A method for full-automatic bending of a turnout curved rail piece

Abstract

A method for fully automated bending of turnout curved rail components includes the following steps: Step 1: Positioning the rail component. An identification device is set up in the bending area. When the rail component moves to the bending area, it stops and is fixed by a fixing device. Step 2: Bending operation. A deflection measuring device is installed on the rail component to be bent, and the bending operation begins. The deflection of the rail component is measured in real time. After the rail component reaches a certain deflection, the bending equipment stops operating, and the rail component is unloaded. The bending equipment is a three-point bending system, and the anvil is a split structure. Step 3: Fine adjustment of the rail component. The deflection measuring device is unloaded, and a 3D scanner is set up in the bending area to scan the bent portion, modeling the curvature and levelness of the rail component. Based on the results, the levelness and curvature of the rail component are automatically fine-tuned. The method provided by this invention realizes fully automated processing of turnout rail components, saving manpower.

Description

Technical Field

[0001] This invention relates to the field of railway turnout manufacturing technology, and in particular to a fully automated bending process for curved turnout rail components. Background Technology

[0002] The main body of a turnout consists of rail components, connectors, track foundation, and electrical structure. The turnout rail components are manufactured through processes such as bending, milling, welding, forging, and heat treatment. Domestic turnout manufacturers have optimized the milling process and machining flow multiple times, effectively improving machining accuracy and production efficiency. However, due to the manual nature of the bending process, there have been no significant optimization measures in recent years.

[0003] Bending operations generally employ a three-point bending method, and in China, manual operation using hydraulic straightening machines is commonly used. The bent rail components in high-speed turnouts are called curved rail components, including the main curved rail, switch rail, long center rail, short center rail, turnout heel switch rail, and wing rail. The bending points may be one or more; curves with greater deflection require multiple-point bending to achieve a smooth finish.

[0004] Currently, all turnout factories nationwide are equipped with manually operated bending machines. The bending process relies entirely on the worker's skill, and there is no data reference available; it depends entirely on the worker's experience. After bending, a flat ruler or template is used to measure the bent area, mainly measuring the side of the rail head.

[0005] Manual bending operations are limited by low worker skill levels and low production efficiency. Furthermore, when repeated bending is performed under certain conditions, the mechanical properties of the rail components at the bending point not only change but may also develop micro-cracks inside or on the outer surface, affecting the turnout's service performance. Simultaneously, because the currently used anvil only contacts the rail web, uneven deformation occurs during bending, resulting in horizontal warping of the bent rail. This necessitates post-bending horizontal leveling, which not only restricts production efficiency but also negatively impacts the turnout's service performance.

[0006] Therefore, a method is needed to achieve fully automated bending of turnout curved rail components and ensure stable mechanical properties of the products. Summary of the Invention

[0007] To overcome existing defects, this invention proposes a fully automated bending process for turnout curved rail components.

[0008] A method for fully automated bending of turnout curved rail components, the method comprising:

[0009] Step 1, Positioning the rail components

[0010] An identification device is set up in the bending operation area. When the rail to be processed moves into the bending operation area, the rail stops and is fixed by the fixing device.

[0011] Step 2, bending operation

[0012] A deflection measuring device is installed on the rail component to be bent, and the bending operation begins. The deflection of the rail component is measured in real time. Once the rail component reaches a certain deflection, the bending equipment stops operating, and the rail component is unloaded. The bending equipment is a three-point bending system, with a split-type anvil structure that allows for independent setting of parameters and application of loads to the rail head, rail web, and rail base. The support parts can conform to the profile of the rail to be processed.

[0013] Step 3, fine-tuning of track components

[0014] The deflection measuring device is unloaded, and a 3D scanner is set up in the bending operation area to scan the bent part, model the curvature and levelness of the rail component, and automatically fine-tune the levelness and curvature of the rail component according to the results to meet the dimensional requirements.

[0015] In step one, the identification device can be an NFC chip, a magnetic nameplate, or a label with a specific shape that can be identified.

[0016] In step two, the bending equipment includes a top anvil assembly and two supports. The top anvil assembly includes a rail head top anvil, a rail web top anvil, and a rail bottom top anvil. Parameters can be set independently for the rail head, rail web, and rail bottom, and loads can be applied. The support parts can conform to the rail profile to be processed. The top anvil assembly and supports can slide on the slide rail to adjust the load position and support distance.

[0017] The deflection measuring device includes an automatic rail head bonding device, a horizontal position holding mechanism, a crossbar, and a measuring sensor. The automatic bonding device is located on both sides of the rail to be processed, the crossbar connects the two automatic bonding devices, the measuring sensor is located on the crossbar, and the crossbar is connected to the bending equipment through the horizontal position holding mechanism.

[0018] The method is designed for preset values ​​of real-time deflection for different rail components. When the crossbar is 750mm, bending stops when the sensor reaches the preset value in real time during the bending operation. The preset value range of real-time deflection when bending stops is: wing rail: 20~40mm / 750mm.

[0019] switch rail: 4~10mm / 750mm;

[0020] Fork rail: 10~20mm / 750mm;

[0021] Short mandrel: 15~35mm / 750mm;

[0022] Basic curve track: 4~10mm / 750mm.

[0023] The method specifies preset values ​​for the real-time deflection of different rail components. The real-time deflection range at which bending stops when the crossbar length is A is:

[0024] Wing rail: 20(A / 750)~40(A / 750) mm / Amm;

[0025] switch rail 4(A / 750)~10(A / 750)mm / Amm;

[0026] Fork support rail: 10(A / 750)~20(A / 750)mm / Amm;

[0027] Short mandrel: 15(A / 750)~35(A / 750)mm / Amm;

[0028] Basic curve track: 4(A / 750)~10(A / 750)mm / Amm.

[0029] This invention provides a fully automated method for bending turnout rail components, achieving fully automated processing and saving manpower. The method quickly bends the rail components to be processed into position, significantly reducing the number of bending operations compared to existing processes, ensuring the service performance of the bent parts, and improving operational efficiency. The bending equipment's anvil is divided into three parts, applying different loads to the rail head, rail web, and rail base respectively, while the support part adheres to the rail. This effectively solves the problem of horizontal warping that occurs when bending rails in existing processes. Attached Figure Description

[0030] Figure 1 A schematic diagram of the process for fully automated bending of turnout curved rail components.

[0031] Figure 2 This is a schematic diagram of the deflection measuring device in operation.

[0032] Figure 3 This is a schematic diagram of the anvil assembly and support in a bending machine.

[0033] Figure 4 This is a schematic diagram of the operation of the measuring sensor and automatic bonding device in the crossbar section. Detailed Implementation

[0034] The following describes in detail, with reference to the accompanying drawings and specific embodiments, a fully automated bending process for turnout curved rail components provided by the present invention.

[0035] Figure 1-4 As shown, a method for fully automated bending of turnout curved rail components is disclosed, the method comprising:

[0036] Step 1, Positioning the rail components

[0037] An identification device is set in the bending operation area of ​​rail component 1. When the rail component to be processed moves to the bending operation area, the rail component stops and is fixed by the fixing device.

[0038] Step 2, bending operation

[0039] A deflection measuring device 2 is installed on the rail component to be bent, and the bending operation begins. The deflection of the rail component is measured in real time. Once the rail component reaches a certain deflection, the bending equipment stops operating, and the rail component is unloaded. The bending equipment is a three-point bending system, and the anvil is a split structure, which allows for independent setting of parameters and application of loads to the rail head, rail web, and rail base. The support part can conform to the profile of the rail to be processed.

[0040] Step 3, fine-tuning of track components

[0041] The deflection measuring device is unloaded, and a 3D scanner is set up in the bending operation area to scan the bent part, model the curvature and levelness of the rail component, and automatically fine-tune the levelness and curvature of the rail component according to the results to meet the dimensional requirements.

[0042] In step one, the identification device can be an NFC chip, a magnetic nameplate, or a label with a specific shape that can be identified.

[0043] In step two, the bending equipment 3 includes a top anvil group 30 and two supports 4. The top anvil group includes a rail head top anvil 31, a rail web top anvil 32 and a rail bottom top anvil 33. The parameters can be set independently for the rail head, rail web and rail bottom and loads can be applied. The support parts can fit the rail profile to be processed. The top anvil group and supports can slide on the slide rail to adjust the load position and support distance.

[0044] The deflection measuring device includes an automatic rail head bonding device 21, a horizontal position holding mechanism 22, a crossbar 23, and a measuring sensor 24. The automatic bonding device is located on both sides of the rail to be processed, the crossbar connects the automatic bonding devices on both sides, the measuring sensor is located on the crossbar, and the crossbar is connected to the bending equipment 3 through the horizontal position holding mechanism 25.

[0045] Among them, the automatic rail head bonding device 21 can be firmly attached to one side of the rail head and can maintain attachment during the bending process, so that the measuring ruler crossbar 23 is always perpendicular to the direction of the applied force during the bending process; the automatic bonding device 21 can be adapted to the processing of various types of curved rails, including point rails, short center rails, wing rails, curved base rails, fork and point rails.

[0046] The horizontal position holding mechanism 22 connects the bending device to the crossbar section of the deflection measuring device. Its function is to keep the crossbar horizontal during operation and prevent it from slipping in the horizontal direction.

[0047] The crossbar section can accommodate measuring sensors and an automatic bonding device. It is rigid enough to prevent deformation during measurement.

[0048] The measurement sensor is a laser rangefinder. Optional sensors include a 3D scanner and a contact sensor.

[0049] The method is designed for preset values ​​of real-time deflection for different rail components. When the crossbar is 750mm, bending stops when the sensor reaches the preset value in real time during the bending operation. The preset value range of real-time deflection when bending stops is: wing rail: 20~40mm / 750mm.

[0050] switch rail: 4~10mm / 750mm;

[0051] Fork rail: 10~20mm / 750mm;

[0052] Short mandrel: 15~35mm / 750mm;

[0053] Basic curve track: 4~10mm / 750mm.

[0054] The method specifies preset values ​​for the real-time deflection of different rail components. The real-time deflection range at which bending stops when the crossbar length is A is:

[0055] Wing rail: 20(A / 750)~40(A / 750) mm / Amm;

[0056] switch rail 4(A / 750)~10(A / 750)mm / Amm;

[0057] Fork support rail: 10(A / 750)~20(A / 750)mm / Amm;

[0058] Short mandrel: 15(A / 750)~35(A / 750)mm / Amm;

[0059] Basic curve track: 4(A / 750)~10(A / 750)mm / Amm.

[0060] In practical work, as shown in Tables 1 and 2, the number of processing operations was significantly reduced after using the deflection measuring device, which improved work efficiency and ensured the mechanical properties of the rail components.

[0061]

[0062] Table 1. Performance of Short Piston Rails (Target Deflection 47mm, Allowable Error 1mm)

[0063] Table 2. Performance of the deflection measuring device on the wing rail (target deflection 58mm, allowable error 1mm)

[0064] Finally, it should be noted that the above embodiments are only used to describe the technical solutions of the present invention and not to limit the technical methods. The present invention can be extended to other modifications, variations, applications and embodiments, and therefore all such modifications, variations, applications and embodiments are considered to be within the scope of the present invention.

Claims

1. A method for fully automated bending of turnout curved rail components, characterized in that, The method includes Step 1, Positioning the rail components An identification device is set up in the bending operation area. When the rail to be processed moves into the bending operation area, the rail stops and is fixed by the fixing device. Step 2, bending operation A deflection measuring device is installed on the rail component to be bent, and the bending operation begins. The deflection of the rail component is measured in real time. Once the rail component reaches a certain deflection, the bending equipment stops operating, and the rail component is unloaded. The bending equipment is a three-point bending system, with a split-type anvil structure that allows for independent setting of parameters and application of loads to the rail head, rail web, and rail base. The support parts can conform to the profile of the rail to be processed. Step 3, fine-tuning of track components The deflection measuring device is unloaded, and a 3D scanner is set up in the bending operation area to scan the bent part, model the curvature and levelness of the rail component, and automatically fine-tune the levelness and curvature of the rail component according to the results to meet the dimensional requirements.

2. The method for fully automated bending of turnout curved rail components according to claim 1, characterized in that, In step one, the identification device can be an NFC chip, a magnetic nameplate, or a label with a specific shape that can be identified.

3. The method for fully automated bending of turnout curved rail components according to claim 1, characterized in that, In step two, the bending equipment includes a top anvil assembly and two supports. The top anvil assembly includes a rail head top anvil, a rail web top anvil, and a rail bottom top anvil. Parameters can be set independently for the rail head, rail web, and rail bottom, and loads can be applied. The support parts can conform to the rail profile to be processed. The top anvil assembly and supports can slide on the slide rail to adjust the load position and support distance.

4. The method for fully automated bending of turnout curved rail components according to claim 1, characterized in that, The deflection measuring device includes an automatic rail head bonding device, a horizontal position holding mechanism, a crossbar, and a measuring sensor. The automatic bonding device is located on both sides of the rail to be processed, the crossbar connects the two automatic bonding devices, the measuring sensor is located on the crossbar, and the crossbar is connected to the bending equipment through the horizontal position holding mechanism.

5. The method for fully automated bending of turnout curved rail components according to claim 1 or 4, characterized in that, The method is designed for preset values ​​of real-time deflection for different rail components. When the crossbar is 750mm, bending stops when the sensor reaches the preset value in real time during the bending operation. The preset value range of real-time deflection when bending stops is: wing rail: 20~40mm / 750mm. switch rail: 4~10mm / 750mm; Fork rail: 10~20mm / 750mm; Short mandrel: 15~35mm / 750mm; Basic curve track: 4~10mm / 750mm.

6. The method for fully automated bending of turnout curved rail components according to claim 1 or 4, characterized in that, The method specifies preset values ​​for the real-time deflection of different rail components. The real-time deflection range at which bending stops when the crossbar length is A is: Wing rail: 20(A / 750)~40(A / 750) mm / Amm; switch rail 4(A / 750)~10(A / 750)mm / Amm; Fork support rail: 10(A / 750)~20(A / 750)mm / Amm; Short mandrel: 15(A / 750)~35(A / 750)mm / Amm; Basic curve track: 4(A / 750)~10(A / 750)mm / Amm.

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