Displacement control sensitivity detection device for steel rail flash welding machine

Abstract

The invention provides a steel rail flash welding machine displacement control sensitivity detection device which comprises a sensitivity signal acquisition device and a data processing device, the sensitivity signal acquisition device is installed on a steel rail flash welding machine, and the sensitivity signal acquisition device transmits data with the data processing device through wireless or wired transmission. A master control system is arranged in the steel rail flash welding machine, and the data processing device is communicated with the master control system. Through the independent flash welding machine displacement control sensitivity detection data processing device, the motion state of current equipment can be analyzed and diagnosed according to sensitivity detection data obtained in real time, and a judgment result is given, so that field users are helped to master the health condition of the motion state in real time, and the work efficiency is improved. And expert-level maintenance suggestions are provided for field maintenance personnel, and related equipment maintenance personnel are helped to carry out equipment maintenance work in time.

Description

Technical Field

[0001] The invention belongs to the technical field of railway rail welding detection, and in particular relates to a displacement control sensitivity detection device for a rail flash welder. Background Art

[0002] Rail flash welding equipment includes mobile rail flash welding machines, fixed rail flash welding machines, mobile rail flash welding machines and integrated heat treatment machines. The above equipment is widely distributed. Among them, mobile rail welding equipment is used in railway construction sites all over the world, and fixed rail welding equipment is distributed in rail welding bases in different regions. Due to poor construction conditions and uneven equipment users, when the movement state of the equipment deviates from the factory, maintenance work cannot be carried out in time. Large deviations may even lead to many unfavorable situations such as reduced quality of rail welding joints and equipment damage. It is difficult for users and related equipment maintenance technicians to quickly and accurately determine the problem and propose effective solutions, resulting in a chain reaction of equipment stagnation and delays in construction progress. On the other hand, the movement state of the equipment changes, and the welding process parameters need to be adjusted to match its changing state. It is difficult for users to make targeted process parameter adjustments during the use of the equipment.

[0003] The current rail welding equipment is highly specialized, scattered and remotely located. The change in the motion state of the equipment has a great impact on the welding process, and it is difficult for operators to make targeted adjustments in time. A displacement control sensitivity detection device that can be applied to mobile rail flash welding machines, fixed rail flash welding machines, and mobile rail flash welding and heat treatment all-in-one machines is needed. Summary of the invention

[0004] In order to overcome the above-mentioned defects of the prior art, the present invention proposes a displacement control sensitivity detection device for a rail flash welding machine.

[0005] A displacement control sensitivity detection device for a rail flash welder, the detection device comprising a sensitivity signal acquisition device and a data processing device, the sensitivity signal acquisition device being installed on the rail flash welder, the sensitivity signal acquisition device transmitting data to the data processing device via wireless transmission, a general control system being arranged in the rail flash welder, and the data processing device being connected to the general control system.

[0006] Wherein, the sensitivity signal acquisition device includes a motion sensor, a vibration sensor and a speed sensor. There are multiple motion sensors, vibration sensors and speed sensors, which are respectively arranged on the moving frame and the static frame of the rail flash welding machine.

[0007] Wherein, the data processing device includes a welding machine motion state diagnosis system.

[0008] Wherein, the data processing device includes a flash welding process parameter adjustment system.

[0009] Wherein, the method comprises:

[0010] By collecting data such as the movement rate, vibration frequency and acceleration of the dynamic frame relative to the static frame of the existing rail flash machine equipment during the welding process, and then using the data processing device to perform signal processing, data calculation, management and transmission, the mechanical sensitivity of the welding equipment at different welding process stages is calculated, and the real-time collection of displacement control sensitivity data signals is completed.

[0011] Wherein, the data processing device is connected to the overall control system of the flash welder, and the overall control system of the flash welder can obtain the sensitivity detection results and data analysis results in real time.

[0012] Among them, the welding machine motion status diagnosis system can diagnose the equipment motion status according to the sensitivity detection results and the current flash welding parameters, and propose maintenance plans based on the diagnosis results.

[0013] Among them, the process parameter adjustment system can judge the rationality of the welding process parameters according to the detection results of the displacement control sensitivity data signal and the current flash welding parameters, and propose a process parameter adjustment plan.

[0014] By using the displacement control sensitivity detection device for a rail flash welder of the present invention, sensors such as vibration, displacement, acceleration, etc. are placed in the overall mechanical structure, so that the motion states of the dynamic and static frames during the rail welding process can be monitored in real time and transmitted to the rail welding overall control system in real time.

[0015] Through the independent flash welder displacement control sensitivity detection data processing device, the current equipment movement state can be analyzed and diagnosed based on the sensitivity detection data obtained in real time, and a judgment result can be given, so as to help on-site users to grasp the health status of the movement state in real time, provide expert maintenance suggestions for on-site maintenance personnel, and help relevant equipment maintenance personnel to carry out equipment maintenance work in a timely manner.

[0016] Through the independent flash welder displacement control sensitivity detection data processing device, a real-time adjustment plan for the welding process parameters can be given based on the sensitivity detection data obtained in real time and combined with the current welding process parameters, helping on-site users to adjust the welding process parameters in real time to ensure welding quality and the overall safety of the system. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The figure is an overall schematic diagram of a displacement control sensitivity detection device for a rail flash welder.

[0018] Figure 2It is a schematic diagram of the overall structure of the displacement control sensitivity detection device of the rail flash welder and the welding machine control system. DETAILED DESCRIPTION

[0019] A rail flash welder displacement control sensitivity detection device provided by the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0020] Attached Figure 1-2 As shown, a displacement control sensitivity detection device for a rail flash welder is provided. The detection device comprises a sensitivity signal acquisition device and a data processing device. The sensitivity signal acquisition device is installed on the rail flash welder. The sensitivity signal acquisition device transmits data to the data processing device via wireless transmission. A general control system is provided in the rail flash welder, and the data processing device is connected to the general control system.

[0021] The sensitivity signal acquisition device is composed of a sensor group distributed in the flash welder. The independent data processing device system is based on MCU. It realizes real-time collection of sensor group data through multi-point distributed communication technology, performs data analysis and processing, establishes communication connection with the welding machine control system, and performs real-time data transmission.

[0022] The sensitivity signal acquisition device comprises a motion sensor, a vibration sensor and a speed sensor. There are multiple motion sensors, vibration sensors and speed sensors, which are respectively arranged on the moving frame and the static frame of the rail flash welding machine.

[0023] By collecting data such as the movement rate, vibration frequency and acceleration of the movable frame relative to the static frame of the existing rail flash welding equipment during the welding process, and then using a data processing device to perform signal processing, data calculation, management and transmission, the mechanical sensitivity of the welding equipment at different welding process stages is calculated.

[0024] The data processing device includes a welding machine motion state diagnosis system.

[0025] The data processing device includes a flash welding process parameter adjustment system.

[0026] The method comprises,

[0027] By collecting data such as the movement rate, vibration frequency and acceleration of the dynamic frame relative to the static frame of the existing rail flash machine equipment during the welding process, and then using the data processing device to perform signal processing, data calculation, management and transmission, the mechanical sensitivity of the welding equipment at different welding process stages is calculated, and the real-time collection of displacement control sensitivity data signals is completed.

[0028] The data processing device is connected to the overall control system of the flash welder, and the overall control system of the flash welder can obtain sensitivity detection results and data analysis results in real time.

[0029] The welding machine motion status diagnosis system can diagnose the equipment motion status according to the sensitivity detection results and the current flash welding parameters, and propose maintenance plans based on the diagnosis results.

[0030] The process parameter adjustment system can judge the rationality of the welding process parameters and propose a process parameter adjustment plan based on the detection results of the displacement control sensitivity data signal and the current flash welding parameters.

[0031] In actual operation, the sensor group collects data signals such as displacement, acceleration, vibration, etc. of the flash welder during welding, and processes and analyzes the data through the MCU to obtain the real-time motion status data of the welder. The sensor group uses multi-point wireless communication technology to achieve "one-to-many" distributed data management. The MCU encapsulates and packages the motion data, establishes a communication relationship with the welding machine control system, and transmits data.

[0032] The independent data processing device is connected to the multi-point distributed vibration sensors and displacement sensors through communication technology, analyzes the collected data, and refers to the parameter settings of the flash welding device to judge the relative motion state of the equipment's dynamic and static frames and the rationality of the process parameters, and proposes maintenance and parameter adjustment suggestions.

[0033] Finally, it should be noted that the above embodiments are only used to describe the technical solution of the present invention rather than to limit the technical method. The present invention can be extended to other modifications, changes, applications and embodiments in application, and therefore it is believed that all such modifications, changes, applications and embodiments are within the spirit and teaching scope of the present invention.

Claims

1. A rail flash welding machine displacement control sensitivity detection device, characterized in that: The detection device includes a sensitivity signal acquisition device and a data processing device. The sensitivity signal acquisition device is installed on the rail flash welder. The sensitivity signal acquisition device transmits data to the data processing device via wireless transmission. A general control system is arranged in the rail flash welder, and the data processing device is connected to the general control system.

2. A rail flash welder displacement control sensitivity detection device according to claim 1, characterized in that: The sensitivity signal acquisition device comprises a motion sensor, a vibration sensor and a speed sensor. There are multiple motion sensors, vibration sensors and speed sensors, which are respectively arranged on the moving frame and the static frame of the rail flash welding machine.

3. A rail flash welder displacement control sensitivity detection device according to claim 1, characterized in that: The data processing device includes a welding machine motion state diagnosis system.

4. According to claim 1, a rail flash welder displacement control sensitivity detection device is characterized in that: The data processing device includes a flash welding process parameter adjustment system.

5. The displacement control sensitivity detection device for rail flash welding machine according to claim 1, characterized in that: The method comprises, By collecting data such as the movement rate, vibration frequency and acceleration of the dynamic frame relative to the static frame of the existing rail flash machine equipment during the welding process, and then using the data processing device to perform signal processing, data calculation, management and transmission, the mechanical sensitivity of the welding equipment at different welding process stages is calculated, and the real-time collection of displacement control sensitivity data signals is completed.

6. A rail flash welder displacement control sensitivity detection device according to claim 5, characterized in that: The data processing device is connected to the overall control system of the flash welder, and the overall control system of the flash welder can obtain sensitivity detection results and data analysis results in real time.

7. A rail flash welder displacement control sensitivity detection device according to claim 6, characterized in that: The welding machine motion status diagnosis system can diagnose the equipment motion status according to the sensitivity detection results and the current flash welding parameters, and propose maintenance plans based on the diagnosis results.

8. The displacement control sensitivity detection device for rail flash welding machine according to claim 5, characterized in that: The process parameter adjustment system can judge the rationality of the welding process parameters and propose a process parameter adjustment plan based on the detection results of the displacement control sensitivity data signal and the current flash welding parameters.

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