High-speed maglev high-precision track plate manufacturing method

Abstract

The application belongs to the technical field of magnetic suspension track manufacturing, and discloses a high-speed magnetic suspension high-precision track plate manufacturing method, which comprises the following steps: S1, installing a sliding plate and a guide plate to a functional area operation platform and connecting the sliding plate and the guide plate; S2, locking and connecting a stator sleeve and a stator screw, and limiting and fixing the stator sleeve and the stator screw to a positioning frame; S3, moving the positioning frame to the functional area operation platform, adjusting the position of the positioning frame, and fixedly welding the stator screw and the sliding plate; S4, assembling the positioning frame to a pouring mold for fixation, binding a track plate reinforcement cage, and then pouring, subsequently removing the positioning frame and the pouring mold, and curing; S5, cutting and processing the sliding plate and the guide plate through a machine tool; S6, processing a stator connecting hole on the stator sleeve through the machine tool; and S7, assembling the stator. Through the above manner, the manufacturing precision of the separately prefabricated track plate is ensured.

Description

Technical Field

[0001] This invention relates to the field of magnetic levitation track manufacturing technology, and in particular to a method for manufacturing high-speed magnetic levitation high-precision track slabs. Background Technology

[0002] Maglev trains, currently the fastest land-based mode of transportation, offer customers numerous conveniences due to their advantages such as large load capacity, high speed, high safety, and comfortable experience.

[0003] The construction method for maglev track structures involves the prefabrication of the track slab and structural beam structures as a whole. This prefabrication method results in large individual weights (each track slab + structural beam weighs over 50 tons), leading to high manufacturing costs and low prefabrication efficiency. Furthermore, after prefabrication, the entire structure needs to be transported to the installation site for installation. This not only incurs high transportation costs but also causes track slab deformation due to bumps during transport, affecting its accuracy. On-site installation requires secondary fine-tuning, which is time-consuming, labor-intensive, and results in a high rework rate.

[0004] Therefore, the current consideration is to prefabricate the track slabs and structural beams (or structural columns) separately and then assemble them as a whole. Since the structural beams lack functional components, their manufacturing precision requirements are low and they can be prefabricated on-site, reducing transportation costs. However, the manufacturing of the track slabs involves high precision requirements for the functional areas consisting of sliding plates, guide plates, and stator components, making the overall track slab manufacturing process complex. Therefore, a construction method is urgently needed to ensure the manufacturing precision of the separately prefabricated track slabs. Summary of the Invention

[0005] The purpose of this invention is to provide a method for manufacturing high-precision track slabs for high-speed maglev trains, ensuring the manufacturing accuracy of separately prefabricated track slabs.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] A method for manufacturing high-precision track slabs for high-speed maglev trains, including:

[0008] S1. Install the sliding plate and guide plate onto the functional area operating platform, and connect the sliding plate and the guide plate;

[0009] S2. Lock the stator sleeve to the stator screw and fix it to the positioning frame;

[0010] S3. Move the positioning frame to the functional area operating platform, adjust the position of the positioning frame, and fix and weld the stator screw to the slide plate.

[0011] S4. The positioning frame is assembled into the casting mold and fixed, and the track plate steel reinforcement cage is tied before casting. Then the positioning frame and the casting mold are removed and cured.

[0012] S5. The sliding surface and the guide surface are machined by cutting using a machine tool;

[0013] S6. The stator connection hole on the stator sleeve is machined using the machine tool;

[0014] S7. Assemble the stator.

[0015] Preferably, in S4...

[0016] First, place the sliding plate on the positioning frame at the bottom of the casting mold, then adjust the position of the positioning frame, and finally tie the track plate reinforcement cage.

[0017] Preferably, in step S5, the specific steps for machining the sliding surface and the guide surface include:

[0018] First, the track slab is pre-inspected and leveled;

[0019] The machining axis of the machine tool is then determined;

[0020] Then, the track plate is fixed on the machine tool and the sliding surface and the guide surface are cut.

[0021] Preferably, the machining axis is formed by measuring the reference points at both ends of the track plate and the positions of the 6 to 8 stator sleeves using a high-precision aiming scope, and then correcting the measurement results through the internal system of the machine tool.

[0022] Preferably, in S6...

[0023] First, a simulated pre-inspection was performed on the position of the stator connection holes;

[0024] The stator connection holes are then machined; the screw holes in the stator connection holes are machined using a high-speed indexable insert drill bit, and the positioning holes in the stator connection holes are machined using a drill-boring composite tool.

[0025] Finally, the completed stator connection holes are inspected; the hole diameter is measured using a gauge, and the hole spacing accuracy and straightness are measured using a high-precision laser tracker.

[0026] Preferably, in both S5 and S6, the machining tool needs to be replaced, and the machining tool is inspected and adjusted by an optical digital display tool setter before machining.

[0027] Preferably, in step S6, after machining the stator connecting hole, the machine tool is cleaned. The cleaning steps include cleaning iron filings, cleaning the machine tool bed guide rails, checking the hydraulic system, resetting the machine tool, and adding lubricant.

[0028] Preferably, step S7 includes the following steps:

[0029] First, the assembly points were re-measured and the stator was subjected to quality inspection.

[0030] Then the stator is assembled from the middle of the track plate to both sides;

[0031] The stator is then aligned using the guide plates at both ends of the track plate as a reference.

[0032] The stator is then connected and fastened by connecting bolts to the screw holes of the stator connection holes;

[0033] Finally, the installed stator is retested to improve accuracy.

[0034] Preferably, the track plate needs to be flipped in S5 and S6.

[0035] Preferably, the method also includes step S8, where the track plates with the stator installed are stacked in a standard arrangement of no more than three pieces.

[0036] The beneficial effects of this invention are:

[0037] The above method allows for the separate prefabrication of structural beams and track slabs. During the prefabrication of track slabs, positioning frames and other methods ensure the accuracy of guide plates, sliding plates, and stator sleeves. Furthermore, the use of integral casting ensures the verticality of stator screws and guide plates, and the horizontality of sliding plates is more precise. In addition, positioning and dimensional accuracy are guaranteed during the processing of stator sleeves and the installation of stator. Attached Figure Description

[0038] Figure 1 This is a flowchart of the high-speed maglev high-precision track slab manufacturing method of the present invention;

[0039] Figure 2 This is a flowchart of step S4 in the high-speed maglev high-precision track slab manufacturing method of the present invention;

[0040] Figure 3 This is a flowchart of step S5 in the high-speed maglev high-precision track slab manufacturing method of the present invention;

[0041] Figure 4 This is a flowchart of step S6 in the high-speed maglev high-precision track slab manufacturing method of the present invention;

[0042] Figure 5 This is a flowchart of step S7 in the high-speed maglev high-precision track slab manufacturing method of the present invention;

[0043] Figure 6This is a cross-sectional schematic diagram of the high-speed maglev track slab structure of the present invention.

[0044] In the picture:

[0045] 1. Sliding plate; 2. Guide plate; 3. Stator sleeve; 4. Stator; 5. Stator screw. Detailed Implementation

[0046] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0047] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0048] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0049] In the description of this embodiment, the terms "upper," "lower," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0050] like Figures 1 to 6 As shown, this embodiment provides a method for manufacturing high-precision track slabs for high-speed maglev trains. This method ensures the manufacturing precision of separately prefabricated track slabs. The method includes:

[0051] S1. Install the sliding plate 1 and guide plate 2 onto the functional area operating platform. The functional area operating platform in this embodiment is existing technology, comprising a platform and guide plate supports fixed to the platform. First, prepare the functional area operating platform, install the guide plate supports one by one, and first vertically rest the guide plate 2 against the guide plate supports, raising the bottom of the guide plate 2 by 10mm. Then, place the sliding plate 1 horizontally on the functional area operating platform, aligning it perpendicularly to the guide plate 2 and tightening it. After initially fixing the positions of the sliding plate 1 and guide plate 2, weld the sliding plate 1 and guide plate 2 together using angle braces, ensuring they are perpendicular and securely connected. The deviation between the sliding plate 1 and guide plate 2 is allowed within ±1mm to reduce shrinkage deformation caused by welding.

[0052] S2. Prepare the positioning frame, which is existing technology and will not be described in detail here. Connect the stator sleeve 3 and the stator screw 5 with a nut. It can be understood that the stator sleeve 3 includes dovetail stator sleeves and non-dovetail stator sleeves. Subsequently, the top surfaces of the locked dovetail stator sleeves and dovetail-less stator sleeves are fixed at equal intervals to the positioning surfaces of the corresponding cylindrical positioning bosses below the longitudinal beams on both sides of the positioning frame. For greater stability, positioning frame screws are provided at opposite ends of the stator screws 5. Two positioning frame screws are provided for the dovetail stator sleeves to prevent rotation of the dovetail stator sleeves. One positioning frame screw is provided for the dovetail stator sleeves. One end of the positioning frame screw is detachably connected to the positioning frame. For example, the positioning frame screw and the positioning frame can be screwed together with a nut. The other end of the positioning frame screw is connected and locked to the bolt insertion slots provided at the center of the lower surface of several stator sleeves 3. The depth of the positioning frame screw must be less than the difference between the initial end face and the final formed surface (the end face of the screw hole part after the stator sleeve 3 is formed) of the stator sleeve 3.

[0053] S3. Then, the positioning frame is hoisted onto the operating platform of the functional area and the position of the positioning frame is adjusted. Then, the distance between the lower end of the stator screw 5 and the slide plate 1 is adjusted, and the connecting nut is tightened at the end of the stator screw 5 near the slide plate 1. Then, the connecting nut is spot welded to the slide plate. At this time, the positioning frame, the slide plate 1 and the guide plate 2 are assembled into a whole, improving the assembly efficiency.

[0054] S4. Using the lifting lugs on the positioning frame, the entire assembly of the positioning frame, sliding plate 1, and guide plate 2 is hoisted into the casting mold. During this process, the sliding plate 1 on the positioning frame needs to be placed at the bottom of the casting mold. This operation ensures the flatness of the bottom surface of the track slab beam and also facilitates the positioning of the positioning frame. The track slab reinforcement cage is tied in the casting mold, and then the concrete is poured. After the concrete has solidified to the required strength, the positioning frame (the positioning frame screw is removed from the stator sleeve 3) and the casting mold are removed and cured. This integral casting prevents the concrete from floating during pouring, making the magnetic levitation track slab safer. The integral casting method ensures the verticality of the stator screw 5 and guide plate 2, and the horizontality of the sliding plate 1 is more accurate.

[0055] S5. The maglev track slab, after maintenance, is flipped using a maglev track slab flipping device, so that the sliding plate 1 faces upwards to facilitate cutting and machining of the sliding plate 1 and guide plate 2. The maglev track slab flipping device in this embodiment is existing technology, and its specific structure will not be described in detail. During the process, sufficient clearance from the ground is ensured for the track slab to be flipped. The electric hoist on the boom of the maglev track slab flipping device is activated to coordinate the synchronous rotation of the slewing mechanism. The flywheel of the slewing mechanism drives the flipping arm to rotate 180°. Simultaneously, the track slab is flipped 180°. The lateral stabilizing rod and the flipping arm are released, and the track slab is detached from the flipping device. Subsequently, the sliding surface and guide surface are machined using a machine tool. The sliding surface refers to the plane where the sliding plate 1 is located, and the guide surface refers to the plane where the guide plate 2 is located.

[0056] In the machining of the sliding surface and guide surface, the track plate first needs to be pre-inspected and leveled, with the two ends of the track plate as reference points. Then, still using the two ends of the track plate as reference points, and in conjunction with the positions of the 6-8 stator sleeves 3 on the track plate, a high-precision aiming scope is used for measurement. The high-precision aiming scope can be integrated into the machine tool. After the measurement is completed, the measurement results are corrected through the internal system of the machine tool to form the machining axis for the machine tool to perform the machining of the sliding surface and guide surface. In this embodiment, the machine tool adopts three-axis linkage, with A (spindle) and B (column) two-axis rotation selected. Considering the excessive length and weight of the track plate, the required machining process of the track plate is completed by keeping the track plate stationary and moving the machine tool. In this embodiment, the machine tool is a floor-type milling and boring machine, with one machine set on each side of the track plate to simultaneously complete the machining process on both sides of the track plate. The machine tool should meet the relevant dimensional requirements for machining, and the machining of the machine tool in the length direction of the track plate should have the characteristic of intermittent operation to facilitate interruption. It is preferred to use rolling guides to move the machine tool. It should be noted that there are no specific requirements for the machining tools used in the cutting of the sliding surface and the guide surface.

[0057] S6. After completing the above-mentioned cutting and machining of the sliding surface and guide surface, the track plate is flipped again using the magnetic levitation track plate flipping device, so that one side of the stator sleeve 3 faces upward, thereby facilitating the cutting and machining of the stator connecting hole on the stator sleeve 3. In this embodiment, the stator connecting hole is a boring hole. It should be noted here that since the stator sleeve 3 includes a dovetail stator sleeve and a non-dovetail stator sleeve, the stator connecting hole on the non-dovetail stator sleeve is a screw hole. The structure of the dovetail stator sleeve and the non-dovetail stator sleeve is existing technology and will not be described in detail here. It should be noted that the stator connecting hole on the dovetail stator sleeve includes a screw hole and a positioning hole. The positioning hole is connected to the screw hole, and the positioning hole is located outside the connecting hole. The cutting of the stator sleeve 3 can be performed with the end face of the screw hole portion of the formed stator sleeve 3 as the reference, so that the end face of the screw hole portion of the formed stator sleeve 3 is flush. When machining the stator connecting holes, a preliminary inspection of the hole positions is first required. A marker can be mounted on the machine tool spindle, and the hole positions can be pre-marked according to the stator connecting hole machining program. This allows for adjustments to the machining program based on the pre-inspected positions, ensuring hole accuracy. After the pre-inspection, machining begins. The threaded holes in the stator connecting holes are machined using high-speed indexable inserts, while the positioning holes are machined using a drill-boring composite tool to improve machining accuracy. Since the stator sleeve 3 is made of ductile iron, coolant is not required during drilling. Finally, the completed stator connecting holes are inspected. A gauge is used to measure the hole diameter, and a high-precision laser tracker is used to measure the hole spacing accuracy and straightness. It is important to note that after step S6, the machine tool's accuracy needs to be checked, and the results analyzed. Necessary corrections are made through the CNC system to ensure the correct spatial position of both sides of the machine tool. If the correction exceeds the limit, the machine bed should be adjusted to restore machining accuracy and ensure the machining quality of the track plate. Furthermore, the machine tool needs to be cleaned. Cleaning steps include removing metal filings, cleaning the machine bed and guide rails, checking the hydraulic system and resetting the machine, and adding lubricant. If necessary, the electrical system can also be cleaned, and all filters cleaned. Any abnormal phenomena should be stopped for inspection to eliminate potential hazards and ensure long-term stable production. It should be noted that during all S5 and S6 machining processes, if the machining tools are changed, they must be inspected and adjusted using an optical digital display tool setter before machining to ensure consistent tool parameters and guarantee machining accuracy requirements.

[0058] S7. The stator 4 can be assembled on the stator 4 mounting platform. In this embodiment, the stator 4 mounting platform can be composed of four to five steel supports. Shims are added between the sliding surface of the track plate and the supports for leveling. When installing the stator 4, the assembly points are first re-measured; this includes random inspection of the connecting bolts according to regulations, and a key inspection of the track plate for the distance and clamping distance between the sliding surface and the stator connecting holes. Before installation, the stator 4 should be quality inspected, including the external dimensions and bolt hole dimensions of the stator 4, such as the height from the bottom surface of the two keys of the stator 4 to the top surface of the stator 4, and the height of the stator 4 when placed on a flat plate.

[0059] Then, the stator 4 is assembled from the middle of the track plate to both sides. Since the stator 4's supplied state differs from its assembled state by 180°, it needs to be flipped using a stator 4 flipping machine, so that the core surface of the stator 4 faces upwards during assembly. This facilitates construction and measurement. The specific type of stator 4 flipping machine is not limited here; it only needs to be capable of flipping the stator 4. After flipping, a hand-cranked stacker and nylon lifting slings are used as lifting tools to a certain height and move it to the installation position. The stator 4 is lowered from top to bottom during installation. After slightly tilting the stator 4, it is aligned with the keyway on the dovetail stator sleeve and pushed in. Once leveled, the nylon lifting slings are removed.

[0060] Then, the stator 4 is aligned using the guide plates 2 at both ends of the track plate as a reference. The center of the stator 4 at both ends should coincide with the axis of the reference, and the end face gap between two adjacent stators 4 should be 2.0mm. After the adjacent stators 4 are in place, the straightness of the stator 4 is checked and corrected with a 1000mm steel ruler, and the end face is tapped with a rubber hammer for fine adjustment.

[0061] After the stator 4 is correctly positioned, it is then connected and tightened to the stator 4 through the connecting bolts and the screw holes of the stator connecting holes. In order to prevent loosening caused by accidents, a small amount of anaerobic adhesive is applied to the screw holes before the connecting bolts are inserted. The connecting bolts are initially tightened to 150 Nm, and the two connecting bolts located in the middle of the stator 4 are tightened first. Then, the final tightening is performed to 300 Nm. All connecting bolts have undergone magnetic particle testing.

[0062] Finally, the installed stator 4 was retested to improve accuracy.

[0063] S8. Stack the track plates with the stator 4 installed in no more than three pieces at a time, with the sliding plate 1 placed at the bottom to ensure that the accuracy of each component of the track plate is not affected.

[0064] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art will be able to make various obvious changes, readjustments, and substitutions without departing from the scope of protection of the present invention. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for manufacturing high-precision track slabs for high-speed maglev trains, characterized in that, include: S1. Install the sliding plate (1) and the guide plate (2) onto the functional area operating platform, and connect the sliding plate (1) and the guide plate (2); S2. Lock the stator sleeve (3) to the stator screw (5) and fix it to the positioning frame; S3. Move the positioning frame to the functional area operating platform, adjust the position of the positioning frame, and fix and weld the stator screw (5) to the sliding plate (1); S4. The positioning frame is assembled into the casting mold and fixed, and the track plate steel reinforcement cage is tied before casting. Then the positioning frame and the casting mold are removed and cured. S5. The sliding surface and guide surface are machined by machine tool cutting. The specific steps include: First, the track slab is pre-inspected and leveled; The machining axis of the machine tool is then determined; Then, the track plate is fixed on a machine tool to cut the sliding surface and the guide surface; Using the two end reference points of the track plate and the positions of 6 to 8 stator sleeves (3), a high-precision aiming scope is used for measurement, and the measurement results are corrected through the internal system of the machine tool to form the machining axis; S6. The stator connecting hole on the stator sleeve (3) is machined by the machine tool. The specific steps include: First, a simulated pre-inspection was performed on the position of the stator connection holes; The stator connection holes are then machined; the screw holes in the stator connection holes are machined using a high-speed indexable insert drill bit, and the positioning holes in the stator connection holes are machined using a drill-boring composite tool. Finally, the completed stator connection holes are inspected; the hole diameter is measured using a gauge, and the hole spacing accuracy and straightness are measured using a high-precision laser tracker. S7. Assemble the stator (4), the specific steps of which include: First, the assembly points were re-measured and the stator (4) was inspected for quality. Then the stator (4) is assembled from the middle of the track plate to both sides; Then, the stator (4) is aligned using the guide plates (2) at both ends of the track plate as a reference. The stator (4) is then connected and fastened by connecting bolts to the screw holes of the stator connection hole; Finally, the installed stator (4) is retested to improve accuracy.

2. The method for manufacturing high-precision track slabs for high-speed maglev trains according to claim 1, characterized in that, In S4, First, place the sliding plate (1) on the positioning frame at the bottom of the casting mold, then adjust the position of the positioning frame, and after the adjustment is completed, tie the track plate steel cage.

3. The method for manufacturing high-precision track slabs for high-speed maglev trains according to claim 1, characterized in that, In both S5 and S6, the machining tools need to be replaced, and the machining tools are inspected and adjusted using an optical digital display tool setter before machining.

4. The method for manufacturing high-precision track slabs for high-speed maglev trains according to claim 1, characterized in that, In step S6, after machining the stator connecting hole, the machine tool is cleaned. The cleaning steps include cleaning iron filings, cleaning the machine tool bed guide rails, checking the hydraulic system, resetting the machine tool, and adding lubricant.

5. The method for manufacturing high-precision track slabs for high-speed maglev trains according to claim 1, characterized in that, In S5 and S6, the track plate needs to be flipped.

6. The method for manufacturing high-precision track slabs for high-speed maglev trains according to claim 1, characterized in that, It also includes S8, where the track plate with the stator (4) installed is stacked in a standard of no more than three pieces.

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