A method for deflecting control of a grinding unit and its application on a rail grinding car

Abstract

The application discloses a grinding unit deflection control method and application thereof to a rail grinding vehicle, and the method comprises the following steps: S11) controlling the deflection of the grinding unit in the parking state of the grinding vehicle, collecting a plurality of groups of actual deflection angle values of the grinding unit and corresponding actuator stroke feedback values during the deflection; S12) adopting a set function fitting, obtaining the parameters of the function according to the data combination of the plurality of groups of actual deflection angle values of the grinding unit and the corresponding actuator stroke feedback values, and returning the new parameters obtained by fitting; S13) replacing the function parameters of the deflection control of the grinding unit with the new parameters obtained by fitting; and S16) controlling the deflection of the grinding unit according to the set function and the new parameters obtained by fitting in the working state of the grinding vehicle. The application can solve the technical problem that the existing grinding deflection control mode is prone to errors due to the machining assembly and structural elastic deformation of the grinding unit, and further causes the low control precision of the deflection angle.

Description

Technical Field

[0001] This invention relates to the field of rail engineering machinery, and in particular to a method for controlling the deflection of a grinding unit and its application in a rail grinding vehicle. Background Technology

[0002] With the continuous increase in railway freight volume and load, various damages and defects easily appear on the surface and inside of rails, such as corrugation, cracks, peeling, crushing, pitting, and edge thickening. If not repaired in time, these defects will deteriorate rapidly, leading to high rail replacement costs. Rail grinding is a primary means of eliminating rail defects and restoring rail profile. Utilizing rail grinding technology for track maintenance has become a consensus in track maintenance both domestically and internationally, and its application is becoming increasingly widespread, creating significant benefits for the railway system.

[0003] A rail grinding machine is used to grind the surface of railway rails to eliminate surface defects (rust, fatigue cracks, unevenness, corrugation, thick edges, deformation, etc.). The grinding machine has multiple grinding carriages at its lower part, which perform continuous grinding operations on the rails under the traction of the main machine. Each grinding carriage contains a grinding unit 100, which is the core mechanism of the rail grinding machine. (See attached image) Figure 1 As shown, the grinding unit 100 consists of a rotatable deflection mechanism 2 (also known as a cradle), a grinding motor 1, a grinding wheel (also known as a grinding head 3), a grinding pressure cylinder (i.e., a pressure drive mechanism 7), a guide rod (i.e., a pressure guide post 4), a guide sleeve (i.e., a pressure guide sleeve 5), and an adjustment mechanism. The upper parts of the two sets of pressure guide posts 4 are connected by a connecting frame 6, and the lower parts of the pressure guide posts 4 are fixedly connected to the deflection mechanism 2. One end of the pressure drive mechanism 7 is connected to the connecting frame 6, and the other end is connected to the outer surface of the grinding motor 1 through a connecting arm plate 10. The grinding motor 1 is directly connected to the grinding head 3 and drives it to rotate at high speed. At the same time, the grinding motor 1 is mounted on the pressure guide sleeve 5. By controlling the pressure drive mechanism 7, the pressure guide sleeve 5 is driven to move axially along the pressure guide post 4 to realize the pressure grinding operation of the grinding motor 1. The adjustment mechanism is used to ensure the grinding position, quality, and efficiency, and to avoid obstacles to ensure safety. With the continuous increase in railway operating speed, especially the rapid development of high-speed railways, the requirements for the operational precision of rail grinding vehicles are becoming increasingly stringent. The core of operational precision lies in the deflection control and pressure control of the grinding unit 100. In particular, the precise adjustment and control of the deflection angle of the grinding unit is a key factor determining the grinding quality and directly affects the profile accuracy of the ground rail. Ensuring its control precision has always been a technical challenge.

[0004] The contact between the grinding head 3 and the rail 200 is linear. Each grinding wheel grinds a bright band (a slender flat surface) on the rail 200. Multiple grinding heads 3, distributed at different angles, form multiple bright bands, thus covering the entire rail surface of the rail 200. The deflection mechanism 2 is equipped with a rotating shaft, which, driven by the deflection drive mechanism 8, can generate the required deflection angle towards the inner and outer sides of the rail. The deflection angle range of the existing national railway grinding car grinding unit 100 is generally -25° to +70°. There are two main forms of angle deflection: one is a single-stage deflection using a deflection cylinder (i.e., deflection drive mechanism 8), and the other is a two-stage deflection using a swing cylinder (i.e., swing drive mechanism 9) + a deflection electric cylinder (i.e., deflection drive mechanism 8). The deflection cylinder and the deflection electric cylinder have built-in stroke sensors, which determine the deflection angle of the grinding head 3 by changes in length. The deflection structure of the grinding unit 100 using the deflection cylinder method is shown in the attached figure. Figure 3 As shown in the attached figure, the deflection structure of the grinding unit 100, which adopts a two-stage deflection method of swing hydraulic cylinder + deflection electric cylinder, is as follows. Figure 4 As shown.

[0005] As attached Figure 5 As shown, the rotation point of the deflection mechanism 2 (i.e., the cradle) is point O, the mounting point of the deflection cylinder (i.e., the deflection drive mechanism 8) on the frame is point B, and the mounting point of the deflection cylinder on the deflection mechanism 2 is point A. The length b of line segment OB is a fixed value, the length a of line segment OA is a fixed value, and the length L of line segment AB changes as the deflection cylinder extends and retracts. The deflection angle α of the grinding motor 1 is the angle between the vertical line of gravity of the grinding motor and the rotation axis. The external deflection angle of the grinding motor is "-", and the internal deflection angle of the grinding motor is "+". When α = 0°, the length of the deflection cylinder or the deflection electric cylinder is L0 (at this time, ∠AOB = θ0).

[0006] According to the Law of Cosines above:

[0007]

[0008] We can obtain:

[0009]

[0010]

[0011] therefore:

[0012]

[0013] The minimum length of the deflection cylinder after retraction is L. mim The feedback voltage is V min The maximum length of the deflection cylinder after extension is L. max The feedback voltage is V max V 目标 For the target length L目标 The corresponding deflection cylinder feedback voltage.

[0014] However, in practical use, it was found that the measured deflection angle of the grinding unit using the existing control method has a significant error compared to the theoretical angle, as shown in the attached figure. Figure 2 As shown in the figure (the vertical axis represents the deflection angle in °; the horizontal axis represents the travel voltage in V), the maximum error reaches 2°, and the errors of different grinding units on the same grinding car are also different, resulting in poor consistency. This does not meet the ±0.5° deflection angle error range required by the standard "TB / T3520-2018 Railway Large Track Maintenance Machinery Rail Grinding Car".

[0015] In summary, the main technical problems with existing deflection control methods for grinding units are:

[0016] (1) Poor deflection control accuracy of the grinding unit severely affects grinding quality. The main reasons for this problem are: First, machining errors. After actual machining and assembly, the positions of points A, O, and B have certain errors, causing deviations in the dimensions of a, b, and L0 from the theoretical values. These deviations cannot be measured on-site and significantly affect the accuracy of the deflection angle. Second, elastic deformation of the grinding unit frame structure. Different deflection angles result in different deformations of the grinding unit due to gravity, leading to different angular deformations under different deflection angles. Third, the impact of clearances on each deflection shaft, mainly the internal clearance of the rotating bearing, the clearance between the bearing and the pin, and the internal clearance of the hydraulic cylinder. Fourth, the accuracy and linearity errors of the feedback voltage signal from the deflection cylinder stroke sensor. Since these four reasons are difficult to eliminate, controlling the deflection angle error becomes a technical challenge, making it difficult to further improve its deflection accuracy.

[0017] (2) Grinding deflection angle calibration is inefficient and prone to human error. The main reasons for this problem are: to improve the accuracy of deflection angle calibration, multi-point calibration and segmented correction are often used, but this involves a relatively large workload. Furthermore, the existing calibration methods use single-axis inclinometers, which must be placed manually on the rotating surface based on observation and experience for the measured incline angle to be accurate. Calibration is greatly affected by human operation, resulting in low efficiency and difficulty in guaranteeing accuracy.

[0018] (3) High temperature and internal pressure during grinding unit operation cause the hydraulic lock of the deflection cylinder to jam. The main reason for this problem is that during grinding, the grinding wheel rotates at high speed on the rail, grinding the top surface of the rail and generating high-temperature sparks, which causes the internal temperature of the grinding carriage to rise sharply, thereby increasing the temperature of the deflection cylinder and the internal hydraulic oil. The hydraulic oil sealed by the hydraulic lock inside the cylinder expands under high temperature, resulting in a significant increase in the hydraulic pressure inside the cylinder, which makes the hydraulic lock unable to open or causes jamming. At the same time, it also causes frequent oil leakage from the hydraulic cylinder, hydraulic lock and oil pipes.

[0019] (4) Excessive vibration during deflection of the grinding unit. When controlling the angle deflection of the grinding motor, severe vibration of the deflection cylinder frequently occurs, preventing the deflection cradle from smoothly stopping at the required angle and failing to achieve the desired grinding effect. Especially when the cradle deflects to a large angle or stops at its designated position, significant vibration occurs. As the deflection angle continues to increase, the amplitude and frequency of vibration increase, causing severe damage to the hydraulic system and the cradle mechanism. The main reason for this problem is that the existing grinding unit deflection control method does not implement acceleration / deceleration control and does not consider the influence of the deflection angle on the output force.

[0020] In the prior art, the following technical solutions are mainly related to this invention:

[0021] Prior art 1 is Chinese invention application CN106873639A, filed by the applicant on February 22, 2017, and published on June 20, 2017. This invention discloses a method for controlling the deflection angle during rail grinding. The rail grinding deflection angle control system includes a deflection motor, a lower guide column, a grinding motor, a deflection cradle, a telescopic cylinder, a cradle, and a control unit. The control unit acquires in real time the error angle between the current feedback angle of the grinding motor and the target angle preset by the host computer, and continuously adjusts the deflection motor's action based on the error angle, causing the grinding motor to deflect to the preset target angle, ultimately enabling the grinding motor to perform grinding operations according to the preset target angle. This invention solves the technical problem of existing rail grinding deflection angle control methods where the grinding angle easily changes during grinding, leading to uneven light bands and non-standard grinding rail profiles.

[0022] Existing technology 1 corrects the deflection angle based on certain conditions (timing, temperature change reaching a certain value, pressure change reaching a certain value). By continuously adjusting the deflection motor's operation, the deflection angle is corrected in real time to avoid changes in the deflection angle during grinding, thus reducing the requirements for system sensitivity and response speed due to frequent corrections. However, it only solves the technical problem of the grinding target angle not being maintained, and does not address the control of the deflection angle of the grinding unit. Furthermore, while this invention can dynamically maintain the position of the hydraulic cylinder to some extent to solve the problem of oil expansion and leakage at high temperatures, dynamic angle control is actually very difficult. This not only requires high precision in each component but also easily leads to instability in the grinding finish.

[0023] Prior art 2 is a Chinese invention application filed on December 31, 2021, by Wuhan University, China Railway Fourth Survey and Design Institute Group Co., Ltd., and Shenyang Aotofu Technology Co., Ltd., and published on April 26, 2022, with publication number CN114395953A. This invention application discloses a portable method and system for calibrating the incident angle of high-pressure water jet steel rail grinding. It uses an accelerometer and a gyroscope to collect raw acceleration and angular velocity data, and combines the sensitivity of the two sensors to obtain triaxial acceleration and angular velocity data. Then, by defining the inertial force vector of the accelerometer, the first set of angle data between this vector and each axis is calculated. To reduce the influence of mechanical vibration and noise during grinding operations, the triaxial angular velocity data obtained from the gyroscope, which is less affected by external vibration, is used as the second set of angle data. The two sets of data are then processed using a first-order complementary algorithm to obtain accurate values, i.e., different weights are assigned to the two sets of data for correction, ultimately determining the incident angle. This method complements the disadvantages of the two sensors, solving the problem of errors caused by mechanical vibration and noise in the calibration of the incident angle of water jet steel rail grinding.

[0024] Existing technology 2 utilizes the complementary properties of two novel sensors (accelerometer and gyroscope) for grinding angle calibration and control. After calibration, the grinding angle remains fixed, but the deflection angle of each water jet during the grinding operation cannot be controlled. Furthermore, it addresses the problem of mechanical vibration affecting traditional inclinometers, which is a technical issue related to the calibration of the sensors used, but does not involve the technical issue of calibrating the deflection angle of the grinding unit. Summary of the Invention

[0025] In view of this, the purpose of the present invention is to provide a grinding unit deflection control method and its application on a rail grinding vehicle, so as to solve the technical problem that the existing grinding unit deflection control method is prone to errors due to the processing and assembly of the grinding unit and the elastic deformation of the structure, which leads to low deflection angle control accuracy.

[0026] To achieve the above-mentioned objectives, the present invention specifically provides a technical implementation scheme for a grinding unit deflection control method, which includes the following steps:

[0027] S11) Control the deflection of the grinding unit when the grinding vehicle is stopped. During the deflection process, collect multiple sets of actual deflection angle values ​​of the grinding unit and the corresponding actuator stroke feedback values.

[0028] S12) The function is fitted using a set function. The parameters of the function are obtained by combining multiple sets of data based on the actual deflection angle value of the grinding unit and the corresponding stroke feedback value of the actuator, and the new parameters obtained by fitting are returned.

[0029] S13) Replace the function parameters of the deflection control of the grinding unit with the new parameters obtained by fitting;

[0030] S16) In the operation state of the grinding machine, the deflection control of the grinding unit is performed according to the set function and the new parameters obtained by fitting.

[0031] Furthermore, the following is included between step S13) and step S16):

[0032] S14) Using the replaced control parameters, control the deflection of the grinding unit when the grinding vehicle is stopped, test the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit, and determine whether there is an error greater than the set angle error value.

[0033] S15) If the judgment error is greater than the set angle error value, reduce the tolerance control range of the target angle, voltage or current value, or refit the function based on the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator.

[0034] Furthermore, the defined function includes, but is not limited to, any one of the following: exponential function, Fourier series, sine function, and polynomial function.

[0035] Furthermore, step S16) includes the following steps:

[0036] The controller sends a control command to the control element based on the deviation between the set angle value and the feedback angle value. The control element then controls the actuator to move, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time. The deflection control unit converts the voltage or current value of the stroke sensor into a feedback angle value according to the set function and parameters and outputs it to the controller, so that the deflection mechanism accurately deflects to the set angle value.

[0037] Furthermore, the defined function is fitted using the following two exponential functions:

[0038] α=f(V)=a*exp(b*V)+c*exp(d*V)

[0039] Where a, b, c, and d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the grinding unit deflection, and V is the voltage value of the stroke sensor.

[0040] Furthermore, step S16) includes the following steps:

[0041] The deflection control unit converts a set angle value into a target voltage or current value based on a set function and parameters. The controller sends a control command to the control element based on the deviation between the target voltage or current value and the feedback value. The control element then controls the actuator to move, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time and outputs the stroke voltage or current feedback value to the controller, ensuring that the deflection mechanism accurately deflects to the set angle value.

[0042] Furthermore, the defined function is fitted using the following first-order Fourier series expansion function:

[0043] V=f(α)=a0+a1*cos(α*ω)+b1*sin(α*ω)

[0044] Where a0, a1, b1, and ω are parameters in the Fourier series, V is the target voltage value of the stroke sensor, and α is the set angle value of the grinding unit deflection.

[0045] Furthermore, step S11) includes:

[0046] During the process of collecting the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator while the deflection angle is calibrated, the grinding head of the grinding unit presses down onto the rail surface with the average downward pressure under normal grinding operation conditions.

[0047] Furthermore, in step S11), during the deflection angle calibration state, the deflection angle calibration control of the grinding unit is achieved by setting the grinding unit number to be deflected, the deflection angle interval, the deflection angle range, and the deflection voltage range. In step S16), during the grinding vehicle operation state, the deflection control unit controls the deflection action of the grinding unit.

[0048] Further, in step S11), under the deflection angle calibration state, the deflection control unit first controls the deflection of the grinding unit according to the theoretical parameters of the fitting function, deflecting the grinding unit to the set maximum angle. Then, it deflects to the other side according to the set angle intervals. When the deflection angle is reached, it automatically stops and presses the grinding head onto the rail surface with the average downward pressure during normal operation. The actual deflection angle value of the grinding unit and the stroke feedback value of the actuator are automatically collected. This step is repeated until the grinding unit deflects to the maximum set angle on the other side and then stops. The grinding head is pressed onto the rail surface with the average downward pressure during normal operation, and the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator are automatically collected, completing the data collection of all calibration points. By executing step S12), all the collected data are fitted to obtain new function fitting parameters. By executing step S13), these parameters are output to the deflection control unit to replace the original control parameters, completing the control parameter calibration.

[0049] Furthermore, step S10 is included before step S11):

[0050] S10) With the grinding machine parked, the tilt sensor is installed on the deflection mechanism, the pressure guide post, or the guide sleeve.

[0051] Repeat steps S10) to S15) above to calibrate the other grinding units.

[0052] Step S11) further includes:

[0053] When the grinding vehicle is stopped, the grinding unit deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle. At the same time, the actual deflection angle value of the grinding unit is obtained through the tilt sensor, and the corresponding actuator stroke feedback value is obtained through the stroke sensor.

[0054] Furthermore, step S10) includes:

[0055] The tilt sensor is fixed to the mounting plane of the deflection mechanism using a magnetic base;

[0056] Alternatively, the tilt sensor can be fixed to the mounting base, and then the mounting base can be fixed to the outer side of the pressure guide post or guide sleeve via a magnetic base.

[0057] Furthermore, step S11) includes:

[0058] The tilt control unit acquires dual-axis data using a tilt sensor and calculates the tilt angle α of the grinding unit in the X direction based on the dual-axis data acquired by the tilt sensor, according to the following formula:

[0059]

[0060] Where x′ and y′ are the dual-axis sensing signal output values ​​of the tilt sensor, respectively, sin -1 It is an arcsine function.

[0061] Furthermore, step S11) includes:

[0062] The tilt angle data from the tilt sensor is received via a wireless gateway as the actual deflection angle value of the grinding unit, and then output to the deflection control unit via the network port.

[0063] Furthermore, step S16) includes:

[0064] When the grinding head performs continuous grinding operations at a set angle, it applies a number of micro-motion deflection actions with a set amplitude at set time intervals based on the set angle value, so as to achieve fine-tuning of the angle and relief of high temperature and overpressure inside the actuator.

[0065] Furthermore, the control element includes a proportional directional valve and a hydraulic lock, and the actuator is a hydraulic cylinder. The two outlet ports of the hydraulic lock are respectively connected to the inlets of the rod-side and rodless-side chambers of the hydraulic cylinder, and the two inlets are respectively connected to the outlet ports of the proportional directional valve. Step S16) includes:

[0066] During the grinding operation, the pressure or flow rate of the proportional directional valve is controlled by the controller to accelerate or decelerate, thereby controlling the movement speed of the hydraulic cylinder. During the acceleration phase when the actuator starts, the opening of the proportional directional valve is controlled from small to large. During the deceleration phase when the set angle value is about to be reached, the opening of the proportional directional valve is controlled from large to small. During the angle jogging fine-tuning phase, the opening of the proportional directional valve is set according to the tilt angle of the grinding unit.

[0067] The present invention also provides a technical implementation scheme for the application of the above-described grinding unit deflection control method on a rail grinding vehicle.

[0068] By implementing the grinding unit deflection control method provided by the present invention and its application on a rail grinding vehicle, the following beneficial effects are achieved:

[0069] (1) The grinding unit deflection control method of the present invention and its application on the rail grinding vehicle can effectively avoid errors caused by the processing and assembly of the grinding unit and the elastic deformation of the structure by collecting actual feedback data of the grinding unit deflection angle and the stroke of the actuator and performing function fitting, thereby improving the control accuracy of the grinding unit deflection angle.

[0070] (2) The grinding unit deflection control method of the present invention and its application on the rail grinding vehicle can improve the calibration efficiency and reduce manual calibration error by calibrating the deflection angle of the grinding unit in fixed-point segmentation. At the same time, the operation can be further simplified and the calibration efficiency and accuracy can be improved by acquiring dual-axis data through the tilt sensor.

[0071] (3) The grinding unit deflection control method of the present invention and its application on the rail grinding vehicle, by using the grinding unit deflection angle jog fine adjustment to realize the deflection cylinder pressure relief, can ensure that the deflection angle accuracy remains unchanged during the grinding operation and avoid the deflection cylinder from jamming, oil leakage and other phenomena.

[0072] (4) The grinding unit deflection control method of the present invention and its application on the rail grinding vehicle, by controlling the acceleration and deceleration during the deflection process of the grinding unit and controlling the output force by associating the angle, can reduce the shaking during the deflection process and reduce the damage of the deflection shaking to the deflection mechanism structure, deflection electric cylinder or deflection oil cylinder.

[0073] (5) The present invention provides a method for controlling the deflection of the grinding unit and its application on a rail grinding vehicle. During the calibration of the deflection angle of the grinding unit, the grinding head is pressed down onto the rail surface according to the average downward pressure during normal operation. The influence of the elastic deformation of the grinding unit structure is taken into account, and the static calibration is changed to semi-dynamic calibration, which further improves the control accuracy of the deflection angle. Attached Figure Description

[0074] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained based on these drawings without creative effort.

[0075] Figure 1 This is a schematic diagram of the structure of a grinding unit applied to the method of the present invention;

[0076] Figure 2 This is a schematic diagram comparing the deviation between the measured angle and the theoretical angle of the deflection unit using the existing deflection control method;

[0077] Figure 3 This is a schematic diagram of the deflection mechanism of a grinding unit in the prior art;

[0078] Figure 4 This is a schematic diagram of the deflection mechanism of another grinding unit in the prior art;

[0079] Figure 5 This is a schematic diagram of the deflection process of the grinding unit in the prior art;

[0080] Figure 6 This is a block diagram illustrating the deflection angle control principle of a specific embodiment of the deflection control device for the grinding unit used in the method of the present invention.

[0081] Figure 7 This is a block diagram illustrating the deflection angle control principle of another specific embodiment of the deflection control device for the grinding unit used in the method of the present invention.

[0082] Figure 8 This is a schematic diagram of a specific embodiment of the deflection control system of the grinding unit used in the method of the present invention;

[0083] Figure 9 This is a system structure block diagram of a specific embodiment of the deflection control system of the grinding unit used in the method of the present invention;

[0084] Figure 10 This is a system structure block diagram of another specific embodiment of the grinding unit deflection control system applied in the method of the present invention;

[0085] Figure 11 These are schematic diagrams of the installation structure of the angle calibration device in two specific embodiments of the grinding unit deflection control system applied in the method of the present invention;

[0086] Figure 12 This is a schematic diagram of the angle calibration device of a specific embodiment of the grinding unit deflection control system applied in the method of the present invention;

[0087] Figure 13 This is a schematic diagram of the angle calibration device of another specific embodiment of the grinding unit deflection control system applied in the method of the present invention;

[0088] Figure 14 This is a schematic diagram of the installation structure of a specific embodiment of the grinding unit deflection control system used in the method of the present invention;

[0089] Figure 15 This is a schematic diagram of the connection structure of the automatic calibration control unit in a specific embodiment of the grinding unit deflection control system used in the method of the present invention;

[0090] Figure 16 This is a schematic diagram of the placement structure of the tilt sensor in a specific embodiment of the deflection control system of the grinding unit used in the method of the present invention.

[0091] Figure 17 This is a schematic diagram of the placement structure of the tilt sensor from another perspective in a specific embodiment of the deflection control system of the grinding unit used in the method of the present invention.

[0092] Figure 18This is a schematic diagram illustrating the principle of calculating the tilt angle of the grinding unit in the X direction in a specific embodiment of the grinding unit deflection control system applied in the method of the present invention.

[0093] Figure 19 This is a schematic diagram of the deflection angle micro-motion control waveform of a specific embodiment of the deflection control system of the grinding unit used in the method of the present invention.

[0094] Figure 20 This is a schematic diagram of the deflection deceleration control mechanism of a specific embodiment of the deflection control system of the grinding unit used in the method of the present invention.

[0095] Figure 21 This is a flowchart of a specific embodiment of the grinding unit deflection control method of the present invention;

[0096] Figure 22 This is a flowchart of the function fitting process of a specific embodiment of the grinding unit deflection control method of the present invention;

[0097] Figure 23 This is a schematic diagram of the interface for actual data acquisition in a specific embodiment of the grinding unit deflection control method of the present invention;

[0098] Figure 24 This is a schematic diagram of the interface for curve fitting based on measured data in a specific embodiment of the grinding unit deflection control method of the present invention.

[0099] In the diagram: 1-Grinding motor, 2-Deflection mechanism, 3-Grinding head, 4-Pressing guide post, 5-Pressing guide sleeve, 6-Connecting frame, 7-Pressing drive mechanism, 8-Deflection drive mechanism, 9-Swing drive mechanism, 10-Connecting arm plate, 11-Controller, 12-Control element, 13-Actuator, 14-Deflection control unit, 15-Stroke sensor, 16-Magnetic base, 17-Tilt sensor, 18-Wireless gateway, 19-Grinding operation control system, 20-Deflection control device, 21-Data acquisition unit, 22-Data fitting unit, 23-Mounting base, 24-Automatic calibration control unit, 100-Grinding unit, 121-Proportional directional valve, 122-Hydraulic lock, 200-Rail, 300-Deflection control system. Detailed Implementation

[0100] For the sake of clarity and reference, the technical terms, abbreviations, or acronyms used below will be recorded as follows:

[0101] Function fitting, also known as curve fitting, is a data processing method that uses a continuous curve to approximate or represent the functional relationship between the coordinates of a discrete set of points on a plane. Fitting involves connecting a series of points on a plane with a smooth curve. Because there are countless possible curves, there are various fitting methods. The fitted curve can generally be represented by a function, and different functions have different names; this is called the fitting function.

[0102] Sum of sin: an abbreviation for approximation of a sine curve.

[0103] PID controller: Proportional-Integral-Derivative controller.

[0104] PI controller: Proportion Integration, short for proportional-integral controller.

[0105] PD controller: Proportion Differentiation controller.

[0106] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0107] As attached Figure 1 To be continued Figure 24 As shown, a specific embodiment of the grinding unit deflection control method of the present invention and its application on a rail grinding vehicle is given. The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0108] Example 1

[0109] As attached Figure 9 and attached Figure 10 As shown, an embodiment of a grinding unit deflection control device upon which the method of the present invention is based specifically includes:

[0110] The deflection control unit 14 controls the deflection of the grinding unit 100 when the grinding machine is stopped, and completes the deflection angle calibration.

[0111] Data acquisition unit 21 collects multiple sets of actual deflection angle values ​​of the grinding unit and corresponding actuator stroke feedback values ​​during the calibration process;

[0112] The data fitting unit 22 uses a set function to fit the data. It obtains the parameters of the function by combining multiple sets of data based on the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value, and then transmits the parameters of the function to the deflection control unit 14.

[0113] When the grinding machine is in operation, the deflection control unit 14 uses a set function and the parameters transmitted by the data fitting unit 22 to control the deflection of the grinding unit 100.

[0114] The defined function includes, but is not limited to, any one of the following: exponential function, Fourier series, sine function, and polynomial function. The output method of the actuator stroke feedback value includes, but is not limited to, any one of the following types: voltage, resistance, current, incremental pulse, and absolute pulse.

[0115] To fully address the technical problem of low deflection angle control accuracy caused by errors in existing methods for calculating the target deflection angle of grinding units due to factors such as the processing and assembly of the grinding unit and structural elastic deformation, the deflection control device 20 described in Embodiment 1 of this invention specifically employs an exponential function fitting algorithm based on measured data. For example, the set function can be further fitted using the following exponential function:

[0116] α=f(V)=a*exp(b*V)+c*exp(d*V)+……

[0117] Where a, d, c, and d are parameters in the exponential function, exp is an exponential function with the natural constant e as its base, α is the feedback angle value of the grinding unit 100 deflection, the output method of the actuator stroke feedback value adopts voltage type, V is the voltage value of the stroke sensor 15, ... represents an exponential function with more terms. By measuring the data relationship between the grinding unit deflection angle and the deflection cylinder feedback voltage, the parameters a, b, c, and d of the exponential function are obtained.

[0118] Of course, the function can also use, but is not limited to, the following algorithms.

[0119] Fourier series fitting:

[0120] α=f(V)=a0+a1*coS(V*ω)+b1*Sin(V*ω)+……

[0121] Where a0, a1, b1, and ω are parameters in the algorithm function, V is the voltage value of the stroke sensor 15, α is the feedback angle value of the deflection of the grinding unit 100, and ... represent higher-order Fourier series expansion terms.

[0122] Sine approximation fitting sum of sin:

[0123] α=f(V)=a1*sin(b1*V+c1)+a2*sin(b2*V+c2)+……

[0124] Where a1, a2, b1, b2, c1, and c2 are parameters in the algorithm function, V is the voltage value of the stroke sensor 15, α is the feedback angle value of the deflection of the grinding unit 100, and ... represent a sine function with more terms.

[0125] The above algorithm function takes voltage value V as input and angle value α as output, and is applied as shown in the attached figure. Figure 6 The deflection control forward algorithm is shown. Correspondingly, the algorithm shown in the attached figure can also be used. Figure 7 The deflection control inverse algorithm shown here uses the angle value α as the input variable and the voltage value V as the output variable. For example, taking Fourier series fitting, the corresponding function becomes:

[0126] V=f(α)=a0+a1*cos(α*ω)+b1*sin(α*ω)+……

[0127] Where a0, a1, b1, and ω are parameters in the algorithm function, V is the target voltage value of the stroke sensor 15, α is the set angle value of the deflection of the grinding unit 100, ... represent higher-order Fourier series expansion terms. When using other algorithm functions to implement the deflection control reverse algorithm, a similar change is made by swapping the positions of the voltage variable V and the angle variable α.

[0128] The specific process of function (curve) fitting is as follows: Data fitting unit 22 uses a set function to fit multiple data combinations of the actual deflection angle value of the grinding unit and its corresponding actuator stroke feedback value, and then returns the fitted parameters. Data fitting unit 22 fits different data combinations of the actual deflection angle value of the grinding unit and the corresponding actuator stroke feedback value to obtain the fitting parameters with the smallest comprehensive error, and then replaces the control parameters of the deflection control unit 14 with these fitted parameters. As a typical specific embodiment, the two data columns of the actual deflection angle value α of the grinding unit and the actuator stroke feedback value V are fitted in data fitting unit 22 according to the fitting algorithm, and then the fitted parameters a, b, c, and d are returned (taking a two-part exponential function fitting as an example). Multiple sets of data are needed before fitting, such as collecting 10-20 sets of data, or more sets of data; the more data combinations, the more accurate the fitting result. The fitting process comprehensively considers all position points to obtain the parameters with the smallest comprehensive error. The parameters in the deflection control algorithm of the grinding unit 100 are then replaced with the new fitted parameters. To improve the accuracy of the fitting, it is best to collect multiple sets of data as evenly as possible across the entire angle range. The start and end points of the angle collection can be selected near the maximum or minimum angle. For example, within the inner 70° deflection angle range, the innermost point can be 65° as the last data collection point.

[0129] Theoretically, the higher the degree of the fitting algorithm function (the more terms), the higher the fitting accuracy. However, considering that a higher degree (more terms) also means more parameters, leading to a greater computational burden, this also applies to other algorithms. Therefore, after verification using actual structural errors, and taking into account the requirement that the fitting accuracy meets the error range of ±0.5° deflection angle, as well as the algorithm's computation speed, a two-term exponential function and a first-order Fourier series expansion function are used to implement the forward deflection control algorithm (as shown in the attached figure). Figure 9 (as shown) and the reverse algorithm (as attached) Figure 10 The function fitting shown is the better approach.

[0130] As attached Figure 15 As shown, the deflection control device 20 also includes an automatic calibration control unit 24, which is connected to the deflection control unit 14, the data acquisition unit 21, and the data fitting unit 22, respectively. The automatic calibration control unit 24 is used to, in the deflection angle calibration state, to achieve the deflection angle calibration control of the grinding unit 100 by setting the grinding unit number to be deflected, the deflection angle interval, the deflection angle range, and the deflection voltage range. In the grinding vehicle operation state, the data acquisition unit 21 and the data fitting unit 22 are not working; the deflection control unit 14 controls the deflection action of the grinding unit 100.

[0131] The grinding unit deflection control device described in Example 1 employs an automatic calibration and fitting method. It collects data by continuously controlling the deflection of the grinding unit 100, then automatically analyzes and calculates the data. Based on a predefined functional relationship, it performs curve fitting between the actual detected stroke sensor voltage and the calibrated tilt angle (obtained through tilt sensor 17) to derive the optimal control parameters and correct the original control parameters. This corrects deviations caused by processing and assembly errors and structural elastic deformation of the grinding unit 100, effectively ensuring the grinding unit deflection control accuracy and grinding deflection angle calibration efficiency. Actual measurements show that the grinding unit deflection control device, using the technical solution described in Example 1, achieves a control accuracy of ±0.2° to ±0.3° for the grinding motor deflection angle, which well meets the railway standard requirement of ±0.5° for grinding motor deflection angle control accuracy.

[0132] Example 2

[0133] The angle deflection control principle of the grinding unit 100 is as follows: During the grinding process, in order to ensure that the deflection mechanism 2 (also known as the grinding unit frame, cradle, etc.) can accurately deflect to the set target angle value, the controller 11, control element 12, actuator 13 (more specifically, in this embodiment, the deflection drive mechanism 8, which can further be a deflection cylinder or deflection electric cylinder) and stroke sensor 15 (cylinder or electric cylinder stroke sensor) need to cooperate with each other. Among them, the controller 11, as the core of the entire deflection control system 300, is the issuer of control commands. After receiving the command, the actuator 13 acts according to a certain pattern to deflect the deflection mechanism 2. During the deflection process, the stroke sensor 15 in the deflection cylinder or deflection electric cylinder detects the displacement of the cylinder or electric cylinder in real time. (See attached...) Figure 6 and attached Figure 9 As shown, in this embodiment, the deflection control unit 14 adopts a deflection control forward algorithm. This control algorithm converts the voltage or current signal of the stroke sensor 15 into the feedback angle value of the deflection mechanism 2 and outputs it to the controller 11, thus forming a closed-loop control system to achieve precise control of the deflection angle of the grinding unit 100.

[0134] As attached Figure 6 and attached Figure 9As shown, an embodiment of a grinding unit deflection control system based on the method of the present invention specifically includes: a controller 11, a control element 12, an actuator 13, a deflection mechanism 2, a stroke sensor 15, and a deflection control device 20 as described in Embodiment 1. During the grinding operation, the controller 11 sends a control command to the control element 12 based on the deviation between the set angle value (also known as the target angle value) and the feedback angle value. The control element 12 then controls the actuator 13 to operate, and the actuator 13 drives the deflection mechanism 2 to perform the deflection operation. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time. The deflection control unit 14 converts the voltage or current value of the stroke sensor 15 into a feedback angle value according to a set function and parameters and outputs it to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value. Specifically, the controller 11 can be a PID controller, a PI controller, a PD controller, etc.

[0135] To fully address the technical problem of low deflection angle control accuracy caused by errors in existing grinding unit deflection angle control methods due to factors such as grinding unit processing, assembly, and structural elastic deformation, this embodiment specifically employs an exponential function fitting algorithm with superior comprehensive measured fitting results to implement the forward deflection control algorithm. For example, the set function can be further fitted using the following two exponential functions:

[0136] α=f(V)=a*exp(b*V)+c*exp(d*V)

[0137] Where a, b, c, and d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the deflection of the grinding unit 100, and V is the voltage value of the stroke sensor 15.

[0138] Of course, in addition to using two exponential functions, the function set by the above-mentioned deflection control forward algorithm can also use exponential functions with more terms or other algorithm functions for fitting.

[0139] During the deflection angle calibration state, when the data acquisition unit 22 collects the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator (such as the deflection cylinder feedback voltage in this embodiment), the grinding head 3 of the grinding unit 100 presses down onto the rail surface of the rail 200 according to the average downward pressure during normal grinding operation (the downward pressure during the grinding process is not a fixed value, but changes in real time because there are ripples on the surface of the rail 200, and the grinding unit 100 will vibrate, which requires real-time adjustment of the downward pressure to stabilize the grinding power. The average downward pressure refers to taking an average value based on the dynamically fluctuating downward pressure for static downward pressure, and then measuring the calibration angle) to solve the influence of processing and manufacturing gaps and structural elastic deformation in traditional methods.

[0140] In the deflection angle calibration state (when the grinding vehicle is stopped), the deflection control unit 14 first controls the deflection of the grinding unit 100 according to the theoretical parameters of the fitting function, deflecting the grinding unit 100 to the set maximum angle. Then, according to the set angle interval (or the deflection angle calibration can be performed by setting a time interval, which is easier to implement and meets the control accuracy requirements), it deflects to the other side. When the deflection angle is reached, it automatically stops and the grinding head 3 is pressed down onto the rail surface of the rail 200 with the average downward pressure during normal operation. The data acquisition unit 21 automatically collects the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator. This operation is repeated until the grinding unit 100 deflects to the maximum set angle on the other side and stops. The grinding head 3 is pressed down onto the rail surface of the rail 200 with the average downward pressure during normal operation. The data acquisition unit 21 automatically collects the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator, completing the data acquisition of all calibration points. All collected data are input into the data fitting unit 22 for fitting to obtain new function fitting parameters, and the parameters are output to the deflection control unit 14 to replace the original control parameters, thus completing the control parameter calibration.

[0141] The deflection control unit 14 controls the deflection of the grinding unit 100 when the grinding vehicle is stopped using the replaced control parameters. It tests the error between the theoretical deflection angle value of the grinding unit 100 (calculated based on the set fitting function and the replaced control parameters) and the actual deflection angle value, and determines whether the error exceeds the set angle error value. If the deflection control unit 14 determines that the error exceeds the set angle error value, it reduces the tolerance control range of the target angle, voltage, or current value, or the data fitting unit 22 re-fits the function based on the actual deflection angle value of the grinding unit and the actuator stroke feedback value.

[0142] The deflection control system 300 also includes a deflection angle calibration subsystem, which includes an inclination sensor 17 mounted on the deflection mechanism 2, the lower guide post 4, or the lower guide sleeve 5 when the grinding machine is stopped. The inclination sensor 17 needs to be removed from its mounting position after deflection angle calibration and before normal grinding operations. When the grinding machine is stopped, the grinding unit 100 deflects once from its innermost angle to its outermost angle or vice versa. Simultaneously, the inclination sensor 17 acquires the actual deflection angle value α of the grinding unit, and the stroke sensor 15 acquires the corresponding actuator stroke feedback voltage value V.

[0143] The deflection angle control of the grinding unit during the deflection angle calibration process can be achieved in various ways. For example, the actuator 13 (which can be a deflection cylinder or a deflection electric cylinder) records data every certain extension length until it is fully extended, and this can be controlled by the stroke of the cylinder. Alternatively, it can be converted into the deflection angle of the grinding unit 100, recording data every set angle. Alternatively, data can be recorded every set time interval. Or, the grinding unit 100 can deflect continuously, automatically recording sufficient data during the deflection process. The deflection control process of the grinding unit during data acquisition can specifically employ, but is not limited to, the following methods: deflection → pause → press down → acquisition; or press down → continuous deflection and acquisition; or press down → deflection → pause → acquisition, etc.

[0144] As attached Figure 11 The diagram shows only the installation positions of the tilt sensor 17 on the deflection mechanism 2 and the lower guide post 4 (or lower guide sleeve 5), and does not indicate that both tilt sensors 17 are simultaneously installed on the deflection mechanism 2 and the lower guide post 4 (or lower guide sleeve 5). (See attached diagram.) Figure 12 and appendix Figure 14 As shown, the tilt sensor 17 is magnetically attached to the mounting plane of the deflection mechanism 2 via the magnetic base 16. Alternatively, the tilt sensor 17 can be fixed to the mounting base 23, which is then magnetically attached to the outer side of the lower guide post 4 or the lower guide sleeve 5 via the magnetic base 16, as shown in the attached diagram. Figure 13 As shown. Meanwhile, the tilt sensor 17 has a wireless node, and the deflection angle calibration subsystem also includes a wireless gateway 18, as shown in the attached diagram. Figure 8 As shown. The wireless gateway 18 receives the tilt angle data from the tilt sensor 17 as the actual deflection angle value of the grinding unit, and outputs it to the deflection control unit 14 through the network port. The deflection control unit 14 is part of the grinding operation control system 19.

[0145] The deflection angle calibration subsystem of the grinding unit 100 is mainly used to improve the accuracy and calibration efficiency of the grinding operation (deflection) angle control. It automatically controls the grinding unit 100 to perform intermittent deflection actions, acquiring the deflection cylinder voltage signal and the tilt sensor deflection angle signal at different angles. The deflection control system 300 described in this embodiment can realize functions such as wireless acquisition, automatic calibration, parameter fitting, and result verification.

[0146] As attached Figure 17 As shown, β refers to the operational error generated during manual placement. Due to the existence of β, X′ and X are not in the same direction. In this embodiment, the tilt sensor 17 can achieve dual-axis data acquisition, and the influence of installation positioning error on tilt angle measurement can be corrected through calculation. (See attached...) Figure 16 To be continued Figure 18As shown, the deflection control unit 14, based on the dual-axis acquisition data of the tilt sensor 17, further calculates the tilt angle α of the grinding unit 100 in the X direction according to the following formula:

[0147]

[0148] Where x′ and y′ are the dual-axis sensing signal output values ​​of the tilt sensor 17, respectively, and sin -1 It is the arcsine function. (Appendix) Figure 16 In the diagram, H represents the horizontal direction.

[0149] The deflection angle calibration subsystem features wireless data acquisition capabilities. The tilt sensor 17 used for calibration is a wireless sensor, enabling long-distance wireless data transmission without the need for wiring, making it convenient to use. Simultaneously, the tilt sensor 17 is equipped with a magnetic base 16, allowing for quick and automatic fixation to the deflection mechanism 2 (i.e., the grinding unit frame) under test, further enhancing ease of use.

[0150] When the grinding head 3 performs continuous grinding operations at a set angle, it applies a number of micro-motion deflection actions of a set amplitude at set time intervals based on the set angle value. This achieves angle inching fine adjustment (i.e., continuous small-amplitude pulsed adjustment) and high-temperature overpressure relief within the actuator, as shown in the attached figure. Figure 19 As shown in the attached document. Figure 20 As shown, the control element 12 further includes a proportional directional valve 121 and a hydraulic lock 122, and the actuator 13 is a hydraulic cylinder. The two oil outlets of the hydraulic lock 122 are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlets of the proportional directional valve 121.

[0151] As a typical specific embodiment, during the grinding operation, if the grinding deflection angle is set to 35°, then two small deflection actions with an amplitude of ±0.5° are performed every 60 seconds. This action can reduce the hydraulic pressure inside the deflection cylinder (i.e., the deflection drive mechanism 8) that has increased due to temperature rise, and discharge a certain amount of hydraulic oil, thereby preventing the hydraulic pressure inside the deflection cylinder from continuously rising, and thus avoiding problems such as the hydraulic lock 122 failing to open, jamming, or leaking oil. The set grinding deflection angle of 35° can also be any grinding angle that may be used during the operation of the grinding unit 100. This angle can be any angle between -35° (negative values ​​represent outward deflection) and 70° (positive values ​​represent inward deflection), and for some vehicle models, it can even be in the range of -45° to 75°. Furthermore, the small deflection action of ±0.5° can also be ±1° or ±2°, generally a small angle, to avoid significantly affecting the angle of rail grinding. As for the 60-second interval for the grinding angle deflection, it can be adjusted every 5 minutes, 10 minutes, or even 20 minutes.

[0152] As attached Figure 20 The area within the dashed box represents the hydraulic lock 122. The hydraulic lock 122 essentially consists of two hydraulically controlled check valves. These check valves lock the circuit, preventing hydraulic fluid flow and ensuring that the hydraulic cylinder (i.e., actuator 13) remains stationary even under external loads. The function of the hydraulic lock 122 is interlocking; that is, when an auxiliary load is applied... Figure 20 When the proportional directional valve 121 is in the neutral position, the left and right cylinders of the hydraulic cylinder are stationary under the action of the two pilot-operated check valves. However, when the proportional directional valve 121 is in the right position, oil enters through port B. At this time, oil enters the right pilot-operated check valve, and at the same time, the control circuit opens the left pilot-operated check valve to release oil. The same logic applies when the proportional directional valve 121 is in the left position.

[0153] In this embodiment, the proportional directional valve 121 is specifically a three-position directional valve with three oil-filled positions: left, center, and right. The proportional directional valve 121 also has four oil pipe interfaces: P, T, A, and B. The left position refers to the valve core being on the left, the right position to the right, and the center position to the position when the hydraulic actuator is stopped. The left and right positions are the positions when the hydraulic actuator is working. The center position is also the normal position of the hydraulic valve; in the center position, the four ports P, T, A, and B perform the center position function. Under the action of the proportional electromagnet, the valve core of the proportional directional valve 121 can not only change position, but the stroke of the change can be continuous or proportionally varied, controlling both the direction and speed of the cylinder's movement. Port P connects to pressurized oil, port T connects to the return oil tank, and ports A and B connect to the inlet or return oil ports of the hydraulic lock 122.

[0154] To address the vibration issue during the deflection of the grinding unit 100, the controller 11 controls the pressure or flow rate of the proportional directional valve 121 to accelerate or decelerate, thereby controlling the movement speed of the hydraulic cylinder. During the acceleration phase when the actuator 13 starts, the opening of the proportional directional valve 121 is controlled from small to large. During the deceleration phase when the set angle value is about to be reached, the opening of the proportional directional valve 121 is controlled from large to small. This minimizes severe vibration during the deflection process of the grinding unit, significantly reducing damage to the grinding hydraulic system (i.e., the proportional directional valve 121 and hydraulic lock 122) and the deflection mechanism 2 (i.e., the rocker arm). During the angle jogging fine-tuning phase, the opening of the proportional directional valve 121 is set according to the tilt angle of the grinding unit 100. The P port pressure of the proportional directional valve 121 is typically 10 MPa, meaning the maximum pressure output of the proportional directional valve 121 is typically 10 MPa, and the minimum pressure output is 0. However, considering the gravitational influence when the grinding unit 100 is deflected at a large angle, the minimum output pressure should be greater than the pressure caused by the gravitational load on the grinding unit 100, and the gravitational load pressure is related to the deflection angle. For example, when the grinding unit 100 is at about 0°, the minimum output pressure can be slightly higher than 0. When the deflection angle is about 60° to 70°, the minimum pressure needs to be about 7MPa to counteract the tilting tendency caused by the gravity of the grinding unit 100.

[0155] It should be noted that in this embodiment, only the grinding unit 100 with a single-stage deflection structure using a deflection cylinder (i.e., deflection drive mechanism 8) is described as an example. When the grinding unit 100 with a two-stage deflection structure using a swing cylinder (i.e., swing drive mechanism 9) + deflection electric cylinder (i.e., deflection drive mechanism 8) is used, a segmented calibration method can be adopted. That is, first control the swing drive mechanism 9 to deflect the grinding unit 100 to a set angle, and then control the deflection drive mechanism 8 to deflect the grinding unit 100 to a calibrated angle in segments. For example, first control the swing drive mechanism 9 to deflect the grinding unit 100 to 0°. Assume that when the deflection drive mechanism 8 extends, the inner side is calibrated from 70° to 0°, and when the deflection drive mechanism 8 retracts, the inner side is calibrated from 0° to 35°. The calibration can be performed in two segments. The specific calibration separation angle can be 0° or any other angle between -35° and 70°.

[0156] The deflection control system 300 described in this embodiment has automatic calibration, automatic fitting, and result self-checking functions, which can effectively ensure the deflection control accuracy of the grinding unit and the calibration efficiency of the grinding deflection angle. The grinding operation computer (i.e., the grinding operation control system 19) is equipped with calibration control software. Data is collected by controlling the continuous deflection of the grinding unit 100, and then the data is automatically analyzed and calculated to obtain the optimal control parameters and correct the original control parameters. This embodiment is based on the correspondence between the stroke sensor data inside the deflection cylinder and the deflection angle. Curve fitting is performed on the relationship between the actually detected stroke sensor voltage and the calibrated tilt angle (obtained through the tilt sensor 17) to correct deviations caused by processing and assembly errors and structural elastic deformation of the grinding unit 100.

[0157] Example 3

[0158] As attached Figure 7 and attached Figure 10 As shown, another embodiment of the grinding unit deflection control system based on the method of the present invention specifically includes: a controller 11, a control element 12, an actuator 13 (more specifically, a deflection drive mechanism 8 in this embodiment, which can further be a deflection cylinder or a deflection electric cylinder), a deflection mechanism 2, a stroke sensor 15, and a deflection control device 20 as described in Embodiment 1. During the grinding operation, the deflection control unit 14 converts the set angle value into a target voltage or current value according to the set function and parameters. The controller 11 sends a control command to the control element 12 according to the deviation between the target voltage or current value and the feedback value. The control element 12 controls the actuator 13 to act, and the actuator 13 drives the deflection mechanism 2 to perform the deflection action. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time and outputs the stroke voltage or current feedback value to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value. As shown in the attached figure. Figure 7 and attached Figure 10 As shown, in this embodiment, the deflection control unit 14 adopts a deflection control reverse algorithm. This control algorithm converts the set angle value of the deflection mechanism 2 into the target voltage or current signal of the stroke sensor 15 and outputs it to the controller 11, thus forming a closed-loop control system to achieve precise control of the deflection angle of the grinding unit 100.

[0159] This embodiment employs Fourier series fitting, which yields the best overall experimental results, to implement the deflection control inverse algorithm. For example, the set function can be further fitted using the following first-order Fourier series expansion function:

[0160] V=f(α)=a0+a1*cos(α*ω)+b1*sin(α*ω)

[0161] Where a0, a1, b1, and ω are parameters in the Fourier series, V is the target voltage value of the stroke sensor 15, and α is the set angle value of the deflection of the grinding unit 100.

[0162] Of course, in addition to using a first-order Fourier series expansion function, the function set by the above-mentioned deflection control inverse algorithm can also use a Fourier series with a higher expansion order or other algorithm functions for fitting.

[0163] The difference between Example 3 and Example 2 lies in the fact that the deflection control unit 14 specifically adopts a deflection control inverse algorithm, thus the specific structure of the deflection control system 300 is different (as shown in the attached figure). Figure 9 and attached Figure 10 (As shown in the figure), the remaining more detailed technical solutions can be found in the relevant descriptions in Embodiment 2, and will not be repeated here.

[0164] Example 4

[0165] As attached Figure 21 As shown, an embodiment of the grinding unit deflection control method of the present invention specifically includes the following steps:

[0166] S11) Control the deflection of the grinding unit when the grinding vehicle is stopped. During the deflection process, collect multiple sets of actual deflection angle values ​​of the grinding unit and the corresponding actuator stroke feedback values.

[0167] S12) The function is fitted using a set function. The parameters of the function are obtained by combining multiple sets of data based on the actual deflection angle value of the grinding unit and the corresponding stroke feedback value of the actuator, and the new parameters obtained by fitting are returned.

[0168] S13) Replace the function parameters of the deflection control of the grinding unit 100 with the new parameters obtained by fitting;

[0169] S16) In the operation state of the grinding machine, the deflection control of the grinding unit 100 is performed according to the set function and the new parameters obtained by fitting.

[0170] Between step S13) and step S16), the following is further included:

[0171] S14) Using the replaced control parameters, control the deflection of the grinding unit 100 when the grinding machine is stopped, test the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit 100, and determine whether there is an error greater than the set angle error value.

[0172] S15) If the judgment error is greater than the set angle error value, reduce the tolerance control range of the target angle, voltage or current value, or refit the function based on the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator.

[0173] Step S10 is included before step S11):

[0174] S10) With the grinding machine parked, install the tilt sensor 17 onto the deflection mechanism 2, the pressure guide post 4, or the pressure guide sleeve 5. Repeat steps S10) to S15) to calibrate the other grinding units 100.

[0175] The function fitting process specifically includes four steps: data acquisition, data processing, parameter fitting, and checking and correction, as shown in the appendix. Figure 22 As shown. The data processing flow mainly includes processing or removing abnormally collected data, converting data units, and processing continuously collected data to obtain representative data. The defined functions include, but are not limited to, any one of the following: exponential function, Fourier series, sine function, and polynomial function.

[0176] Steps S14) to S15) above use new algorithm parameters to test the error between the theoretically calculated angle and the actual detected angle of the grinding unit 100, and determine whether there is a phenomenon where the deflection angle error is greater than ±0.5°. If the angle error exceeds ±0.5° when the grinding unit deflection angle is large, it is possible to consider reducing the tolerance range of the control target voltage or current, or to readjust the curve fitting parameters for this segment. For example, the target angle value of the grinding unit 100 deflection is set to 30°. While controlling the deflection of the grinding motor 1, the deviation between the feedback angle value and the set (target) angle value is calculated. If the deviation is less than the tolerance of 0.5°, it means that the grinding motor 1 has deflected to the correct position and the deflection action can be ended. If there is an angle error exceeding ±0.5°, in order to improve the control accuracy, the tolerance can be modified from 0.5° to 0.3°, that is, the control will only end when the feedback angle is in the range of 29.7° to 30.3°.

[0177] When the deflection control unit 14 adopts the forward deflection control algorithm, step S16) further includes the following steps:

[0178] The controller 11 sends a control command to the control element 12 based on the deviation between the set angle value and the feedback angle value. The control element 12 then controls the actuator 13 (more specifically, the deflection drive mechanism 8 in this embodiment, which can be further described as a deflection hydraulic cylinder or a deflection electric cylinder) to move, and the actuator 13 drives the deflection mechanism 2 to perform the deflection action. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time. The deflection control unit 14 converts the voltage or current value of the stroke sensor 15 into a feedback angle value according to the set function and parameters and outputs it to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value.

[0179] The defined function can be further fitted using the following two exponential functions:

[0180] α=f(V)=a*exp(b*V)+c*exp(d*V)

[0181] Where a, b, c, and d are parameters in the exponential function, exp is an exponential function with the natural constant e as the base, α is the feedback angle value of the deflection of the grinding unit 100, and V is the voltage value of the stroke sensor 15.

[0182] When the deflection control unit 14 employs the deflection control reverse algorithm, step S16) further includes the following steps:

[0183] The deflection control unit 14 converts the set angle value into a target voltage or current value according to the set function and parameters. The controller 11 sends a control command to the control element 12 based on the deviation between the target voltage or current value and the feedback value. The control element 12 controls the actuator 13 to operate, and the actuator 13 drives the deflection mechanism 2 to perform the deflection action. During the deflection process, the stroke sensor 15 detects the stroke displacement of the actuator 13 in real time and outputs the stroke voltage or current feedback value to the controller 11, so that the deflection mechanism 2 accurately deflects to the set angle value.

[0184] The defined function can be further fitted using the following first-order Fourier series expansion:

[0185] V=f(α)=a0+a1*cos(α*ω)+b1*sin(α*ω)

[0186] Where a0, a1, b1, and ω are parameters in the Fourier series, V is the target voltage value of the stroke sensor 15, and α is the set angle value of the deflection of the grinding unit 100.

[0187] As attached Figure 23 The diagram shown is a schematic of the interface for acquiring measured data of the deflection control method of the grinding unit, as attached. Figure 24 The diagram shows the interface for curve fitting based on the aforementioned measured data. The vertical axis represents the stroke voltage (in V), and the horizontal axis represents the deflection angle (in °). The measured curve reflects the actual relationship between the actual deflection angle of the grinding unit and the stroke sensor voltage. The theoretical curve refers to the curve corresponding to the design dimensions when designing the deflection control system 300, without considering errors caused by manufacturing defects and gravity deformation.

[0188] Step S11) further includes:

[0189] In the deflection angle calibration state, during the process of collecting the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator, the grinding head 3 of the grinding unit 100 presses down onto the rail surface of the rail 200 with the average downward pressure under normal grinding operation conditions. Simultaneously, before performing deflection angle (automatic) calibration, the automatic deflection calibration program is entered on the display, and relevant parameters are set: selecting the grinding unit number to be deflected, the deflection angle interval, the deflection angle range, and the deflection voltage range, etc. When the automatic calibration program is executed, in the deflection angle calibration state, the deflection angle calibration control of the grinding unit 100 is achieved through the set grinding unit number to be deflected, the deflection angle interval, the deflection angle range, and the deflection voltage range. In step S16), under the grinding vehicle operation state, the deflection control unit 14 controls the deflection action of the grinding unit 100.

[0190] In step S11), under the deflection angle calibration state, the deflection control unit 14 first controls the deflection of the grinding unit 100 according to the theoretical parameters of the fitting function, deflecting the grinding unit 100 to the set maximum angle. Then, it deflects to the other side according to the set angle intervals. When the deflection angle is reached, it automatically stops and the grinding head 2 is pressed down onto the rail surface of the rail 200 with the average downward pressure during normal operation. The actual deflection angle value of the grinding unit and the stroke feedback value of the actuator are automatically collected. This step is repeated until the grinding unit 100 deflects to the maximum set angle on the other side and then stops. The grinding head 3 is pressed down onto the rail surface of the rail 200 with the average downward pressure during normal operation, and the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator are automatically collected, completing the data collection of all calibration points. By executing step S12), all the collected data are fitted to obtain new function fitting parameters, and by executing step S13), these parameters are output to the deflection control unit 14 to replace the original control parameters, completing the control parameter calibration. At this point, the theoretical parameters of the fitting function are completely based on the design dimensions of the grinding unit 100, and the parameters of the algorithm function are fitted to the angle and voltage data corresponding to the trigonometric relationship of A, O, B (i.e., a, b, L0), which are the theoretical function parameters. In this case, the influence of factors such as processing structure error and deformation is not considered. The fitting curve is based on the actual measured curve, without considering the theoretical curve. Before obtaining the measured curve, the theoretical curve can be fitted to obtain preliminary parameters a, b, c, d (taking the fitting of two exponential functions as an example). With the preliminary parameters a, b, c, d, the corresponding control algorithm of the deflection control unit 14 can roughly control the grinding unit to perform deflection action and angle calibration, and then the parameters a, b, c, d are fitted and corrected by the measured curve.

[0191] Step S11) further includes:

[0192] When the grinding vehicle is stationary, the grinding unit 100 deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle. Simultaneously, the tilt sensor 17 acquires the actual deflection angle value of the grinding unit, and the stroke sensor 15 acquires the corresponding actuator stroke feedback value. The number of calibration points can be changed by altering the deflection time interval setting or by referencing a theoretical algorithm function to set the angle interval. Changing the deflection angle range alters the calibration range of the grinding motor 1, improving the accuracy of small-range angle calibration. The settings for parameters such as the time interval and deflection angle can meet various customized calibration needs, better satisfying different application requirements at the work site.

[0193] During the deflection angle calibration process in step S11), the tilt angle data from the tilt sensor 17 is further received via the wireless gateway 18 as the actual deflection angle value of the grinding unit, and output to the deflection control unit 14 via the network port. Simultaneously, to correct the influence of installation positioning errors on tilt angle measurement and thus improve the control accuracy of the grinding unit's deflection angle, step S11) further includes:

[0194] Dual-axis data acquisition is performed via tilt sensor 17. Based on the dual-axis data acquired by tilt sensor 17, deflection control unit 14 calculates the tilt angle α of grinding unit 100 in the X direction according to the following formula:

[0195]

[0196] Where x′ and y′ are the dual-axis sensing signal output values ​​of the tilt sensor 17, respectively, and sin -1 It is the arcsine function. (See attached image.) Figure 16 and attached Figure 17 The diagram shown is a schematic of the installation of a dual-axis tilt sensor, where H represents the horizontal direction. (See attached diagram.) Figure 18 The combined calculation of the tilt vectors in the two directions shown can correct the influence of installation positioning errors on tilt measurement.

[0197] In step S10), the tilt sensor 17 is further fixed on the mounting plane of the deflection mechanism 2 by the magnetic base 16; or the tilt sensor 17 is fixed on the mounting base 23, and then the mounting base 23 is fixed to the outer side of the pressure guide post 4 or the pressure guide sleeve 5 by the magnetic base 16.

[0198] Because the grinding machine has a large number of grinding units, calibration needs to be performed on each grinding unit 100 individually. Therefore, the tilt sensor 17 needs to be frequently moved between each grinding unit 100, resulting in a large workload for operation and installation, and requiring the provision of installation interfaces, and even handheld fixation. To solve this technical problem, as shown in the attached... Figure 16 and attached Figure 17The tilt sensor 17 shown has a magnetic base 16, which allows for quick and automatic fixation to the grinding unit frame (i.e., deflection mechanism 2) under test, making operation very convenient. The magnetic base 16 has two structural forms: one is a calibration installation method based on a plane on the grinding unit frame, and the other is a calibration installation method based on the pressure guide post 4 or the pressure guide sleeve 5. The first type of magnetic base 16 has a planar positioning structure on its mounting surface, while the second type has a V-groove positioning structure on its mounting surface.

[0199] During the grinding operation, the grinding head 3 rotates at high speed on the rail 200, grinding the top surface of the rail 200, generating high-temperature sparks. This can easily cause a sharp increase in the internal temperature of the grinding carriage, thereby raising the temperature of the deflection cylinder (i.e., the deflection drive mechanism 8) and the internal hydraulic oil. The hydraulic oil sealed by the hydraulic lock inside the cylinder expands at high temperatures, leading to a significant increase in the internal hydraulic pressure, which can cause the hydraulic lock 122 to fail to open or become stuck. Simultaneously, this can also cause frequent oil leaks from the hydraulic cylinder, hydraulic lock 122, and oil pipes. To solve this technical problem, this embodiment employs micro-motion control measures, i.e., when the grinding head 3 performs continuous grinding operations at a set angle, it performs a small deflection movement at regular intervals. As a further improvement of this embodiment, step S16) also includes:

[0200] When the grinding head 3 performs continuous grinding operations at a set angle, it applies a number of micro-motion deflection actions with a set amplitude at set intervals based on the set angle value, so as to realize the angle jog fine adjustment and the high temperature overpressure relief inside the deflection cylinder.

[0201] The control element 12 further includes a proportional directional valve 121 and a hydraulic lock 122, and the actuator 13 further employs a hydraulic cylinder. The two oil outlets of the hydraulic lock 122 are respectively connected to the oil inlets of the rod-side and rodless-side chambers of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlets of the proportional directional valve 121. To address the technical problem of deflection vibration in the grinding unit, as a further improvement of this embodiment, step S16) further includes:

[0202] During the grinding operation, the controller 11 controls the pressure or flow rate of the proportional directional valve 121 to accelerate or decelerate, thereby controlling the movement speed of the hydraulic cylinder. During the acceleration phase when the actuator 13 starts, the opening of the proportional directional valve 121 is controlled from small to large. During the deceleration phase when the set angle value is about to be reached, the opening of the proportional directional valve 121 is controlled from large to small. During the angle jogging fine-tuning phase, the opening of the proportional directional valve 121 is set according to the tilt angle of the grinding unit 100.

[0203] In embodiments 2-4 of the present invention, a grinding unit 100 with a single-stage deflection structure using a deflection cylinder (i.e., deflection drive mechanism 8) is described as an example. When the grinding unit 100 with a two-stage deflection structure using a swing cylinder (i.e., swing drive mechanism 9) and a deflection electric cylinder (i.e., deflection drive mechanism 8) is used, a segmented calibration method can be adopted. That is, first, the swing drive mechanism 9 is controlled to deflect the grinding unit 100 to a set angle, and then the deflection drive mechanism 8 is controlled to deflect the grinding unit 100 to a calibrated angle in segments. In addition, the deflection control device, system and method described in the embodiments of the present invention can be applied to multi-stage deflection structures. The deflection cylinder involved in the deflection control system 300 can also be replaced by a deflection electric cylinder (electric push rod). The proportional speed control valve 121 in the deflection speed control structure can also be a hydraulic valve with a certain speed regulation function, such as a throttle valve or a servo valve. Although the forward deflection control algorithm in the deflection control algorithm is illustrated using exponential function fitting as an example, and the inverse deflection control algorithm is illustrated using Fourier series fitting as an example, other fitting function forms based on measured data can also be used. The deflection angle calibration subsystem adopts an automatic angle calibration method based on measured data, which can be implemented using wireless or wired data transmission.

[0204] Based on actual application test results, regardless of whether exponential function, Fourier series, sine function or polynomial function is used for fitting, the fitting accuracy can be controlled within the error range of ±0.2° to ±0.3°. After further increasing the fitting degree of the function, it can even reach within ±0.2°, which well meets the requirement of ±0.5° deflection angle error range of the grinding unit.

[0205] Example 5

[0206] A specific embodiment of the application of the grinding unit deflection control method as described in Example 4 on a rail grinding vehicle.

[0207] In the description of this application, it should be noted that when an element is referred to as being "fixed to" or "set on" another element, it may be directly or indirectly set on another element; when an element is referred to as being "connected to" another element, it may be directly or indirectly connected to another element.

[0208] It should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0209] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" or "several" means two or more, unless otherwise explicitly specified.

[0210] Those skilled in the art will further recognize that the units and steps of the various examples described in connection with the specific embodiments of the present invention can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of each example have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of the present invention.

[0211] The methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented directly using hardware, software modules executed by a processor, or a combination of both. The software modules can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, various programmable logic devices, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. The processor executing the software module can be a central processing unit (CPU), embedded processor, microcontroller (MCU), digital signal processor (DSP), single-chip microcomputer, system-on-a-chip (SoC), programmable logic device, or any other form of device with control and processing functions known in the art.

[0212] It should be noted that the structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which this application can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this application can produce, should still fall within the scope of the technical content disclosed in this application.

[0213] By implementing the grinding unit deflection control method described in the specific embodiments of the present invention and its application on a rail grinding vehicle, the following technical effects can be achieved:

[0214] (1) The grinding unit deflection control method described in the specific embodiments of the present invention and its application on the rail grinding vehicle can effectively avoid errors caused by the processing and assembly of the grinding unit and the elastic deformation of the structure by collecting actual feedback data of the grinding unit deflection angle and the stroke of the actuator and performing function fitting, thereby improving the control accuracy of the grinding unit deflection angle.

[0215] (2) The grinding unit deflection control method described in the specific embodiments of the present invention and its application on the rail grinding vehicle can improve calibration efficiency and reduce manual calibration error by calibrating the deflection angle of the grinding unit in fixed-point segmentation. At the same time, the operation can be further simplified and the calibration efficiency and accuracy can be improved by acquiring dual-axis data through the tilt sensor.

[0216] (3) The grinding unit deflection control method described in the specific embodiments of the present invention and its application on the rail grinding vehicle, by using the grinding unit deflection angle jog fine adjustment to realize the deflection cylinder pressure relief, can ensure that the deflection angle accuracy remains unchanged during the grinding operation and avoid phenomena such as jamming and oil leakage of the deflection cylinder.

[0217] (4) The grinding unit deflection control method described in the specific embodiments of the present invention and its application on the rail grinding vehicle, by controlling the acceleration and deceleration during the deflection process of the grinding unit and at the same time controlling the output force by associating the angle, can reduce the shaking during the deflection process and reduce the damage of the deflection shaking to the deflection mechanism structure, deflection electric cylinder or deflection oil cylinder.

[0218] (5) The grinding unit deflection control method described in the specific embodiments of the present invention and its application on the rail grinding vehicle, in the grinding unit deflection angle calibration process, the grinding head is pressed down onto the rail surface according to the average downward pressure during normal operation. The influence of the elastic deformation of the grinding unit structure is taken into account, and the static calibration is changed to semi-dynamic calibration, which further improves the control accuracy of the deflection angle.

[0219] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0220] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention using the methods and techniques disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the spirit and technical essence of the present invention. Therefore, any simple modifications, equivalent substitutions, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall still fall within the protection scope of the technical solutions of the present invention.

Claims

1. A method for controlling the deflection of a grinding unit, characterized in that, Includes the following steps: S11) When the grinding vehicle is parked, the deflection control unit controls the grinding unit to deflect and completes the deflection angle calibration. During the deflection angle calibration process, multiple sets of actual deflection angle values ​​of the grinding unit and the corresponding actuator stroke feedback values ​​are collected. S12) The function is fitted using a set function. The parameters of the function are obtained by combining multiple sets of data based on the actual deflection angle value of the grinding unit and the corresponding stroke feedback value of the actuator, and the new parameters obtained by fitting are returned. S13) Replace the function parameters of the deflection control of the grinding unit with the new parameters obtained by fitting; S16) In the operation state of the grinding machine, the deflection control of the grinding unit is performed according to the set function and the new parameters obtained by fitting.

2. The deflection control method for the grinding unit according to claim 1, characterized in that, Between step S13) and step S16), the following is further included: S14) Using the replaced control parameters, control the deflection of the grinding unit when the grinding vehicle is stopped, test the error between the theoretical deflection angle value and the actual deflection angle value of the grinding unit, and determine whether there is an error greater than the set angle error value. S15) If the judgment error is greater than the set angle error value, reduce the tolerance control range of the target angle, voltage or current value, or refit the function based on the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator.

3. The grinding unit deflection control method according to claim 2, characterized in that: The defined function includes, but is not limited to, any one of the following: exponential function, Fourier series, sine function, and polynomial function.

4. The deflection control method for the grinding unit according to claim 3, characterized in that, Step S16) further includes the following steps: The controller sends a control command to the control element based on the deviation between the set angle value and the feedback angle value. The control element controls the actuator to move, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time. The deflection control unit converts the voltage or current value of the stroke sensor into a feedback angle value according to the set function and parameters and outputs it to the controller, so that the deflection mechanism accurately deflects to the set angle value.

5. The deflection control method for the grinding unit according to claim 4, characterized in that, The defined function is fitted using the following two exponential functions: ； in, , , , These are the parameters in the exponential function. For the natural constant An exponential function with base 0. To refine the feedback angle value of the unit deflection, This is the voltage value of the travel sensor.

6. The deflection control method for the grinding unit according to claim 3, characterized in that, Step S16) further includes the following steps: The deflection control unit converts the set angle value into a target voltage or current value according to the set function and parameters. The controller sends a control command to the control element based on the deviation between the target voltage or current value and the feedback value. The control element controls the actuator to move, and the actuator drives the deflection mechanism to perform the deflection action. During the deflection process, the stroke sensor detects the stroke displacement of the actuator in real time and outputs the stroke voltage or current feedback value to the controller, so that the deflection mechanism accurately deflects to the set angle value.

7. The grinding unit deflection control method according to claim 4, characterized in that, The defined function is fitted using the following first-order Fourier series expansion function: ； in, , , , For the parameters in the Fourier series, The target voltage value for the travel sensor. The set angle value for the deflection of the grinding unit.

8. The grinding unit deflection control method according to claim 4, 5, 6 or 7, characterized in that, Step S11) further includes: During the process of collecting the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator while the deflection angle is calibrated, the grinding head of the grinding unit presses down onto the rail surface with the average downward pressure under normal grinding operation conditions.

9. The deflection control method for the grinding unit according to claim 8, characterized in that: In step S11), under the deflection angle calibration state, the deflection angle calibration control of the grinding unit is achieved by setting the grinding unit number to be deflected, the deflection angle interval, the deflection angle range and the deflection voltage range; in step S16), under the grinding vehicle operation state, the deflection control unit controls the operation deflection action of the grinding unit.

10. The deflection control method for the grinding unit according to claim 9, characterized in that: In step S11), under the deflection angle calibration state, the deflection control unit first controls the deflection of the grinding unit according to the theoretical parameters of the fitting function, deflecting the grinding unit to the set maximum angle; then, it deflects to the other side according to the set angle intervals. When the deflection angle is reached, it automatically stops and presses the grinding head onto the rail surface with the average downward pressure during normal operation. The actual deflection angle value of the grinding unit and the stroke feedback value of the actuator are automatically collected. This step is repeated until the grinding unit deflects to the maximum set angle on the other side and stops. The grinding head is then pressed onto the rail surface with the average downward pressure during normal operation, and the actual deflection angle value of the grinding unit and the stroke feedback value of the actuator are automatically collected, completing the data collection of all calibration points. By executing step S12), all the collected data are fitted to obtain new function fitting parameters. By executing step S13), these parameters are output to the deflection control unit to replace the original control parameters, completing the control parameter calibration.

11. The grinding unit deflection control method according to claim 4, 5, 6, 7, 9 or 10, characterized in that, Step S10 is included before step S11). S10) With the grinding machine parked, install the tilt sensor on the deflection mechanism, the pressure guide post, or the guide sleeve; Repeat steps S10 to S15 above to calibrate the other multiple grinding units; Step S11) further includes: When the grinding vehicle is stopped, the grinding unit deflects once from the innermost angle to the outermost angle or from the outermost angle to the innermost angle. At the same time, the actual deflection angle value of the grinding unit is obtained through the tilt sensor, and the corresponding actuator stroke feedback value is obtained through the stroke sensor.

12. The deflection control method for the grinding unit according to claim 11, characterized in that, Step S10) further includes: The tilt sensor is fixed to the mounting plane of the deflection mechanism using a magnetic base; Alternatively, the tilt sensor can be fixed to the mounting base, and then the mounting base can be fixed to the outer side of the pressure guide post or guide sleeve via a magnetic base.

13. The grinding unit deflection control method according to claim 12, characterized in that, Step S11) further includes: The tilt control unit acquires dual-axis data using a tilt sensor and calculates the grinding unit's position based on this data according to the following formula. Inclination of direction : ； in, , These are the dual-axis sensing signal output values ​​of the tilt sensor. It is an arcsine function.

14. The deflection control method for the grinding unit according to claim 13, characterized in that, Step S11) further includes: The tilt angle data from the tilt sensor is received via a wireless gateway as the actual deflection angle value of the grinding unit, and then output to the deflection control unit via the network port.

15. The deflection control method for a grinding unit according to any one of claims 1, 2, 4, 5, 6, 7, 9, 10, 12, 13 or 14, characterized in that, Step S16) further includes: When the grinding head performs continuous grinding operations at a set angle, it applies a number of micro-motion deflection actions with a set amplitude at set time intervals based on the set angle value, so as to achieve fine-tuning of the angle and relief of high temperature and overpressure inside the actuator.

16. The deflection control method for a grinding unit according to any one of claims 4, 5, 6, 7, 9, 10, 12, 13 or 14, characterized in that, The control element includes a proportional directional valve and a hydraulic lock, and the actuator is a hydraulic cylinder; the two oil outlets of the hydraulic lock are respectively connected to the oil inlets of the rod chamber and the rodless chamber of the hydraulic cylinder, and the two oil inlets are respectively connected to the oil outlet of the proportional directional valve; step S16) further includes: During the grinding operation, the pressure or flow of the proportional directional valve is controlled by the controller to accelerate or decelerate, thereby controlling the movement speed of the hydraulic cylinder. During the acceleration phase when the actuator starts, the opening of the proportional directional valve is controlled from small to large. During the deceleration phase when the set angle value is about to be reached, the opening of the proportional directional valve is controlled from large to small. During the angle jogging fine adjustment phase, the opening of the proportional directional valve is set according to the tilt angle of the grinding unit.

17. The application of a grinding unit deflection control method as described in any one of claims 1 to 16 on a rail grinding vehicle.

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