A method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels

Abstract

The invention discloses a method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels. The abnormal analysis adopts a temperature rise analysis method and specifically comprises the following steps: S1, selecting two axle temperature monitoring points a and b with a distance of not less than 1 km near the worn rail and performing fixed-point temperature measurement on the axle heads of the same axle positions of the passing molten iron cars; S2, recording the axle head temperature of the molten iron car A at point a as aA, recording the axle head temperature of the molten iron car A at point b as bA, recording the axle head temperature of the molten iron car B at point a as aB, and recording the axle head temperature of the molten iron car B at point b as bB; S3, if bB-aB≈bA-aA, it is determined that the passability of cars A and B is normal; if the difference between bB-aB and bA-aA is significantly large, it is determined that the passability of car A or car B with a high temperature difference is limited. The invention can ensure the long-term stable operation of equipment, save the cost of replacing spare parts, and reduce maintenance man-hours and labor costs.

Description

Technical Field

[0001] The present invention relates to the technical field of logistics and transportation of molten iron cars in metallurgical enterprises, and in particular to a method for analyzing and preventing abnormal wear of rails and wheels on metallurgical railways. Background Art

[0002] Rail wear on metallurgical railway lines has always been a major factor affecting the safe and stable operation of the lines. The operation of heavy-haul metallurgical trains places immense pressure and friction on the rails, leading to severe rail wear, shortening their service life and increasing maintenance costs.

[0003] Enterprise-owned railways often have small curve radii and many S-bend lines, so rail wear has become a relatively common phenomenon in enterprise railway transportation. When the rails show obvious powder loss, it is called abnormal wear. At the same time as the rails are abnormally worn, the wheels in contact with them also experience abnormal wear, which is mainly reflected in the wear of the wheel flanges and the side of the rails. Often due to the lack of intuitive dynamic inspection methods and the relatively complex wheel-rail relationship, it is difficult to determine whether the cause is the "road" or the "vehicle". When vehicles pass, there is a shrill screaming sound, which mainly occurs in small radius curves and S-bend railway areas. Other railway curves with slightly larger radii generally do not have obvious powder loss.

[0004] As companies gradually shifted their focus to increasing molten iron feeding temperatures, the turnover rate of the molten iron ladle increased significantly, leading to increasingly prominent wheel and rail wear issues. Powder loss on tight curves on the railway became increasingly severe. Despite inspections and adjustments to the railway and rolling stock, as well as speed control, the worsening wear situation remained largely unresolved. Wheel rims experienced an average annual 2.5mm wear, while newly replaced rails, four months old, experienced an average monthly lateral wear of 3.6mm. This trend continued to intensify, posing a significant safety hazard to the fast-paced molten iron transportation process and requiring immediate action.

[0005] Therefore, studying an effective metallurgical railway rail anti-wear technology and method is of great significance to improving the safety and stability of railway lines. Summary of the Invention

[0006] The purpose of the present invention is to solve the problem that the rails of metallurgical enterprises are prone to abnormal wear due to the operation of carrying heavy-load high-temperature molten metal, which increases maintenance costs and affects the safety and stability of train operation; at the same time, the line occupancy rate is high, resulting in short window inspection time, and the cause of abnormal rail wear is difficult to analyze and measure. A method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels is provided.

[0007] The specific technical solution of the present invention is as follows: a method for analyzing abnormal wear of metallurgical railway rails and wheels and preventing wear, wherein the abnormal analysis adopts a temperature rise analysis method and specifically comprises the following steps:

[0008] S1. Select two sets of hot metal car axle temperature monitoring points a and b with a distance of no less than 1 km near the worn rails and measure the temperature of the axle heads of the same axle positions of the passing hot metal cars respectively;

[0009] S2. Record the shaft head temperature of molten iron car A at point a as aA, record the shaft head temperature of molten iron car A at point b as bA, record the shaft head temperature of molten iron car B at point a as aB, and record the shaft head temperature of molten iron car B at point b as bB;

[0010] S3. If bB-aB ≈ bA-aA, then the passability of vehicle A and vehicle B is normal. If the difference between bB-aB and bA-aA is significantly large, then the passability of vehicle A or vehicle B due to the high temperature difference is limited.

[0011] The anti-wear method is to apply grease or lubricating oil to the inner side of the rail section that is prone to abnormal wear.

[0012] Furthermore, the anti-wear method adopts an automatic oiling device, which includes two groups of brackets arranged on both sides of the easily worn section of the rail. Each group of brackets is equipped with an oil storage cylinder, and the bottom end of the oil storage cylinder is provided with an oil outlet. The oil outlet is equipped with an oil discharge mechanism, and the outlet end of the oil discharge mechanism is aligned with the upper surface of the rail. The oil discharge mechanism is connected to a controller.

[0013] Furthermore, a sensor is provided along the rail at a distance from the oil discharge mechanism, the sensor being used to detect whether a molten iron car passes by, and the sensor is connected to the controller signal.

[0014] Furthermore, the oil discharge mechanism and the controller are connected to solar panels and are powered by the solar panels.

[0015] Furthermore, the fixed-point temperature measurement adopts an infrared temperature measuring device to measure the temperature. The infrared temperature measuring device is provided with a wireless communication module, and the wireless communication module is connected to the remote control center for communication.

[0016] Furthermore, the abnormality analysis also includes using video monitoring methods to monitor the rail sections that are prone to wear, clean the rail sections, and then observe the rail sections at regular intervals to see whether there is iron powder generated by wear. If iron powder is present, the iron powder is traced back to the specific molten iron car that passed by and the molten iron car was determined to be a problem molten iron car and was taken offline for processing.

[0017] The beneficial effects of the present invention are as follows: it can timely discover problematic molten iron cars with abnormal passability, reduce the wear of the rails, greatly improve the safety assurance capability of molten iron transportation equipment, and ensure the long-term stable operation of the equipment; at the same time, it saves the cost of replacing spare parts such as rails and locomotive wheels, and also reduces maintenance hours and labor costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a three-dimensional schematic diagram of the automatic oiling device and the rail of the present invention;

[0019] Figure 2 yes Figure 1 A top view of

[0020] In the figure: 1. Rail; 2. Oil storage tank; 3. Oil discharge mechanism; 4. Bracket; 5. Sensor. DETAILED DESCRIPTION

[0021] The present embodiment provides a method for analyzing abnormal wear of metallurgical railway rails 1 and wheels and preventing wear. The abnormal analysis adopts a temperature rise analysis method, which specifically includes the following steps: S1. Select two groups of molten iron car axle temperature monitoring points a and b separated by no less than 1 km near the worn rail 1, and perform fixed-point temperature measurement on the axle heads of the same axle positions of the passing molten iron cars; S2. Record the axle head temperature of molten iron car A at point a as aA, record the axle head temperature of molten iron car A at point b as bA, record the axle head temperature of molten iron car B at point a as aB, and record the axle head temperature of molten iron car B at point b as bB; S3. If bB-aB≈bA-aA, it is determined that the passability of car A and car B is normal. If the difference between bB-aB and bA-aA is significantly large, it is determined that the passability of car A or car B with a high temperature difference is limited; The anti-wear method is to apply grease or lubricating oil to the inner side of the section of rail 1 that is prone to abnormal wear.

[0022] In actual application, it can be divided into the following situations: 1. For molten iron cars of the same model but different numbers: the temperature rise of the axle heads of the same axle position at the two monitoring points a and b is basically the same, that is, bB-aB≈bA-aA, and it can be considered that the passing performance of the molten iron cars included in the comparison is normal; if the temperature rise bB-aB of an individual axle head of a certain molten iron car is significantly higher than the temperature rise bA-aA of the axle heads of the same position in other molten iron cars, then the passing performance of the axle at that position of the molten iron car is considered to be limited, and the internal parts of the axle box can be checked offline for signs of mutual wear or interference under heavy load conditions.

[0023] 2. For different models of hot metal cars: If the temperature rise of the axle heads at the same axle position at two monitoring points a and b is essentially the same, i.e., bB-aB ≈ bA-aA, the two models of hot metal cars included in the comparison can be considered to have normal runnability. If the axle head temperature rise bB-aB of a certain model of hot metal car is generally significantly higher than the axle head temperature rise bA-aA of the same position of other models, the overall runnability of this model of hot metal car may be limited, and the local design may not be suitable for operation on small-radius curves.

[0024] 3. For hot metal cars of the same model but with different local structural designs—primarily those with different center plates, side bearings, and axlebox internal and external structures—if the temperature rise of the axle heads at two monitoring points a and b for the same axle position is essentially the same, i.e., bB-aB ≈ bA-aA, the compared hot metal cars can be considered to have normal trafficability. If the temperature rise bB-aB of the axle heads of a hot metal car with a different structure is generally significantly higher than the temperature rise bA-aA of the axle heads of other structures at the same position, the hot metal car's trafficability is considered to be limited and the design may not be suitable for operation on tight curves.

[0025] 4. If the temperature rise of the axle head at the same axle position on each molten iron car at two monitoring points a and b is essentially the same, that is, bB-aB≈bA-aA, but the difference between bB-aB or bA-aA is generally large, then the overall trafficability of the molten iron car is considered to be limited. If the minimum turning radius of the molten iron car meets the requirements, then the local technical condition of the railway curve is considered to be poor. Furthermore, the fixed-point temperature measurement is performed using an infrared temperature measuring device equipped with a wireless communication module, which is connected to the remote control center.

[0026] Furthermore, the abnormality analysis also includes using video surveillance to monitor rail sections prone to wear. Before monitoring, all loose rail dust is removed from the inside of this section, and the contact surface between the rail and the wheel flange within 100 meters is also properly cleaned. Inspections are conducted every four hours. If dust dust is detected, the affected molten iron car is promptly checked and recorded. Cleaning is then repeated until all in-service molten iron cars have been checked. The affected molten iron car is then periodically inspected according to production schedules until confirmed.

[0027] In order to avoid omissions, after the problematic molten iron car is taken off the production line, the observation time interval of other molten iron cars in use can be appropriately extended, and repeated inspections can be carried out until the abnormal wear is reduced or eliminated.

[0028] See also Figure 1-2 The anti-wear method described in this embodiment utilizes an automatic lubricating device. This device comprises two sets of brackets 4 positioned on either side of a wearable section of rail 1. Each set of brackets 4 houses an oil reservoir 2, each with an outlet at its bottom. This outlet houses an oil discharge mechanism 3, the outlet of which is aligned with the upper surface of rail 1. The discharge mechanism 3 is connected to a controller. Furthermore, a sensor 5 is positioned along rail 1, spaced a distance from the discharge mechanism 3. This sensor 5 detects the presence of a molten iron car and is signal-connected to the controller.

[0029] Furthermore, the oil discharge mechanism 3 and the controller are connected to solar panels and powered by the solar panels.

[0030] The automatic oiling device of this embodiment is installed near a section of rail 1 with a smaller turning radius. When the train passes by, the sensor 5 detects the passage of a molten iron car and sends a signal to the controller. The controller discharges the grease to the surface of the rail 1 through the oil discharge mechanism 3 according to the set parameters. Then, when the molten iron car passes by, the lubricating oil naturally sticks to the wheel rims and is evenly applied to the inner side of the curved rail 1 that the train will pass through. The oil film generated between the wheel and the inner side of the rail 1 changes the friction between the two from dry friction to oil-lubricated friction, greatly reducing the friction coefficient and the friction and radial shear force caused by the train gnawing on the rail when turning. This reduces the wear of the wheels and rail 1, significantly reduces driving noise, and reduces train vibration.

Claims

1. A method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels, characterized by: The abnormality analysis adopts the temperature rise analysis method, which specifically includes the following steps: S1. Select two sets of hot metal car axle temperature monitoring points a and b with a distance of no less than 1 km near the worn rails and measure the temperature of the axle heads of the same axle positions of the passing hot metal cars respectively; S2. Record the shaft head temperature of molten iron car A at point a as aA, record the shaft head temperature of molten iron car A at point b as bA, record the shaft head temperature of molten iron car B at point a as aB, and record the shaft head temperature of molten iron car B at point b as bB; S3. If bB-aB ≈ bA-aA, then the passability of vehicle A and vehicle B is normal. If the difference between bB-aB and bA-aA is significantly large, then the passability of vehicle A or vehicle B due to the high temperature difference is limited. The anti-wear method is to apply grease or lubricating oil to the inner side of the rail section that is prone to abnormal wear.

2. The method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels according to claim 1, characterized in that: The anti-wear method adopts an automatic oiling device, which includes two groups of brackets arranged on both sides of the easily worn section of the rail. Each group of brackets is equipped with an oil storage cylinder, and the bottom end of the oil storage cylinder is provided with an oil outlet. The oil outlet is equipped with an oil discharge mechanism, the outlet end of the oil discharge mechanism is aligned with the upper surface of the rail, and the oil discharge mechanism is connected to a controller.

3. The method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels according to claim 2, characterized in that: A sensor is provided along the rail at a distance from the oil discharge mechanism. The sensor is used to detect whether a molten iron car passes by. The sensor is connected to the controller signal.

4. The method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels according to claim 2, characterized in that: The oil discharge mechanism and the controller are connected to a solar panel and are powered by the solar panel.

5. The method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels according to claim 1, characterized in that: The fixed-point temperature measurement adopts an infrared temperature measuring device to measure the temperature. The infrared temperature measuring device is provided with a wireless communication module, and the wireless communication module is connected to the remote control center for communication.

6. The method for analyzing and preventing abnormal wear of metallurgical railway rails and wheels according to claim 1, characterized in that: The abnormality analysis also includes using video surveillance to monitor rail sections prone to wear, cleaning these sections, and then observing them at regular intervals to see if there is iron powder generated by wear. If iron powder is present, the specific molten iron car that produced the iron powder is identified as the problem car and is taken offline for processing.

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