A rail butt welding process

Abstract

The present application relates to a kind of rail butt welding process, first, build special welding workshop, the special welding workshop have finished product track storage area, track lower rail surface polishing area, track upper rail surface polishing area, track end polishing area, material preparation area, square steel track conveying system and flash welding machine;First, the end of segmented track is polished, then the end of two segmented tracks is flash welded using flash welding machine, and the upper rail surface and lower rail surface of the track are finely polished after welding, to complete the whole butt welding process.The rail butt welding process of the present application uses flash welding to replace traditional manual arc welding, with high welding efficiency and stable quality, solving the drawbacks of low welding efficiency, large deformation and difficult weld quality control caused by traditional manual arc welding.

Description

Technical Field

[0001] This invention relates to the field of track manufacturing, specifically a track welding process. Background Technology

[0002] With the increasingly severe overseas pandemic situation and the continued development of the global economy, port trade activities are becoming more frequent, thus placing higher and higher demands on the performance of port machinery and prompting continuous progress in the port machinery manufacturing industry. As a crucial component ensuring the safe and stable operation of the main trolley of port machinery, the quality of the trolley track is of paramount importance.

[0003] Currently, the existing trolley track docking uses manual electric arc welding. This welding method requires a lot of time to control the preheating temperature, interlayer and interpass temperature, and post-weld heat preservation. The post-weld deformation is large and the defect rate is high. A lot of time needs to be spent on post-weld repair, correction, grinding and other work. The process is complicated, which not only results in low production efficiency, but also makes quality control difficult and cannot meet the development needs of the port machinery manufacturing industry. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a rail butt welding process that is convenient to weld and can effectively reduce the cost of rail docking.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is: a rail butt welding process, the innovation of which is that the butt welding process includes the following steps. S1: First, construct a dedicated welding workshop, which includes... A factory building has a rectangular welding area within it. The long axis of the welding area is defined as the first direction, and the width of the welding area is defined as the second direction. The welding area is divided into three processing areas along the second direction: the first processing area, the second processing area, and the third processing area. The first processing area is divided into a finished rail storage area and a rail lower surface grinding area along the first direction. The second processing area is divided into a rail upper surface grinding area, a rail end grinding area, and a material preparation area along the first direction. The third processing area is a rail conveying area. A square steel rail conveying system is set up in the rail conveying area. A flash welding machine is set up in the rail conveying area near the rail end grinding area. S2: Material preparation, sending the processed sections of the track to the material preparation area, waiting for welding; S3: Pre-welding grinding. The segmented rails are transported from the material preparation area to the rail end grinding area by a crane. The ends of the segmented rails are ground to prepare for welding. S4: Butt welding. After grinding, the segmented rails are placed on the square steel rail conveying system by a crane. The square steel rail conveying system transports each segmented rail. When the segments of two adjacent rails are transported to the flash welding machine, the flash welding machine performs flash welding on the ends of the two adjacent rails, welding the two adjacent rails together until all the rail segments are welded into a single rail unit. S5: Post-weld grinding. The entire rail is lifted by a crane to the upper rail surface grinding area, where the welded joints on the upper rail surface are finely ground. Then, the entire rail is lifted by a crane to the lower rail surface grinding area, where the welded joints on the lower rail surface are finely ground. S6: Storage. The polished track is transported to the finished track storage area by a crane, completing the track welding.

[0006] Furthermore, the square steel rail conveying system includes A base comprising a plurality of concrete foundations arranged side by side along a first direction, wherein a pair of trusses arranged side by side along a second direction are installed on each concrete foundation, and the two trusses extend along the first direction. A conveying assembly mounted on a base includes an active conveying assembly and a passive conveying assembly. The active conveying assembly includes an array of active conveying rollers arranged in parallel along a first direction, with each array located above a concrete foundation. Each active conveying roller array consists of three active conveying rollers arranged in parallel, and the active conveying rollers are driven to rotate by a motor mounted on the concrete foundation. The passive conveying assembly consists of several passive conveying rollers arranged in parallel along the first direction. An anti-tilt assembly mounted on a base includes several anti-tilt plates arranged side by side along a first direction. The two sides of the anti-tilt plates are mounted on a truss. A pair of vertically arranged anti-tilt rollers are mounted on the anti-tilt plates, and a gap is left between the two anti-tilt rollers to allow a track to pass through.

[0007] Furthermore, in step S4, after flash welding the segmented track, a special pusher is used to pre-push the weld joint of the entire track. The special pusher includes a bottom knife, a first side knife, a top knife and a second side knife connected in sequence. The bottom blade is horizontally set, the first side blade is connected to the upper end face of the bottom blade and is located on one side of the bottom blade, and the first side blade is fixedly connected to the bottom blade. The other side of the first side blade is hinged to the top blade, the other side of the top blade is hinged to the second side blade, and the other side of the second side blade is connected to the other side of the bottom blade through a pin. After the second side cutter is connected to the bottom cutter, the bottom cutter, the first side cutter, the top cutter and the second side cutter work together to form an enclosed cavity that surrounds the square steel rail.

[0008] Furthermore, the side of the top cutter closest to the first side cutter and the second side cutter is an arc-shaped surface.

[0009] Furthermore, the connection between the second side blade and the bottom blade is as follows: on the side of the second side blade away from the top blade, there is a connecting section extending out of the second side blade, so that the second side blade as a whole forms a convex structure. In the middle of the side of the bottom blade adjacent to the second side blade, there is a groove for the connecting section to be embedded, so that the bottom blade forms a concave structure. A first through hole for a pin to pass through is also opened on the connecting section, and a second through hole for a pin to pass through is opened on the bottom blade. After the connecting section is embedded in the groove of the bottom blade, the second side blade and the bottom blade are relatively fixed by the pin passing through the second through hole and the first through hole in sequence.

[0010] The advantages of this invention are as follows: The rail butt welding process of this invention uses flash welding to replace traditional manual arc welding, which has high welding efficiency and stable quality. It solves the drawbacks of traditional manual arc welding, such as low welding efficiency, large deformation, and difficulty in controlling weld quality. Furthermore, by using a dedicated welding workshop, and by dividing the interior into three different processing areas, and by coordinating the different processing zones within each area, orderly butt welding of the square steel rails can be achieved within a limited rectangular space, avoiding mutual interference and ensuring the smooth flow of the entire butt welding process.

[0011] Before grinding the welded track, a special weld bead remover is used to remove most of the weld beads generated during the flash welding process. This reduces the workload of subsequent fine grinding of the upper and lower rail surfaces and improves the overall processing efficiency.

[0012] The design of the dedicated cleaning tool involves the cooperation of the bottom blade, the first side blade, the top blade, and the second side blade to form an enclosed cavity that surrounds the square steel rail. This allows for the cleaning of all four sides of the square steel rail with a single operation, greatly improving work efficiency.

[0013] The design of the top cutter with curved surfaces on both sides is to create a clearance space between the top cutter and the first side cutter, and between the top cutter and the second side cutter, during rotation, so as to ensure that the top cutter and the second side cutter can rotate smoothly.

[0014] The connection between the second side cutter and the bottom cutter is achieved by the cooperation of the connecting section on the second side cutter and the groove on the side end of the bottom cutter. The connecting section is embedded in the groove to limit the relative position between the second side cutter and the bottom cutter. Then, the pin passes through the first through hole and the second through hole to fix the second side cutter and the bottom cutter, ensuring the stability of the connection between the two. Attached Figure Description

[0015] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0016] Figure 1 This is a schematic diagram of the internal layout of the dedicated welding workshop in this invention.

[0017] Figure 2 The square steel track conveying system of the present invention Figure 3 This is a schematic diagram of the pusher blade for square steel rails according to the present invention.

[0018] Figure 4 This is a schematic diagram showing the usage state of the pusher blade for square steel rails according to the present invention.

[0019] Figure 5 This is a schematic diagram of the second side blade in this invention.

[0020] Figure 6 This is a schematic diagram of the bottom blade in this invention. Detailed Implementation

[0021] The following embodiments are intended to enable those skilled in the art to more fully understand the present invention, but do not limit the invention to the scope of the embodiments described.

[0022] The rail welding process of the present invention is achieved through the following steps: S1: First, build a dedicated welding workshop, such as... Figure 1 As shown in the schematic diagram, the dedicated welding workshop includes... A factory building 101 has a rectangular welding area within it. The long axis of the welding area is defined as the first direction, and the width of the welding area is defined as the second direction.

[0023] The welding area is divided into three processing areas along the second direction: the first processing area, the second processing area, and the third processing area. In the first processing area, along the first direction, there are two separate areas: a finished track storage area 102 and a lower track surface grinding area 103. The finished track storage area 102 and the lower track surface grinding area 103 are separated from each other. In the second processing area, along the first direction, there are three separate areas: an upper track surface grinding area 104, a track end grinding area 105, and a material preparation area 106. The upper track surface grinding area 104, the track end grinding area 105, and the material preparation area 106 are separated from each other, and the upper track surface grinding area 104 is connected to the lower track surface grinding area 10. The third processing area is a track conveying area, in which a square steel track conveying system is installed. A flash welding machine 107 is installed in the track conveying area near the track end grinding area.

[0024] S2: Material preparation. The processed sections of the track are sent to the material preparation area 106, waiting for welding.

[0025] S3: Pre-welding grinding. The segmented track is transported from the material preparation area 106 to the track end grinding area 105 by a crane. The ends of the segmented track are ground in the track end grinding area 105 to prepare for welding.

[0026] S4: After welding and grinding, the segmented rails are placed on a square steel rail conveying system by a crane. The square steel rail conveying system then transports each segmented rail. Figure 2 As shown in the schematic diagram, the square steel rail conveying system includes... A base includes several concrete foundations 201 arranged in parallel along a first direction. The concrete foundations 201 are cuboid in shape. A pair of trusses 202 arranged in parallel along a second direction are installed on the upper surface of each concrete foundation 201. The bottom ends of the two trusses 202 are respectively supported on each concrete foundation 201 and fixed to the concrete foundations 201 by bolts. The two trusses 202 extend along the first direction.

[0027] A conveying assembly mounted on a base, comprising an active conveying assembly and a passive conveying assembly, wherein... The active conveying assembly includes an array of active conveying rollers arranged in parallel along a first direction, with each set of active conveying rollers located above the cement foundation 201. Each set of active conveying rollers consists of three active conveying rollers 203 arranged in parallel. The two sides of the active conveying rollers 203 are mounted on two trusses 202 through the cooperation of bearings and bearing seats. The three active conveying rollers 203 are synchronized and move in the same direction through the cooperation of a linkage sprocket and a linkage chain. Any one of the active conveying rollers 203 is driven to rotate by a motor mounted on the cement foundation 201, thereby driving the three active conveying rollers 203 to rotate synchronously.

[0028] The conveying assembly comprises several driven conveying rollers 204 arranged in parallel along a first direction. The two sides of the driven conveying rollers 204 are mounted on two trusses 202 through the cooperation of bearings and bearing seats.

[0029] An anti-tilt assembly is installed on the base. The anti-tilt assembly includes several anti-tilt plates 205 arranged in parallel along a first direction. The two sides of the anti-tilt plates 205 are respectively installed on the truss 202. A pair of vertically arranged anti-tilt rollers 206 are installed on the anti-tilt plates 205, and a gap is left between the two anti-tilt rollers 206 to allow the track to pass through.

[0030] The segmented track is suspended on the active conveyor roller 203 and the driven conveyor roller 204 by a crane, and the two sides of the segmented track are located between the two anti-tilt rollers 206. Then, the active conveyor roller 203 is driven by a motor to rotate, thereby driving the segmented track to move horizontally along the first direction.

[0031] When the two adjacent segmented tracks are transported to the flash welding machine 107 at their ends, the flash welding machine 107 performs flash welding on the ends of the two adjacent segmented tracks, so that the two adjacent segmented tracks are welded together, until all the segmented tracks are welded into a single track.

[0032] After flash welding of the segmented track, a special sprue is used to pre-remove the weld joints of the entire track, such as... Figures 3-6 As shown in the diagram, the special tumor-pushing knife includes a bottom knife 1, a first side knife 2, a top knife 3, and a second side knife 4 connected in sequence.

[0033] The bottom cutter 1 is horizontally positioned. The first side cutter 2 is connected to the upper surface of the bottom cutter 1 and is located on one side of the bottom cutter 1. The first side cutter 2 is fixedly connected to the bottom cutter 1. The other side of the first side cutter 2 is hinged to the top cutter 3, and the other side of the top cutter 3 is hinged to the second side cutter 4. The side of the top cutter 3 closest to the first side cutter 2 and the second side cutter 3 is an arc-shaped surface. The arc-shaped surface design on both sides of the top cutter 3 is to create a clearance space between the top cutter 3 and the first side cutter 2, and between the top cutter 3 and the second side cutter 4 during rotation, ensuring that the top cutter 3 and the second side cutter 4 can rotate smoothly and avoiding mutual interference between them.

[0034] The other side of the second side cutter 4 is connected to the other side of the bottom cutter 1 via a pin. The connection between the second side cutter 4 and the bottom cutter 1 is as follows: on the side of the second side cutter 4 away from the top cutter 3, there is a connecting section 41 extending out of the second side cutter 4, so that the second side cutter 4 as a whole forms a convex-shaped structure, such as... Figure 3 As shown, a groove 11 for embedding the connecting section 41 is also provided in the middle of the side adjacent to the bottom blade 1 and the second side blade 4, so that the bottom blade 1 forms a U-shaped structure, as shown. Figure 4As shown, a first through hole 42 for a pin to pass through is provided on the connecting section 41, and a second through hole 12 for a pin to pass through is provided on the bottom knife 1. After the connecting section 41 is embedded in the groove of the bottom knife 1, the pin passes through the second through hole 12 and the first through hole 42 in sequence to achieve relative fixation between the second side knife 4 and the bottom knife 1. The connection between the second side knife 4 and the bottom knife 1 is achieved by the cooperation of the connecting section 41 on the second side knife 4 and the groove 11 on the side end of the bottom knife 1. The connection of the connecting section 41 embedded in the groove 11 plays a relative limiting role in the relative position between the second side knife 4 and the bottom knife 1. The pin passes through the first through hole 42 and the second through hole 12 to fix the second side knife 4 and the bottom knife 1, ensuring the stability of the connection between the second side knife 4 and the bottom knife 1. In this way, the pusher knife and the segmented track 5 can be detached, making it convenient to remove the pusher knife from the segmented track 5 in a timely manner and effectively preventing the pusher knife from being burned by the high temperature during welding.

[0035] After the second side blade 4 and the bottom blade 1 are connected by a pin, the bottom blade 1, the first side blade 2, the top blade 3 and the second side blade 4 work together to form an enclosed cavity that surrounds the segmented track 5. The size of the enclosed cavity is slightly larger than the size of the segmented track 5, which ensures the pushing effect while effectively preventing damage to the base material.

[0036] Before flash welding the segmented track using the flash welding machine 107, a special pusher blade needs to be installed on one side of the segmented track end. First, place the bottom blade 1 under the segmented track 5, and the first side blade 2 on the side of the segmented track 5. Then, flip the top blade 3 so that it rotates to the top surface of the segmented track 5. Next, flip the second side blade 4 so that it is located on the other side of the segmented track 5, and embed the connecting section 41 of the second side blade 4 into the groove 11. Finally, use a pin to fix it, completing the installation of the pusher blade. Figure 2 As shown, the weld beads on the segmented track 5 are then cleaned by pushing the weld bead remover. This way, the weld bead removal operation can be performed on all four sides of the segmented track 5 with just one action, which greatly improves work efficiency. The weld bead remover in this invention is suitable for square steel tracks, filling the gap in weld bead removers for this type of track.

[0037] S5: Post-weld grinding. The entire track is lifted by a crane to the upper rail surface grinding area 104 for fine grinding of the welded joints on the upper rail surface. Then, the entire track is lifted by a crane to the lower rail surface grinding area 103 for fine grinding of the welded joints on the lower rail surface.

[0038] S6: Storage. The polished track is transported to the finished track storage area 102 by a crane for storage, completing the track welding.

[0039] The rail butt welding process of this invention uses flash welding to replace traditional manual arc welding, resulting in high welding efficiency and stable quality. It solves the drawbacks of traditional manual arc welding, such as low welding efficiency, large deformation, and difficulty in controlling weld quality. Furthermore, it utilizes a dedicated welding workshop, which is divided into three different processing areas. With the different processing zones in each area, orderly butt welding of the steel rails can be achieved within a limited rectangular space, avoiding mutual interference and ensuring the smooth flow of the entire butt welding process.

[0040] Those skilled in the art should understand that this invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to this invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A rail butt welding process, wherein the rail is a square steel rail, characterized in that: The butt welding process includes the following steps S1: First, construct a dedicated welding workshop, which includes... A factory building has a rectangular welding area within it. The long axis of the welding area is defined as the first direction, and the width of the welding area is defined as the second direction. The welding area is divided into three processing areas along the second direction: the first processing area, the second processing area, and the third processing area. The first processing area is divided into a finished rail storage area and a rail lower surface grinding area along the first direction. The second processing area is divided into a rail upper surface grinding area, a rail end grinding area, and a material preparation area along the first direction. The third processing area is a rail conveying area. A square steel rail conveying system is set up in the rail conveying area. A flash welding machine is set up in the rail conveying area near the rail end grinding area. The square steel rail conveying system includes A base comprising a plurality of concrete foundations arranged side by side along a first direction, wherein a pair of trusses arranged side by side along a second direction are installed on each concrete foundation, and the two trusses extend along the first direction. A conveying assembly mounted on a base includes an active conveying assembly and a driven conveying assembly. The active conveying assembly includes an array of active conveying rollers arranged in parallel along a first direction, with each array located above a concrete foundation. Each active conveying roller array consists of three active conveying rollers arranged in parallel, and the active conveying rollers are driven to rotate by a motor mounted on the concrete foundation. The driven conveying assembly consists of several driven conveying rollers arranged in parallel along the first direction. An anti-tilt assembly installed on a base includes several anti-tilt plates arranged side by side along a first direction. The two sides of the anti-tilt plates are mounted on a truss. A pair of vertically arranged anti-tilt rollers are installed on the anti-tilt plates, and a gap is left between the two anti-tilt rollers to allow the track to pass through. S2: Material preparation, sending the processed sections of the track to the material preparation area, waiting for welding; S3: Pre-welding grinding. The segmented rails are transported from the material preparation area to the rail end grinding area by a crane. The ends of the segmented rails are ground to prepare for welding. S4: Butt welding. After grinding, the segmented rails are placed on the square steel rail conveying system by a crane. The square steel rail conveying system transports each segmented rail. When the segments of two adjacent rails are transported to the flash welding machine, the flash welding machine performs flash welding on the ends of the two adjacent rails, welding the two adjacent rails together until all the rail segments are welded into a single rail unit. S5: Post-weld grinding. The entire rail is lifted by a crane to the upper rail surface grinding area, where the welded joints on the upper rail surface are finely ground. Then, the entire rail is lifted by a crane to the lower rail surface grinding area, where the welded joints on the lower rail surface are finely ground. S6: Storage. The polished track is transported to the finished track storage area by a crane, completing the track welding.

2. The rail butt welding process according to claim 1, characterized in that: In step S4, after flash welding of the segmented track, a special pusher is used to pre-push the weld joint of the track as a whole. The special pusher includes a bottom knife, a first side knife, a top knife and a second side knife connected in sequence. The bottom blade is horizontally set, the first side blade is connected to the upper end face of the bottom blade and is located on one side of the bottom blade, and the first side blade is fixedly connected to the bottom blade. The other side of the first side blade is hinged to the top blade, the other side of the top blade is hinged to the second side blade, and the other side of the second side blade is connected to the other side of the bottom blade through a pin. After the second side cutter is connected to the bottom cutter, the bottom cutter, the first side cutter, the top cutter and the second side cutter work together to form an enclosed cavity that surrounds the square steel rail.

3. The rail butt welding process according to claim 2, characterized in that: The top blade has an arc-shaped surface on the side closest to the first and second side blades.

4. The rail butt welding process according to claim 2, characterized in that: The connection between the second side blade and the bottom blade is as follows: on the side of the second side blade away from the top blade, there is a connecting section extending out of the second side blade, so that the second side blade as a whole forms a convex structure. In the middle of the side of the bottom blade adjacent to the second side blade, there is a groove for the connecting section to be embedded, so that the bottom blade forms a concave structure. A first through hole for a pin to pass through is also opened on the connecting section, and a second through hole for a pin to pass through is opened on the bottom blade. After the connecting section is embedded in the groove of the bottom blade, the second side blade and the bottom blade are relatively fixed by the pin passing through the second through hole and the first through hole in sequence.

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