A method for optimizing rail profile grinding by converting power of grinding stone angle

Abstract

The present invention discloses a method for optimizing the profile grinding of rails by converting the power of a grinding stone into an angle. First, the profile of the entire line is measured, and the measured profiles obtained are classified according to the daily grinding plan. Then, a representative profile corresponding to the grinding interval profile is designed, and the representative profile is compared with the grinding profile. A fixed angle and fixed power grinding mode for grinding the representative profile to the corresponding grinding profile are designed. Then, the entire interval profile is compared with the grinding profile in sequence. According to the deviation between the measured interval profile and the grinding profile, the positive and negative angle grinding power of the grinding mode are adjusted to achieve the goal of grinding the entire interval with a fixed angle grinding mode, and different grinding amounts of rails at different positions can be achieved. After grinding, the line section is measured every 500m. If the acceptance fails, the representative profile design and variable power grinding scheme design are re-performed according to the above process. If the acceptance passes, the grinding ends.

Description

Technical Field

[0001] The patent of this invention relates to the field of railway rail grinding, specifically a method for optimizing rail profile grinding by converting the power of the grinding stone angle. Background Art

[0002] Rail grinding is of great significance for extending the service life of rails and improving the quality of train operation. However, due to the large differences in wheel treads of different trains, the rail profiles of different mileages and sections are also quite different due to the wheel-rail relationship. The rail grinding car adjusts the angle of the grinding stone to grind different positions on the rail profile surface. When using the grinding car to grind the rails, due to the obvious differences in rail profiles of different mileages, the grinding stone angle needs to be frequently switched during the grinding process. The frequent switching mode of the grinding stone angle of the grinding car has two main disadvantages:

[0003] (1) Frequent switching of the grinding stone angle can easily cause the rail surface to be uneven and cause rail surface corrugation;

[0004] (2) The grinding machine needs to stop working when the grinding stone angle is switched, which affects the grinding efficiency. Summary of the Invention

[0005] In order to solve the above problems, the present invention proposes a method for optimizing the grinding of rail profiles by converting the power of the grinding stone angle. The specific method is as follows:

[0006] Step 1: Collect rail profile data for the entire line.

[0007] Step 2: Create a daily polishing interval plan.

[0008] Step 3: Design the average representative profile of the daily construction interval. The specific method is as follows:

[0009] A. Discretize the measured profiles of the daily grinding intervals at equal intervals along the transverse direction of the rail, and convert the measured profiles into a large number of discrete points. Then determine the point with the largest y-axis of each measured profile, define it as point A1, and align the A1 points of each measured profile. Then draw a line L1 parallel to the X-axis through point A1, and further draw a line L2 parallel to L1 16mm downward. L2 intersects with each measured profile at the left and right points A2 and A3. Finally, align A1 and A2 on each measured profile. The alignment principle is that the distance between the A1 points on the two profiles plus the distance between the A2 points of the two profiles is the shortest.

[0010] B. Divide the aligned measured profile into 10 regions along the horizontal direction of the rail. Each region consists of n measured profiles, and each region has k discrete points.

[0011] C. The average representative profile of the design interval is designed in the same way, specifically:

[0012] The calculation formula for the horizontal and vertical coordinates (xi, yi) of the representative profile point of the i-th discrete point of the n measured profiles in each interval is:

[0013]

[0014] Where x ni ,y ni are the horizontal and vertical coordinates of the i-th discrete point of the n-th measured profile respectively.

[0015] In this way, the coordinates of the representative profile points of each discrete point of each measured profile in all intervals are obtained, a total of 10 times k.

[0016] D. Fit 10 times k representative profile points to obtain the designed average representative profile.

[0017] Step 4: Align the average representative profile with the standard profile. Define the normal distance between each angle point on the standard profile rail head and the average representative profile as the required grinding amount based on the angle distribution of the grinding profile rail head. Then, obtain the grinding pattern, which includes the angles to be ground and the power required for each angle.

[0018] Furthermore, all measured profiles in the section are aligned with the standard profile, and the grinding amount of each rail head angle of the standard profile and each measured profile is calculated in turn. According to the grinding angle calculated from the average representative profile, the angular power of the grinding mode is changed without changing the grinding stone angle deflection, and then the grinding mode and grinding plan of the entire section are obtained.

[0019] After polishing, the line section is measured every 500m. If the acceptance fails, the representative profile design and variable power polishing plan design are re-performed according to the above process. If the acceptance passes, the polishing is completed. Finally, the connection between the two adjacent polishing sections is polished to avoid corrugation and pits in the polishing connection.

[0020] The advantages of the present invention are that the entire section line can be polished without switching the grinding stone angle, and the entire section profile can be polished to the acceptance standard. At the same time, the problem of the grinding vehicle needing to stop working when the grinding stone angle is switched is avoided, thereby improving the grinding efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is the overall flow chart of the method of the present invention;

[0022] Figure 2 This is the data arrangement method for the Beijing-Hong Kong High-Speed ​​Railway profile;

[0023] Figure 3 Schematic diagram of the measured profile alignment method for daily polishing intervals in the method of the present invention;

[0024] Figure 4 Schematic diagram of the method for dividing the measured profile area after alignment in the method of the present invention;

[0025] Figure 5 Schematic diagram of the interval average representative profile obtained in the method of the present invention;

[0026] Figure 6 This is the angle distribution diagram of the new 60N profile rail head;

[0027] Figure 7 This is a graph showing the normal distance between each angle point and the average representative profile on the new 60N profile rail head; DETAILED DESCRIPTION

[0028] The present invention will be further described in detail below with reference to the accompanying drawings.

[0029] The present invention provides a method for optimizing the grinding of rail profiles by converting the power of the grinding stone angle into a grinding stone. Figure 1 As shown, the specific steps are:

[0030] Step 1: Survey and collect rail profile data at every 500m interval along the entire line.

[0031] Step 2: Polish the interval profile classification every day.

[0032] According to the daily construction section plan formulated by the railway engineering department, the rail profile of the entire line is sorted out, and the section profile that needs to be polished every day is placed in a folder, which is convenient for the subsequent average representative profile design of the section profile. Taking the Beijing-Hong Kong High-Speed ​​Railway as an example, the 670km-716km upstream is polished. According to the daily polishing construction plan shown in Table 1, about 10km is polished every day. The daily polished profile is placed in a separate folder, such as Figure 2 shown.

[0033] Table 1 Daily grinding construction schedule for Beijing-Hong Kong High-Speed ​​Railway

[0034]

[0035] Step 3: Daily polishing interval average representative silhouette design.

[0036] There are many profiles in the daily grinding interval, and there are differences between different profiles. Therefore, it is necessary to unify the different profiles into one profile, which is called the average representative profile. The initial grinding mode is designed according to the average representative profile. In this way, the grinding mode with a fixed grinding angle can be used to grind the rail profile in this grinding interval. The specific design method is as follows:

[0037] A. Daily polishing interval measured profile alignment

[0038] like Figure 3As shown, the measured profiles collected in step 1 within the daily grinding interval are discretized at intervals of 0.5 mm along the x-axis (transverse direction of the rail), converting the measured profiles into a large number of discrete points. Subsequently, the point with the largest y-axis for each measured profile in the interval is found and defined as point A1. The A1 points of each measured profile are aligned, and a line L1 parallel to the x-axis is drawn through point A1. A line L2 parallel to L1 is further drawn 16 mm downward. L2 intersects each measured profile at points A2 and A3 on the left and right. Finally, A1 and A2 on each measured profile are aligned. The alignment principle is that the distance between the A1 points of the two profiles plus the distance between the A2 points of the two profiles is the shortest, that is, A1 and A2 on the two measured profiles are considered aligned.

[0039] B. Average representative silhouette design

[0040] like Figure 4 As shown in , after the measured profiles are aligned, the aligned measured profiles are evenly divided into 10 regions along the x-axis, as shown in Figure 4 As shown in the figure, if the rail head width is 75 mm, the measured rail profile is discretized at intervals of 0.5 mm along the horizontal x-axis, with a total of 150 discrete points. The discrete points are defined as 1, 2, 3, ... 150 points according to the horizontal coordinate from small to large. Since the rail is divided into 10 areas, each area has 15 discrete points for each profile. The discrete points of each area are designed separately. Each area consists of n measured profiles, and n measured profiles have a total of 15*n discrete points.

[0041] Then, the average representative silhouette of each area is designed. The design method is the same. The following takes area 1 as an example to illustrate the design of the average representative silhouette of each area. The method is:

[0042] The n measured profiles in area 1 are defined as B1, B2…B n The discrete points of the measured profile B1 are defined as B according to the x-axis coordinates from small to large. 11 (x 11 、y 11 ), B 12 (x 12 、y 12 ), B 13 (x 13 、y 13 )…B 115 (x 115 、y 115 ), the discrete points of B2 outline are defined as B according to the x-axis from small to large 21 (x 21 、y 21 ), B 22 (x 22 、y 22 ), B 23 (x23 、y 23 )…B 215 (x 215 、y 215 ), and so on, B n The discrete points of the outline are defined as B according to the x-axis from small to large n1 (x n1 、y n1 ), B n2 (x n2 、y n2 ), B n3 (x n3 、y n3 )…B n15 (x n115 、y n115 ).

[0043] Let the discrete points with x-axis coordinates from small to large in the n measured profiles in region 1 be discrete points 1 to 15, and design representative profile points for each discrete point, as follows:

[0044] The calculation formula for the horizontal and vertical coordinates (x1, y1) of the representative contour point of the No. 1 discrete point of the n measured contours in area 1 is:

[0045]

[0046] The calculation formula for the horizontal and vertical coordinates (x2, y2) of the representative contour point of the No. 2 discrete point of the n measured contours in area 1 is:

[0047]

[0048] …

[0049] By analogy, the calculation formula for the horizontal and vertical coordinates (x15, y15) of the 15th discrete point representing the n measured profiles in area 1 is:

[0050]

[0051] Then, the representative contour points of the other 9 intervals were designed according to the above method, and a total of 150 representative contour points were designed.

[0052] Finally, the least squares method is used to fit the 150 representative silhouette points, and the average representative silhouette of the design is obtained by fitting, as shown in Figure 5 shown.

[0053] Step 4: Design of grinding scheme with varying grinding stone angle and power

[0054] By aligning the designed average representative profile with the standard profile (usually the new 60N profile, which is selected according to the line conditions), the alignment method is the same as the measured profile alignment method in the above step A. According to the new 60N profile rail head angle distribution specified in the "High-speed Railway Rail Grinding Management Measures", as shown in Figure 6 The normal distance between each angle point on the new 60N profile rail head and the average representative profile is defined as the required grinding amount, as shown in Figure 7 The grinding pattern is designed based on the grinding amount between each angle and the average representative profile on the new 60N profile rail head. The grinding pattern includes the angle to be ground and the power required for each angle. The grinding amount for each angle is controlled by the grinding power. The greater the power, the greater the grinding amount, as shown in Table 2.

[0055] Table 2 Average representative profile grinding angles and corresponding grinding powers

[0056] Represents the profile polishing angle Grinding angle corresponding to power -8.0 Power 60% -7.0 Power 60% -5.0 Power 60% -3.0 Power 60% -10 Power 60% -6.0 Power 60% -5.0 Power 60% -4.0 Power 60% -30 Power 60% -10 Power 60% 45.0 Power 70% 40.0 Power 70% 36.0 Power 70% 32.0 Power 70% 30.0 Power 70% 28.0 Power 70% 25.0 Power 70% 23.0 Power 70% 20.0 Power 70% 17.0 Power 70% 14.0 Power 70% 10.0 Power 70% 5.0 Power 70% 2.0 Power 70%

[0057] Since each measured profile differs from the average representative profile, all measured profiles in the interval are aligned with the new 60N profile in the same manner as the measured profile alignment in step A. The grinding amount at each rail head angle for the new 60N profile and each measured profile is calculated sequentially. Based on the grinding angle calculated from the average representative profile, the positive and negative angle grinding power of the grinding mode is adjusted without changing the grinding stone angle deflection, achieving a fixed-angle grinding mode for the entire interval while achieving different grinding amounts for rails at different locations. As shown in Tables 3 and 4, by adjusting the angle power of the grinding mode, all measured profiles can be made into the same profile, so that there is no difference in the profile of the entire interval after grinding.

[0058] Table 3 Interval grinding mode

[0059]

[0060] Table 4 Interval grinding plan

[0061] Serial number Lineage starting point Final Occupation length left stock Right stock Number of times 1 superior 299 300.5 1.50 1 2 1 2 superior 300.5 301.5 1.00 3 2 1 3 superior 301.5 302.5 1.00 2 5 1 4 superior 302.5 303.5 1.00 4 5 1 5 superior 303.5 304.5 1.00 1 2 1 6 superior 304.5 305.5 1.00 1 4 1 7 superior 305.5 306.5 1.00 2 1 1 8 superior 306.5 307.5 1.00 3 2 1 9 superior 307.5 308.5 1.00 2 1 1 10 superior 308.5 309.5 1.00 2 3 1 11 superior 309.5 310.5 1.00 1 5 1 12 superior 310.5 311.5 1.00 1 3 1 13 superior 311.5 312.5 1.00 3 2 1 14 superior 312.5 313.5 1.00 1 5 1

[0062] Step 5: Polishing profile and real-time online acceptance

[0063] After grinding, the rail profile of the entire section is immediately measured every 0.5km. After grinding, the measured profile is aligned with the new 60N profile according to the above method. The qualification requirement for each profile is that the average deviation of each angle of the rail profile and the grinding profile is less than 0.2mm. If 80% of the profiles of the section line pass the acceptance, the entire section is qualified. If less than 80% of the profiles of the section line pass the acceptance, the rails need to be further ground again according to the above process.

[0064] Step 6: Grind and connect adjacent sections

[0065] When the current section is qualified after grinding, the rail grinding vehicle will easily leave very obvious grinding marks and over-grinding at the cutting point at the initial position of the section grinding. At this time, the difference in profile at the intersection of the two adjacent sections will be more obvious. In order to avoid this problem, a small manual grinder is needed to grind the intersection of the sections after grinding to ensure that the rail profiles at the intersection of the sections are consistent.

Claims

1. A method for optimizing rail profile grinding by converting the power of a grinding stone into an angle, characterized by: The specific steps are designed as follows: Step 1: Collect rail profile data for the entire line; Step 2: Create a daily polishing interval plan; Step 3: Design the average representative profile of the daily construction interval. The specific method is as follows: A. Discretize the measured profiles of the daily grinding intervals at equal intervals along the horizontal direction of the rail, converting the measured profiles into a large number of discrete points. Then, determine the point with the largest y-axis value for each measured profile, defining it as point A1. Align the A1 points of each measured profile. Then, draw a line L1 parallel to the X-axis through point A1. Further down, draw a line L2 parallel to L1 16 mm. L2 intersects each measured profile at points A2 and A3 on the left and right. Finally, align A1 and A2 on each measured profile. The alignment principle is that the distance between the A1 points of the two profiles plus the distance between the A2 points of the two profiles is the shortest. B. Divide the aligned measured profile into 10 regions along the rail transverse direction, each region consists of n measured profiles, and each region has k discrete points; C. The average representative profile of the design interval is designed in the same way, specifically: The calculation formula for the horizontal and vertical coordinates (xi, yi) of the representative profile point of the i-th discrete point of the n measured profiles in each interval is: Where x ni ,y ni are the horizontal and vertical coordinates of the ith discrete point of the nth measured profile respectively; Thus, the coordinates of the representative profile points of each discrete point of each measured profile in all intervals are obtained, a total of 10 times k; D. Fit 10 times k representative profile points to obtain the designed average representative profile; Step 4: Align the average representative profile with the standard profile. Based on the angle distribution of the rail head, define the normal distance between each angle point on the standard profile rail head and the average representative profile as the required grinding amount, and then obtain the grinding pattern. The grinding pattern includes the angles to be ground and the power required for each angle. Furthermore, all measured profiles in the section are aligned with the standard profile, and the grinding amount of each rail head angle of the standard profile and each measured profile is calculated in turn. According to the grinding angle calculated from the average representative profile, the angular power of the grinding mode is changed without changing the grinding stone angle deflection, and then the grinding mode and grinding plan of the entire section are obtained.

2. The method for optimizing rail profile grinding by converting grinding stone angle power as claimed in claim 1, characterized in that: In step 2, save the daily polishing interval profiles in the same folder.

3. The method for optimizing rail profile grinding by converting grinding stone angle power as claimed in claim 1, characterized in that: In step 4, the alignment of the average representative silhouette with the standard silhouette and the alignment of the measured silhouette with the standard silhouette are both performed in the manner of step A.

4. The method for optimizing rail profile grinding by converting power into grinding stone angle according to claim 1, characterized in that: After grinding, the rail profile is measured every 0.5 km in the section, and the profile after grinding is measured and aligned with the standard. The qualified requirement for each profile is that the average deviation of each angle of the rail profile and the grinding profile is less than 0.2 mm. If 80% of the profiles of the section line pass the acceptance inspection, the entire section is qualified for grinding. If less than 80% of the profiles of the section line pass the acceptance inspection, steps 3 and 4 need to be repeated to further grind the rails.

5. The method for optimizing rail profile grinding by converting power into grinding stone angle according to claim 4, characterized in that: After polishing, the measured profile is aligned with the standard profile using the method in step A.

6. The method for optimizing rail profile grinding by converting power into grinding stone angle according to claim 1, characterized in that: After the intervals are polished, use a manual polishing machine to polish the intersections of the intervals.

Images