Air control spraying and lubricating machine and spraying method for high viscosity grease of steel rail bolt

Abstract

The application discloses a kind of high viscous grease full-automatic pneumatic control spraying oiling machine and spraying method for rail bolt, including rack, PLC controller, hydraulic pneumatic system and multiple sets of spraying system;Each set of spraying system includes two groups of oil injection unit, and hydraulic pneumatic system includes motor, air compressor, gas tank, oil circuit and gas circuit;The oil circuit includes oil tank and pneumatic diaphragm pump, the outlet end of gas tank is connected with the gas inlet pipe of pneumatic diaphragm pump, the oil inlet pipe of pneumatic diaphragm pump is connected with oil tank, the oil outlet of pneumatic diaphragm pump is connected with the fluid inlet pipe of each fluid control valve, and the fluid outlet of fluid control valve is connected with nozzle pipe.The hydraulic pneumatic system of the application uses the method of low viscous fluid to control high viscous fluid to complete the control and spraying of high viscous grease oil, discards the scheme of electromagnetic valve directly controlling high viscous grease, reduces the failure rate of system, and greatly improves the robustness of system.

Description

Technical Field

[0001] This invention belongs to the field of railway track maintenance and relates to a high-viscosity grease pneumatic spraying machine and spraying method for rail bolts. Background Technology

[0002] Railway rails are bolted to the ground. During rail maintenance, the bolts need to be lubricated to prevent rust. Traditional methods of lubricating bolts include manual brushing, which is inefficient, results in uneven application, and is labor-intensive. Another method uses a lubricating machine to lubricate all bolts along the track, which, while reducing labor costs to some extent, suffers from low automation, energy waste, significant pollution, and low efficiency. High-viscosity greases are effective at preventing rust on rail bolts, but currently, most high-viscosity grease applications remain manual, which is particularly time-consuming and labor-intensive.

[0003] The utility model patent "A Fully Automatic Oil Sprayer for Rail Bolts" with application number 202121390729.6 and publication number CN 215042790 U uses a PLC control module as its core. The PLC control module sends an oil spraying command to the solenoid valves of the hydraulic system. The solenoid valves open, and lubricating oil is instantly sprayed onto the rail bolts through the nozzles. The hydraulic system for oil spraying includes an oil tank, an overflow valve, an oil pump, a check valve, an accumulator, and two solenoid valves connected by an oil circuit. The oil pump draws oil from the oil tank and divides it into two paths: one path goes through the overflow valve to the oil tank, and the other path goes through the check valve and then enters the accumulator and the two solenoid valves respectively. Each solenoid valve controls a corresponding nozzle. However, this patent still has shortcomings. Specifically, the solenoid valve-controlled oil circuit opening and closing scheme cannot meet the requirements for high-viscosity greases. On the one hand, the oil circuit in the solenoid valve is too small to allow the grease to pass through smoothly and cannot reach the theoretical output value. On the other hand, high-viscosity greases are prone to clogging the oil circuit channels, and the solenoid valve cannot obtain the switching force to overcome the viscosity of the grease, which can easily burn out the solenoid valve coil. Based on the above two reasons, the solenoid valve-controlled oil circuit opening and closing scheme cannot be used for spraying high-viscosity greases. Summary of the Invention

[0004] The purpose of this invention is to provide a pneumatic spraying machine and method for high-viscosity grease coating on rail bolts. It abandons the technology of controlling the nozzle to spray oil with a solenoid valve and adopts a PLC controller to control the hydraulic and pneumatic system. The hydraulic and pneumatic system makes corresponding actions and automatically controls the nozzle to complete the spraying of high-viscosity grease.

[0005] To achieve the above objectives, the present invention employs the following technical solutions.

[0006] A high-viscosity grease pneumatic spraying machine for rail bolts includes a frame, PLC controller, hydraulic and pneumatic system and multiple spraying systems; Each spraying system includes two sets of spraying units, each set of spraying units includes a nozzle and a fluid control valve; the fluid control valve includes a valve body and a cylinder, the valve body is provided with a fluid inlet and a fluid outlet, and the cylinder is provided with two air holes. The hydraulic-pneumatic system includes a motor, an air compressor, an air tank, an oil circuit, and an air circuit. The motor is connected to the air compressor. The outlet of the air compressor is connected to the inlet of the air tank via a pipeline. Starting from the outlet of the air tank, the pipeline splits into two paths: one connecting to the oil circuit and the other connecting to the air circuit. The oil circuit includes an oil tank and a pneumatic diaphragm pump. The outlet of the air tank is connected to the air inlet pipeline of the pneumatic diaphragm pump, the oil tank is connected to the oil inlet pipeline of the pneumatic diaphragm pump, the oil outlet of the pneumatic diaphragm pump is connected to the fluid inlet pipeline of each fluid control valve, and the fluid outlet of the fluid control valve is connected to the nozzle pipeline.

[0007] In the above-mentioned high-viscosity grease pneumatic spraying oiling machine for rail bolts, the valve body is provided with a valve cavity, and the fluid inlet, fluid outlet and valve cavity are connected; the two air holes on the cylinder are the first air hole and the second air hole, the first air hole is connected to the front chamber of the cylinder and the second air hole is connected to the rear chamber of the cylinder.

[0008] In the aforementioned high-viscosity grease pneumatic spraying machine for rail bolts, the pneumatic circuit includes multiple two-position two-way solenoid valves and multiple two-position five-way solenoid valves; the number of two-position two-way solenoid valves, two-position five-way solenoid valves, and oil spraying units are equal; one oil spraying unit corresponds to one two-position two-way solenoid valve, and one oil spraying unit corresponds to one two-position five-way solenoid valve; the outlet end of the air tank is connected to the pipelines of each two-position two-way solenoid valve and each two-position five-way solenoid valve, each two-position two-way solenoid valve is then connected to the corresponding nozzle pipeline, and the two working ports of each two-position five-way solenoid valve are then connected to the two air hole pipelines of the corresponding fluid pneumatic control valve.

[0009] In the above-mentioned high-viscosity grease pneumatic spraying oiling machine for rail bolts, the motor, the two-position two-way solenoid valve and the two-position five-way solenoid valve are respectively controlled by a PLC controller.

[0010] In the above-mentioned high-viscosity grease pneumatic spraying machine for rail bolts, the multiple spraying systems are respectively set on the left and right sides of the bottom of the frame; each spraying system also includes an electric push rod and a horizontal mounting plate, one end of the electric push rod is fixed to the bottom of the frame, and the other end is fixed to the horizontal mounting plate; two sets of oil spraying units are respectively set on the left and right ends of the horizontal mounting plate; the electric push rod is controlled by a PLC controller.

[0011] In the above-mentioned high-viscosity grease pneumatic spraying oiling machine for rail bolts, multiple detection systems are installed at the bottom of the frame. The number of detection systems is the same as the number of spraying systems, with one detection system corresponding to one spraying system. The detection system includes a sensor, a sensor extension block, and a right-angle folding bracket. The right-angle folding bracket is fixed to the bottom of the frame, and the sensor is installed on the right-angle folding bracket. The sensor contact is provided with a sensor extension block.

[0012] In the above-mentioned high-viscosity grease pneumatic spraying oiling machine for rail bolts, the bottom of the frame is provided with multiple traveling wheels; all or some of the traveling wheels are provided with a drive device; the drive device includes a stepper motor and a reducer, the stepper motor is connected to the reducer, and the reducer is connected to the wheel drive shaft of the traveling wheel by a key; the stepper motor is controlled by a PLC controller.

[0013] The method for spraying high-viscosity grease using the aforementioned pneumatic sprayer for rail bolts includes the following steps: Step 1, First, adjust the position of the sensor and sensor extension block so that the sensor extension block can touch the rail bolts during the movement of the oiling machine; then, the PLC controller controls the electric push rods of all spraying systems to extend simultaneously so that the nozzles are lower than the upper surface of the rail. Step 2, The drive unit rotates the traveling wheels, and the oiling machine begins to move on the rails and start its formal work. Step 3, 3.1 When the oiling machine starts to move, the PLC controller controls the motor to start working, the air compressor provides air source and compresses gas, and delivers the compressed gas to the air tank for storage. The air tank then delivers compressed gas to the pneumatic diaphragm pump and air circuit. 3.2 When compressed gas enters the pneumatic diaphragm pump, the highly viscous grease in the oil tank is drawn into the pneumatic diaphragm pump; at this time, the two-position two-way solenoid valve is closed, the two-position five-way solenoid valve is de-energized, and the valve body of the fluid control valve is closed; the pneumatic diaphragm pump delivers the grease to the fluid inlet of the valve body but cannot pass through the valve body; no gas passes through the two-position two-way solenoid valve; 3.3 During the movement of the oiling machine, if the sensor extension block touches the rail bolt, the sensor sends a spraying signal to the PLC controller. After receiving the signal, the PLC controller energizes the 2-position 5-way solenoid valve, opening the valve body of the fluid control valve. The oil at the fluid inlet flows directly into the nozzle through the valve body. After a certain period of time, the oil fills the nozzle cavity. The PLC controller then de-energizes the 2-position 5-way solenoid valve, closing the valve body of the fluid control valve pump and stopping the supply of oil to the nozzle. At the same time, the PLC controller energizes the 2-position 2-way solenoid valve, opening it. Gas passes through the 2-position 2-way solenoid valve and flows to the nozzle. Under the pressure of the gas, the oil in the nozzle is sprayed out to coat the rail bolt. Step 4, After the first batch of rail bolts is sprayed, the oil in the nozzle cavity is used up. The pneumatic diaphragm pump will continue to deliver oil to the fluid inlet of the valve body. When the sensor extension block touches the next batch of rail bolts, the sensor sends a spraying signal to the PLC controller again. After receiving the signal, the PLC controller operates the two-position two-way solenoid valve and the two-position five-way solenoid valve to complete the spraying work of the nozzle again. Step 5, After the entire rail bolt spraying work is completed, the detection system and spraying system are retrieved to prevent them from colliding or rubbing against other objects.

[0014] In step 3.2 above, the two-position five-way solenoid valve is in a de-energized state. The compressed air from the air tank flows through the pipeline and the two-position five-way solenoid valve into the second air port of the fluid control valve. The air in the rear chamber increases, the piston rod extends, and the excess air in the front chamber is discharged from the first air port. The end of the piston rod blocks the valve cavity of the valve body. At this time, the valve body is in a closed state, and the oil cannot pass through the valve body at the fluid inlet. In step 3.3 above, the PLC controller energizes the two-position five-way solenoid valve. At this time, the compressed gas delivered by the gas tank passes through the pipeline and the two-position five-way solenoid valve. The gas flows into the first air hole of the fluid control valve pump and into the front chamber. The piston rod retracts, and the excess gas in the rear chamber is discharged from the second air hole. The valve body opens, and the oil at the fluid inlet flows directly into the nozzle through the valve body.

[0015] The beneficial effects of this invention are: The hydraulic-pneumatic system of this invention uses a low-viscosity fluid (gas) to control a high-viscosity fluid (oil) to control and spray high-viscosity grease, eliminating the need for a solenoid valve to directly control high-viscosity grease, reducing the system's failure rate and greatly improving its robustness.

[0016] This invention uses a low-pressure pneumatic spraying method to complete the grease spraying action, reducing the overall pressure of the hydraulic system, ensuring operation in a safe environment for the human body, and greatly improving system safety.

[0017] 3. This invention uses a PLC controller to control a hydraulic and pneumatic system. The hydraulic and pneumatic system performs corresponding actions, controlling the flow of high-viscosity grease by controlling the cylinder movement of the fluid control valve. The fluid control valve has a wide fluid channel, which prevents high-viscosity grease from clogging, allowing the grease to pass smoothly and resulting in a relatively stable output volume.

[0018] 4. The hydraulic-pneumatic system of this invention controls the operation of a pneumatic diaphragm pump by delivering compressed gas. Compared to gear pumps, centrifugal pumps, and vane pumps, the pneumatic diaphragm pump has unparalleled advantages in pumping highly viscous greases and oils. Specifically, these advantages are: First, the pneumatic diaphragm pump is more suitable for liquids with higher viscosity, and the diaphragm pump itself is less prone to wear. For high-viscosity greases containing impurities, the lifespan of the pneumatic diaphragm pump is significantly increased compared to gear pumps, centrifugal pumps, and vane pumps. Second, using a pneumatic diaphragm pump eliminates the need for an electric diaphragm pump, improving the pump's lifespan and reducing the overall system power. Third, using a pneumatic diaphragm pump increases the utilization rate of gas, reduces the redundancy of the pneumatic system, fully utilizes the pneumatic system, and unifies the control medium for oil supply, oil control, and oil injection, thus unifying the overall control scheme.

[0019] 5. The detection system, hydraulic and pneumatic system and spraying system of this invention work together precisely to automatically complete the oil spraying work, and the spraying is accurate and error-free; moreover, the oiling machine does not need to be stopped during spraying. Attached Figure Description

[0020] Figure 1 This is a front view of the pneumatic spray painting machine of the present invention; Figure 2 for Figure 1 A bottom view; Figure 3 for Figure 1 The left view; Figure 4 This is a schematic diagram of the spraying system in the oiling machine of the present invention; Figure 5 This is a schematic diagram of the fluid pneumatic control valve in the oiling machine of the present invention; Figure 6 This is a schematic diagram of the hydraulic and pneumatic system in the oiling machine of the present invention; (the solid lines in the figure represent the oil circuit, and the dashed lines represent the air circuit). Figure 7 This is a schematic diagram of the detection system in the oiling machine of the present invention; Figure 8 This is a schematic diagram of the traveling wheels and drive device in the oiling machine of the present invention; Figure 9 This is a schematic diagram of the structure of the first component box in the oiling machine of the present invention, which is mounted on the machine frame; Figure 10This is a block diagram illustrating the working principle of the PLC controller in the oiling machine of the present invention.

[0021] In the picture: 1. Detection system; 101. Sensor; 102. Sensor expansion block; 103. Mounting block; 104. Right-angle folding bracket; 105. Spring; 106. Contact; 2. Spraying system; 201. Electric actuator; 202. Horizontal mounting plate; 203. Nozzle; 204. Fluid pneumatic control valve; 205. Spraying unit; 2041. Valve body; 2042. Cylinder; 2043. Fluid inlet; 2044. Fluid outlet; 2045. Piston; 2046. Piston rod; 2047. Front chamber; 2048. Rear chamber; 2049. First air port; 2050. Second air port; 301. Traveling wheel; 302. Support plate; 303. Stepper motor; 304. Reducer; 305. Wheel drive shaft; 4. PLC controller display screen; 5. Rack; 6. Hydraulic and pneumatic system; 601. Motor; 602. Air compressor; 603. Air tank; 604. Exhaust valve; 605. First pressure regulating valve; 606. Second pressure regulating valve; 607. Oil tank; 608. Pneumatic diaphragm pump; 609. Relief valve; 610. Two-position two-way solenoid valve; 611. Two-position five-way solenoid valve; 612. Pressure gauge; 613. First pipeline; 614. Second pipeline; 615. Third pipeline; 616. Fourth pipeline; 7. Seat; 8. First component box; 9. Second component box; 10. Third component box. Detailed Implementation

[0022] like Figure 1 , Figure 2 and Figure 3 As shown, the present invention provides a high-viscosity grease pneumatic spraying machine for rail bolts, including a frame 5, a PLC controller, a hydraulic and pneumatic system 6, multiple traveling wheels 301, multiple detection systems 1, and multiple spraying systems 2. All traveling wheels 301, all detection systems 1, and all spraying systems 2 are located at the bottom of the frame 5.

[0023] like Figure 2 As shown, multiple spraying systems 2 are respectively installed on the left and right sides of the bottom of the frame 5. Figure 4As shown, each spraying system 2 includes an electric push rod 201, a horizontal mounting plate 202, and two sets of spraying units 205. One end of the electric push rod 201 is fixed to the bottom of the frame 5, and the other end is fixed to the horizontal mounting plate 202. The electric push rod 201 can extend and retract, controlled by a PLC controller. The two sets of spraying units 205 are respectively located at the left and right ends of the horizontal mounting plate 202. Each set of spraying units 205 includes a nozzle 203 and a fluid control valve 204.

[0024] like Figure 5 As shown, the pneumatic fluid control valve 204 includes a valve body 2041 and a cylinder 2042. The valve body 2041 has a fluid inlet 2043 and a fluid outlet 2044, and a valve cavity is provided within the valve body 2041, with the fluid inlet 2043, fluid outlet 2044, and valve cavity communicating with each other. The cylinder 2042 has a piston 2045 and a piston rod 2046, with the piston 2045 dividing the cylinder 2042's inner cavity into a front chamber 2047 and a rear chamber 2048. The cylinder 2042 also has a first air port 2049 and a second air port 2050, with the first air port 2049 communicating with the front chamber 2047 and the second air port 2050 communicating with the rear chamber 2048. The pneumatic fluid control valve 204 can be purchased directly from the market; the manufacturer is Delixi Electric Co., Ltd., and the product model is Q22HD-15.

[0025] like Figure 6As shown, the hydraulic-pneumatic system 6 includes a motor 601, an air compressor 602, an air tank 603, an oil circuit, and an air circuit. The motor 601 is connected to the air compressor 602; the outlet end of the air compressor 602 is connected to the inlet end of the air tank 603 via a pipeline. Starting from the outlet end of the air tank 603, the pipeline splits into two paths: one path connects to the oil circuit via a first pipeline 613, and the other path connects to the air circuit via a third pipeline 615. The oil circuit includes an oil tank 607 and a pneumatic diaphragm pump 608. The oil tank 607 contains highly viscous grease. The outlet of the air storage tank 603 is connected to the air inlet of the pneumatic diaphragm pump 608 through a first pipe 613. The oil tank 607 is connected to the oil inlet pipe of the pneumatic diaphragm pump 608. The oil outlet of the pneumatic diaphragm pump 608 is connected to a second pipe 614. The second pipe 614 then branches and connects to the fluid inlet 2043 pipe of each fluid control valve 204. The fluid outlet 2044 of the fluid control valve 204 is connected to the nozzle 203 pipe. The air circuit includes multiple two-position two-way solenoid valves 610 and multiple two-position five-way solenoid valves 611; the number of two-position two-way solenoid valves 610, two-position five-way solenoid valves 611 and fuel injection units 205 are equal; one fuel injection unit 205 corresponds to one two-position two-way solenoid valve 610, and one fuel injection unit 205 corresponds to one two-position five-way solenoid valve 611; the outlet end of the air tank 603 is connected to a third pipe 615, which branches to each two-position two-way solenoid valve 610 and each two-position five-way solenoid valve 611; each two-position two-way solenoid valve 610 is connected to the corresponding nozzle 203; and the two working ports of each two-position five-way solenoid valve 611 are connected to the two air holes (first air hole 2049 and second air hole 2050) of the corresponding fluid control valve 204.

[0026] Both the 2-position 2-way solenoid valve 610 and the 2-position 5-way solenoid valve 611 can be purchased directly from the market. The manufacturer and product model of the 2-position 2-way solenoid valve 610 is Airtac 2V025-08-B; the manufacturer and product model of the 2-position 5-way solenoid valve 611 is Airtac 4V 210-06-B.

[0027] Additionally, an exhaust valve 604 is installed at the outlet of the gas storage tank 603, at the intersection of the first pipe 613 and the third pipe 615. In the oil circuit, a first pressure regulating valve 605 is installed on the first pipe 613, and a pressure gauge 612 is installed on the second pipe 614; furthermore, a fourth pipe 616 connects the oil tank 607 to the oil outlet of the pneumatic diaphragm pump 608, and an overflow valve 609 is installed on the fourth pipe 616. In the air circuit, a second pressure regulating valve 606 is installed on the third pipe 615.

[0028] The method for spraying rail bolts using a hydraulic-pneumatic system 6 and a spraying system 2 is as follows: like Figure 6 and Figure 10 As shown, the PLC controller controls the motor 601 to work, the motor 601 drives the head of the air compressor 602 to move, the air compressor 602 provides an air source and compresses the gas, and then delivers the compressed gas to the air tank 603 for storage; starting from the outlet end of the air tank, the pipeline is divided into two paths, one leading to the oil circuit and the other leading to the air circuit.

[0029] Compressed gas is delivered from the outlet of the gas storage tank 603 to the pneumatic diaphragm pump 608 via the first pipe 613. The required gas pressure for the pneumatic diaphragm pump 608 is regulated by the first pressure regulating valve 605. When the compressed gas enters the pneumatic diaphragm pump 608, it first pushes one diaphragm to move in the opposite direction, creating a negative pressure in one chamber of the pneumatic diaphragm pump 608. This opens the suction valve, drawing the high-viscosity grease from the oil tank 607 into the pneumatic diaphragm pump 608 through the pipe. Then, compressed air passes through the pneumatic valve of the pneumatic diaphragm pump 608, driving the other diaphragm to move in the opposite direction. At this time, the diaphragm in the chamber that previously created the negative pressure moves, causing the oil to be discharged from the pneumatic diaphragm pump 608 under pressure through the discharge valve. With the continuous switching of the pneumatic valve in the pneumatic part of the pneumatic diaphragm pump 608, the two diaphragms move alternately, achieving continuous and uninterrupted oil delivery. When the oil reaches the fluid inlet 2043 of each fluid control valve 204 via the pneumatic diaphragm pump 608, the 2-position 2-way solenoid valve 610 is closed, and the 2-position 5-way solenoid valve 611 is de-energized. Compressed air from the air tank 603 flows through the third pipe 615 and its branch pipes, and through the 2-position 5-way solenoid valve 611, into the second air port 2050 of the fluid control valve 204. This increases the air volume in the rear chamber 2048, causing the piston rod 2046 to extend. Excess air in the front chamber 2047 is discharged through the first air port 2049. The end of the piston rod 2046 blocks the valve cavity of the valve body 2041, thus closing the valve body 2041. Oil cannot pass through the valve body 2041 at the fluid inlet 2043. Since the 2-position 2-way solenoid valve 610 is closed, no gas passes through it.

[0030] When the PLC controller receives the spraying signal, it energizes the two-position five-way solenoid valve 611. At this time, the compressed gas delivered by the gas tank 603 passes through the third pipe 615 and its branch pipes, and through the two-position five-way solenoid valve 611. The gas flows into the first air hole 2049 of the fluid control valve pump 204 and into the front chamber 2047. The piston rod 2046 retracts, and excess gas in the rear chamber 2048 is discharged from the second air hole 2050. The valve body 2041 opens, and the oil at the fluid inlet 2043 passes through the valve body 2041. 1. The oil flows directly into the nozzle 203. After a certain period of time, the inner cavity of the nozzle 203 is filled with oil. The PLC controller then de-energizes the two-position five-way solenoid valve 611, and the valve body 2041 of the fluid pneumatic control valve pump 204 closes, stopping the supply of oil to the nozzle 203. At the same time, the PLC controller then energizes the two-position two-way solenoid valve 610, and the two-position two-way solenoid valve 610 opens. The gas passes through the two-position two-way solenoid valve 610 and flows to the nozzle 203. Under the pressure of the gas, the oil in the nozzle 203 is sprayed out to coat the rail bolts.

[0031] Furthermore, when the gas storage tank 603 supplies compressed gas to the gas circuit, the gas pressure required by the gas circuit is regulated by the second regulating valve 606. Each of the two-position two-way solenoid valve 610, two-position five-way solenoid valve 611, nozzle 203, and fluid control valve 204 can be controlled independently without affecting each other during operation.

[0032] The gas pressure required by the pneumatic diaphragm pump 608 and the gas pressure in the pipeline after the second pressure regulating valve 606 are different. Different pressure thresholds need to be set according to the target requirements. The oil circuit coordination is different under different pressure combinations, and the pressure set is also different under different operating conditions. Therefore, the gas pressure required by the pneumatic diaphragm pump 608 is regulated by the first pressure regulating valve 605, and the gas pressure in the third pipeline 615 and its branch pipelines is regulated by the second regulating valve 606.

[0033] Furthermore, in the oil circuit, the overflow valve 609 installed on the fourth pipe 616 ensures the safety of the oil circuit system. When the oil pressure in the oil circuit exceeds the preset pressure, the overflow valve 609 automatically opens, and the excess oil flows back to the oil tank 607 to ensure the stability of the oil pressure in the oil circuit. The pressure gauge 612 installed on the second pipe 614 can monitor the oil pressure in the oil circuit in real time.

[0034] After the entire oiling process of the oiling machine is completed, the exhaust valve 604 is opened to quickly depressurize the gas in the air tank 603, the first pipe 613 and the air circuit. The gas pressure in the air tank 603 is zero, and the moisture in the compressed gas can also be discharged.

[0035] like Figure 1 , Figure 2 , Figure 3 and Figure 7 As shown, multiple detection systems 1 are also installed at the bottom of the frame 5. The number of detection systems 1 is the same as the number of spraying systems 2, with one detection system 1 corresponding to one spraying system 2. The detection system 1 includes a sensor 101, a sensor extension block 102, and a right-angle folding bracket 104. The right-angle folding bracket 104 is fixed to the bottom of the frame 5, and the sensor 101 is mounted on the right-angle folding bracket 104 via a mounting block 103. The sensor extension block 102 is installed on the contact 106 of the sensor 101. When the right-angle folding bracket 104 is fully extended, the spring 105 and contact 106 of the sensor 101 are perpendicular to the ground. When the oiling machine is working, if the sensor extension block 102 touches the rail bolt, the sensor 101 sends a spraying signal to the PLC controller. After receiving the signal, the PLC controller controls the hydraulic and pneumatic system 6 and the spraying system 2 to spray the rail bolt. The manufacturer and model of sensor 101 is Omron WLNJ-TH-N; sensor extension block 102 is a flat block structure installed at the end of contact 106 of sensor 101. Its wide surface is perpendicular to the rail and is used to widen the sensor detection range, increase sensing stability, and ensure that all bolts can be detected smoothly during operation.

[0036] like Figure 1 , Figure 2 , Figure 3 and Figure 8 As shown, the bottom of the frame 5 is equipped with multiple traveling wheels 301, which are symmetrically arranged on the left and right sides of the bottom of the frame 5. Specifically, the traveling wheels 301 are suspended and fixed to the support plate 302, which is in turn fixed to the bottom of the frame 5 by bolts. All or some of the traveling wheels 301 are equipped with a drive device, which includes a stepper motor 303 and a reducer 304. The stepper motor 303 is connected to the reducer 304, and the reducer 304 is connected to the wheel drive shaft 305 of the traveling wheel 301 by a key.

[0037] like Figure 10 As shown, the stepper motor 303 is controlled by a PLC controller. When the pneumatic spray painting machine is working, the PLC controller controls the stepper motor 303 to start working. After being reduced in speed by the reducer 304, the stepper motor 303 transmits torque through a key to the traveling wheels 301, causing them to rotate and enabling the painting machine to move. After the work is completed, the PLC controller controls the stepper motor 303 to stop working, the traveling wheels 301 stop rotating, and the entire painting machine stops moving. Alternatively, drive devices can be installed on all the traveling wheels 301, or on only some of them, for example, only on the two traveling wheels 301 at the very front of the frame 5. Figure 2 As shown.

[0038] like Figure 1As shown, three component boxes are fixed on the frame 5: the first component box 8, the second component box 9, and the third component box 10. Figure 9 As shown, the air compressor 602, air tank 603, pneumatic diaphragm pump 608, and oil tank 607 are placed inside the first component box 8 and fixed to the bottom of the first component box 8. The motor 601, all two-position two-way solenoid valves 610, and all two-position five-way solenoid valves 611 are centrally located in the second component box 9. The PLC controller is located in the third component box 10. Figure 3 As shown, the first component box 8 is fixed on top of the frame 5, and a seat 7 is also fixed on top of the first component box 8. A PLC controller display screen 4 is installed in front of the seat 7. When the oiling machine is working, the operator sits on the seat 7 and operates the PLC controller on the PLC controller display screen 4 to control the PLC controller, thereby controlling the forward and backward movement of the oiling machine and the oil spraying status. The manufacturer and model of the PLC controller is Mitsubishi FX3U-32MT.

[0039] The method for spraying oil onto rail bolts using the oiling machine of this invention is as follows: Step 1, When preparing the oiling machine, first fully unfold the right-angle folding bracket 104 of the detection system 1, ensuring that the spring 105 and contact 106 of the sensor 101 point vertically to the ground. Then, adjust the position of the sensor 101 so that the sensor extension block 102 can touch the rail bolts during the oiling machine's movement. Once the positions of the sensor 101 and sensor extension block 102 are adjusted, the PLC controller controls the simultaneous extension of the electric push rods 201 of all spraying systems 2, causing the spraying unit 205 to descend to a suitable position. At this point, the nozzle 203 is lower than the upper surface of the rail, ensuring that the nozzle 203 can achieve the ideal spraying state.

[0040] Step 2, After the above preparations are completed, the PLC controller controls the stepper motor 303 to start working. After the stepper motor 303 is reduced in speed by the reducer 304, the torque is transmitted through the key to the driving force to the walking wheel 301, which drives the walking wheel 301 to rotate. The oiling machine starts to move on the rail and begins to work.

[0041] Step 3, 3.1 When the oiling machine starts to move, the PLC controller controls the motor 601 to work, the air compressor 602 provides the air source and compresses the gas, and delivers the compressed gas to the air tank 603 for storage. The air tank 603 then delivers compressed gas to the pneumatic diaphragm pump 608 and the air circuit. 3.2 When compressed gas enters the pneumatic diaphragm pump 608, the highly viscous grease in the oil tank 607 is drawn into the pneumatic diaphragm pump 608. At this time, the two-position two-way solenoid valve 610 is closed, the two-position five-way solenoid valve 611 is de-energized, and the valve body 2041 of the fluid control valve 204 is closed. The pneumatic diaphragm pump 608 delivers the grease to the fluid inlet 2043 of the valve body 2041, but it cannot pass through the valve body 2041. No gas passes through the two-position two-way solenoid valve 610. 3.3 During the movement of the oiling machine, if the sensor extension block 102 touches the rail bolt, the sensor 101 sends a spraying signal to the PLC controller. After receiving the signal, the PLC controller energizes the two-position five-way solenoid valve 611, opening the valve body 2041 of the fluid control valve 204. The oil at the fluid inlet 2043 flows directly into the nozzle 203 through the valve body 2041. After a certain period of time, the oil fills the inner cavity of the nozzle 203. The PLC controller then de-energizes the two-position five-way solenoid valve 611, closing the valve body 2041 of the fluid control valve pump 204 and stopping the supply of oil to the nozzle 203. At the same time, the PLC controller energizes the two-position two-way solenoid valve 610, opening it. Gas passes through the two-position two-way solenoid valve 610 and flows to the nozzle 203. Under the pressure of the gas, the oil in the nozzle 203 is sprayed out to spray the rail bolt.

[0042] Step 4, After the first batch of rail bolts is sprayed, the oil in the inner cavity of nozzle 203 is used up. The pneumatic diaphragm pump 608 will continue to deliver oil to the fluid inlet 2043 of valve body 2041. When sensor extension block 102 touches the next batch of rail bolts, sensor 101 sends a spraying signal to PLC controller again. After receiving the signal, PLC controller operates two-position two-way solenoid valve 610 and two-position five-way solenoid valve 611 to complete the spraying work of nozzle 203 again.

[0043] Step 5, After the entire rail bolt spraying work is completed, the right-angle folding bracket 104 of the detection system 1 is retracted, so that the spring 105 and contact 106 of the sensor 101 are in a horizontal state, avoiding friction and collision between the detection system 1 and other objects. At the same time, the PLC controller controls the electric push rods 201 of all spraying systems 2 to retract, so that the nozzle 203 is higher than the upper surface of the rail and higher than the traveling wheel 301, avoiding damage to the nozzle 203 and ensuring the safety of the device. Finally, the exhaust valve 604 is opened to quickly depressurize the gas in the air tank 603, the first pipeline 613 and the air circuit, so that the gas pressure in the air tank 603 is zero and the moisture in the compressed gas is discharged.

Claims

1. A pneumatically controlled spraying machine for applying high-viscosity grease to rail bolts, characterized in that: Includes a frame (5), a PLC controller, a hydraulic and pneumatic system (6), and multiple spraying systems (2); Each spraying system (2) includes two sets of spraying units (205), each set of spraying units (205) includes a nozzle (203) and a fluid control valve (204); The fluid pneumatic control valve (204) includes a valve body (2041) and a cylinder (2042); the valve body (2041) is provided with a fluid inlet (2043) and a fluid outlet (2044), and a valve cavity is provided inside the valve body (2041), wherein the fluid inlet (2043), the fluid outlet (2044) and the valve cavity are connected; the cylinder (2042) is provided with two air holes, namely a first air hole (2049) and a second air hole (2050), the first air hole (2049) is connected to the front chamber (2047) of the cylinder (2042), and the second air hole (2050) is connected to the rear chamber (2048) of the cylinder (2042); The hydraulic pneumatic system (6) includes a motor (601), an air compressor (602), an air tank (603), an oil circuit, and an air circuit; the motor (601) is connected to the air compressor (602); the outlet end of the air compressor (602) is connected to the inlet end of the air tank (603) through a pipeline; starting from the outlet end of the air tank (603), the pipeline is divided into two paths, one path connecting to the oil circuit and the other path connecting to the air circuit; The oil circuit includes an oil tank (607) and a pneumatic diaphragm pump (608). The outlet end of the air storage tank (603) is connected to the air inlet pipe of the pneumatic diaphragm pump (608). The oil tank (607) is connected to the oil inlet pipe of the pneumatic diaphragm pump (608). The oil outlet of the pneumatic diaphragm pump (608) is connected to the fluid inlet (2043) pipe of each fluid control valve (204). The fluid outlet (2044) of the fluid control valve (204) is connected to the nozzle (203) pipe. The air circuit includes multiple two-position two-way solenoid valves (610) and multiple two-position five-way solenoid valves (611); the number of two-position two-way solenoid valves (610), two-position five-way solenoid valves (611) and fuel injection units (205) are equal; one fuel injection unit (205) corresponds to one two-position two-way solenoid valve (610), and one fuel injection unit (205) corresponds to one two-position five-way solenoid valve (611); the outlet end of the air tank (603) is connected to the pipes of each two-position two-way solenoid valve (610) and each two-position five-way solenoid valve (611), each two-position two-way solenoid valve (610) is then connected to the pipe of the corresponding nozzle (203), and the two working ports of each two-position five-way solenoid valve (611) are then connected to the two air holes of the corresponding fluid control valve (204).

2. The high-viscosity grease pneumatic spraying oiling machine for rail bolts according to claim 1, characterized in that: The motor (601), the two-position two-way solenoid valve (610), and the two-position five-way solenoid valve (611) are controlled by a PLC controller.

3. The high-viscosity grease pneumatic spraying oiling machine for rail bolts according to claim 1, characterized in that: The multiple spraying systems (2) are respectively set on the left and right sides of the bottom of the frame (5); each spraying system (2) also includes an electric push rod (201) and a horizontal mounting plate (202). One end of the electric push rod (201) is fixed to the bottom of the frame (5), and the other end is fixed to the horizontal mounting plate (202); two sets of oil spraying units (205) are respectively set on the left and right ends of the horizontal mounting plate (202); the electric push rod (201) is controlled by a PLC controller.

4. The high-viscosity grease pneumatic spraying oiling machine for rail bolts according to claim 1, characterized in that: The bottom of the frame (5) is provided with multiple detection systems (1), the number of detection systems (1) is the same as the number of spraying systems (2), and one detection system (1) corresponds to one spraying system (2); the detection system (1) includes a sensor (101), a sensor extension block (102) and a right-angle folding bracket (104); the right-angle folding bracket (104) is fixed at the bottom of the frame (5), and the sensor (101) is set on the right-angle folding bracket (104); the sensor extension block (102) is provided on the contact (106) of the sensor (101).

5. The high-viscosity grease pneumatic spraying oiling machine for rail bolts according to claim 1, characterized in that: The frame (5) is provided with multiple walking wheels (301) at the bottom; all or some of the walking wheels (301) are provided with driving devices; the driving devices include stepper motors (303) and reducers (304), the stepper motors (303) are connected to the reducers (304), and the reducers (304) are connected to the wheel drive shafts (305) of the walking wheels (301) by a key; the stepper motors (303) are controlled by a PLC controller.

6. The high-viscosity grease pneumatic spraying oiling machine for rail bolts according to claim 1, characterized in that: The multiple spraying systems (2) are respectively set on the left and right sides of the bottom of the frame (5); each spraying system (2) also includes an electric push rod (201) and a horizontal mounting plate (202). One end of the electric push rod (201) is fixed to the bottom of the frame (5), and the other end is fixed to the horizontal mounting plate (202); two sets of oil spraying units (205) are respectively set on the left and right sides of the horizontal mounting plate (202); The bottom of the frame (5) is provided with multiple detection systems (1), the number of detection systems (1) is the same as the number of spraying systems (2), and one detection system (1) corresponds to one spraying system (2); the detection system (1) includes a sensor (101) and a sensor expansion block (102); the sensor (101) has a sensor expansion block (102) on its contact (106); The bottom of the frame (5) is provided with multiple wheels (301), and all or some of the wheels (301) are provided with a drive device; The motor (601), the two-position two-way solenoid valve (610), the two-position five-way solenoid valve (611), and the electric push rod (201) are controlled by a PLC controller.

7. A method for spraying high-viscosity grease pneumatic spraying machine for rail bolts as described in claim 6, characterized in that, The following steps are included: Step 1, First, adjust the position of the sensor (101) and the sensor extension block (102) so that the sensor extension block (102) can touch the rail bolt during the movement of the oiling machine; then the PLC controller controls the electric push rods (201) of all spraying systems (2) to extend simultaneously so that the nozzle (203) is lower than the upper surface of the rail. Step 2, The drive unit drives the walking wheels (301) to rotate, and the oiling machine begins to move on the rails and start working. Step 3, 3.1 When the oiling machine starts to move, the PLC controller controls the motor (601) to start working, the air compressor (602) provides air source and compresses gas, and delivers the compressed gas to the air storage tank (603) for storage. The air storage tank (603) then delivers compressed gas to the pneumatic diaphragm pump (608) and the air circuit. 3.2 When compressed gas enters the pneumatic diaphragm pump (608), the high-viscosity grease in the oil tank (607) is drawn into the pneumatic diaphragm pump (608); at this time, the two-position two-way solenoid valve (610) is closed, the two-position five-way solenoid valve (611) is de-energized, and the valve body (2041) of the fluid control valve (204) is closed; the pneumatic diaphragm pump (608) delivers the grease to the fluid inlet (2043) of the valve body (2041) but it cannot pass through the valve body (2041); no gas passes through the two-position two-way solenoid valve (610); 3.3 During the movement of the oiling machine, if the sensor extension block (102) touches the rail bolt, the sensor (101) sends a spraying signal to the PLC controller. After receiving the signal, the PLC controller controls the two-position five-way solenoid valve (611) to be energized, and the valve body (2041) of the fluid control valve (204) opens. The oil at the fluid inlet (2043) flows directly into the nozzle (203) through the valve body (2041); after a certain period of time, the oil fills the nozzle (203). Inside the cavity, the PLC controller then de-energizes the two-position five-way solenoid valve (611), and the valve body (2041) of the fluid control valve (204) closes, stopping the supply of oil to the nozzle (203); at the same time, the PLC controller then energizes the two-position two-way solenoid valve (610), and the two-position two-way solenoid valve (610) opens, and the gas passes through the two-position two-way solenoid valve (610) and flows to the nozzle (203). Under the pressure of the gas, the oil in the nozzle (203) is sprayed out to spray the rail bolts; Step 4, After the first batch of rail bolts is sprayed, the oil in the inner cavity of the nozzle (203) is used up. The pneumatic diaphragm pump (608) will continue to deliver the oil to the fluid inlet (2043) of the valve body (2041). When the sensor extension block (102) touches the next batch of rail bolts, the sensor (101) sends a spraying signal to the PLC controller again. After receiving the signal, the PLC controller operates the two-position two-way solenoid valve (610) and the two-position five-way solenoid valve (611) to complete the spraying work of the nozzle (203) again. Step 5, After the entire rail bolt spraying work is completed, the detection system (1) and the spraying system (2) are retrieved to avoid collisions and friction between the detection system (1) and the spraying system (2) and other objects.

8. The method for spraying high-viscosity grease using a pneumatic spray coating machine according to claim 7, characterized in that: In step 3.2, the two-position five-way solenoid valve (611) is de-energized. Compressed air from the air tank (603) flows through the pipeline and the two-position five-way solenoid valve (611) into the second air hole (2050) of the fluid control valve (204). The air in the rear chamber (2048) increases, the piston rod (2046) extends, and the excess air in the front chamber (2047) is discharged from the first air hole (2049). The end of the piston rod (2046) blocks the valve cavity of the valve body (2041). At this time, the valve body (2041) is in the closed state, and the oil cannot pass through the valve body (2041) at the fluid inlet (2043). In step 3.3, the PLC controller energizes the two-position five-way solenoid valve (611). At this time, the compressed gas delivered by the gas storage tank (603) passes through the pipeline and the two-position five-way solenoid valve (611). The gas flows into the first air hole (2049) of the fluid control valve (204) and into the front chamber (2047). The piston rod (2046) retracts, and the excess gas in the rear chamber (2048) is discharged from the second air hole (2050). The valve body (2041) opens, and the oil at the fluid inlet (2043) flows directly into the nozzle (203) through the valve body (2041).

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