Rail saw, rail sawing method and computer readable storage medium

Abstract

The present application relates to the technical field of rail cutting, and discloses a rail sawing machine, wherein a cutting member is movably installed on a cutting support under the driving of a cutting power mechanism; the cutting support is movably installed on a rail fixing support along a feeding track under the driving of a feeding power mechanism, and the feeding track is located in the cross section of the rail; a processor is signal-connected with the control end of the feeding power mechanism and is configured to control at least one of the feeding direction and the feeding speed of the feeding power mechanism. The present application has the beneficial effect that by controlling at least one of the feeding direction and the feeding speed of the feeding power mechanism, the feeding can be considered in the following two aspects: first, to ensure the normal and stable operation of the rail sawing machine and avoid the change of crystal phase organization (such as bluing) caused by the excessively high temperature of the rail cross section, thereby affecting the mechanical properties; second, to cut the rail as fast as possible within the strength range of the rail sawing machine and within the allowable temperature range of the rail, thereby ensuring the cutting efficiency.

Description

Technical Field

[0001] This invention relates to the field of railway construction machinery technology, and in particular to a rail sawing machine, a rail sawing method, and a computer-readable storage medium. Background Technology

[0002] During railway construction, there is often a need to cut rails. This is typically done using a rail saw. It usually consists of a power unit (or gasoline engine) driving a cutting element (such as a circular saw blade or band saw). The power unit drives the cutting element to rotate or reciprocate, while simultaneously feeding the cutting element relative to the rail, thus cutting the rail. For example, in the invention patent with authorization announcement number CN217749621U, the power unit is an electric motor, and the feed motion is achieved by the user operating the saw blade to rotate around the support shaft of the rail clamping device.

[0003] Clearly, the feed direction and feed speed depend entirely on the user's operation. Since users' skill levels and physical fitness vary, it is easy to cause insufficient feed (feed speed too slow) or excessive feed (feed speed too fast). Insufficient feed will cause a serious drop in work efficiency, while excessive feed may damage the cutting workpiece, the power unit, and the transmission unit between them. At the same time, excessive feed will also cause the rail to heat up severely, resulting in changes in the rail's crystalline structure or even oxidation (the cut surface of the rail turns blue).

[0004] During the cutting process, some rail saws, in order to avoid excessive feed, will impose the following requirements on the user's actual operation based on extensive testing: when cutting to a specific position, or when the temperature of the exposed surface of the rail is found to be too high (which can be measured by a temperature sensor or observed by visual inspection to see if the surface is bluish), the blade should be retracted (the cutting part moves away from the cutting position by a small amount), and then reset after a certain period of time (the cutting part cuts the cutting position again). Since there is no relative cutting between the cutting part and the rail after the blade is retracted (in fact, due to the retraction action, there is a very small amount of cutting), it is hoped that the temperature of the cutting part will drop quickly after it leaves the cutting position. However, the retraction range, the retraction speed, and whether the cutting part is still working during the retraction (e.g., if the cutting part is a circular saw blade, whether the cutting part is still driven by a motor or gasoline engine) are all manually controlled by the user, which is uncontrollable and will cause uncertain risks. For example, if the retraction range is too large, the retraction and reset will take too long, reducing the work efficiency.

[0005] Therefore, there is an urgent need to develop rail sawing machines, rail sawing methods, and computer-readable storage media to solve the aforementioned technical problems. Summary of the Invention

[0006] To address the aforementioned problems caused by the uncontrollable feed direction and speed during rail cutting, the first aspect of this invention provides a rail sawing machine, comprising a cutting device, an automatic feed device, and a processor, wherein:

[0007] The cutting device includes:

[0008] Cutting bracket;

[0009] Cutting power mechanism;

[0010] The cutting component is movably mounted on the cutting bracket under the drive of the cutting power mechanism;

[0011] The automatic feeding device includes:

[0012] The rail fixing bracket has a clamping end that can be clamped onto the rail;

[0013] Feed power mechanism;

[0014] The cutting bracket is movably mounted on the rail fixing bracket along the feed trajectory under the drive of the feed power mechanism, and the feed trajectory is located within the cross-section of the rail;

[0015] The processor is connected to the control terminal of the feed power mechanism and configured to control at least one of the feed direction and feed speed of the feed power mechanism.

[0016] A second aspect of the present invention discloses a rail sawing method using any of the above-mentioned rail sawing machines, comprising the step of: controlling at least one of the feed direction and feed speed of the feed power mechanism.

[0017] A third aspect of the present invention discloses a computer-readable storage medium storing instructions that, when executed by the processor, perform any of the above-described sawing methods.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] By controlling at least one of the feed direction and feed speed of the feed power mechanism, the feed can be balanced in two ways: First, it ensures the normal and stable operation of the rail saw and avoids excessive temperature rise of the rail section, which could cause changes in the crystal structure (such as bluing) and affect its mechanical properties; Second, it ensures that the rail saw can cut the rail as quickly as possible within its strength range and within the allowable temperature range of the rail, thus ensuring cutting efficiency.

[0020] This avoids the problems caused by manual feed control by the user: insufficient feed leading to low cutting efficiency and prolonged cutting time; excessive feed causing damage to the saw (especially the cutting parts are easily damaged); excessive deformation causing the flatness and perpendicularity of the cut surface to fail to meet requirements; and excessive force between relatively movable connected parts leading to reduced assembly accuracy. Attached Figure Description

[0021] To make the advantages of the invention more readily apparent, the invention briefly described above will be described in more detail with reference to the specific embodiments shown in the accompanying drawings. It will be understood that these drawings depict only typical embodiments of the invention and should not be construed as limiting its scope of protection. The invention is described and explained with reference to the drawings to provide additional features and details.

[0022] Figure 1 A first-view perspective three-dimensional structural schematic diagram of an embodiment of a rail, wherein the rail is partially cut to show the cut surface and cut location;

[0023] Figure 2 for Figure 1 A magnified view of a portion of region Z in the middle;

[0024] Figure 3 for Figure 1 End view;

[0025] Figure 4 Schematic diagram illustrating the principle of excessive cutting caused by oscillating feed;

[0026] Figure 5 A schematic diagram illustrating the principle of multiple cutting positions in an oscillating feed mode;

[0027] Figure 6 This is a schematic diagram of the working principle of a single cut in an embodiment of the rail sawing machine of the present invention. In the figure, the dotted lines from left to right are, in order, the edge that the cutting part can reach along the feed trajectory, the longitudinal axis of symmetry of the rail (the center line of symmetry of the rail), the extension line of the rail head near the mounting component along the height of the rail web, and the extension line of the mounting component near the rail web along the height of the rail web. The upper position to be cut and the lower position to be cut are also shown.

[0028] Figure 7This diagram illustrates the working principle of the rail sawing machine of the present invention, which involves two cuts. The dashed lines in the diagram, from left to right, represent: the extension of the mounting assembly along the rail web height direction when cutting the rail from the left; the extension of the left side of the rail head along the rail web height direction; the longitudinal axis of symmetry of the rail (the center line of symmetry of the rail); the extension of the rail web near the mounting assembly along the rail web height direction; the extension of the right side of the rail head along the rail web height direction; and the extension of the mounting assembly near the rail web on the right side along the rail web height direction. It also shows the starting point (upper right cutting position) and ending point (lower right cutting position) of the feed trajectory when the cutting piece is on the right, and a position between the starting point and ending point of the feed trajectory when the cutting piece is on the left.

[0029] Figure 8 For application Figure 6 A three-dimensional structural schematic diagram of the rail saw machine in the cutting state from one perspective according to the embodiment;

[0030] Figure 9 for Figure 8 A magnified view of a portion of region Z in the middle;

[0031] Figure 10 for Figure 8 A schematic diagram of the three-dimensional structure from another perspective;

[0032] Figure 11 For application Figure 7 A three-dimensional structural schematic diagram of the rail saw in the cutting state of the embodiment from one perspective;

[0033] Figure 12 This is a schematic diagram illustrating the working principle when the feed trajectory coincides with the height direction of the rail web.

[0034] Figure 13 Schematic diagram of the working principle when the feed trajectory is perpendicular to the height direction of the rail web;

[0035] Figure 14 The working principle diagram is as follows: the feed trajectory forms an acute angle with the height direction of the rail web, where the position to be cut is located diagonally below the cutting position;

[0036] Figure 15 The diagram illustrates the working principle when the feed trajectory forms an acute angle with the height direction of the rail web. It shows the position to be cut and the cutting position, with the position to be cut located diagonally above the cutting position, and a larger cutting saw blade is used to cut the rail in one go.

[0037] Figure 16 for Figure 15 The embodiment illustrates the feed adjustment area, i.e., the feed trajectory between the axes of the two cutting pieces;

[0038] Figure 17 for Figure 15 A three-dimensional structural schematic diagram of the rail saw machine from a first-view perspective in the embodiment;

[0039] Figure 18 for Figure 17 A schematic diagram of the three-dimensional structure from a second-person perspective;

[0040] Figure 19 for Figure 17 End view;

[0041] Figure 20 This diagram illustrates the working principle when the feed trajectory forms an acute angle with the height direction of the rail web. A smaller cutting saw blade is used to cut the rail in two stages. The first and second side cutting stations are part of the rail fixing bracket.

[0042] Figure 21 A schematic diagram illustrating the working principle of an embodiment where the feed trajectory is arc-shaped and the swing axis is located directly above the rail.

[0043] Figure 22 for Figure 21 A three-dimensional structural schematic diagram of the rail saw machine from a first-view perspective in the embodiment;

[0044] Figure 23 for Figure 22 A two-dimensional structural diagram from a second perspective. In order to show the transmission parts of the cutting power mechanism and the feed power mechanism, the cover outside the transmission parts has been removed.

[0045] Figure 24 A schematic diagram illustrating the working principle of a feed trajectory that is arc-shaped and a swing axis that is offset laterally (towards the first direction) from the rail by a clearance distance;

[0046] Figure 25 A schematic diagram illustrating the working principle of a feed trajectory that is arc-shaped and a swing axis that is offset laterally (towards the second direction) from the rail by a clearance distance;

[0047] Figure 26 This is a control block diagram of one embodiment of a rail saw.

[0048] The attached figures are labeled as follows:

[0049] 100. Rail; 110. Rail head; 111. Rail top surface; 120. Rail bottom; 130. Rail web; 140. Cut surface; 150. Side space; 160. Cutting position;

[0050] 210. Cutting bracket; 220. Cutting power mechanism; 221. Motor; 222. Belt drive; 230. Cutting component; 231. Cutting teeth; 240. Mounting assembly;

[0051] 310. Track fixing bracket; 311. Fixing bayonet; 312. Rotating shaft; 313. Movable bayonet; 314. Fixing pin; 315. First side cutting station; 316. Second side cutting station; 320. Feed power mechanism; 321. Servo motor; 322. Lead screw; 323. Reduction gear set; 330. Swing shaft;

[0052] 400. Processor;

[0053] 510. Rotational speed sensor; 520. Torque sensor; 530. First temperature sensor; 540. Second temperature sensor; 550. Broken tooth sensor; 560. Cut-off detection unit; 561. Current sampling circuit; 562. Timer; 563. Position sensor;

[0054] 600, Battery; 700, Protective cover; 800, Control terminal; 900, Feed trajectory. Implementation

[0055] In the following description, numerous specific details are set forth in order to provide a more thorough understanding of the invention. However, it will be apparent to those skilled in the art that embodiments of the invention may be practiced without one or more of these details. In other instances, certain technical features well-known in the art have not been described in order to avoid confusion with embodiments of the invention.

[0056] To fully understand the embodiments of the present invention, detailed structures will be presented in the following description. Obviously, the implementation of the embodiments of the present invention is not limited to the specific details familiar to those skilled in the art. Preferred embodiments of the present invention are described in detail below; however, in addition to these detailed descriptions, the present invention may have other embodiments.

[0057] In the description of this invention, the term "A and / or B" refers to all possible combinations of A and B, such as only A, only B, or A and B. The terms "at least one A or B" or "at least one of A and B" have a similar meaning to "A and / or B" and can include only A, only B, or A and B. The singular terms "a" or "this" can also include plural forms. The terms "inner side," "outer side," "longitudinal," "lateral," "upper," "lower," "top," "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the invention and do not require the invention to be constructed and operated in a specific orientation, and therefore should not be construed as limiting the invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In addition, in the description of this invention, unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0058] The embodiments of the present invention will be described in further detail below with reference to the accompanying drawings:

[0059] like Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, the rail 100 includes a rail head 110, a rail web 130, and a rail base 120 arranged sequentially from top to bottom. The rail head 110 and rail base 120 extend laterally beyond the rail web 130, thus forming a lateral space 150 between the rail head 110, rail web 130, and rail base 120. The extension distance of the rail base 120 is greater than the extension distance of the rail head 110. Furthermore, the overall height of the rail 100 (from the rail base 120) is greater than its overall width. To clearly illustrate the orientation of this application, a... Figure 1 The spatial coordinate system shown has the X-axis representing the length (extension direction) of rail 100, the Y-axis representing the transverse direction of rail 100, and the Z-axis representing the height direction of rail 100 (the height direction of rail web 130). The YZ plane represents the cross-section of rail 100. Rail 100 is partially cut, with the cut surface 140 and cut position 160 shown. The top surface 111 of the rail, also known as the rail tread, contacts the train wheels.

[0060] This invention is applied to rail cutting, specifically, cutting the rail 100 at a certain position along its length, with the cut surface 140 theoretically perpendicular to the length direction (i.e., the extension direction) of the rail. Figure 1 As shown. Figure 3 The image shown is a view of the end face of the rail (a plane perpendicular to the length of the rail, i.e., the theoretically cut surface 140 mentioned above).

[0061] The first aspect of this invention discloses a rail sawing machine, such as... Figures 6 to 24 As shown, it includes a cutting device, an automatic feeding device, and a processor 400. The cutting device includes a cutting bracket 210, a cutting power mechanism 220, and a cutting element 230. The cutting element 230 is movably mounted on the cutting bracket 210 under the drive of the cutting power mechanism 220. The cutting power mechanism 220 may include a power source, such as an electric motor 221 or an internal combustion engine (such as a gasoline engine), and may also include various reducers (such as gear reducers, belt drive reducers 222) so that the power source operates to directly (without reducers) or indirectly (with reducers) drive the cutting element 230 to move relative to the cutting bracket 210 to cut the rail 100. The cutting element 230 can be an abrasive wheel (which will wear down as cutting progresses, and its radius will decrease as cutting progresses), a cutting saw blade (whose hardness is much greater than that of the steel rail 100 material; for example, using high-hardness metal oxides, ceramic oxides, or metal-ceramic oxides, there is almost no wear during cutting, and its radius hardly decreases as cutting progresses), or a band saw. Correspondingly, when it is an abrasive wheel or a cutting saw blade, the cutting element 230 can be rotatably mounted on the cutting bracket 210 via a bearing; when it is a band saw, the cutting element 230 can be reciprocated and mounted on the track wheel that drives the track, and the track wheel is driven by the aforementioned power source.

[0062] One specific embodiment of the automatic feeding device includes a rail fixing bracket 310 and a feeding power mechanism 320, wherein the rail fixing bracket 310 has a clamping end capable of clamping onto the rail 100. See also... Figure 8 , Figure 9 and Figure 10 The cutting bracket 210 is movably mounted on the rail fixing bracket 310 along the feed trajectory 900 under the drive of the feed power mechanism 320. The feed trajectory 900 is located within the cross-section of the rail 100. The processor 400 is signal-connected to the control terminal 800 of the feed power mechanism 320 and is configured to control at least one of the feed direction and feed speed of the feed power mechanism 320.

[0063] By controlling at least one of the feed direction and feed speed of the feed power mechanism 320, the feed can be balanced in two ways: First, it ensures the normal and stable operation of the rail saw and avoids excessive temperature rise of the rail 100 section, which could cause changes in the crystal structure (such as bluing) and affect its mechanical properties; Second, it ensures that the rail saw can cut the rail 100 as quickly as possible within its strength range and within the allowable temperature range of the rail 100, thus ensuring cutting efficiency.

[0064] This avoids the following problems caused by manual feed control: insufficient feed leading to low cutting efficiency and prolonged cutting time; excessive feed causing damage to the saw (especially the cutting part 230 is very easy to damage); excessive deformation causing the flatness and perpendicularity of the cutting surface 140 to fail to meet requirements; and excessive force between relatively movable connected parts leading to a reduction in their assembly accuracy.

[0065] It should be noted that the clamping end of the rail fixing bracket 310 is designed to clamp / release the rail 100, allowing for quick clamping and disassembly. A specific structure of this clamping end, as shown in the figure, includes a fixed bayonet 311, a rotating shaft 312, a movable bayonet 313, and a fixing pin 314. The fixing opening includes a first fixing arm and a second fixing arm. The free end of the first fixing arm forms a clamping groove that engages the rail head 110 from the first side. The free end of the second fixing arm forms an open opening to facilitate the passage of the rail head 110. The fixed bayonet 311 is rotatably mounted on the fixed bayonet 311 via the rotating shaft 312. As the movable bayonet 313 rotates, its free end can press against the second side of the rail head 110, thereby fixing it to the rail 100.

[0066] The working state of the feed power mechanism 320 needs to be controlled by the processor 400, so one specific form of the feed power mechanism 320 is a servo motor 321.

[0067] The feed trajectory 900 includes at least a cutting position and a cutting position. The cutting element 230 is rotatably mounted on the cutting bracket 210 via the mounting assembly 240. In the cutting position, the cutting element 230 is in contact with or maintains a safe distance from the rail 100. During the movement from the cutting position to the cutting position, the mounting assembly 240 can pass over the rail head 110 or rail bottom 120 of the rail 100 and enter the side space 150, and the trajectory traveled by the outer edge of the cutting element 230 exceeds the outer contour of the rail 100. In the cutting position, the cutting element 230 is in contact with or maintains a safe distance from the rail 100. The cutting saw blade in the upper part of the figure represents the state when maintaining a safe distance. The movement of the cutting element 230 requires a certain amount of time to reach a stable state. This safe distance is set to ensure that the cutting element 230 can reach the aforementioned stable movement state within the time between moving from the cutting position along the feed trajectory 900 to the contact position. Stable movement of the cutting element 230 facilitates stable and reliable operation of the cutting process.

[0068] During the movement from the position to the cutting position, the mounting assembly 240 can pass over the rail head 110 of the rail 100 and enter the side space 150, and the trajectory of the outer edge of the cutting piece 230 extends beyond the outer contour of the rail 100. This configuration allows the rail 100 to be completely cut off in a single feed along the feed trajectory 900 (this action is referred to as a one-cut cut). See [link to documentation]. Figure 6 , Figure 8 , Figure 9 and Figure 10 This improves work efficiency. The installation component 240 can be inserted into the side space 150, allowing the use of a smaller cutting piece 230 (shown as a smaller diameter cutting saw blade) while still achieving a one-cut cut. This reduces the overall size and weight. Furthermore, given a fixed power of the cutting power mechanism 220, the smaller cutting piece 230 has greater cutting force than the larger cutting piece 230, ensuring the cutting can proceed. In other words, a one-cut cut can be achieved by combining the advantages of a one-cut cut, a smaller cutting piece 230, and a lower-power cutting power mechanism 220.

[0069] It should also be noted that when the cutting component 230 is a disc-shaped part, such as an abrasive wheel (which wears rapidly during cutting, resulting in a rapid decrease in outer diameter) or a cutting saw blade (with a blade head welded to the outer edge made of wear-resistant material, which can be metal ceramic, having greater hardness than the rail 100, resulting in minimal wear during cutting and minimal change in outer diameter), the aforementioned mounting component 240 is a flange gasket. The purpose of cutting the rail 100 is to cut it off, and the smaller the cutting amount, the better, that is, the smaller the cutting width (the distance between two cutting surfaces), the better. As the cutting width decreases, the thickness of the cutting component 230 also decreases. Therefore, in order to ensure the strength of the cutting component 230, a mounting component 240 is fixed on the outside of the cutting component 230. When the cutting component 230 is a disc structure, the mounting component 240 can be a flange gasket. Both the flange gasket and the cutting component 230 are fixed to a rotating shaft 312 driven by the cutting power mechanism 220.

[0070] The processor 400 is further configured to control at least one of the feed direction and feed speed according to a preset program. This preset program consists of control instructions pre-stored in the processor 400. For example, when the cutting support 210 moves to a preset value (at which the cutting piece 230 contacts the rail 100 more, i.e., has a larger cutting amount), it retracts (moves in the opposite direction of the feed trajectory 900, i.e., moves from the cutting position to the position to be cut). The speed of the cutting support 210 can remain constant, only its direction of movement changes. Alternatively, the speed of the cutting support 210 can be increased simultaneously with retraction for rapid retraction, in which case both the feed direction and feed speed are controlled. Alternatively, only the feed speed can be controlled while the feed direction remains constant. For example, when the cutting support 210 moves to the aforementioned preset value, the feed speed can be reduced; when the cutting amount is small, the feed speed can be appropriately increased.

[0071] Based on the above-mentioned preset program control method, the feed direction and feed speed can also be constant. The feed direction is the movement from the position to be cut to the cutting position as shown in the figure during the cutting process without retraction (there will be no movement from the cutting position to the position to be cut). If the speed in the preset program is based on the maximum allowable cutting speed in the actual cutting experiment (exceeding this speed will at least cause one of the following: the temperature of the rail 100 rises too high and causes bluing; the strength of the cutting part 230 is exceeded and the cutting part 230 is damaged), the cutting bracket 210 feeds at a constant speed of this maximum allowable cutting speed.

[0072] Embodiments of the present invention may further include a feed signal detection unit for acquiring feed input parameters, such as... Figure 26As shown, the processor 400 is also configured to control at least one of the movement direction and movement speed of the feed power mechanism 320 based on the feed input parameters. By acquiring the feed input parameters and comparing them with preset values ​​stored in the processor 400, at least one of the feed direction and feed speed is controlled accordingly, thereby achieving real-time detection and dynamic closed-loop control. This ensures a faster possible feed speed when conditions permit (such as the temperature of the rail 100, the load on the cutting power mechanism 220, and the strength of the cut piece 230), thus guaranteeing cutting efficiency.

[0073] See also Figures 1 to 5 The rail 100 has an irregular shape. During cutting, the cutting amount varies at different points on the feed trajectory 900. Based on extensive experiments by the inventors, at least one position with the largest cutting amount (maximum load position) can be determined on the feed trajectory 900. Correspondingly, the load on the cutting piece 230 and the cutting power mechanism 220 is the maximum at this position. The cutting power mechanism 220 also experiences the maximum load at the maximum load position. A feed adjustment zone is formed near the maximum load position (within a certain distance (e.g., 5mm) along the feed trajectory 900, which is part of the distance of the line on which the feed trajectory 900 lies). The maximum load position can be a continuous value or a point value. Specifically, the feed speed gradually decreases when moving from the position to be cut to the feed adjustment zone, and gradually increases when moving from the feed adjustment zone to the cutting position. This setting ensures that the rail 100, the cutting piece 230, and the cutting power mechanism 220 can feed at the highest possible speed under permissible conditions, thereby maximizing cutting efficiency. A safety factor can also be set to improve reliability. Similarly, when the cutting support 210 is in the feed adjustment zone, the cutting support 210 can retract from the cutting position 150 and return to the cutting position 150. The speed adjustment and the retraction adjustment can be performed individually or simultaneously.

[0074] In addition, the input parameters include at least one of the following: the rotational speed of the cutting power mechanism 220, the torque applied to the cutting piece 230, the temperature of the cutting position 150, and the temperature of the cutting piece 230. These parameters can be detected using a rotational speed sensor, a torque sensor, a first temperature sensor, and a second temperature sensor. Correspondingly, the processor 400 stores preset value ranges corresponding to these four parameters. Taking the temperature of the cutting piece 230 as an example, its automatic control logic will be explained. Let the preset temperature range of the cutting piece 230 be T. 高 (where: T) 高 = Bluing temperature - safety factor. For example, if the bluing temperature is 550℃ and the safety factor is 50℃, the maximum temperature that the corresponding steel rail 100 can withstand is 500℃. When the temperature of the cut part 230 reaches T... 高At this time, the processor 400 sends a command to the feed power mechanism 320 to retract the tool and / or reduce the feed speed. Alternatively, at least two of the above parameters can be used as inputs to control the feed, thereby simultaneously satisfying the requirements of the parameters corresponding to the two inputs.

[0075] In addition, the power source of the cutting power mechanism 220 can be an electric motor 221 or an internal combustion engine (such as a gasoline engine), and the feed power mechanism 320 includes a servo motor 321.

[0076] The input parameters also include the current of motor 221. The load on motor 221 is monitored based on its current; the monitoring logic is simple and accurate. It can effectively determine whether motor 221 is overloaded due to excessive cutting volume. Excessive cutting volume will cause a sharp drop in motor 221 speed and a sudden increase in current, ensuring the normal operation of motor 221.

[0077] Cutting teeth 231 are formed on the outer edge of the cutting element 230. These cutting teeth 231 are made of a material with a hardness higher than that of the rail 100 (such as the aforementioned metal oxide, ceramic oxide, or metal-ceramic oxide). The cutting operation is almost wear-free. A gap is formed between the cutting teeth 231. This gap facilitates chip removal and increases the contact area with air for heat dissipation, thereby preventing chips from accumulating at the cutting position 150, which would be detrimental to the cutting operation. The good heat dissipation performance helps to reduce the temperature of the cutting element 230 and the rail 100, preventing the strength, stiffness, or hardness of the cutting element 230 from decreasing as the temperature rises. It also prevents the mechanical properties from decreasing due to changes in the crystal phase structure (such as bluing) caused by excessive temperature rise when the rail 100 is cut. The cutting element 230 is made of wear-resistant material (such as high-hardness metal oxide, ceramic oxide, or metal-ceramic oxide). As the cutting progresses, the outer diameter of the cutting element 230 does not decrease significantly.

[0078] Due to the adoption of the aforementioned toothed structure and wear-resistant materials, the disc-shaped cutting saw blade possesses excellent heat dissipation and high-temperature resistance, thus ensuring its stable and reliable operation without causing excessive temperature rise in the rail 100. Therefore, a spraying device for spraying coolant onto the cutting position 150 of the cutting workpiece 230 and / or the rail 100 is not required, and cooling of the rail 100 and / or the cutting workpiece 230 is not necessary. The coolant can be water or cooling oil (such as cutting fluid used in machining). The spraying device can include pipelines connecting to the coolant, and valves and pumps can also be installed on these pipelines.

[0079] It should also be noted that the input parameters may include a broken tooth detection sensor, which is installed on the cutting bracket 210 and used to detect whether the cutting tooth 231 has a broken tooth. The signal output terminal of the broken tooth detection sensor is connected to the processor 400. When a broken tooth is detected, the machine stops and an alarm is triggered. This cutting detection unit can be a sensor that emits probe rays to the cutting tooth 231 using ultrasonic or laser energy. The presence of a broken tooth is determined by detecting the number of times the probe rays return to the cutting tooth 231 within one revolution of the cutting piece 230.

[0080] Embodiments of the present invention may further include a cut-off detection unit, see below. Figure 25 The cutting detection unit is configured to detect whether a cut has occurred. The controller is also configured to: if no cut has occurred, drive the cutting bracket 210 to continue moving along the feed trajectory 900; if a cut has occurred, reset and / or stop the machine. Resetting involves driving the cutting bracket 210 from the cutting position to the position to be cut, and stopping involves the cutting power mechanism 220 stopping its operation. Automatic reset and / or stopping after cutting saves energy and prevents damage to the flatness and parallelism of the cut surface caused by the cutting piece 230 spinning idly.

[0081] One embodiment of the cut-off detection unit includes a current sampling circuit configured to collect the current of the motor 221. When the collected current returns to the no-load current, it indicates that the cut-off is complete. The detection logic is simple and reliable. Another embodiment of the cut-off detection unit is a position sensor configured to detect the relative position of the cutting bracket 210 relative to the track fixing bracket 310. The distance between these relative positions is used to determine whether a cut has occurred.

[0082] When the cut-off detection unit uses a current sampling circuit, it also includes a timer. If the current sampling circuit detects that the motor 221's current drops to the no-load current and maintains it for a duration T... 切断 (e.g., 2 seconds) is considered a cutoff.

[0083] Embodiments of the present invention may further include a battery 600 and / or terminals to provide power to the cutting power mechanism 220, the feed power mechanism 320, the processor 400, the feed signal detection unit, and the cut-off detection unit.

[0084] Embodiments of the present invention may further include a control terminal 800 connected to the processor 400 to control at least one of the feed direction and feed speed. The control terminal 800 may be a remote control or a smart mobile terminal (such as a tablet computer or mobile phone). The control terminal 800 and the processor 400 may be connected via a network cable or via wireless communication protocols such as 4G or WiFi.

[0085] One way to make the feed trajectory 900 is a straight line, see [link / reference]. Figures 6 to 20Linear feed, compared to oscillating feed, has a simpler structure, higher precision, and more stable operation.

[0086] When the feed trajectory 900 is a straight line, the feed trajectory 900 is set to one of the following:

[0087] The feed trajectory 900 is parallel to the height direction of the rail web 130 (e.g.) Figures 6 to 11 (As shown) or coincident, that is, cutting from top to bottom or from bottom to top; the feed trajectory 900 and the height direction of the rail web 130 form an acute angle, as shown. Figures 14 to 20 As shown, i.e., a bevel cut, considering the limited space below when the rail 100 is fixed, a top-down bevel cut is preferred. Of course, when the cutting part 230 is small or the rail 100 is not in a fixed state, a bottom-up bevel cut can also be performed; the feed trajectory 900 is perpendicular to the height direction of the rail web 130, as shown. Figure 13 As shown, it is a horizontal cut.

[0088] The feed trajectory 900 is parallel to the height direction of the rail web 130. The cutting component 230 is laterally offset relative to the rail 100 by a clearance distance to avoid interference between the cutting bracket 210 and the rail 100, and between the mounting component 240 and the rail 100, allowing for a single cut and enabling the mounting component 240 to enter the lateral space. The parallel setting of the feed trajectory 900 to the height direction of the rail web 130 is based on the structural characteristic that the height H of the rail 100 is greater than its width D. If the feed trajectory 900 is horizontal, its minimum length from the start of cutting to the end (complete cut) can be the width D; if the feed trajectory 900 is along the height direction of the rail web 130, its minimum length can be the height H of the rail 100. With the rail 100 fixed, the overall cutting volume is constant. The smaller the cutting volume per unit time, the lower the load requirement on the cutting power mechanism 220. Based on this consideration, the feed trajectory 900 is set to be parallel to the height direction of the rail web 130.

[0089] The feed motion (feed trajectory 900) of the cutting bracket 210 relative to the rail fixing bracket 310 is parallel to the height direction of the rail web 130. During its movement along this feed trajectory 900, the cutting saw blade is offset laterally (within a cross-section perpendicular to the length direction of the rail 100) relative to the rail 100 by a clearance distance. This provides movement space for the cutting bracket 210 and the mounting assembly 240, preventing interference between the cutting bracket 210 and the rail 100, and between the mounting assembly 240 and the rail 100. This allows the rail 100 to be cut using a cutting saw blade with the smallest possible radius. Compared to oscillating feed, the feed trajectory 900 is a straight line (parallel to the height direction of the rail web 130), resulting in a smaller cutting depth along the feed direction and lower requirements for the cutting force (torque) of the cutting power mechanism 220. Using a smaller power source or a reduction mechanism with a smaller speed ratio; compared to oscillating feed, feeding along the height direction of the rail web 130 results in a smaller change in the cutting amount along the feed direction, which makes the load change of the cutting power mechanism 220 smaller and the operation more stable; compared to oscillating feed, feeding along the height direction of the rail web 130, for the same size cutting piece 230, the number of cutting positions 150 is drastically reduced, or smaller cutting pieces 230 can be used, which greatly reduces the size and weight of the equipment, while avoiding the possible damage to the cutting piece 230 caused by alternating axial loads due to frequent entry and exit from the cutting position 150, and also avoiding axial movement caused by the positional deviation between the cut sections of different cutting positions 150 and the application of axial force to the cutting piece 230, thus ensuring the accuracy of the cutting section.

[0090] The inventors also discovered that under actual design and operating conditions, situations may arise where a single cut cannot be achieved. For example, when the cutting component 230 uses a grinding wheel, as the cutting progresses, the outer diameter of the grinding wheel gradually decreases. Originally, a new grinding wheel moving along the feed trajectory could achieve a single cut, but the reduced outer diameter leads to the inability to achieve a single cut. Considering both increasing the cutting force of the cutting component 230 (which manifests as output torque when the cutting component 230 is a grinding wheel or a cutting saw blade) and reducing the overall size and weight, the cutting power mechanism 220 can be reduced by decreasing the external dimensions of the cutting component 230, given a certain limit. However, reducing the external dimensions makes it impossible to achieve the aforementioned single cut capability.

[0091] To address the situation where a single cut is not possible, a two-cut approach can be used for a single cutting operation. Figure 7 , Figure 11 and Figure 20 As shown, the rail 100 is cut once from both the left and right sides, ensuring that both cuts occur along the same length of the rail 100. One specific form of the feed trajectory is as follows:

[0092] The cutting bracket 210 is switchably mounted on the track fixing bracket 300 at the first cutting station 315 and the second cutting station 316, wherein:

[0093] The first side cutting station 315 and the second side cutting station are arranged on both sides of the rail 100, and each corresponds to a cutting trajectory.

[0094] Correspondingly, there are two feed trajectories, each including a cut-off position and a cut-off position. In the cut-off position, the cutting part 230 is in contact with the rail 100 or maintains a safe distance.

[0095] During the movement from the position to the cutting position, the mounting assembly 240 can pass over the rail head 110 of the rail 100 and enter the side space, and the trajectory of the outer edge of the cutting component 230 exceeds the outer contour of the rail 100. By feeding the cutting component 230 along two feed paths sequentially, and ensuring that the two movement trajectories of the cutting component 230 overlap, the rail 100 can be cut in two separate cuts. This design balances the low power requirements of the cutting power mechanism 220, the small size and light weight of the rail saw, and the achievement of a large cutting force.

[0096] It should also be noted that the distances from the first side cutting station 315 and the second side cutting station 316 to the vertical center line of the rail 100 can be equal or unequal, as long as the two cuts can completely cover the cross-sectional area of ​​the rail 100. Figure 7 , Figure 11 and Figure 20 The diagram shows the case where the distances from the first side cutting station 315 and the second side cutting station 316 to the vertical center line of the rail 100 are equal.

[0097] One implementation of the first side cutting station 315 and the second side cutting station 316 includes a reversing swing arm (not shown in the figure). The reversing swing arm is rotatably mounted on the rail fixing bracket 300 within the cross-section of the rail 100, and the rotation trajectory of the reversing swing arm includes the first side cutting station 315 and the second side cutting station 316. By swinging the reversing swing arm to two positions, the cutting bracket 210 is positioned at the first side cutting station 315 and the second side cutting station 316 respectively, so that after the first cutting is completed, it can swing to the other side of the rail 100 to perform the second cutting, making the reversing operation convenient.

[0098] A second implementation of the first side cutting station 315 and the second side cutting station 316 includes a reversing slide 500, such as... Figure 11As shown, the cutting bracket 210 is slidably mounted on the track fixing bracket 300 via the reversing slide 500, and the sliding trajectory of the cutting bracket 210 has a first side cutting position 315 and a second side cutting position 316. By adjusting the sliding position of the cutting bracket 210 relative to the reversing slide 500, the cutting bracket 210 can be positioned at the first side cutting position 315 and the second side cutting position 316 respectively to perform cutting.

[0099] A third implementation of the first side cutting station 315 and the second side cutting station 316 is that the first side cutting station 315 and the second side cutting station 316 are part of the track fixing bracket 300, such as... Figure 20 As shown. In this method, the cutting bracket 210 is installed at two different positions on the track fixing bracket 300, so that the cutting bracket 210 can be located at the first side cutting station 315 and the second side cutting station 316 respectively to perform cutting, which is convenient for operation.

[0100] The embodiments of the present invention may further include a protective cover 700, which is rotatably mounted on the cutting bracket 210 and covers a portion of the cutting component 230. The protective cover 700 is rotatably mounted, and the cutting bracket 210 can be switched between two positions (first side cutting position 315 and second side cutting position 316). With these two positions combined, the protective cover 700 can be rotated to prevent interference between the protective cover 700 and the rail 100 after the cutting bracket 210 changes position. This configuration makes reverse-direction cutting possible.

[0101] When the feed path 900 is an arc, see Figure 21 and Figure 25 Driven by the feed power mechanism 320, the cutting bracket 210 is oscillatingly mounted on the track fixing bracket 310 around a swing axis 330, thereby realizing the feeding of the cutting workpiece 230.

[0102] The swing axis 330 is located directly above the rail 100. Alternatively, the swing axis 330 is laterally offset relative to the rail 100 by a clearance distance to avoid interference between the cutting bracket 210 and the rail 100, and between the mounting component 240 and the rail 100. This allows the mounting component 240 to enter the lateral space, thereby maximizing the use of the cutting piece 230 without interference. In other words, a single cut can be made using a relatively small cutting piece 230.

[0103] like Figures 17 to 20As shown, in one embodiment of the cutting power mechanism 220, the motor 221 drives the cutting workpiece 230 to rotate around the cutting bracket 210 via a reduction gear set (the motor axis and the cutting workpiece axis intersect in the direction shown in the figure, and bevel gears are used for reversal); in another embodiment of the feeding power mechanism 320, the servo motor 321 drives the cutting bracket 210 to slide along the track fixed bracket 310 via a lead screw 322 to achieve feeding.

[0104] like Figure 22 and Figure 23 As shown, in one embodiment of the cutting power mechanism 220, the motor 221 drives the cutting workpiece 230 to rotate around the cutting bracket 210 via the belt drive 222; in another embodiment of the feeding power mechanism 320, the servo motor 321 drives the cutting bracket 210 to swing around the swing axis 330 relative to the track fixed bracket 310 via the reduction gear set, thereby realizing feeding.

[0105] A second aspect of this invention discloses a rail sawing method using any of the aforementioned rail sawing machines, comprising the step of controlling at least one of the feed direction and feed speed of the feed power mechanism 320. It possesses the advantages of the aforementioned rail sawing machines, which will not be repeated here.

[0106] One embodiment of the sawing method may further include the following steps:

[0107] At the position to be cut, the cutting part 230 is in contact with the rail 100 or maintains a safe distance;

[0108] During the movement from the position to the cutting position, the mounting component 240 can pass over the rail head 110 or rail bottom 120 of the rail 100 and enter the side space 150, and the trajectory of the outer edge of the cutting component 230 exceeds the outer contour of the rail 100.

[0109] The feed trajectory 90° of this sawing method is either a straight line or an arc.

[0110] When the cutting workpiece 230 uses the aforementioned cutting saw blade, the heat and chips generated during the cutting process are effectively released due to the gaps between the cutting teeth 231, effectively controlling the temperature rise of the cutting workpiece 230 and / or the rail 100. Therefore, it is not necessary to spray coolant onto the cutting position 150 of the cutting workpiece 230 and / or the rail 100 during the cutting process. The coolant can be water or cooling oil (such as cutting fluid used in machining). The spraying device can include pipelines connecting to the coolant, and valves and pumps can also be installed on these pipelines.

[0111] A third aspect of the present invention discloses a computer-readable storage medium storing instructions that, when executed by the processor 400, perform any of the aforementioned sawing methods.

[0112] The processor may include one or more processing cores. It connects to various parts of the server via various interfaces and lines, executing instructions, programs, code sets, or instruction sets stored in memory, and accessing data stored in memory to perform various server functions and process data. Optionally, the processor may be implemented using at least one hardware form of Digital Signal Processing (DSP), Field-Programmable Gate Array (FPGA), or Programmable Logic Array (PLA). The processor may integrate one or more of the following: Central Processing Unit (CPU), Graphics Processing Unit (GPU), and modem. The CPU primarily handles the operating system, user interface graphics, and applications; the GPU is responsible for rendering and drawing the content to be displayed on the screen; and the modem handles wireless communication. It is understood that the modem may also be implemented as a separate chip without being integrated into the processor.

Claims

1. A rail sawing machine, characterized in that, It includes a cutting device, an automatic feeding device, and a processor, wherein: The cutting device includes: Cutting bracket; Cutting power mechanism; The cutting component is movably mounted on the cutting bracket under the drive of the cutting power mechanism; The automatic feeding device includes: The rail fixing bracket has a clamping end that can be clamped onto the rail; Feed power mechanism; The cutting bracket is movably mounted on the rail fixing bracket along the feed trajectory under the drive of the feed power mechanism, and the feed trajectory is located within the cross-section of the rail; The processor is connected to the control terminal of the feed power mechanism and configured to control at least one of the feed direction and feed speed of the feed power mechanism. The feed trajectory includes at least one maximum load position, and the feed speed of the feed power mechanism is determined based on the maximum load position; The maximum load position is within a preset value before and after the feed trajectory direction, which is the feed adjustment area. When moving from the position to be cut to the feed adjustment area, the feed speed gradually decreases, and when moving from the feed adjustment area to the cut-off position, the feed speed gradually increases.

2. The rail sawing machine according to claim 1, characterized in that, The feed trajectory includes at least one cutting position and one cutting position, and the cutting element is rotatably mounted on the cutting bracket via a mounting assembly, wherein: At the position to be cut, the cutting element is in contact with the rail or maintains a safe distance; During the movement from the position to be cut to the cutting position, the mounting component can pass over the rail head or rail bottom and enter the side space, and the trajectory traveled by the outer edge of the cutting component exceeds the outer contour of the rail.

3. The rail sawing machine according to claim 2, characterized in that, The cutting bracket can be switched between the first cutting station and the second cutting station on the track fixing bracket, wherein: The first side cutting station and the second side cutting station are arranged on both sides of the rail, and each corresponds to a cutting trajectory; Correspondingly, there are two feed trajectories, each including a cutting position and a cutting position, wherein: At the position to be cut, the cutting element is in contact with the rail or maintains a safe distance; During the movement from the position to be cut to the cutting position, the mounting assembly can pass over the rail head and enter the side space, and the trajectory traveled by the outer edge of the cutting piece exceeds the outer contour of the rail.

4. The rail sawing machine according to claim 3, characterized in that, It also includes the reversing control arm, in which: The reversing swing arm is rotatably mounted on the rail fixing bracket within the cross-section of the rail, and the rotation trajectory of the reversing swing arm has a first side cutting station and a second side cutting station.

5. The rail sawing machine according to claim 3, characterized in that, It also includes a reversing slide, in which: The cutting bracket is slidably mounted on the track fixing bracket via the reversing slide, and the sliding trajectory of the cutting bracket has a first side cutting station and a second side cutting station.

6. The rail sawing machine according to claim 3, characterized in that, The first side cutting station and the second side cutting station are part of the track fixing bracket.

7. The rail sawing machine according to claim 2, characterized in that, The processor is also configured to control at least one of the feed direction and the feed speed according to a preset program.

8. The rail sawing machine according to claim 7, characterized in that, Both the feed direction and the feed speed are constant.

9. The rail sawing machine according to claim 2, characterized in that, It also includes a feed signal detection unit for acquiring feed input parameters, and the processor is further configured to: The feed power mechanism is controlled based on the feed input parameters, controlling at least one of its motion direction and motion speed.

10. The rail sawing machine according to claim 7 or 9, characterized in that, The feed trajectory also includes a maximum load position, at which the load on the cutting power mechanism is at its maximum. A feed adjustment zone is formed near the maximum load position, which can be a continuous value or a point value, wherein: When moving from the position to be cut to the feed adjustment area, the feed speed gradually decreases; when moving from the feed adjustment area to the cutting position, the feed speed gradually increases; and / or; In the feed adjustment zone, the cutting bracket retracts from the cutting position and returns to the cutting position.

11. The rail sawing machine according to claim 10, characterized in that, The feed input parameters include at least one of the following: The rotational speed of the cutting power mechanism, the torque applied to the cutting component, the temperature at the cutting position, and the temperature of the cutting component.

12. The rail sawing machine according to claim 11, characterized in that, The cutting power mechanism includes an electric motor or an internal combustion engine, and the feeding power mechanism includes a servo motor; The feed input parameters also include the motor current.

13. The rail sawing machine according to claim 10, characterized in that, The outer edge of the cutting element forms cutting teeth, and the cutting element is made of wear-resistant material. As cutting proceeds, the outer diameter of the cutting element does not decrease significantly.

14. The rail sawing machine according to claim 13, characterized in that, Excluding a spraying device that sprays coolant onto the cutting location of the cut piece and / or rail.

15. The rail sawing machine according to claim 14, characterized in that, The feed input parameters also include a broken tooth detection sensor, wherein: The broken tooth detection sensor is installed on the cutting bracket and is used to detect whether the cutting tooth is broken. The signal output terminal of the broken tooth detection sensor is connected to the processor signal.

16. The rail sawing machine according to claim 12, characterized in that, It also includes a cut-off detection unit, wherein: The cutting detection unit is configured to detect whether a cut has occurred; The processor is also configured to: If the cut is not made, drive the cutting bracket to continue moving along the feed trajectory; If the machine is cut, reset and / or stopped, the reset is to drive the cutting bracket from the cutting position to the position to be cut, and the stop is to stop the cutting power mechanism.

17. The rail sawing machine according to claim 16, characterized in that, The cut-off detection unit includes a current sampling circuit configured to collect the current of the motor; or, The cutting detection unit is a position sensor configured to detect the relative position of the cutting bracket with respect to the track fixing bracket.

18. The rail sawing machine according to claim 17, characterized in that, The cut-off detection unit includes the current sampling circuit and the timer; The processor is further configured to, if the current sampling circuit detects that the motor current has dropped to the no-load current and then maintains it for a duration T... 切断 It was determined to be a cut.

19. The rail sawing machine according to claim 18, characterized in that, It also includes a battery and / or terminals to provide power to the cutting power mechanism, the feed power mechanism, the processor, the feed signal detection unit, and the cutting detection unit.

20. The rail sawing machine according to claim 10, characterized in that, It also includes a control terminal that is signal-connected to the processor.

21. The rail sawing machine according to claim 10, characterized in that, The feed trajectory is a straight line.

22. The rail sawing machine according to claim 21, characterized in that, The feed trajectory is set to one of the following: The feed trajectory is parallel to or coincides with the height direction of the rail web; The feed trajectory forms an acute angle with the height direction of the rail web; The feed trajectory is perpendicular to the height direction of the rail web.

23. The rail sawing machine according to claim 22, characterized in that, The feed trajectory is parallel to the height direction of the rail web, and the cutting component is offset laterally relative to the rail by a clearance distance to avoid interference between the cutting bracket and the rail, and between the mounting component and the rail.

24. The rail sawing machine according to claim 10, characterized in that, The feed trajectory is arc-shaped; Driven by the feed power mechanism, the cutting bracket is oscillatingly mounted on the track fixing bracket around a swing axis.

25. The rail sawing machine according to claim 24, characterized in that, The swing axis is located directly above the rail; or, The swing axis is offset laterally relative to the rail by a clearance distance to avoid interference between the cutting bracket and the rail, and between the mounting assembly and the rail.

26. A method for sawing rails, characterized in that, Using any one of claims 1 to 25, the rail saw includes a cutting bracket and a cutting element, the feed trajectory including at least a cutting position and a cutting position; the cutting element is rotatably mounted to the cutting bracket by a mounting assembly; It includes Step: Control at least one of the feed direction and feed speed of the feed power mechanism; The feed trajectory includes at least one maximum load position, and the feed speed of the feed power mechanism is determined based on the maximum load position.

27. The sawing method according to claim 26, characterized in that, At the position to be cut, the cutting element is in contact with the rail or maintains a safe distance; During the movement from the position to be cut to the cutting position, the mounting component can pass over the rail head or rail bottom and enter the side space, and the trajectory traveled by the outer edge of the cutting component exceeds the outer contour of the rail.

28. The sawing method according to claim 27, characterized in that, The feed trajectory is a straight line or an arc.

29. The sawing method according to claim 28, characterized in that, There is no need to spray coolant onto the cutting location of the workpiece and / or rail during the cutting process.

30. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores instructions that, when executed by the processor, perform the sawing method according to any one of claims 26 to 29.

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