surrounds the rail forging block die and is evenly distributed outside the rail forging block die.

3. The rail forging movable block die preheating and heat preservation device according to claim 2, characterized in that: The heating tube unit is composed of a mold non-working surface heating unit (1-1) and a mold working surface heating unit (1-2); the mold non-working surface heating unit (1-1) is arc-shaped and surrounds the left and right sides of the rail forging block mold symmetrically with the left and right axes; the mold working surface heating unit (1-2) is Y-shaped and is arranged at the center of the rail forging block mold, and its Y-shaped bifurcation surrounds and covers the top of the rail forging block mold and is connected to the mold non-working surface heating unit (1-1).

4. The rail forging movable block die preheating and heat preservation device according to claim 1 or 2, characterized in that: The front end plate (102) and the rear end plate (103) are provided with positioning slots (108) adapted to engage with the ends of the rail forging movable block die.

5. The rail forging movable block die preheating and heat preservation device according to claim 1 or 2, characterized in that: The heating tube (107) is a stainless steel electric heating rod; the spacing between adjacent heating tubes (107) and the distance between each heating tube (107) and the rail forging block die are less than or equal to 20 mm.

6. The rail forging movable block die preheating and heat preservation device according to claim 1, characterized in that: The rail forging movable block die preheating and insulation device also includes a press control system; the press control system is electrically connected to a heating control unit, a temperature control unit, a time management unit, a power control unit and a network monitoring unit; the temperature control unit is used to set the preheating temperature; the time management unit is used to set the preheating time, the insulation time, the start time and the stop time; the network monitoring unit is used to monitor and manage the operation process of the rail forging movable block die preheating and insulation device.

7. A method for preheating and heat preservation of a rail forging movable block die, characterized in that: The method for preheating and heat preservation of the rail forging movable block die uses a rail forging movable block die preheating and heat preservation device as described in any one of claims 1 to 6; before the end of the rail forging shift and before the next shift connects the plate, the movable preheating device (1) and the fixed preheating device (2) are used to preheat the rail forging movable block die; the shift handover time and part of the time before the end of the shift and before the next shift connects the plate are fully utilized to preheat the rail forging movable block die.

8. The method for preheating and heat-insulating a rail forging movable piece die according to claim 7, characterized in that: If there is a mold change plan during normal production, the mold to be replaced is placed in the fixed preheating device (2) 1 hour in advance, and the fixed preheating device (2) preheats the mold according to the set time and temperature, and the mold is replaced after preheating is completed; if there is no mold change plan during normal production, after the production of the last product is completed, if there is a mold change plan, the mold is replaced and no preheating operation is performed; after the production of the last product is completed, if there is no mold change plan, the movable preheating device (1) is hoisted into place according to the number of workstations; after selecting the mold preheating formula, the personnel leave their posts; during the personnel change of posts, the movable preheating device (1) preheats the mold according to the set time and temperature; after the next shift of personnel arrives at their posts, the movable preheating device (1) completes preheating according to the set time; When the production rail parts are in place, they are lifted off the movable preheating device (1) and the trial production of the in-place rail parts is carried out.

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