Railway long rail replacement work vehicle-mounted welding equipment and welding work method

Abstract

The application discloses a railway long steel rail replacement operation vehicle-mounted welding device and a welding operation method, which comprises a welding operation vehicle and a power flat car, a flash welding machine, a heat treatment machine, auxiliary centering devices a1, b1, a2 and b2, straightening machines a and b, and a controller; a first heat treatment machine head is integrated on a first welding machine head, and a second heat treatment machine head is integrated on a second welding machine head; the first welding machine head and the second welding machine head are slidably arranged along the length direction of the welding operation vehicle; the auxiliary centering device a1 is used for assisting in clamping a steel rail a1, the auxiliary centering device a2 is used for assisting in clamping a steel rail a2, the auxiliary centering device b1 is used for assisting in clamping a steel rail b1, and the auxiliary centering device b2 is used for assisting in clamping a steel rail b2. The railway long steel rail replacement operation vehicle-mounted welding device and the welding operation method improve the rail replacement efficiency and reduce the deformation of the welding joint.

Description

Technical Field

[0001] This invention relates to the field of railway rail replacement technology, and more specifically, to a vehicle-mounted welding equipment and welding method for railway long rail replacement operations. Background Technology

[0002] High-speed railways operate at speeds of 200-350 kilometers per hour and are passenger trains, requiring high safety standards. Therefore, placing items on either side of the track is prohibited. This necessitates that no rails or tools be left behind after track maintenance and construction, thus establishing the requirement of "cleanliness after work" for high-speed railway construction.

[0003] The existing technology for replacing long rails presents the following problems: First, unloading, laying, welding, and collecting old rails require separate locomotives and multi-locomotive scheduling, making it impossible to complete the work within the same maintenance window. Multiple maintenance windows are needed for joint operations. During the operation, the new and old rails need to be stored on both sides of the line. Therefore, the high-speed train needs to reduce its speed during maintenance operations on this line. This operation mode not only results in low rail replacement efficiency but also affects the normal operation of the high-speed train and brings safety hazards. Second, rail welding cars and heat treatment cars need to operate separately and be provided with separate power, which increases the number of train formations and power locomotives for track replacement and overhaul, reducing the efficiency of rail replacement. Third, when ordinary mobile rail flash welding machines are used for welding, the welding head first clamps the two adjacent rails separately before welding. After welding, the clamping parts of the rails need to be loosened before heat treatment, which can easily cause deformation of the welded joint.

[0004] Therefore, it is necessary to solve the above-mentioned technical problems. Summary of the Invention

[0005] In view of this, the purpose of this invention is to provide a vehicle-mounted welding equipment and welding operation method for railway long rail replacement, so as to improve rail replacement efficiency, reduce the deformation of welded joints, and reduce the safety risks of high-speed railway rail overhaul construction.

[0006] To achieve the above objectives, the present invention provides a vehicle-mounted welding equipment for railway long rail replacement operations, comprising a welding vehicle and a powered flatbed vehicle, wherein: the welding vehicle includes a flash welding machine, a heat treatment machine, auxiliary centering devices a1, b1, a2, and b2, a straightening machine a, a straightening machine b, and a controller; the welding vehicle is equipped with multiple first rollers and multiple second rollers, the multiple first rollers being used to place or move rails a1 and b1, and the multiple second rollers being used to place or move rails a2 and b2; the powered flatbed vehicle includes a power supply device and an air compressor; the heat treatment machine includes a first heat treatment head and a second heat treatment machine. The flash welding machine includes a first welding head and a second welding head. One end of the first welding head integrates a first heat treatment head, and one end of the second welding head integrates a second heat treatment head. The first welding head and the second welding head are arranged opposite each other along the width direction of the welding vehicle. The first welding head is used to weld the opposing rails a1 and b1 to form a first welded joint. The air compressor is used to cool the first welded joint. The first heat treatment head is used to perform heat treatment on the first welded joint. The second welding head is used to weld the opposing rails a2 and b2 to form a second welded joint. The second heat treatment head... The welding head is used to heat treat the second welded joint, and the air compressor is used to cool the second welded joint. Both the first and second welding heads are slidably arranged along the length of the welding vehicle. The auxiliary centering device a1 is used to assist in clamping the rail a1, the auxiliary centering device a2 is used to assist in clamping the rail a2, the auxiliary centering device b1 is used to assist in clamping the rail b1, and the auxiliary centering device b2 is used to assist in clamping the rail b2. The welding vehicle has welding lines I and II arranged parallel to each other along its width. The auxiliary centering device b1, the first heat treatment head, and the first welding head... The head, straightening machine a, and auxiliary centering device a1 are arranged sequentially on welding line I; the auxiliary centering device b2, the second heat treatment head, the second welding head, straightening machine b, and auxiliary centering device b1 are arranged sequentially on welding line II; the straightening machine a is used to perform heat straightening treatment on the first welded joint after heat treatment, and the straightening machine b is used to perform heat straightening treatment on the second welded joint after heat treatment; the controller controls the opening and closing of the flash welding machine, the heat treatment machine, the auxiliary centering device a1, the auxiliary centering device b1, the auxiliary centering device a2, the auxiliary centering device b2, the straightening machine a, and the straightening machine b.

[0007] Optionally, it also includes rail brake a1 and rail brake a2, wherein rail brake a1 is used to brake or release rail a1, and rail brake a2 is used to brake or release rail a2.

[0008] Optionally, the auxiliary alignment device a1 includes a first hydraulic cylinder, a double-sided rack, a first swing arm, and a second swing arm. One end of the first swing arm is provided with a first rotating shaft and a first gear that can rotate around the first rotating shaft. The other end of the swing arm is provided with a first pressure head. One end of the second swing arm is provided with a second rotating shaft and a second gear that can rotate around the second rotating shaft. The other end of the second swing arm is provided with a second pressure head. The two sides of the double-sided rack are respectively meshed with the first gear and the second gear. The first hydraulic cylinder includes a first telescopic rod, and the double-sided rack is installed on the end face of the first telescopic rod. The first swing arm and the second swing arm are respectively provided on both sides of the double-sided rack. When the first telescopic rod extends or retracts, the double-sided rack drives the first pressure head and the second pressure head to clamp or release the rail a1. The auxiliary alignment devices b1, a2, and b2 are all structurally identical to the auxiliary alignment device a1.

[0009] Optionally, the rail brake a1 includes a second hydraulic cylinder, a third swing arm, a fourth swing arm, a first connecting shaft, and a second connecting shaft. The second hydraulic cylinder includes a cylinder body and a piston rod. One end of the first connecting shaft is rotatably mounted on the cylinder body, and the other end of the first connecting shaft is fixed to one end of the third swing arm. The other end of the third swing arm is provided with a third rotating shaft and a first roller that can rotate around the third rotating shaft. One end of the second connecting shaft is rotatably mounted on the piston rod, and the other end of the second connecting shaft is fixed to one end of the fourth swing arm. The other end of the fourth swing arm is provided with a fourth rotating shaft and a second roller that can rotate around the fourth rotating shaft. When the piston rod extends or retracts, it drives the first roller and the second roller to brake or release the rail a1. The rail brake a2 has the same structure as the rail brake a1 and is used to brake or release the rail a2.

[0010] Optionally, the first welding head further includes a first ranging sensor and a second ranging sensor, and the second welding head further includes a third ranging sensor and a fourth ranging sensor. The first ranging sensor, the second ranging sensor, the third ranging sensor and the fourth ranging sensor are all communicatively connected to the controller.

[0011] Optionally, the flash welding machine may also include an autotransformer.

[0012] Optionally, the welding vehicle may also include a hydraulic station and a chiller.

[0013] Optionally, the power supply device includes an isolation transformer, an energy storage converter, and a battery pack.

[0014] Based on the same inventive concept, this invention also provides a welding operation method, using the aforementioned railway long rail replacement vehicle-mounted welding equipment for welding operations, including the following steps: Step 1, two rails a1 and a2 to be welded enter the welding operation vehicle, respectively entering parallel welding lines I and II. On welding line I, rail a1, driven by the first roller, sequentially passes through the auxiliary centering device b1, the first heat treatment head, the first welding head, the auxiliary centering device a1, the straightening machine a, and the rail brake a1, until the tail end of rail a1 reaches the welding position of the first welding machine head. At this point, the rail brake a1 is activated, stopping rail a1. Simultaneously, on welding line II, rail a2, driven by the second roller, sequentially passes through the auxiliary centering device b2, the second heat treatment head, the second welding head, the auxiliary centering device a2, the straightening machine b, and the rail brake a2, until rail a1... When the tail end of rail 2 reaches the welding station of the second welding machine head, the rail brake a2 is activated to stop rail a2; then, two rails b1 and b2 are fed into welding line I and welding line II respectively. The head of rail b1 passes through the auxiliary centering device b1 and the first heat treatment head in sequence to reach the welding station of the first welding machine head. At the same time, the head of rail b2 passes through the auxiliary centering device b2 and the second heat treatment head in sequence to reach the welding station of the second welding machine head. Welding station of the head; Step 2, the auxiliary centering device b1 on welding line I clamps and centers the rail b1, and the auxiliary centering device a1 clamps and centers the rail a1, completing the auxiliary centering action of rail a1 and rail b1. At the same time, the auxiliary centering device a2 on welding line II clamps and centers the rail a2, and the auxiliary centering device b2 clamps and centers the rail b2, completing the auxiliary centering action of rail a2 and rail b2.Step 3: First, start the first welding head to complete the welding of rail a1 and rail b1 on welding line I, forming the first welded joint. Then, start the first pressure-holding and pushing device to hold pressure and push the first welded joint. Next, start the air compressor to spray air to cool the first welded joint. While cooling the first welded joint, start the second welding head to complete the welding of rail a2 and rail b2 on welding line II, forming the second welded joint. Then, start the second pressure-holding and pushing device to hold pressure and push the second welded joint. Finally, start the air compressor to cool the second welded joint. The joint is cooled by air jet cooling. Simultaneously, the integrated first welding head is moved so that the first heat treatment head is aligned with the first weld joint. The first heat treatment head is activated to heat-treat the first weld joint. Then, the air compressor is activated to cool the heat-treated first weld joint with air jet cooling. Simultaneously, the integrated second welding head is moved so that the second heat treatment head is aligned with the second weld joint. The second heat treatment head is activated to heat-treat the second weld joint. Finally, the air compressor is activated to cool the heat-treated... The second welded joint is cooled by air jetting; Step four, while the second welded joint, which has undergone heat treatment, is cooled by air jetting, the first welded joint is ground and its straightness is measured using a handheld portable grinding and measuring tool. If necessary, straightening machine a is started to perform hot straightening treatment on the first welded joint, and a handheld portable flaw detector is used to perform flaw detection on the first welded joint, forming the first long rail; Step five, the second welded joint is ground and its straightness is measured using a handheld portable grinding and measuring tool. If necessary, straightening machine b is started to perform hot straightening treatment on the second welded joint, and a handheld portable flaw detector is used to perform flaw detection on the second welded joint. Step six involves performing flaw detection to form the second long rail; then, the first long rail is driven by the first roller until its tail reaches the welding station of the first welding head, and the second long rail is driven by the second roller until its tail reaches the welding station of the second welding head. The two rails to be welded are then fed into welding line I and welding line II respectively, until they reach the welding stations of the first and second welding heads respectively. This welding process is repeated sequentially to continue welding subsequent new rails until the day's rail welding task is completed.

[0015] This invention provides a vehicle-mounted welding equipment and welding method for railway long rail replacement operations. The vehicle-mounted welding equipment for railway long rail replacement operations includes a welding operation vehicle and a powered flatbed car. The welding operation vehicle includes a flash welding machine, a heat treatment machine, auxiliary centering devices a1, b1, a2, and b2, a straightener a, a straightener b, and a controller. The powered flatbed car includes a power supply device and an air compressor. The welding operation vehicle is equipped with multiple first rollers and multiple second rollers. After welding rails a1 and b1, a first welded joint is formed; after welding rails a2 and b2, a second welded joint is formed. During heat treatment of the first welded joint, the auxiliary centering devices a1 and b1 continuously clamp rails a1 and b1, respectively, reducing the deformation of the first welded joint during heat treatment. Similarly, the auxiliary centering devices a2 and b2 continuously clamp rails a2 and b2, respectively. 2. Continuous clamping is achieved, which also reduces the deformation of the second welded joint during heat treatment, thus lowering the safety risks of high-speed railway rail overhaul construction. The integrated first welding head and first heat treatment head only require horizontal movement of the integrated first welding head to align the first heat treatment head with the first welded joint and perform heat treatment, reducing the time required for welding and heat treatment of the first welded joint and improving rail replacement efficiency. Similarly, the integrated second welding head also reduces the time required for welding and heat treatment of the second welded joint, further improving rail replacement efficiency. The railway long rail replacement operation vehicle-mounted welding equipment and welding operation method provided by this invention can realize the online rail laying and rail welding within the same maintenance window, and welding lines I and II can carry out different welding operation procedures simultaneously, improving rail replacement efficiency. Attached Figure Description

[0016] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, which will help to understand the purpose and advantages of the present invention, wherein:

[0017] Figure 1 This is a schematic diagram of the welding vehicle in the vehicle-mounted welding equipment for railway long rail replacement operations according to an embodiment of the present invention;

[0018] Figure 2 This is a schematic diagram of the structure of the powered flatbed car in the vehicle-mounted welding equipment for railway long rail replacement operations according to an embodiment of the present invention;

[0019] Figure 3 This is a schematic diagram of the structure of auxiliary centering device a1, auxiliary centering device a2, auxiliary centering device b1, or auxiliary centering device b2 in the vehicle-mounted welding equipment for railway long rail replacement operations according to an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the structure of rail brake a1 or rail brake a2 in the vehicle-mounted welding equipment for railway long rail replacement operations according to an embodiment of the present invention.

[0021] Figure 5 This is a flowchart of a welding operation method according to an embodiment of the present invention.

[0022] Explanation of reference numerals in the attached figures:

[0023] 1: Welding work vehicle; 2: Power flatbed vehicle; 3: Controller; 4: Auxiliary centering device a1; 5: Auxiliary centering device b1; 6: Auxiliary centering device a2; 7: Auxiliary centering device b2; 8: Rail brake a1; 9: Rail brake a2; 10: Straightening machine a; 11: Straightening machine b; 12: First welding head; 13: Second welding head; 14: First heat treatment head; 15: Second heat treatment head; 16: Welding line I; 17: Welding line II; 18: Rail a1; 19: Rail a2; 20: Rail b1; 21: Rail b2; 22: First hydraulic... 23: Pressure cylinder; 24: Double-sided rack; 25: First swing arm; 26: Second swing arm; 27: First rotating shaft; 28: Second rotating shaft; 29: Second gear; 30: Second hydraulic cylinder; 31: Third swing arm; 32: Fourth swing arm; 33: First connecting shaft; 34: Second connecting shaft; 35: Third rotating shaft; 36: First roller; 37: Fourth rotating shaft; 38: Second roller; 39: Autotransformer; 40: Hydraulic station; 41: Chiller; 42: Air compressor; 43: Isolation transformer; 44: Energy storage converter; 45: Battery pack; 46: Heat treatment power supply. Detailed Implementation

[0024] The present invention will now be described in detail with reference to embodiments. Identical components are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0025] like Figure 1 and Figure 2As shown, the railway long rail replacement and laying operation vehicle-mounted welding equipment provided by the present invention includes a welding operation vehicle 1 and a powered flatbed vehicle 2. The welding operation vehicle 1 includes a flash welding machine, a heat treatment machine, auxiliary centering devices a1 4, b1 5, a2 6, and b2 7, a straightening machine a 10, a straightening machine b 11, and a controller 3. The welding operation vehicle 1 is equipped with multiple first rollers and multiple second rollers. The multiple first rollers are used to place or move rails a1 18 and b1 20, and the multiple second rollers are used to place or move rails a2 19 and b2 20. 21. The moving, powered flatbed trolley 2 includes a power supply unit and an air compressor 42; the heat treatment machine includes a first heat treatment head 14 and a second heat treatment head 15; the flash welding machine includes a first welding head 12 and a second welding head 13, one end of the first welding head 12 is integrated with the first heat treatment head 14, and one end of the second welding head 13 is integrated with the second heat treatment head 15. The first welding head 12 and the second welding head 13 are arranged opposite to each other along the width direction of the welding work vehicle 1; the first welding head 12 is used to weld the oppositely joined rails a1 18 and b1 20 to form a first welded joint, the first heat treatment head 14 is used to perform heat treatment on the first welded joint, and the air compressor 42 is used to cool the first welded joint; the second welding head 13 is used to weld the oppositely joined rails a2 19 and b2 21. A second welded joint is formed. The second heat treatment head 15 is used to heat treat the second welded joint, and the air compressor 42 is used to cool the second welded joint. The first welding head 12 and the second welding head 13 are both slidably arranged along the length direction of the welding vehicle 1. The auxiliary centering device a1 4 is used to assist in clamping the rail a1 18, the auxiliary centering device a2 6 is used to assist in clamping the rail a2 19, the auxiliary centering device b1 5 is used to assist in clamping the rail b1 20, and the auxiliary centering device b2 7 is used to assist in clamping the rail b2 21. The welding vehicle 1 has welding line I 16 and welding line II 17 arranged parallel to each other along the width direction of the welding vehicle 1. The auxiliary centering device b1 5, the first heat treatment head 14, the first welding head 12, the straightening machine a 10, and the auxiliary centering device a1 4 are arranged sequentially on welding line I 16. The auxiliary centering device b2 7. The second heat treatment head 15, the second welding head 13, the straightening machine b 11, and the auxiliary centering device b1 5 are arranged sequentially on welding line II 17; the straightening machine a 10 is used to perform heat straightening treatment on the first welded joint after heat treatment, and the straightening machine b 11 is used to perform heat straightening treatment on the second welded joint after heat treatment; the controller 3 controls the opening and closing of the flash welding machine, the heat treatment machine, the auxiliary centering device a1 4, the auxiliary centering device b1 5, the auxiliary centering device a2 6, the auxiliary centering device b2 7, the straightening machine a 10, and the straightening machine b 11.

[0026] It should be noted that flash welding can also be replaced by a gas pressure welding machine. Before welding, the two opposing steel rails need to be clamped by the clamping mechanism inside the flash welding machine. This process is common knowledge known to those skilled in the art. The clamping structure inside the welding machine in this invention is a structure known to those skilled in the art, for example, it can be the structure described in Chinese Patent ZL202022073542.5. Figure 2 , Figure 3 The structure is shown in Figure 7; the straightening machine a 10 and the straightening machine b 11 in this invention are both existing technologies, that is, they can realize the function of hot straightening of the welded joint; the heat treatment machine also includes a heat treatment power supply 46, which converts three-phase AC power into a single-phase medium-frequency current of a certain frequency to power the heat treatment circuit.

[0027] The present invention provides a vehicle-mounted welding equipment for railway long rail replacement operations, comprising a welding operation vehicle 1 and a powered flatbed vehicle 2. The welding operation vehicle 1 includes a flash welding machine, a heat treatment machine, auxiliary centering devices a1 4, b1 5, a2 6, and b2 7, a straightening machine a10, a straightening machine b11, and a controller 3. The powered flatbed vehicle 2 includes a power supply device and an air compressor 42. The welding operation vehicle 1 is equipped with multiple first rollers and multiple second rollers. Rails a1 18 and b1 20 are welded to form a first weld joint, and rails a2 19 and b2 21 are welded to form a second weld joint. During heat treatment of the first weld joint, the auxiliary centering devices a1 4 and b1 5 continuously clamp rails a1 18 and b1 20, respectively, reducing the deformation of the first weld joint during heat treatment. Similarly, the auxiliary centering devices a2 6 and b2 7... 6. The auxiliary alignment devices b2 and 7 continuously clamp rails a2 19 and b2 21 respectively, reducing the deformation of the second welded joint during heat treatment and lowering the safety risks of high-speed railway rail overhaul construction. The integrated first welding head 12 and first heat treatment head 14 only need to be moved horizontally when heat treating the first welded joint to align the first heat treatment head 14 with the first welded joint, reducing the time required for welding and heat treatment of the first welded joint and improving rail replacement efficiency. Similarly, the integrated second welding head 13 also reduces the time required for welding and heat treatment of the second welded joint, further improving rail replacement efficiency. The railway long rail replacement operation vehicle-mounted welding equipment and welding operation method provided by this invention can realize the online rail laying and rail welding within the same maintenance window, and welding lines I 16 and II 17 can carry out different welding operation procedures simultaneously, improving rail replacement efficiency.

[0028] like Figure 1 As shown, the system also includes rail brakes a1 8 and a2 9. Rail brake a1 8 is used to brake or release rail a1 18, and rail brake a2 9 is used to brake or release rail a2 19. In this embodiment, rail brake a1 8 ensures that rail a1 18 stops precisely after reaching the welding position, and similarly, rail brake a2 9 ensures that rail a2 19 stops precisely after reaching the welding position, thus improving the ease of use of the on-board welding equipment for railway long rail replacement operations.

[0029] like Figure 1 and Figure 3 As shown, the auxiliary centering device a1 4 includes a first hydraulic cylinder 22, a double-sided rack 23, a first swing arm 24, and a second swing arm 25. One end of the first swing arm 24 is provided with a first rotating shaft 26 and a first gear 27 that can rotate around the first rotating shaft 26. The other end of the swing arm is provided with a first pressure head. One end of the second swing arm 25 is provided with a second rotating shaft 28 and a second gear 29 that can rotate around the second rotating shaft 28. The other end of the second swing arm 25 is provided with a second pressure head. The two sides of the double-sided rack 23 are respectively meshed with the first gear 27 and the second gear 29. The first hydraulic cylinder 22 includes a first telescopic rod, and the end face of the first telescopic rod is equipped with the double-sided rack 23. The first swing arm 24 and the second swing arm 25 are respectively located on both sides of the double-sided rack 23. When the first telescopic rod extends or retracts, the double-sided rack 23 drives the first pressure head and the second pressure head to clamp or release the rail a1 18. Auxiliary centering devices b1 5, a2 6, and b2 are also included. All 7 are structurally identical to the auxiliary centering device a1 4. In this embodiment, the extension or retraction of the first telescopic rod enables the auxiliary centering device a1 4 to clamp or release rail a1 18, thereby improving the accuracy of rail centering and improving the straightness of the rail welded joint. Similarly, the clamping or releasing of rail a2 19 by auxiliary centering device a2 6, the clamping or releasing of rail b1 20 by auxiliary centering device b1 5, and the clamping or releasing of rail b2 21 by auxiliary centering device b2 7 can all be achieved using the same clamping device as auxiliary centering device a1 4, further improving the accuracy of rail centering and improving the straightness of the rail welded joint.

[0030] like Figure 1 and Figure 4As shown, rail brake a1 8 includes a second hydraulic cylinder 30, a third swing arm 31, a fourth swing arm 32, a first connecting shaft 33, and a second connecting shaft 34. The third hydraulic cylinder includes a cylinder body and a piston rod. One end of the first connecting shaft 33 is rotatably mounted on the cylinder body, and the other end of the first connecting shaft 33 is fixed to one end of the third swing arm 31. The other end of the third swing arm 31 is provided with a third rotating shaft 35 and a first roller 36 that can rotate around the third rotating shaft 35. One end of the second connecting shaft 34 is rotatably mounted on the piston rod, and the other end of the second connecting shaft 34 is fixed to one end of the fourth swing arm 32. The other end of the fourth swing arm 32 is provided with a fourth rotating shaft 37 and a second roller 38 that can rotate around the fourth rotating shaft 37. When the piston rod extends or retracts, it drives the first roller 36 and the second roller 38 to clamp or release rail a1 18. Rail brake a2 9 has the same structure as rail brake a1 8 and is used to clamp or release rail a2 19. It should be noted that the piston rod and cylinder move simultaneously in opposite directions or retract simultaneously in the same direction. In this embodiment, the extension or retraction of the piston rod and cylinder achieves the braking or release of rail a118, thereby improving the accuracy of the parking position of rail a118; similarly, rail brake a29 can also achieve the braking or release of rail a219, further improving the accuracy of the parking position of rail a219.

[0031] In one embodiment of the present invention, the first welding head 12 further includes a first ranging sensor and a second ranging sensor, and the second welding head 13 further includes a third ranging sensor and a fourth ranging sensor. The first ranging sensor, the second ranging sensor, the third ranging sensor and the fourth ranging sensor are all communicatively connected to the controller 3. The relative position of the top surfaces of rails a1 18 and b1 20 can be identified by a first ranging sensor, and the relative position of the working edges of rails a1 18 and b1 20 can be identified by a second ranging sensor. This allows for more accurate adjustment of the positions of rails a1 18 and b1 20, resulting in better alignment of rails a1 18 and b1 20 and improving rail alignment accuracy, which is beneficial for improving the straightness of the welded joint. Similarly, the relative position of the top surfaces of rails a2 19 and b2 21 can be identified by a third ranging sensor, and the relative position of the working edges of rails a2 19 and b2 21 can be identified by a fourth ranging sensor. This allows for more accurate adjustment of the positions of rails a2 19 and b2 21, resulting in better alignment of rails a2 19 and b2 21 and further improving rail alignment accuracy, which is beneficial for improving the straightness of the welded joint.

[0032] In one embodiment of the present invention, the flash welding machine further includes an autotransformer 39. The autotransformer 39 ensures that the voltage of the flash welding machine is relatively stable during use, thereby improving the stability of flash welding during operation and thus improving the stability of the on-board welding equipment for railway long rail replacement operations.

[0033] In one embodiment of the present invention, the first welding head 12 further includes a second welding head 13, and the second welding head 13 further includes a second pressure-holding and pushing device. It should be noted that the first and second pressure-holding and pushing devices inside the welding machine in this invention are structures known to those skilled in the art, for example, the structure illustrated in Figure 6 of Chinese Patent ZL202022073542.5. The first pressure-holding and pushing device performs a pressure-holding and pushing process on the first weld joint, thereby ensuring the welding quality and straightness of the first weld joint. The second pressure-holding and pushing device performs a pressure-holding and pushing process on the second weld joint, thereby ensuring the welding quality and straightness of the second weld joint.

[0034] like Figure 2 As shown, the welding operation vehicle 1 also includes a hydraulic station 40 and a chiller 41. In one embodiment of the present invention, the chiller 41 cools the first heat treatment head 14 and the second heat treatment head 15 during operation, ensuring the normal operation of the first welding joint, the second welding joint, the first heat treatment head, and the second heat treatment head.

[0035] like Figure 2 As shown, the power supply device includes an isolation transformer 43, an energy storage converter 44, and a battery pack 45. The battery pack 45 provides new energy power for the onboard welding equipment used in railway long rail replacement operations, reducing environmental pollution caused by traditional diesel generators and ensuring the safety of workers. The isolation transformer 43 prevents common-mode interference and isolates different potentials, while the energy storage converter 44 controls the charging and discharging process of the battery pack 45, improving the power supply stability of the power supply device.

[0036] like Figures 1 to 5As shown, based on the same inventive concept, one embodiment of the present invention also provides a welding operation method, which uses the on-board welding equipment for railway long rail replacement operations described in the aforementioned embodiment to perform welding operations, including the following steps: Step 1, two rails a1 18 and rail a2 19 to be welded enter the welding operation vehicle 1, and respectively enter the parallel welding line I 16 and welding line II 17. Rail a1 18 on welding line I 16 passes sequentially through the auxiliary centering device b1 5, the first heat treatment head 14, the first welding head 12, the auxiliary centering device b1 4, the straightening machine a 10, and the rail brake a18 under the drive of the first roller, until the tail end of rail a1 18 reaches the welding position of the first welding head, the rail brake a1 8 is activated to stop rail a1 18. At the same time, rail a2 19 on welding line II 17... Driven by the second roller, rail a219 passes sequentially through auxiliary centering device b27, second heat treatment head 15, second welding head 13, auxiliary centering device a26, straightener b11, and rail brake a29 until the tail end of rail a219 reaches the welding position of the second welding head. Then, rail brake a29 is activated to stop rail a219. Next, two rails to be welded, b120 and b221, are fed into welding line I 16 and welding line II 17 respectively. The head of rail b120 passes sequentially through auxiliary centering device b15 and first heat treatment head 14 to reach the welding position of the first welding head. Simultaneously, the head of rail b221 passes sequentially through auxiliary centering device b27 and second heat treatment head 15 to reach the welding position of the second welding head. In step two, the auxiliary centering device b15 on welding line I aligns rail b120 with the welding head of the second welding head. 20 performs auxiliary centering clamping, and auxiliary centering device a1 4 performs auxiliary centering clamping on rail a1 18 to complete the auxiliary centering action of rail a1 18 and rail b1 20. At the same time, auxiliary centering device a2 6 on welding line II 17 performs auxiliary centering clamping on rail a2 19, and auxiliary centering device b2 7 performs auxiliary centering clamping on rail b2 21 to complete the auxiliary centering action of rail a2 19 and rail b2 21.Step 3: First, start the first welding head 12 to complete the welding of rails a1 18 and b1 20 on welding line I 16, forming the first welded joint. Then, start the first pressure-holding and pushing device to hold the pressure and push the joint. Next, start the air compressor to cool the first welded joint with compressed air. While cooling the first welded joint with compressed air, start the second welding head 13 to complete the welding of rails a2 19 and b2 on welding line II 17. Welding step 21 forms the second weld joint. The second pressure-holding and pushing device is activated to maintain pressure and push the second weld joint. The air compressor is then activated to cool the second weld joint with compressed air. Simultaneously, the integrated first welding head 12 is moved so that the first heat treatment head 14 is aligned with the first weld joint. The first heat treatment head 14 is activated to heat-treat the first weld joint. The air compressor is then activated to cool the heat-treated first weld joint with compressed air. Simultaneously, the integrated second welding head 13 is moved so that the second heat treatment head 15 is aligned with the second weld joint. The second heat treatment head 15 is activated to heat-treat the second weld joint. The air compressor is then activated to cool the heat-treated second weld joint with compressed air. In step four, while the heat-treated second weld joint is being cooled with compressed air, a handheld portable grinding and measuring tool is used to grind the first weld joint and measure its straightness. If necessary, the straightening machine a is activated. Step 10: Perform hot straightening on the first welded joint and use a handheld portable flaw detector to inspect the first welded joint, forming the first long rail; Step 5: Use a handheld portable grinding and measuring tool to grind and measure the straightness of the second welded joint. If necessary, start the straightening machine b 11 to perform hot straightening on the second welded joint and use a handheld portable flaw detector to inspect the second welded joint, forming the second long rail; Step 6: Drive the first long rail with the first roller until the tail of the first long rail reaches the welding station of the first welding head 12. Drive the second long rail with the second roller until the tail of the second long rail reaches the welding station of the second welding head 13. Then, put the two rails to be welded into welding line I 16 and welding line II 17 respectively, until the two rails to be welded reach the welding stations of the first welding head 12 and the second welding head 13 respectively. Repeat the above welding process to continue welding the subsequent new rails until the rail welding task for the day is completed.

[0037] It should be noted that: auxiliary centering devices a1 4, b1 5, a2 6, and b2 7 are all coarse centering devices.

[0038] This invention provides a vehicle-mounted welding equipment and welding method for railway long rail replacement operations. The vehicle-mounted welding equipment for railway long rail replacement operations includes a welding operation vehicle 1 and a powered flatbed vehicle 2. The welding operation vehicle 1 includes a flash welding machine, a heat treatment machine, auxiliary centering devices a1 4, b1 5, a2 6, and b2 7, a straightening machine a10, a straightening machine b11, and a controller 3. The powered flatbed vehicle 2 includes a power supply device and an air compressor 42. The welding operation vehicle 1 is equipped with multiple first rollers and multiple second rollers. After welding rails a1 18 and b1 20, a first welded joint is formed. After welding rails a2 19 and b2 21, a second welded joint is formed. During the heat treatment of the first welded joint, the auxiliary centering devices a1 4 and b1 5 are used to heat treat rails a1 18 and b1 20 respectively. 20 achieves continuous clamping, reducing the deformation of the first welded joint during heat treatment. Similarly, the auxiliary centering devices a26 and b27 are used to center rails a219 and b219 respectively. The continuous clamping mechanism 21 reduces the deformation of the second welded joint during heat treatment, thus lowering the safety risks of high-speed railway rail overhaul construction. The integrated first welding head 12 and first heat treatment head 14 allow for easy alignment of the first heat treatment head 14 with the first welded joint during heat treatment by simply moving the integrated first welding head 12 horizontally. This reduces the time required for welding and heat treatment of the first welded joint, improving rail replacement efficiency. Similarly, the integrated second welding head 13 also reduces the time required for welding and heat treatment of the second welded joint, further improving rail replacement efficiency. The railway long rail replacement operation vehicle-mounted welding equipment and welding method provided by this invention can complete online rail laying and welding within the same maintenance window. Furthermore, welding lines 16 and 17 can perform different welding operations simultaneously, further improving rail replacement efficiency.

[0039] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A vehicle-mounted welding device for railway long rail replacement operations, characterized in that, Including welding work vehicles and powered flatbed trucks, among which: The welding operation vehicle includes a flash welding machine, a heat treatment machine, auxiliary centering device a1, auxiliary centering device b1, auxiliary centering device a2, auxiliary centering device b2, straightening machine a, straightening machine b, and a controller. The welding operation vehicle is equipped with multiple first rollers and multiple second rollers. The multiple first rollers are used to place or move rail a1 and rail b1, and the multiple second rollers are used to place or move rail a2 and rail b2. The powered flatbed vehicle includes a power supply unit and an air compressor; The heat treatment machine includes a first heat treatment head and a second heat treatment head; The flash welding machine includes a first welding head and a second welding head. One end of the first welding head integrates a first heat treatment head, and one end of the second welding head integrates a second heat treatment head. The first welding head and the second welding head are arranged opposite each other along the width direction of the welding vehicle. The first welding head is used to weld the opposing rails a1 and b1 to form a first welded joint. The first heat treatment head is used to heat-treat the first welded joint, and the air compressor is used to cool the first welded joint. The second welding head is used to weld the opposing rails a2 and b2 to form a second welded joint. The second heat treatment head is used to heat-treat the second welded joint, and the air compressor is used to cool the second welded joint. Both the first welding head and the second welding head are slidably arranged along the length direction of the welding vehicle. The auxiliary centering device a1 is used to assist in clamping the rail a1, the auxiliary centering device a2 is used to assist in clamping the rail a2, the auxiliary centering device b1 is used to assist in clamping the rail b1, and the auxiliary centering device b2 is used to assist in clamping the rail b2. The welding operation vehicle has welding line I and welding line II arranged parallel to each other along its width. The auxiliary centering device b1, the first heat treatment head, the first welding head, the straightening machine a, and the auxiliary centering device a1 are arranged sequentially on welding line I. The auxiliary centering device b2, the second heat treatment head, the second welding head, the straightening machine b, and the auxiliary centering device b1 are arranged sequentially on welding line II. The straightening machine a is used to perform hot straightening treatment on the first welded joint after heat treatment, and the straightening machine b is used to perform hot straightening treatment on the second welded joint after heat treatment. The controller controls the opening and closing of the flash welding machine, the heat treatment machine, the auxiliary centering device a1, the auxiliary centering device b1, the auxiliary centering device a2, the auxiliary centering device b2, the straightening machine a, and the straightening machine b; The device also includes a rail brake a1 and a rail brake a2, wherein the rail brake a1 is used to brake or release the rail a1, and the rail brake a2 is used to brake or release the rail a2.

2. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 1, characterized in that, The auxiliary centering device a1 includes a first hydraulic cylinder, a double-sided rack, a first swing arm, and a second swing arm. One end of the first swing arm is provided with a first rotating shaft and a first gear that can rotate around the first rotating shaft. The other end of the swing arm is provided with a first pressure head. One end of the second swing arm is provided with a second rotating shaft and a second gear that can rotate around the second rotating shaft. The other end of the second swing arm is provided with a second pressure head. The two sides of the double-sided rack are respectively meshed with the first gear and the second gear. The first hydraulic cylinder includes a first telescopic rod. The double-sided rack is installed on the end face of the first telescopic rod. The first swing arm and the second swing arm are respectively provided on both sides of the double-sided rack. When the first telescopic rod extends or retracts, the double-sided rack drives the first pressure head and the second pressure head to clamp or release the rail a1. The auxiliary centering device b1, the auxiliary centering device a2 and the auxiliary centering device b2 are all structurally identical to the auxiliary centering device a1.

3. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 2, characterized in that, The rail brake a1 includes a second hydraulic cylinder, a third swing arm, a fourth swing arm, a first connecting shaft, and a second connecting shaft. The second hydraulic cylinder includes a cylinder body and a piston rod. One end of the first connecting shaft is rotatably mounted on the cylinder body, and the other end of the first connecting shaft is fixed to one end of the third swing arm. The other end of the third swing arm is provided with a third rotating shaft and a first roller that can rotate around the third rotating shaft. One end of the second connecting shaft is rotatably mounted on the piston rod, and the other end of the second connecting shaft is fixed to one end of the fourth swing arm. The other end of the fourth swing arm is provided with a fourth rotating shaft and a second roller that can rotate around the fourth rotating shaft. When the piston rod extends or retracts, it drives the first roller and the second roller to brake or release the rail a1. The rail brake a2 has the same structure as the rail brake a1 and is used to brake or release the rail a2.

4. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 3, characterized in that, The first welding head further includes a first ranging sensor and a second ranging sensor, and the second welding head further includes a third ranging sensor and a fourth ranging sensor. The first ranging sensor, the second ranging sensor, the third ranging sensor and the fourth ranging sensor are all communicatively connected to the controller.

5. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 4, characterized in that, The flash welding machine also includes an autotransformer.

6. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 5, characterized in that, The first welding head further includes a first pressure-holding and scalpel pushing device, and the second welding head further includes a second pressure-holding and scalpel pushing device.

7. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 6, characterized in that, The welding vehicle also includes a hydraulic station and a chiller.

8. The vehicle-mounted welding equipment for railway long rail replacement operations according to claim 7, characterized in that, The power supply device includes an isolation transformer, an energy storage converter, and a battery pack.

9. A welding operation method, characterized in that, The welding operation using the vehicle-mounted welding equipment for railway long rail replacement as described in claim 8 includes the following steps: Step 1: Two rails, a1 and a2, to be welded enter the welding vehicle and respectively enter the parallel welding lines I and II. On welding line I, rail a1, driven by the first roller, sequentially passes through the auxiliary centering device b1, the first heat treatment head, the first welding head, the auxiliary centering device a1, the straightening machine a, and the rail brake a1 until the tail end of rail a1 reaches the welding position of the first welding head. At this point, the rail brake a1 is activated, stopping rail a1. Simultaneously, on welding line II, rail a2, driven by the second roller, sequentially passes through the auxiliary centering device b2, the first heat treatment head, the first welding head, the auxiliary centering device b1, the straightening machine a, and the rail brake a1. The process involves the second heat treatment head, the second welding head, the auxiliary centering device a2, the straightening machine b, and the rail brake a2. When the tail end of rail a2 reaches the welding position of the second welding head, the rail brake a2 is activated to stop rail a2. Then, two rails, b1 and b2, are fed into welding lines I and II respectively. The head of rail b1 passes sequentially through the auxiliary centering device b1 and the first heat treatment head to reach the welding position of the first welding head. Simultaneously, the head of rail b2 passes sequentially through the auxiliary centering device b2 and the second heat treatment head to reach the welding position of the second welding head. Step 2: On welding line I, auxiliary centering device b1 clamps and centers rail b1, and auxiliary centering device a1 clamps and centers rail a1, completing the auxiliary centering action of rail a1 and rail b1. Simultaneously, on welding line II, auxiliary centering device a2 clamps and centers rail a2, and auxiliary centering device b2 clamps and centers rail b2, completing the auxiliary centering action of rail a2 and rail b2. Step 3: First, start the first welding head to complete the welding of rail a1 and rail b1 on welding line I, forming the first welded joint. Then, start the first pressure-holding and pushing device to hold pressure and push the first welded joint. Next, start the air compressor to spray air to cool the first welded joint. While cooling the first welded joint, start the second welding head to complete the welding of rail a2 and rail b2 on welding line II, forming the second welded joint. Then, start the second pressure-holding and pushing device to hold pressure and push the second welded joint. Finally, start the air compressor to spray air to cool the second welded joint. However, while the second welded joint is being cooled by air spray, the integrated first welding head is moved so that the first heat treatment head is aligned with the first welded joint, and the first heat treatment head is started to heat treat the first welded joint. Then the air compressor is started to cool the heat-treated first welded joint by air spray. While the first welded joint is being cooled by air spray, the integrated second welding head is moved so that the second heat treatment head is aligned with the second welded joint, and the second heat treatment head is started to heat treat the second welded joint. Then the air compressor is started to cool the heat-treated second welded joint by air spray. Step 4: While the second welded joint that has undergone heat treatment is cooled by air spray, the first welded joint is ground and its straightness is measured by hand-held portable grinding and measuring tools. If necessary, the straightening machine a is started to perform hot straightening treatment on the first welded joint, and the first welded joint is inspected by hand-held portable flaw detector to form the first long rail. Step 5: Use a handheld portable grinding and measuring tool to grind and measure the straightness of the second welded joint. If necessary, start the straightening machine b to perform hot straightening treatment on the second welded joint, and use a handheld portable flaw detector to perform flaw detection on the second welded joint to form the second long rail. Step Six: The first long rail is driven by the first roller until its tail reaches the welding station of the first welding head. The second long rail is driven by the second roller until its tail reaches the welding station of the second welding head. The two rails to be welded are then fed into welding line I and welding line II respectively until they reach the welding stations of the first and second welding heads respectively. The above welding process is repeated to continue welding subsequent new rails until the rail welding task for the day is completed.

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