Method for controlling helical roller segments for online inspection of 100-meter rails
By setting up two inspection points in the online inspection process of 100-meter rail surface quality and using reverse and forward spiral methods to control the roller conveyor in segments, the problem of limited inspection speed of rail surface quality was solved, production efficiency and pace were improved, and equipment investment and consumption were reduced.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HANDAN IRON & STEEL GROUP CO LTD
- Filing Date
- 2023-11-24
- Publication Date
- 2026-08-04
AI Technical Summary
The online inspection process for the surface quality of 100-meter steel rails cannot be replaced by intelligent machines, which limits the speed of steel passing through, becomes a production bottleneck, and affects production efficiency and production line rhythm.
Two inspection points are set up in the online surface quality inspection process. The roller conveyor is controlled in sections using a reverse spiral method, while the inner inspection area is controlled in sections using a forward spiral method. The section length of the transport roller conveyor is determined according to the process layout and formula calculation to achieve tight connection and conflict-free operation of the front and rear rails.
It improved production efficiency, reduced redundant equipment investment and ineffective consumption, and achieved the optimal compact production rhythm of front and rear rails.
Smart Images
Figure CN117680510B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a method for controlling the online inspection of 100-meter steel rails via a spiral roller conveyor segmentation, belonging to the technical field of profile production methods in the metallurgical industry. Background Technology
[0002] The production process of 100-meter steel rails is as follows: continuous casting billet loading into the furnace → heating → unloading from the furnace → high-pressure water descaling → BD1 billet rolling → BD2 billet rolling → URE unit continuous rolling → UF precision rolling → thermal printing → hot sawing → pre-bending → cooling bed → horizontal and vertical composite straightening → online visual inspection of surface quality → online inspection of internal quality of the rail → bidirectional hydraulic straightening → sawing → collection on the platform → hoisting and warehousing → loading and delivery.
[0003] In the aforementioned process, the online inspection of the surface quality of 100-meter rails cannot currently be replaced by intelligent machines and must be carried out manually via visual inspection. The speed at which the rail passes through the steel is limited; exceeding 0.5 m / s causes significant visual fatigue for workers within a short period. Therefore, the online inspection speed must be limited to within 0.5 m / s. Consequently, the online inspection of the rail surface quality has become a bottleneck process in the production of 100-meter rails, restricting the production rhythm and efficiency of the entire production line.
[0004] To overcome the bottleneck effect of the online surface quality inspection process for rails and improve the production line's efficiency and capacity, it is essential to shorten the total time for 100-meter rails to pass through the online surface quality inspection process. Therefore, the connection between the preceding and following rails must be extremely tight, achieving the shortest possible interval. Based on the characteristics of the online visual inspection process for 100-meter rails and the operation of the preceding and following processes, after the online surface quality inspection of the preceding 100-meter rail is completed, it immediately enters the rail internal quality online inspection center for flaw detection. The flaw detection speed is 1.0~1.5 m / s. The passing and following connection of the preceding and following 100-meter rails must meet the operational requirements under the slowest detection speed (i.e., 1.0 m / s). When the preceding 100-meter rail is running at a detection speed ≥1.0 m / s, the next 100-meter rail must immediately follow and enter the online surface quality inspection point for visual inspection. The relevant process parameters are: following rail feeding speed ≥2.0 m / s, visual inspection speed 0.5 m / s. Summary of the Invention
[0005] The purpose of this invention is to provide a method for controlling the segmentation of a spiral roller conveyor for online inspection of 100-meter steel rails. By setting two inspection points in the online surface quality inspection process to simultaneously perform online surface quality checks, the roller conveyor in the surface inspection area is segmented and controlled in a reverse spiral manner, while the roller conveyor in the internal inspection area is segmented and controlled in a forward spiral manner. The length of each segment of the transport roller conveyor is calculated and determined according to the process layout conditions and the spiral segmentation calculation formula. This method can precisely control the following movement of the preceding and following rails during the online surface quality inspection of 100-meter steel rails, ensuring that the production rhythm of the preceding and following 100-meter rails reaches the optimal compactness through the online surface quality inspection and internal quality inspection processes. Simultaneously, it avoids conflicts and collisions between the preceding and following 100-meter rails. This method improves the production rhythm and efficiency of 100-meter steel rails while reducing unnecessary redundant equipment and construction costs, as well as waste from ineffective operation during the production process, effectively solving the aforementioned problems existing in the background technology.
[0006] The technical solution of this invention is: a method for controlling the online inspection of 100-meter steel rail sections using a spiral roller conveyor, comprising the following steps:
[0007] S1. The surface quality online inspection process is set up with two inspection points, namely inspection point 1 and inspection point 2. The roller conveyor in the surface inspection area between inspection point 1 and inspection point 2 is controlled in a reverse spiral manner, which is divided into three control sections: surface inspection roller conveyor one, surface inspection roller conveyor two, and surface inspection roller conveyor three. After the 100-meter steel rail is transported to the surface quality online inspection process via the roller conveyor, the start, stop, and speed of surface inspection roller conveyor one, surface inspection roller conveyor two, and surface inspection roller conveyor three are controlled respectively to achieve simultaneous online surface quality inspection of the 100-meter steel rail at inspection point 1 and inspection point 2.
[0008] S2. Internal quality online inspection process: The roller conveyor in the internal inspection area between inspection point 2 and the rail internal quality online inspection center is controlled in a positive spiral manner, divided into four control sections: internal inspection roller conveyor one, internal inspection roller conveyor two, internal inspection roller conveyor three, and internal inspection roller conveyor four. After the surface quality online inspection of 100 meters of rail is completed, internal quality online inspection is carried out. Internal inspection roller conveyor one, internal inspection roller conveyor two, and internal inspection roller conveyor three are shared by the two processes of surface quality online inspection and internal quality online inspection. The surface quality online inspection and internal quality online inspection of 100 meters of rail are achieved by controlling the start, stop, and speed of internal inspection roller conveyor one, internal inspection roller conveyor two, internal inspection roller conveyor three, and internal inspection roller conveyor four respectively.
[0009] S3. The length of each segment of the transport roller conveyor is calculated and determined according to the process layout conditions and the spiral segment calculation formula, so that the process of internal quality flaw detection of the first 100 meters of rail and rapid steel feeding and slow surface quality visual inspection of the last 100 meters of rail can be closely connected.
[0010] In the online inspection process of rail surface quality, inspection points 1 and 2 are each responsible for simultaneously inspecting 52-meter sections of the 100-meter rail; the reverse spiral segmentation method for the surface inspection area roller conveyor: the length of the first surface inspection roller conveyor is determined by S. 表检辊道一 = (Time to deliver the head end of the last 100 meters of rail to inspection point 1 + Safety delay time for the following rail) × Inspection speed of the first 100 meters of rail; The length of inspection roller conveyor 2 is determined by S. 表检辊道二 =Time taken for the last 100 meters of rail head to reach the junction of inspection roller conveyor 1 and inspection roller conveyor 2 from inspection point 1 × Flaw detection speed of the first 100 meters of rail; The length of inspection roller conveyor 3 is determined by S. 表检辊道三 =Time taken for the last 100 meters of rail head to travel from the junction of inspection roller conveyor 1 and inspection roller conveyor 2 to the junction of inspection roller conveyor 3 × Flaw detection speed of the first 100 meters of rail; The total length of the roller conveyor in the surface quality online inspection process is determined to ensure that the visual inspection of surface quality covers the entire length of the 100-meter rail, i.e., S 表检辊道一 + S 表检辊道二 +S 表检辊道三 = 50.2 meters.
[0011] In the aforementioned online internal quality inspection process, the method for determining the length of the first internal inspection roller conveyor in the spiral segmentation method of the internal inspection area is as follows: S 内检辊道一 =A pre-set collision avoidance safety distance of 4-5m is set between the end of the first 100 meters of rail and the beginning of the next 100 meters of rail; the length of the second inner inspection roller conveyor is determined by S. 内检辊道二 =Time taken for the last 100 meters of rail to be visually inspected from inspection point 2 and slowly moved to the junction of inner inspection roller conveyor 1 and inner inspection roller conveyor 2, multiplied by the flaw detection speed of the first 100 meters of rail; the length of inner inspection roller conveyor 3 is determined by S. 内检辊道三 =Time taken for the rail head end of the last 100 meters to continuously visually inspect surface quality from the junction of inner inspection roller track 1 and inner inspection roller track 2 to the junction of inner inspection roller track 2 and inner inspection roller track 3 × the flaw detection speed of the first 100 meters of rail; the length of inner inspection roller track 4 is determined by S. 内检辊道四 =The time taken for continuous visual inspection of the surface quality of the last 100 meters of rail from the junction of inner inspection roller conveyor two and inner inspection roller conveyor three to the junction of inner inspection roller conveyor three and inner inspection roller conveyor four, multiplied by the flaw detection speed of the first 100 meters of rail; The total length of the inner inspection area roller conveyor in the online internal quality inspection process is the sum of the lengths of each section of inner inspection roller conveyor one, inner inspection roller conveyor two, inner inspection roller conveyor three, and inner inspection roller conveyor four, i.e., S 内检辊道一 + S 内检辊道二 +S 内检辊道三 +S 内检辊道四 =Distance of the process flow layout between checkpoint No. 2 and the exit location of the online quality inspection center for the internal quality of the rails.
[0012] The length values of the three control sections of the surface inspection area roller conveyor, namely surface inspection roller conveyor one, surface inspection roller conveyor two, and surface inspection roller conveyor three, gradually change from maximum to minimum values in a reverse spiral manner; the length values of the four control sections of the inner inspection area roller conveyor, namely inner inspection roller conveyor one, inner inspection roller conveyor two, inner inspection roller conveyor three, and inner inspection roller conveyor four, gradually change from minimum to maximum values in a forward spiral manner.
[0013] During continuous production, the following distance between the first 100 meters and the last 100 meters of rails has a parabolic relationship with the running time; the respective positions of the tail end of the first 100 meters of rails and the head end of the last 100 meters of rails have a spiral relationship with the running time.
[0014] In step S3, the internal quality flaw detection of the first 100 meters of rail is carried out at a speed of ≥1.0m / s, and the subsequent 100 meters of rail are fed rapidly at a speed of ≥2.0m / s, and the surface quality is visually inspected at a slow speed of 0.5m / s.
[0015] The beneficial effects of this invention are as follows: By setting two inspection points in the online surface quality inspection process to simultaneously conduct online surface quality inspection, the roller conveyor in the surface inspection area is segmented and controlled in a reverse spiral manner, while the roller conveyor in the internal inspection area is segmented and controlled in a forward spiral manner. The length of each segment of the transport roller conveyor is calculated and determined according to the process layout conditions and the spiral segmentation calculation formula. This allows for precise control of the following movement of the front and rear rails during the online surface quality inspection of 100-meter rails, ensuring that the production rhythm of the front and rear 100-meter rails through the online surface quality inspection process and the online internal quality inspection process reaches the optimal compactness, while avoiding conflicts and collisions between the front and rear 100-meter rails. This not only improves the production rhythm and efficiency of 100-meter rails but also reduces unnecessary redundant equipment and its construction capital investment, as well as waste such as ineffective operation consumption during the production process. Attached Figure Description
[0016] Figure 1 This is the process layout diagram of the present invention;
[0017] Figure 2 This is a segmented diagram of the roller conveyor in the inspection area of this invention;
[0018] Figure 3 This is a diagram showing the positions of the steel bars before and after the inspection roller conveyor of this invention.
[0019] Figure 4 This is a diagram showing the positions of the steel on the inspection roller conveyor and the front and rear sections of the present invention.
[0020] Figure 5 This is a diagram showing the positions of the steel bars before and after the inspection roller conveyor of this invention.
[0021] Figure 6 This is a segmented diagram of the roller conveyor in the internal inspection area of this invention;
[0022] Figure 7 This is a diagram showing the positions of the inner inspection roller conveyor and the steel bars before and after it.
[0023] Figure 8 This is a diagram showing the positions of the inner inspection roller conveyor and the steel bars before and after it.
[0024] Figure 9 This is a diagram showing the positions of the steel bars before and after the inner inspection roller conveyor of this invention;
[0025] Figure 10 This is a diagram showing the positions of the inner inspection roller conveyor and the steel bars before and after it.
[0026] Figure 11 This is a segmented diagram of the roller conveyor for controlling online inspection of 100-meter steel rails according to the present invention;
[0027] Figure 12 This is a graph showing the relationship between the 100-meter rail following distance and the running time in relation to the present invention.
[0028] Figure 13 This is a graph showing the relationship between the position of the tail end and head end of the 100-meter steel rail before and after the invention and the running time.
[0029] In the diagram: 1. Backing frame 1, 2. Inspection roller conveyor 1, 3. Inspection roller conveyor 2, 4. Inspection roller conveyor 3, 5. Internal inspection roller conveyor 1, 6. Internal inspection roller conveyor 2, 7. Internal inspection roller conveyor 3, 8. Internal inspection roller conveyor 4, 9. Inspection point 2, 10. Online inspection center for internal quality of rails, 11. Last 100 meters of rail, 12. First 100 meters of rail, 13. Inspection area roller conveyor, 14. Internal inspection area roller conveyor, 15. Time position 0 point of the first 100 meters of rail, 16. Time relationship curve of the tail position of the first 100 meters of rail, 17. Time relationship curve of the head position of the last 100 meters of rail, 18. Detailed Implementation
[0030] To make the purpose, technical solutions, and advantages of the invention's embodiments clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described are only a small part of the embodiments of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.
[0031] A method for controlling the segmentation of a spiral roller conveyor for online inspection of 100-meter steel rails includes the following steps:
[0032] S1. The surface quality online inspection process is set up with two inspection points, namely inspection point 1 and inspection point 2. The roller conveyor in the surface inspection area between inspection point 1 and inspection point 2 is controlled in a reverse spiral manner, which is divided into three control sections: surface inspection roller conveyor one, surface inspection roller conveyor two, and surface inspection roller conveyor three. After the 100-meter steel rail is transported to the surface quality online inspection process via the roller conveyor, the start, stop, and speed of surface inspection roller conveyor one, surface inspection roller conveyor two, and surface inspection roller conveyor three are controlled respectively to achieve simultaneous online surface quality inspection of the 100-meter steel rail at inspection point 1 and inspection point 2.
[0033] S2. Internal quality online inspection process: The roller conveyor in the internal inspection area between inspection point 2 and the rail internal quality online inspection center is controlled in a positive spiral manner, divided into four control sections: internal inspection roller conveyor one, internal inspection roller conveyor two, internal inspection roller conveyor three, and internal inspection roller conveyor four. After the surface quality online inspection of 100 meters of rail is completed, internal quality online inspection is carried out. Internal inspection roller conveyor one, internal inspection roller conveyor two, and internal inspection roller conveyor three are shared by the two processes of surface quality online inspection and internal quality online inspection. The surface quality online inspection and internal quality online inspection of 100 meters of rail are achieved by controlling the start, stop, and speed of internal inspection roller conveyor one, internal inspection roller conveyor two, internal inspection roller conveyor three, and internal inspection roller conveyor four respectively.
[0034] S3. The length of each segment of the transport roller conveyor is calculated and determined according to the process layout conditions and the spiral segment calculation formula, so that the process of internal quality flaw detection of the first 100 meters of rail and rapid steel feeding and slow surface quality visual inspection of the last 100 meters of rail can be closely connected.
[0035] In the online inspection process of rail surface quality, inspection points 1 and 2 are each responsible for simultaneously inspecting 52-meter sections of the 100-meter rail; the reverse spiral segmentation method for the surface inspection area roller conveyor: the length of the first surface inspection roller conveyor is determined by S. 表检辊道一 = (Time to deliver the head end of the last 100 meters of rail to inspection point 1 + Safety delay time for the following rail) × Inspection speed of the first 100 meters of rail; The length of inspection roller conveyor 2 is determined by S. 表检辊道二 =Time taken for the last 100 meters of rail head to reach the junction of inspection roller conveyor 1 and inspection roller conveyor 2 from inspection point 1 × Flaw detection speed of the first 100 meters of rail; The length of inspection roller conveyor 3 is determined by S. 表检辊道三 =Time taken for the last 100 meters of rail head to travel from the junction of inspection roller conveyor 1 and inspection roller conveyor 2 to the junction of inspection roller conveyor 3 × Flaw detection speed of the first 100 meters of rail; The total length of the roller conveyor in the surface quality online inspection process is determined to ensure that the visual inspection of surface quality covers the entire length of the 100-meter rail, i.e., S 表检辊道一 + S 表检辊道二 +S 表检辊道三 = 50.2 meters.
[0036] In the aforementioned online internal quality inspection process, the method for determining the length of the first internal inspection roller conveyor in the spiral segmentation method of the internal inspection area is as follows: S 内检辊道一 =A pre-set collision avoidance safety distance of 4-5m is set between the end of the first 100 meters of rail and the beginning of the next 100 meters of rail; the length of the second inner inspection roller conveyor is determined by S. 内检辊道二 =Time taken for the last 100 meters of rail to be visually inspected from inspection point 2 and slowly moved to the junction of inner inspection roller conveyor 1 and inner inspection roller conveyor 2, multiplied by the flaw detection speed of the first 100 meters of rail; the length of inner inspection roller conveyor 3 is determined by S. 内检辊道三 =Time taken for the rail head end of the last 100 meters to continuously visually inspect surface quality from the junction of inner inspection roller track 1 and inner inspection roller track 2 to the junction of inner inspection roller track 2 and inner inspection roller track 3 × the flaw detection speed of the first 100 meters of rail; the length of inner inspection roller track 4 is determined by S. 内检辊道四 =The time taken for the last 100 meters of rail head end to continuously undergo surface quality visual inspection from the junction of inner inspection roller conveyor two and inner inspection roller conveyor three to the junction of inner inspection roller conveyor three and inner inspection roller conveyor four × the flaw detection speed of the first 100 meters of rail; The total length of the inner inspection area roller conveyor in the online internal quality inspection process is the sum of the lengths of each section of inner inspection roller conveyor one, inner inspection roller conveyor two, inner inspection roller conveyor three, and inner inspection roller conveyor four, i.e., S 内检辊道一 + S 内检辊道二 +S 内检辊道三 +S 内检辊道四 =Distance of the process flow layout between checkpoint No. 2 and the exit location of the online quality inspection center for the internal quality of the rails.
[0037] The length values of the three control sections of the surface inspection area roller conveyor, namely surface inspection roller conveyor one, surface inspection roller conveyor two, and surface inspection roller conveyor three, gradually change from maximum to minimum values in a reverse spiral manner; the length values of the four control sections of the inner inspection area roller conveyor, namely inner inspection roller conveyor one, inner inspection roller conveyor two, inner inspection roller conveyor three, and inner inspection roller conveyor four, gradually change from minimum to maximum values in a forward spiral manner.
[0038] During continuous production, the following distance between the first 100 meters and the last 100 meters of rails has a parabolic relationship with the running time; the respective positions of the tail end of the first 100 meters of rails and the head end of the last 100 meters of rails have a spiral relationship with the running time.
[0039] In step S3, the internal quality flaw detection of the first 100 meters of rail is carried out at a speed of ≥1.0m / s, and the subsequent 100 meters of rail are fed rapidly at a speed of ≥2.0m / s, and the surface quality is visually inspected at a slow speed of 0.5m / s.
[0040] In practical applications, such as Figure 1In the production process of 100-meter steel rails, surface quality inspection and internal quality inspection are located in adjacent upstream and downstream processes, respectively. The process layout distance between the two processes should be minimized to meet the requirements of high production efficiency and low cost. The online surface quality inspection process has two inspection points, namely Inspection Point 1 (2) and Inspection Point 2 (10), which are carried out simultaneously and are responsible for visually inspecting the surface quality within a 52-meter length of the 100-meter steel rail. The surface inspection area roller conveyor 14 between inspection point 1 and inspection point 2 is divided into three control sections using a reverse spiral method. The internal inspection area roller conveyor 15 between inspection point 2 and the rail internal quality online inspection center 11 is divided into four control sections using a forward spiral method. The length of each section of the transport roller conveyor is calculated and determined according to the process layout conditions and spiral segmentation calculation method. This ensures a tight connection during the process of internal quality flaw detection of the first 100 meters of rail 13 at a speed of ≥1.0m / s and rapid steel feeding and slow surface quality visual inspection of the last 100 meters of rail 12 at a speed of ≥2.0m / s and 0.5m / s respectively, achieving the shortest connection distance between the first and last 100 meters of rail and the shortest transit time for the 100 meters of rail.
[0041] like Figure 2 The online surface quality inspection process component includes inspection point 1 (2), inspection point 2 (10), and the surface inspection area roller conveyor 14 located between them. This roller conveyor 14 is divided into three control sections: inspection roller conveyor one (3), inspection roller conveyor two (4), and inspection roller conveyor three (5). After the last 100 meters of rail 12 are transported to the online inspection process via the roller conveyors, the start, stop, and speed of inspection roller conveyor one (3), inspection roller conveyor two (4), and inspection roller conveyor three (5) are controlled respectively to achieve simultaneous online surface quality inspection of the last 100 meters of rail 12 at inspection points 1 (2) and 2 (10).
[0042] like Figure 6 The internal quality online inspection process components include a 100-meter rail internal quality online inspection center system 11 and an internal inspection area roller conveyor 15 located after inspection point 2 10. This internal inspection area roller conveyor is divided into four control sections: internal inspection roller conveyor one 6, internal inspection roller conveyor two 7, internal inspection roller conveyor three 8, and internal inspection roller conveyor four 9. After the first 100 meters of rail 13 completes the surface quality online inspection, the internal quality online inspection is performed. The first three sections of the internal inspection area roller conveyor 15—internal inspection roller conveyor one 6, internal inspection roller conveyor two 7, and internal inspection roller conveyor three 8—are shared by both the surface quality online inspection and the internal quality online inspection processes. The online surface quality inspection and the internal quality online inspection of the 100-meter rail are achieved by controlling the start, stop, and speed of internal inspection roller conveyor one 6, internal inspection roller conveyor two 7, internal inspection roller conveyor three 8, and internal inspection roller conveyor four 9, respectively.
[0043] like Figure 3 The method for determining the length of the inspection roller conveyor 3 is as follows: S 表检辊道一3= (Time to deliver the head of the last 100 meters of rail 12 to inspection point 2 + Safety delay time for the following rail) × Flaw detection speed of the first 100 meters of rail 13; where the time to deliver the head of the last 100 meters of rail 12 to inspection point 2 = Distance of the chain steel taking trolley transporting the last 100 meters of rail 12 from the exit of the straightening frame 1 to the preceding roller conveyor of inspection point 2 / Chain steel taking trolley moving speed + Lowering stroke of the chain steel taking trolley to lower the last 100 meters of rail 12 onto the roller conveyor surface / Trolley lowering speed + Distance of the head of the last 100 meters of rail 12 transported to inspection point 2 / Steel feeding speed of the preceding roller conveyor of inspection point 2; where the safety delay time for the following rail is determined based on the shortest following distance between the head of the following rail and the tail of the preceding rail, and is generally taken as 3-6s.
[0044] like Figure 4 The method for determining the length of roller conveyor 24 is as follows: S 表检辊道二4 = The time it takes for the end of the last 100 meters of rail 12 to reach the junction of inspection roller conveyor 1 (3) and inspection roller conveyor 2 (4) from inspection point 1 (2) × the flaw detection speed of the first 100 meters of rail 13; where the time it takes for the end of the last 100 meters of rail 12 to reach the junction of inspection roller conveyor 1 (3) and inspection roller conveyor 2 (4) from inspection point 1 (2) = S 表检辊道一3 / Check the steel feeding speed of the roller conveyor (generally ≥2.0m / s).
[0045] As shown in the figure, the method for determining the length of the inspection roller conveyor 35 is as follows: S 表检辊道三5 = The time it takes for the end of the last 100 meters of rail 12 to travel from the junction of inspection roller conveyor 1 (3) and inspection roller conveyor 2 (4) to the junction of inspection roller conveyor 2 (4) and inspection roller conveyor 3 (5) × the flaw detection speed of the first 100 meters of rail 13; where the time it takes for the end of the last 100 meters of rail 12 to travel from the junction of inspection roller conveyor 1 (3) and inspection roller conveyor 2 (4) to the junction of inspection roller conveyor 2 (4) and inspection roller conveyor 3 (5) = S 表检辊道二4 / Check the steel feeding speed of the roller conveyor (generally ≥2.0m / s).
[0046] like Figure 2 The method for determining the total length of the roller conveyor in the online inspection process for the surface quality of 100-meter steel rails is as follows: It must ensure that the visual inspection of surface quality covers the entire length of the 100-meter steel rail, i.e., S... 表检辊道一3 + S 表检辊道二4 + S 表检辊道三5 = 50.2 meters.
[0047] like Figure 7 The method for determining the length of the internal inspection roller conveyor 6 in the internal quality online inspection process is as follows: S 内检辊道一6 = The pre-set anti-collision safety distance between the end of the first 100 meters of rail 13 and the beginning of the last 100 meters of rail 12 is 4-5m.
[0048] like Figure 8 The method for determining the length of the inner inspection roller conveyor 7 is as follows: S 内检辊道二7= The surface quality of the last 100 meters of rail 12 is visually inspected starting from inspection point 2 (10). The rail is then moved slowly to S... 内检辊道一6 and S 内检辊道二7 The time at the junction is multiplied by the flaw detection speed of the first 100 meters of rail 13; the surface quality of the latter 100 meters of rail 12 is visually inspected starting from inspection point 2, and then slowly moved to S. 内检辊道一6 and S 内检辊道二7 Time at the boundary = S 内检辊道一6 / Visual inspection speed (approximately 0.5 m / s).
[0049] like Figure 9 The method for determining the length of the inner inspection roller conveyor 38 is as follows: S 内检辊道三8 = The last 100 meters of rail, 12 ends from S 内检辊道一6 and S 内检辊道二7 Continuous visual inspection of surface quality at the junction is carried out until S 内检辊道二7 and S 内检辊道三8 The time at the junction × the flaw detection speed of the first 100 meters of rail 13; where the head of the latter 100 meters of rail 12 starts from S 内检辊道一6 and S 内检辊道二7 Continuous visual inspection of surface quality at the junction is carried out until S 内检辊道二7 and S 内检辊道三8 Time at the boundary = S 内检辊道二7 / Visual inspection speed (approximately 0.5 m / s).
[0050] like Figure 10 The method for determining the length of the inner inspection roller conveyor 49 is as follows: S 内检辊道四9 = The last 100 meters of rail, 12 ends from S 内检辊道二7 and S 内检辊道三8 Continuous visual inspection of surface quality at the junction is carried out until S 内检辊道三8 and S 内检辊道四9 The time at the junction × the flaw detection speed of the first 100 meters of rail 13; where the head of the latter 100 meters of rail 12 starts from S 内检辊道二7 and S 内检辊道三8 Continuous visual inspection of surface quality at the junction is carried out until S 内检辊道三8 and S 内检辊道四9 Time at the boundary = S 内检辊道三8 / Visual inspection speed (approximately 0.5 m / s).
[0051] like Figure 6 The total length of the internal inspection area roller conveyor 15 is the sum of the lengths of the four internal inspection roller conveyor sections, i.e., S. 内检辊道一6 + S 内检辊道二7 +S 内检辊道三8 + S 内检辊道四9 = The process flow layout distance between checkpoint 10 (No. 2) and the exit position of the online quality inspection center for rail internals (No. 11).
[0052] like Figure 11 The online inspection process for the surface quality of 100-meter steel rails and the online inspection process for internal quality are arranged sequentially and adjacently in the process. The segment length values of the three sections of the surface inspection area roller conveyor 14 (surface inspection roller conveyor 1, 3, 4, and 5) gradually change from the maximum value to the minimum value in a reverse spiral manner. The segment length values of the four sections of the internal inspection area roller conveyor 15 (internal inspection roller conveyor 1, 6, 7, 8, and 9) gradually change from the minimum value to the maximum value in a forward spiral manner.
[0053] like Figure 12 and Figure 13 During continuous production, the following distance between the first 100 meters and the last 100 meters of rails has a parabolic relationship with the running time; the position of the tail end of the first 100 meters of rails and the head end of the last 100 meters of rails has a spiral relationship with the running time.
[0054] This invention can precisely control the following movement of the front and rear rails during the online inspection of the surface quality of 100-meter rails, so that the production rhythm of the front and rear 100-meter rails through the online surface quality inspection process and the online inspection process of the internal quality of the rails can reach the optimal compactness, while avoiding conflicts and collisions between the front and rear 100-meter rails. This not only improves the production rhythm and efficiency of 100-meter rails, but also reduces unnecessary redundant equipment and its construction capital investment, as well as waste such as ineffective operation consumption in the production process.
Claims
1. A method for controlling the segmentation of a spiral roller conveyor for online inspection of 100-meter steel rails, characterized in that... Includes the following steps: S1. The online surface quality inspection process has two inspection points, namely inspection point 1 and inspection point 2. The roller conveyor in the inspection area between inspection point 1 and inspection point 2 is controlled in a reverse spiral manner, which is divided into three control sections: inspection roller conveyor one, inspection roller conveyor two, and inspection roller conveyor three. The length values of inspection roller conveyor one, inspection roller conveyor two, and inspection roller conveyor three gradually change from the maximum value to the minimum value in a reverse spiral manner. After the 100-meter steel rail is transported to the online surface quality inspection process via the roller conveyor, the start, stop, and speed of inspection roller conveyor one, inspection roller conveyor two, and inspection roller conveyor three are controlled respectively to achieve simultaneous online surface quality inspection of the 100-meter steel rail at inspection point 1 and inspection point 2. S2. Internal Quality Online Inspection Process: The roller conveyor in the internal inspection area between inspection point 2 and the rail internal quality online inspection center is segmented and controlled in a positive spiral manner, consisting of four control sections: Internal Inspection Roller Conveyor 1, Internal Inspection Roller Conveyor 2, Internal Inspection Roller Conveyor 3, and Internal Inspection Roller Conveyor 4. The length values of Internal Inspection Roller Conveyor 1, Internal Inspection Roller Conveyor 2, Internal Inspection Roller Conveyor 3, and Internal Inspection Roller Conveyor 4 gradually change from a minimum to a maximum value in a positive spiral manner. After the surface quality online inspection of the 100-meter rail is completed, internal quality online inspection is performed. Internal Inspection Roller Conveyor 1, Internal Inspection Roller Conveyor 2, and Internal Inspection Roller Conveyor 3 are shared by both the surface quality online inspection and internal quality online inspection processes. The surface quality online inspection and internal quality online inspection of the 100-meter rail are achieved by controlling the start, stop, and speed of Internal Inspection Roller Conveyor 1, Internal Inspection Roller Conveyor 2, Internal Inspection Roller Conveyor 3, and Internal Inspection Roller Conveyor 4 respectively. S3. The length of each segment of the transport roller conveyor is calculated and determined according to the process layout conditions and the spiral segment calculation formula, so that the process of internal quality flaw detection of the first 100 meters of rail and rapid steel feeding and slow surface quality visual inspection of the last 100 meters of rail can be closely connected. During continuous production, the following distance between the first 100 meters and the last 100 meters of rails has a parabolic relationship with the running time; the respective positions of the tail end of the first 100 meters of rails and the head end of the last 100 meters of rails have a spiral relationship with the running time.
2. The method for controlling online inspection of 100-meter steel rails via a spiral roller conveyor segmentation according to claim 1, characterized in that: In the online inspection process of rail surface quality, inspection points 1 and 2 are each responsible for simultaneously inspecting 52-meter sections of the 100-meter rail. The method for segmenting the roller conveyor in the surface inspection area using a reverse spiral design includes: the length of roller conveyor one is determined by S. 表检辊道一 = (Time to deliver the head end of the last 100 meters of rail to inspection point 1 + Safety delay time for the following rail) × Inspection speed of the first 100 meters of rail; The length of inspection roller conveyor 2 is determined by S. 表检辊道二 =Time taken for the last 100 meters of rail head to reach the junction of inspection roller conveyor 1 and inspection roller conveyor 2 from inspection point 1 × Flaw detection speed of the first 100 meters of rail; The length of inspection roller conveyor 3 is determined by S. 表检辊道三 =Time taken for the last 100 meters of rail head to travel from the junction of inspection roller conveyor 1 and inspection roller conveyor 2 to the junction of inspection roller conveyor 3 × Flaw detection speed of the first 100 meters of rail; The total length of the roller conveyor in the surface quality online inspection process is determined to ensure that the visual inspection of surface quality covers the entire length of the 100-meter rail, i.e., S 表检辊道一 + S 表检辊道二 +S 表检辊道三 = 50.2 meters.
3. The method for controlling online inspection of 100-meter steel rails via a spiral roller conveyor segmentation according to claim 1, characterized in that: In the aforementioned online internal quality inspection process, the method for segmenting the inner inspection area roller conveyor into a positive spiral includes: the method for determining the length of inner inspection roller conveyor one is S. 内检辊道一 =A pre-set collision avoidance safety distance of 4-5m is set between the end of the first 100 meters of rail and the beginning of the next 100 meters of rail; the length of the second inner inspection roller conveyor is determined by S. 内检辊道二 =Time taken for the last 100 meters of rail to be visually inspected from inspection point 2 and slowly moved to the junction of inner inspection roller conveyor 1 and inner inspection roller conveyor 2, multiplied by the flaw detection speed of the first 100 meters of rail; the length of inner inspection roller conveyor 3 is determined by S. 内检辊道三 =Time taken for the rail head end of the last 100 meters to continuously visually inspect surface quality from the junction of inner inspection roller track 1 and inner inspection roller track 2 to the junction of inner inspection roller track 2 and inner inspection roller track 3 × the flaw detection speed of the first 100 meters of rail; the length of inner inspection roller track 4 is determined by S. 内检辊道四 =The time taken for the last 100 meters of rail head end to continuously undergo surface quality visual inspection from the junction of inner inspection roller conveyor two and inner inspection roller conveyor three to the junction of inner inspection roller conveyor three and inner inspection roller conveyor four × the flaw detection speed of the first 100 meters of rail; The total length of the inner inspection area roller conveyor in the online internal quality inspection process is the sum of the lengths of each section of inner inspection roller conveyor one, inner inspection roller conveyor two, inner inspection roller conveyor three, and inner inspection roller conveyor four, i.e., S 内检辊道一 + S 内检辊道二 +S 内检辊道三 +S 内检辊道四 =Distance of the process flow layout between checkpoint No. 2 and the exit location of the online quality inspection center for the internal quality of the rails.
4. The method for controlling online inspection of 100-meter steel rails via a spiral roller conveyor segmentation according to claim 1, characterized in that: In step S3, the internal quality flaw detection of the first 100 meters of rail is carried out at a speed of ≥1.0m / s, and the subsequent 100 meters of rail are fed rapidly at a speed of ≥2.0m / s, and the surface quality is visually inspected at a slow speed of 0.5m / s.