Orbital laser enhanced integrated processing apparatus and orbital enhanced processing method

Abstract

The application provides a track laser reinforcement integrated processing device and a track reinforcement processing method, and comprises the following steps: S1: the track laser reinforcement integrated processing device is driven to a track section to be reinforced, and a synchronous wheel is pressed against the upper surface and the inner surface of the track by a longitudinal pressing module and a transverse pressing module; S2: the track laser reinforcement integrated processing device is driven on the track section, a heating device, a spraying device and a laser device are turned on, heating heads, spraying gun heads and laser heads arranged in the vehicle bottom in sequence pass through the track section in sequence, the heating heads heat the surface of the track section, the spraying gun heads spray reinforcement materials on the surface of the track section heated by the heating heads, the sprayed reinforcement materials are dried by the residual heat of the track section before the laser heads pass through the track section on which the reinforcement materials are sprayed, and the laser emitted by the laser heads scans the track section on which the reinforcement materials are sprayed, so that the alloy coating and the surface layer of the track are subjected to a metallurgical chemical reaction, and a reinforcement layer is formed on the surface of the track.

Description

Technical Field

[0001] This invention relates to a track enhancement processing device, and more particularly to a track laser enhancement integrated processing device. The track enhancement processing device is installed on a vehicle running on the track to achieve online performance enhancement of the already laid and operational railway track, while improving the efficiency of track enhancement processing. Background Technology

[0002] With the rapid development of technology in the rail transit field, rail strengthening technology has also made remarkable progress. In particular, the method of strengthening the rail surface using lasers has attracted widespread attention.

[0003] Methods for strengthening rail surfaces with lasers include laser cladding and laser alloying. Among them, invention patent CN101125394A discloses a laser cladding technology for railway rails. In this patent, a high-frequency induction heater is used to synchronously heat the workpiece, and an automatic powder feeder delivers cladding powder to the laser irradiation area on the workpiece surface. The alloy powder melts instantaneously under the action of the laser beam, forming an alloy layer, which is a raised coating protruding from the rail surface.

[0004] Unlike laser cladding technology, which produces a protruding alloy layer, invention patent CN107881498A discloses a laser alloying technology for railway rails. Based on existing rails, a micro-molten pool is formed on the surface of the rail specimen using a laser alloying process. This allows the alloy coating to undergo a metallurgical-chemical reaction with the rail surface structure, forming a reinforcing layer. The reinforcing layer and the rail matrix form a strong metallurgical bond, strengthening the rail without affecting its surface profile, thus creating a composite reinforcing material structure.

[0005] Both laser cladding and laser alloying technologies involve the spraying of reinforcing materials and laser scanning processes. Due to their long track lengths, mobile equipment that can operate along the route is more convenient for construction operations.

[0006] The following patents, published under CN110886166A (titled "An End-Driven Semi-Open Rail Laser Strengthening Vehicle"), CN110843805A (titled "An Intermediate-Driven Containerized Rail Laser Strengthening Vehicle"), CN110843820A (titled "A Multifunctional Flatbed Cart for Rail Laser Strengthening or Repair and Its Operating Method"), CN110843803A (titled "An Offline / Online Shared Containerized Rail Laser Strengthening Center and Its Operating Method"), CN110846957A (titled "A Remotely Controlled Rail Laser Strengthening Vehicle and Its Remote Control Method"), CN110843804A (titled "A Dual-Power Constant Low-Speed ​​Rail Laser Strengthening Vehicle and Its Control Method"), and CN110835869A (titled "An Image Recognition-Based Rail Laser Strengthening Vehicle and Its Operating Method"), all disclose vehicle-type rail laser enhancement processing equipment.

[0007] However, these devices only include laser equipment. Heating and spraying equipment are also needed throughout the track strengthening process. This not only increases equipment costs and makes scheduling difficult, but also makes it challenging to maintain consistent coordination between different processes on different traveling devices. Therefore, this results in low strengthening efficiency, poor uniformity and stability of the process, and ultimately, compromised track quality. Summary of the Invention

[0008] In view of the shortcomings of existing equipment, the present invention provides a high-efficiency and stable track laser enhancement integrated processing equipment. Specifically, the track enhancement processing equipment is installed on a vehicle running on the track. The track enhancement equipment includes a spraying device, a laser device and a drying device.

[0009] The technical solution adopted by the present invention to solve the above-mentioned technical problems is: a track laser enhancement integrated processing equipment, which includes a car body and a heating device, a spraying device, a laser device and at least one synchronization device on the car body; The heating device includes a heating head, the spraying device includes a spray gun head, and the laser device includes a laser head; The synchronization device is located at the bottom of the vehicle body and includes a mounting plate assembly, a synchronization wheel, a longitudinal pressing module, and a lateral pressing module. The longitudinal pressing module provides the synchronous pulley with a continuous longitudinal pressure perpendicular to the track, and the lateral pressing module provides the synchronous pulley with a continuous lateral pressure perpendicular to the track tangent, so that the synchronous pulley can always be in close contact with the track. The mounting plate assembly is connected to the synchronous pulley. The heating head, spray gun head, and laser head are mounted on the mounting plate assembly. The heating head, spray gun head, and laser head are arranged sequentially along the length of the vehicle body at the bottom of the vehicle body. When the vehicle body travels along the track, the synchronous wheel is pressed onto the track by the longitudinal pressing module and the transverse pressing module. The heating head, spray gun head and laser head face the track and move together with the synchronous wheel, while their relative positions with the track in the transverse and longitudinal directions remain unchanged.

[0010] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: when the vehicle body travels at a predetermined speed on the track section, the heating device, the spraying device and the laser device complete the strengthening treatment of the track at the predetermined speed.

[0011] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is: including a first synchronization device and a second synchronization device; The first synchronization device includes a first mounting plate assembly, a first synchronization wheel, a first longitudinal pressing module, and a first transverse pressing module; The second synchronization device includes a second mounting plate assembly, a second synchronization wheel, a second longitudinal pressing module, and a second transverse pressing module; The heating head and spray gun head are fixed on the first mounting plate assembly, and the laser head is fixed on the second mounting plate assembly.

[0012] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: the heating head and the spray gun head are adjacent to each other and the center distance between them is less than 100mm, so as to facilitate spraying on the heated track surface, and the sprayed reinforcing material is dried by the residual heat on the track.

[0013] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: the synchronous wheel includes a wheel body and a limiting disk coaxially arranged with the wheel body. The diameter of the limiting disk is larger than that of the wheel body and it is located inside the wheel body. The boundary between the limiting disk and the wheel body on the outer surface is rounded.

[0014] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: the longitudinal pressing module includes a first cylinder, which acts downward on the mounting plate assembly so that the synchronous wheel is always subjected to a downward pressing force; the transverse pressing module includes a second cylinder, which acts on the mounting plate assembly from the inside so that the synchronous wheel is always subjected to a transverse pressing force from the inside out.

[0015] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: when the rail vehicle travels on the track in one direction, the heating head, spray gun head and laser head only perform reinforcement treatment on one side of the track; The vehicle body is equipped with a direction switching device, which includes several guide rails extending along the width of the vehicle body. The heating head, spray gun head and laser head are arranged on the corresponding guide rails. The heating head, spray gun head, and laser head are movably switched to the other side of the vehicle body along the guide rail; corresponding synchronization devices are provided on both sides of the vehicle body; the heating head, spray gun head, and laser head are connected to the synchronization device on their respective sides; The direction switching device is used to switch the heating head, spray gun head and laser head to the other side of the vehicle body so that the heating head, spray gun head and laser head can enhance the track on the other side.

[0016] The technical solution adopted by this invention to solve the above-mentioned technical problems is: a track strengthening method, which includes at least the following steps: Step S1: Drive the track laser enhancement integrated processing equipment to the track section to be enhanced, and the synchronous wheel is pressed against the upper and inner surfaces of the track by the longitudinal pressing module and the transverse pressing module; Step S2: The track laser enhancement integrated processing equipment travels on the above-mentioned track section, and the heating device, spraying device and laser device are turned on; The heating head, spray gun head, and laser head pass through the track section in sequence; after the heating head heats the surface of the track section, the spray gun head sprays the reinforcing material onto the heated surface of the track section. Before the laser head passes through the track section coated with reinforcing material, the coated reinforcing material is dried by the residual heat on the track section. The laser head emits a laser that scans the track section coated with reinforcing material, causing the alloy coating to undergo a metallurgical chemical reaction with the track surface, forming a reinforcing layer on the track surface.

[0017] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: at least one end of the vehicle body is provided with a traction device, and the traction device is used to connect to a tractor vehicle; Before step S1, the track laser enhancement integrated processing equipment is towed to the track section to be enhanced at speed A using a tractor; then the track laser enhancement integrated processing equipment is detached from the tractor. In step S2, the track laser enhancement integrated processing equipment travels at a constant speed B on the track section, and the heating device, spraying device and laser device simultaneously perform enhancement treatment on the surface of the track section at a speed B, wherein the speed A is greater than the speed B.

[0018] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problem is as follows: in step S2, the speed B is in the range of 200-1000 meters per hour.

[0019] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problem is as follows: In step S2, the temperature at which the heating head heats the surface of the track section is 50-80 degrees Celsius.

[0020] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problem is as follows: the vehicle body is provided with a direction switching device, which is used to switch the heating head and the laser head to the other side of the vehicle body; Synchronization devices are provided on the first and second sides of the vehicle body width respectively; the heating head and laser head are connected to the synchronization devices on their respective sides; When the aforementioned track laser enhancement integrated processing equipment travels on the track section, the heating head, spray gun head, and laser head located on the first side of the vehicle body enhance one side of the track. The heating head and laser head are disconnected from the synchronization device on the first side, and after being translated and switched to the second side, they are reconnected to the synchronization device on the second side. When the track laser enhancement integrated processing equipment travels in the opposite direction on the aforementioned track section, the heating head, spray gun head, and laser head located on the second side of the vehicle body enhance the track on the other side.

[0021] The preferred technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: the heating head and the spray gun head are adjacent to each other and the center distance between them is less than 100mm, so as to facilitate spraying on the heated track surface and the sprayed reinforcing material is dried by the residual heat on the track.

[0022] Compared with existing technologies, the advantages of this invention are: by integrating multiple processes of the railway rail laser strengthening and alloying method onto a single device using a rail laser enhancement integrated processing equipment, the construction of each process can be carried out along the route by means of vehicle movement, thereby completing the railway rail laser strengthening and alloying treatment efficiently and conveniently.

[0023] The synchronization device ensures that the heating head, spray gun head, and laser head each have a defined relative position to the track when passing through the same location, enabling them to perform operations on the same point on the track. Even when the vehicle changes position, the heating head, spray gun head, and laser head at different locations on the track always maintain their defined relative positions, ensuring that the work performed at different locations on the track remains consistent, thus guaranteeing the uniformity and stability of the reinforcement operation. Attached Figure Description

[0024] The present invention will be further described in detail below with reference to the accompanying drawings and preferred embodiments. However, those skilled in the art will understand that these drawings are drawn only for the purpose of explaining the preferred embodiments and therefore should not be construed as limiting the scope of the invention. Furthermore, unless specifically indicated, the drawings are only schematic representations of the composition or structure of the described objects and may contain exaggerated depictions, and the drawings are not necessarily drawn to scale.

[0025] Figure 1A schematic diagram of the track structure and the area to be reinforced during the construction of the track laser enhancement integrated processing equipment; Figure 2 A schematic diagram of the track after the installation of the track laser enhancement integrated processing equipment; Figure 3 Flowchart for the construction of track laser enhancement integrated processing equipment; Figure 4 A schematic diagram of an integrated orbital laser enhancement processing device; Figure 5 This is a schematic diagram of the internal structure of an integrated orbital laser enhancement processing device. Figure 6 This is a bottom view of the orbital laser enhancement integrated processing equipment; Figure 7 For orbital laser enhancement integrated processing equipment Figure 4 Enlarged view of a part Figure 8 Schematic diagram of the synchronization device for the orbital laser enhancement integrated processing equipment Figure 9 Schematic diagram of the synchronous wheel assembly for a track laser enhancement integrated processing device Figure 10 Schematic diagram of the heating head and spray gun head of the track laser enhanced integrated processing equipment; Figure 11 A schematic diagram of the assembly of the heating head and direction switching device for the track laser enhancement integrated processing equipment; Figure 12 This is a schematic diagram of a track laser enhancement integrated processing equipment and a tractor.

[0026] Figure label: 100mm track laser enhancement integrated processing equipment; 200mm tractor; 300mm track; Area requiring reinforcement: P; rail head: r; inner half of top surface: P1; inner side surface: P2; reinforcement layer: z; protrusion: g Heating head 1; mounting base 101 of heating head 1; head 102 of heating head 1; upper heating zone 131; side heating zone 132; spray gun head 2; laser head 3; guide rail f; Synchronization device 10; First synchronization device 10a; Second synchronization device 10b; Mounting plate assembly 11; cantilever 111; first mounting plate 112; second mounting plate 113; Synchronous pulley 12; First synchronous pulley 12a; Second synchronous pulley 12b; Wheel body 121; Limiting disc 122; Annular part e; Longitudinal pressing module 13; First cylinder 130; Lateral pressing module 14; Second cylinder 140; 4. Heating unit; 5. Coating unit; 6. Laser generator; 7. Laser control cabinet; 8. Cooling module; 9. Battery pack; 20. Diesel generator; 30. Motor; 40. Control room; 50. Traction device. Detailed Implementation

[0027] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Those skilled in the art will appreciate that these descriptions are merely descriptive and exemplary and should not be construed as limiting the scope of the invention.

[0028] It should be noted that similar labels in the following figures indicate similar items; therefore, once an item is defined in one figure, it may not be further defined and explained in subsequent figures.

[0029] In the description of this invention, it should be noted that the terms "upper" and "lower" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed when in use. They are only used to facilitate the description of this invention and to simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0030] This embodiment provides an integrated orbital laser enhancement processing device 100 and a method for rapidly and efficiently enhancing an orbit 300 using this integrated orbital laser enhancement processing device 100.

[0031] like Figure 1 As shown, the areas of easy wear on track 300 are concentrated near the rounded corners on the inner side of the upper part of the track. Therefore, the areas P that need to be reinforced include the inner half of the top surface of the rail head r, P1, and the inner side surface of the rail head r, P2. The width of the inner half of the top surface, P1, is 15-30 mm, and the upper part of the inner side surface, P2, is 15-30 mm wide.

[0032] like Figure 4 As shown, the track laser enhancement integrated processing equipment 100 includes a vehicle body and a heating device, a spraying device, a laser device, and at least one synchronization device 10 carried on the vehicle body.

[0033] like Figure 4 , 6 As shown, the heating device includes a heating head 1, the spraying device includes a spray gun head 2, and the laser device includes a laser head 3. The heating head 1, spray gun head 2, and laser head 3 are sequentially arranged along the length of the vehicle body at the bottom of the vehicle. As the vehicle travels along the track, the heating head 1, spray gun head 2, and laser head 3 sequentially pass the same position on the track, thereby enabling different processing operations to be performed on the same position on the track.

[0034] like Figure 7-8As shown, the synchronization device 10 is located at the bottom of the vehicle body and includes a mounting plate assembly 11, a synchronization wheel 12, a longitudinal pressing module 13, and a transverse pressing module 14. The synchronization device 10 is used to define the positions of the heating head 1, the spray gun head 2, and the laser head 3, so that the heating head 1, the spray gun head 2, and the laser head 3, passing through different positions on the track, always have a position consistent with the surface of the track.

[0035] In this way, the heating head 1, spray gun head 2, and laser head 3 each have a defined relative position with respect to the track when passing through the same location, enabling them to perform operations on the same location on the track. Furthermore, when the vehicle moves and changes position, the heating head 1, spray gun head 2, and laser head 3, passing through different locations on the track, always maintain their defined relative positions with respect to the track, ensuring that the work performed on different locations on the track remains consistent, thus guaranteeing the uniformity and stability of the strengthening operation.

[0036] Specifically, the longitudinal pressing module 13 provides the synchronous pulley 12 with a continuous longitudinal pressure perpendicular to the track, and the lateral pressing module 14 provides the synchronous pulley 12 with a continuous lateral pressure perpendicular to the track tangent, so that the synchronous pulley 12 can always be in close contact with the track.

[0037] The mounting plate assembly 11 is connected to the synchronous wheel 12, and the heating head 1, the spray gun head 2, and the laser head 3 are mounted on the mounting plate assembly 11. Under the action of the longitudinal pressing module 13 and the transverse pressing module 14, the relative height between the synchronous wheel 12 and the longitudinal direction of the track is constant, and the transverse relative position between the synchronous wheel 12 and the track in the normal direction perpendicular to the tangent direction of the track is constant.

[0038] Due to the constraint of the position of the synchronous wheel 12, the relative position of the mounting plate assembly 11 and the track is restricted. That is, during the movement of the vehicle, the longitudinal two degrees of freedom and the horizontal two degrees of freedom of the mounting plate assembly 11 and the track are restricted, thereby ensuring that the relative positions of the heating head 1, the spray gun head 2 and the laser head 3 set on the mounting plate assembly 11 and the track remain consistent.

[0039] When the track laser enhancement integrated processing equipment 100 is running, the heating head 1, the spray gun head 2, and the laser head 3 sequentially pass through the track section; the heating head 1 heats the surface of the corresponding track section. The spray gun head 2 sprays a reinforcing material onto the heated track surface. In this embodiment, the reinforcing material includes metal powder, ceramic powder, and a liquid carrier. Of course, the reinforcing material may also include only metal powder and a liquid carrier.

[0040] The laser head 3 emits a laser beam that scans the track section coated with reinforcing material, causing a metallurgical chemical reaction between the alloy coating and the track surface structure, forming a layer on the track surface that resembles... Figure 2 The reinforcement layer z shown represents the reinforcement layer used to strengthen the orbital.

[0041] It should be understood that heating the track first, using its residual heat to dry the reinforcing material, ensures that the interface between the track and the reinforcing material is dried first. This facilitates the uniform spreading of the reinforcing material and also promotes a stronger bond between the reinforcing material and the track.

[0042] As the temperature gradually decreases over time, the reinforcing material needs to be sprayed while the surface temperature of the track section is still relatively high to facilitate its drying. A suitable time interval is required after spraying to allow the reinforcing material to dry completely before the laser treatment.

[0043] Based on this, such as Figure 4 As shown, the heating head 1 and the spray gun head 2 are adjacent to each other, and the distance between the spray gun head 2 and the laser head 3 is greater than the distance between the spray gun head 2 and the heating head 1.

[0044] In this embodiment, the heating head 1 and the spray gun head 2 are located adjacent to each other and the center distance between them is less than 100mm. This distance avoids interference between the heating head 1 and the spray gun head 2, and also ensures that the corresponding track still has a high temperature when the spray gun head 2 is spraying, so as to facilitate spraying the heated track surface and drying the sprayed material by the residual heat on the track.

[0045] The track laser enhancement integrated processing equipment 100 integrates multiple processes of the railway track laser strengthening alloying method onto a single device, and performs each process sequentially along the route by moving the vehicle. The time relationship between processes is controlled by the spacing between the heating head 1, the spray gun head 2, and the laser head 3, completing the strengthening process while the vehicle is in motion, thus efficiently and conveniently completing the railway track laser strengthening alloying treatment.

[0046] Furthermore, it should be noted that conducting the entire track strengthening operation in real time along the route, with a short time difference between heating, spraying, and laser treatment, makes it less likely to introduce impurities or other adverse factors, which is more conducive to ensuring the quality of the strengthening operation.

[0047] It should be noted that the heating head 1, the spray gun head 2 and the laser head 3 can be set on the same set of synchronization devices 10, or they can be set on different synchronization devices 10; or two of them can be set on the same set of synchronization devices 10, while the other one can be set on a separate synchronization device 10.

[0048] In this embodiment, as Figure 4 , 6As shown in Figure 7, since the heating head 1 and the spray gun head 2 are adjacent to each other, they are both mounted on the first synchronization device 10a. The laser head 3 is independently mounted on the second synchronization device 10b. The first synchronization device 10a includes a first mounting plate assembly, a first synchronization wheel 12a, a first longitudinal pressing module, and a first transverse pressing module. The second synchronization device 10b includes a second mounting plate assembly, a second synchronization wheel 12b, a second longitudinal pressing module, and a second transverse pressing module.

[0049] The heating head 1 and the spray gun head 2 are fixed to the first mounting plate assembly, and the laser head 3 is fixed to the second mounting plate assembly. The first synchronous wheel 12a and the second synchronous wheel 12b are located on the outer sides of the heating head 1, the spray gun head 2, and the laser head 3. The first synchronous wheel 12a and the second synchronous wheel 12b work together to ensure that the heating head 1, the spray gun head 2, and the laser head 3 maintain consistent positional relationships with the track.

[0050] like Figure 9 As shown, the synchronous pulley 12 includes a pulley body 121 and a limiting disk 122 coaxially disposed with the pulley body 121. The limiting disk 122 has a larger diameter than the pulley body 121 and is located inside the pulley body 121. The boundary between the limiting disk 122 and the pulley body 121 is rounded at the outer surface. The lower side of the outer circumferential surface of the pulley body 121 contacts the upper surface of the track, and the limiting disk 122 is located inside the track.

[0051] The limiting disc 122 has an annular portion e protruding from the wheel body 121. The annular portion e near the annular surface of the track is used to limit the lateral position of the limiting disc 122. Through the structure of the synchronous wheel 12 itself and the action of the longitudinal pressing module 13 and the lateral pressing module 14, the relative position of the synchronous wheel 12 with respect to the track in the longitudinal and normal directions remains constant.

[0052] The arc transition at the junction of the limiting disc 122 and the wheel body 121 on the outer surface is to adapt to the contour of the track and play a guiding role in avoiding obstacles.

[0053] like Figure 7-8 As shown, the mounting plate assembly 11 is connected to the axle of the synchronous pulley 12 via two cantilever arms 111. The upper end of the cantilever arm 111 is fixed to the mounting plate assembly 11, and the lower end of the cantilever arm 111 is rotatably connected to the end of the axle of the synchronous pulley 12.

[0054] Mounting plate assembly 11 includes a first mounting plate 112 and a second mounting plate 113. The second mounting plate 113 is connected to the lower side of the first mounting plate 112 and is connected to the synchronous pulley 12. The longitudinal position between the second mounting plate 113 and the first mounting plate 112 is defined to ensure that they move synchronously in the longitudinal direction. The first mounting plate 112 is vertically movably connected to the bottom of the vehicle body. When the synchronous pulley 12 changes position vertically with the track height, the second mounting plate 113 and the first mounting plate 112 float vertically together.

[0055] Meanwhile, the second mounting plate 113 is laterally movable and connected to the lower side of the first mounting plate 112. When the synchronous pulley 12 changes its lateral position due to changes in the track angle or lateral position, the second mounting plate 113 floats laterally relative to the first mounting plate 112.

[0056] The longitudinal pressing module 13 includes a first cylinder 130, which acts downward on the mounting plate assembly 11 so that the synchronous pulley 12 is always subjected to a downward pressing force. In this embodiment, the first cylinder 130 acts downward on the first mounting plate 112, thus always pressing the first mounting plate 112 and the second mounting plate 113 downward to longitudinally press the synchronous pulley 12 onto the track.

[0057] The lateral pressing module 14 includes a second cylinder 140, which acts on the second mounting plate 113 from the inside so that the synchronous wheel 12 connected to the second mounting plate 113 is always subjected to a lateral pressing force from the inside to the outside, so as to press the synchronous wheel 12 laterally onto the track.

[0058] Furthermore, the second mounting plate 113 has a mounting part k for mounting functional components such as the heating head 1, the spray gun head 2, and the laser head 3. The six degrees of freedom of the second mounting plate 113 and the synchronous wheel 12 in terms of vertical, horizontal, and rotational freedom are all limited, thus ensuring that the reference position of the heating head 1, the spray gun head 2, and the laser head 3 relative to the track remains consistent.

[0059] In this embodiment, when the vehicle body travels unidirectionally on the track, the heating head 1, spray gun head 2, and laser head 3 on one side only enhance the track on that side.

[0060] To save on production costs and improve the compactness of the equipment, only one set of heating head 1 and laser head 3 is installed on the vehicle body, while the spray gun head 2 is installed on both sides of the vehicle body. The vehicle body is equipped with a direction switching device, which is used to switch the heating head 1 and laser head 3 from the first side of the vehicle body to the second side to facilitate the processing of the other side of the track.

[0061] In operation, the heating head 1, spray gun head 2, and laser head 3 are connected to the synchronization device 10 on one side, thus preventing the heating head 1 and laser head 3 from moving via the direction switching device. When a position switch is required, the heating head 1 and laser head 3 disengage from the synchronization device 10 on one side, allowing them to move to the other side of the vehicle body using the direction switching device.

[0062] Therefore, in this embodiment, the heating head 1 and the laser head 3 are detachably connected to the synchronization device 10, including screw assembly connection, snap-fit ​​connection, etc.

[0063] Furthermore, the heating head 1, spray gun head 2, and laser head 3 all include a mounting base and a head. To ensure precise alignment of the heating head 1, spray gun head 2, and laser head 3 with the track work area, the mounting base and head are connected by an angle-adjustable connection. After angle adjustment, the mounting base and head are fixed to prevent changes in the actual position of the head during operation.

[0064] like Figure 10-11 As shown, taking heating head 1 as an example, the mounting base 101 of heating head 1 is used to connect with the synchronization device 10, and the head 102 of heating head 1 is the part that actually heats the track. The head of heating head 1 can rotate relative to the mounting base of heating head 1.

[0065] Especially after switching directions, the relative position of the head of heating head 1 and the track changes, requiring rotation between the mounting base and the head to align the head with the track working area.

[0066] The direction switching device includes several guide rails extending along the width of the vehicle body, with the heating head 1 and the laser head 3 mounted on the corresponding guide rails.

[0067] like Figure 6 , 11 As shown, the mounting base 101 of the heating head 1 is movably connected to the guide rail f for switching the position of the heating head 1. The mounting base 101 of the heating head 1, which is detached from the synchronization device 10, moves along the guide rail f to achieve switching between the two sides.

[0068] like Figure 10 As shown, the head 102 of the heating head 1 includes an induction coil, which is close to the track surface, 5-10 mm away from the reinforced track surface. The alternating current flowing through the induction coil generates an alternating magnetic field, causing eddy currents in the track to achieve heating. In addition, maintaining an appropriate distance between the head surface of the heating head 1 and the track can cope with track undulations and dimensional changes during operation.

[0069] Furthermore, such as Figure 10 , 11As shown, the head 102 of the heating head 1 has an L-shaped cross-section, such that the head of the heating head 1 includes an upper heating area 131 located on the upper side of the track and a side heating area 132 located on the inner side of the track. Both the upper heating area 131 and the side heating area 132 extend along the track, and each is provided with a linearly distributed induction coil.

[0070] The head 102 of the L-shaped heating head 1 is consistent with the shape of the area to be strengthened. This targeted design enables all-round three-dimensional heating of the area to be strengthened, ensuring uniform temperature distribution, uniform drying of the strengthening material, and improving the quality stability of the subsequently prepared strengthening layer.

[0071] like Figure 5 As shown, the heating device also includes a heating host 4; the spraying device also includes a paint host 5; and the laser device also includes a laser generator 6, a laser control cabinet 7, and a cooling module 8. All of these devices are installed inside the vehicle body.

[0072] In addition, the carriage is equipped with a battery pack 9 and a diesel generator 20. The battery pack 9 supplies power to the laser generator 6 and the laser control cabinet 7. The heating device, spraying device, and the vehicle's power system are powered by the diesel generator 20. The battery pack 9 is connected to a battery controller, which controls the opening, closing, and operation of the battery pack 9. When the track laser enhancement integrated processing equipment 100 is not in operation, the diesel generator 20 charges the battery pack 9.

[0073] like Figure 4 , 5 As shown, the active power source of the vehicle's power system is the electric motor 30 that drives the wheels. The generator operates under system control to drive the vehicle. In this embodiment, an operator's cab 40 is provided inside the vehicle's compartment, where operators control the operation of the power system and the corresponding equipment.

[0074] Preferably, a real-time monitoring system is also provided at the bottom of the vehicle body. The real-time monitoring system includes several video monitors, which are arranged near the spray gun head 2 and the laser head 3 to monitor the spraying effect, the drying effect of the strengthening material, and the laser strengthening effect in real time.

[0075] like Figure 4 , 12 As shown, both ends of the vehicle body are equipped with traction devices 50. The traction devices 50 are used to connect to the traction vehicle 200, and the traction vehicle 200 is used to pull the track laser enhancement integrated processing equipment 100 to the track section to be enhanced at a relatively fast speed.

[0076] In summary, as Figure 3 As shown, the orbit strengthening method using the aforementioned orbit laser enhancement integrated processing equipment 100 includes at least the following steps: Step S1: Drive the track laser enhancement integrated processing equipment 100 to the track section to be enhanced. The synchronous wheel 12 is pressed against the upper and inner surfaces of the track by the longitudinal pressing module 13 and the transverse pressing module 14.

[0077] Step S2: The track laser enhancement integrated processing equipment 100 travels on the above-mentioned track section. During the travel of the track laser enhancement integrated processing equipment 100, the relative positions of the heating head 1, the spray gun head 2 and the laser head 3 with the track are always kept consistent.

[0078] During the journey, the heating device, spraying device, and laser device are activated; the heating head 1, spraying gun head 2, and laser head 3 pass through the track section in sequence.

[0079] In this process, the process is carried out step by step at the same location on the track. After the heating head 1 heats the surface of the corresponding track segment, the spray gun head 2 evenly sprays the reinforcing material onto the heated track segment surface. Before the laser head 3 passes over the track segment sprayed with the reinforcing material, the sprayed reinforcing material is dried by the residual heat on the track segment; when the laser head 3 passes over, the laser emitted by the laser head 3 scans the track segment sprayed with the reinforcing material, causing the alloy coating to undergo a metallurgical chemical reaction with the track surface structure, forming a reinforcing layer on the track surface.

[0080] Preferably, the heating temperature is 50-80 degrees Celsius. This ensures that the surface of the corresponding track segment has a high temperature for a subsequent period of time, which is used to dry the subsequently sprayed liquid-dispersed reinforcing material.

[0081] like Figure 2 As shown, the laser-strengthened track surface acquires a 0.2-1.0 mm deep strengthening layer z with a hardness of HRC45-HRC64, beneath which lies the pearlitic structure of the track steel, with a hardness of HRC30-HRC40. The surface morphology of the strengthening layer z on the rail head has slight protrusions g, but the protrusions g are tiny, basically maintaining the original dimensions of the track, without surface defects such as cracks, pits, or holes. The strengthening layer structure is a particle-reinforced composite strengthening structure, with particle reinforcing phases dispersed within a tough binder phase structure, possessing the advantages of combining strength and toughness. Due to the presence of the surface strengthening layer, the strengthened track specimen exhibits excellent fatigue resistance, effectively resisting the impact of train wheels and rails without the strengthening layer peeling off, and also possesses excellent wear resistance.

[0082] Furthermore, the track-mounted laser enhancement integrated processing equipment 100 travels at a constant speed B, and this speed can be preset. The track-mounted laser enhancement integrated processing equipment 100 travels at a constant speed on the aforementioned track section, and the heating device, spraying device, and laser device perform surface enhancement treatment on the track section at this speed. To ensure the enhancement effect, the speed B is generally 200-1000 m / h. In this embodiment, 500 m / h is preferred.

[0083] It should be understood that the laser head 3's dotting or scanning speed is coordinated with the speed of the rail vehicle, and the laser does dotting or scanning of the track section coated with reinforcing material along the track length as the rail vehicle travels.

[0084] In step S2, when the track laser enhancement integrated processing equipment 100 travels unidirectionally on the track, the heating head 1, spray gun head 2, and laser head 3 only enhance one side of the track. That is, when the track laser enhancement integrated processing equipment 100 travels on the track section, the heating head 1, spray gun head 2, and laser head 3 located on the first side of the vehicle body enhance one side of the track.

[0085] After completing the work on one side of the track, proceed with the following steps: Step S3: The heating head 1 and the laser head 3 are disengaged from the synchronization device 10 on the first side of the vehicle body to which they are connected, and are moved and switched to the second side of the vehicle body along the guide rail f, and connected to the synchronization device 10 on the second side, while adjusting the angle by rotation.

[0086] Step S4: Then, the track laser enhancement integrated processing equipment 100 reverses direction, using the original rear of the vehicle as the front. The heating head 1, spray gun head 2, and laser head 3, located on the second side of the vehicle body, enhance the track on the other side. This completes the separate operation on both sides of the track, reducing the total power and energy consumption requirements of the equipment inside the vehicle.

[0087] To further improve efficiency, step S0 is included before step S1, in which the track laser enhancement integration processing equipment 100 is towed to the track section to be enhanced by a tractor at speed A; then the track laser enhancement integration processing equipment 100 is detached from the tractor. Speed ​​A is greater than speed B. The speed A is generally 40-80 km / h.

[0088] After completing the track strengthening operation, the heating device, spraying device, and laser device are turned off. The tractor is driven to the location of the track laser enhancement integrated processing equipment 100. The tractor and traction device are connected, and the tractor pulls the equipment back to the garage.

[0089] To ensure the smooth completion of the work and the quality of the track reinforcement layer, this embodiment also utilizes the real-time monitoring system built into the track laser enhancement integrated processing equipment to monitor the spraying effect, the drying effect of the reinforcement material, and the laser strengthening effect. Operators can view this directly via video from the control room. If any abnormality is detected, the equipment can be stopped immediately, and the affected section of track can be repaired. After repair, the equipment can be restarted to continue subsequent operations.

[0090] To avoid omissions in manual monitoring and improve real-time monitoring efficiency, the track laser enhancement integrated processing equipment can also be equipped with an image processing module and an alarm module. The image processing module stores a large amount of image data on the track surface conditions after different processes under normal and abnormal conditions, and performs deep learning on this data. After the real-time monitoring system's image monitor extracts images of the track surface in real time, the image processing module can process and judge these images. When an anomaly is detected, the alarm module is triggered to indicate the operational abnormality, allowing operators to promptly identify problems.

[0091] The orbital laser enhancement integrated processing equipment and orbital strengthening processing method provided by the present invention have been introduced above. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the present invention and its core ideas. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. An integrated processing device for orbital laser enhancement, characterized in that: Includes the vehicle body and heating devices, spraying devices, laser devices, and at least one synchronization device on the vehicle body; The heating device includes a heating head, the spraying device includes a spray gun head, and the laser device includes a laser head; The synchronization device is located at the bottom of the vehicle body and includes a mounting plate assembly, a synchronization wheel, a longitudinal pressing module, and a lateral pressing module. The longitudinal pressing module provides the synchronous pulley with a continuous longitudinal pressure perpendicular to the track, and the lateral pressing module provides the synchronous pulley with a continuous lateral pressure perpendicular to the track tangent, so that the synchronous pulley can always be in close contact with the track. The mounting plate assembly is connected to the synchronous pulley. The heating head, spray gun head, and laser head are mounted on the mounting plate assembly. The heating head, spray gun head, and laser head are arranged sequentially along the length of the vehicle body at the bottom of the vehicle body. When the vehicle body travels along the track, the synchronous wheel is pressed onto the track by the longitudinal pressing module and the transverse pressing module. The heating head, spray gun head and laser head face the track and move together with the synchronous wheel, while their relative positions with the track in the transverse and longitudinal directions remain unchanged. The mounting plate assembly is connected to the axle of the synchronous pulley via two cantilever arms. The upper end of the cantilever arm is fixed to the mounting plate assembly, and the lower end of the cantilever arm is rotatably connected to the end of the axle of the synchronous pulley. The mounting plate assembly includes a first mounting plate and a second mounting plate. The second mounting plate is connected to the lower side of the first mounting plate and is connected to the synchronous pulley. The longitudinal position between the second mounting plate and the first mounting plate is defined so that the two move synchronously in the longitudinal direction. The first mounting plate is movably connected to the bottom of the vehicle body. When the synchronous pulley changes position up and down with the change of track height, the second mounting plate and the first mounting plate float up and down together. The second mounting plate is laterally movable and connected to the lower side of the first mounting plate. When the synchronous wheel changes its lateral position due to changes in the track angle or lateral position, the second mounting plate floats laterally relative to the first mounting plate. The synchronous pulley includes a wheel body and a limiting disc coaxially arranged with the wheel body. The diameter of the limiting disc is larger than that of the wheel body and it is located inside the wheel body. The boundary between the limiting disc and the wheel body on the outer surface is rounded. The longitudinal pressing module includes a first cylinder, which acts downward on the first mounting plate so that the synchronous pulley is always subjected to a downward pressing force; The lateral pressing module includes a second cylinder, which acts on the second mounting plate from the inside so that the synchronous pulley connected to the second mounting plate is always subjected to a lateral pressing force from the inside to the outside, so as to press the synchronous pulley laterally onto the track. The second mounting plate has a mounting portion for mounting the heating head, spray gun head, and laser head.

2. The orbital laser enhancement integrated processing equipment according to claim 1, characterized in that... When the vehicle body travels at a predetermined speed on the track section, the heating device, spraying device, and laser device complete the reinforcement treatment of the track at the predetermined speed.

3. The orbital laser enhancement integrated processing equipment according to claim 1, characterized in that... The heating head and the spray gun head are located adjacent to each other and the center distance between them is less than 100mm, so as to facilitate spraying on the heated track surface, and the sprayed reinforcing material is dried by the residual heat on the track.

4. The orbital laser enhancement integrated processing equipment according to claim 1, characterized in that, When the vehicle body travels unidirectionally on the track, the heating head, spray gun head, and laser head only reinforce one side of the track. The vehicle body is equipped with only one set of heating head and laser head, while the spray gun head is set on both sides of the vehicle body; The vehicle body is equipped with a direction switching device, which is used to switch the heating head and laser head from the first side of the vehicle body to the second side. The direction switching device includes several guide rails extending along the width direction of the vehicle body, and the heating head and laser head are arranged on the corresponding guide rails. The vehicle body is equipped with corresponding synchronization devices on both sides; when a position switch is required, the heating head and laser head disengage from the synchronization device on one side, and the heating head and laser head move along the guide rail to the other side of the vehicle body; the heating head and laser head are connected to the synchronization device on the side where they are located, so that the heating head and laser head can enhance the track on the other side.

5. A method for track enhancement processing, employing the track laser enhancement integrated processing equipment according to claim 1, characterized in that... At least the following steps are included: Step S1: Drive the track laser enhancement integrated processing equipment to the track section to be enhanced, and the synchronous wheel is pressed against the upper and inner surfaces of the track by the longitudinal pressing module and the transverse pressing module; Step S2: The track laser enhancement integrated processing equipment travels on the above-mentioned track section, and the heating device, spraying device and laser device are turned on; The heating head, spray gun head, and laser head pass through the track section in sequence; after the heating head heats the surface of the track section, the spray gun head sprays the reinforcing material onto the heated surface of the track section. Before the laser head passes through the track section coated with reinforcing material, the coated reinforcing material is dried by the residual heat on the track section. The laser head emits a laser that scans the track section coated with reinforcing material, causing the alloy coating to undergo a metallurgical chemical reaction with the track surface, forming a reinforcing layer on the track surface.

6. The track strengthening treatment method according to claim 5, characterized in that... At least one end of the vehicle body is provided with a traction device, which is used to connect to a tractor vehicle; Before step S1, the track laser enhancement integrated processing equipment is towed to the track section to be enhanced at speed A using a tractor; then the track laser enhancement integrated processing equipment is detached from the tractor. In step S2, the track laser enhancement integrated processing equipment travels at a constant speed B on the track section, and the heating device, spraying device and laser device simultaneously perform enhancement treatment on the surface of the track section at a speed B, wherein the speed A is greater than the speed B.

7. The track strengthening treatment method according to claim 6, characterized in that, In step S2, the speed B ranges from 200 to 1000 meters per hour.

8. The track strengthening treatment method according to claim 5, characterized in that, In step S2, the heating head heats the surface of the track section to a temperature of 50-80 degrees Celsius.

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