Milling and grinding combined steel rail corrugation disease treatment method

Abstract

The invention discloses a milling and grinding combined steel rail surface fatigue disease treatment method, which comprises the following steps of: firstly, detecting steel rail surface fatigue diseases before treatment, formulating different steel rail surface fatigue disease treatment schemes according to a detection result, firstly, removing the steel rail surface fatigue diseases through milling and grinding, and preliminarily finishing the profile; grinding operation is conducted through a grinding wagon, the profile of the steel rail is corrected emphatically, and the wheel-rail contact state is improved; by designing a disease treatment operation scheme, arranging a disease treatment operation plan and reasonably arranging a milling and grinding combined operation mode and method, respective advantages of milling and grinding operation and grinding operation are fully exerted; and executing operation according to the designed operation scheme and carrying out quality acceptance. By means of the method, high-efficiency, high-quality and high-economical-efficiency treatment on the surface fatigue damage of the steel rail is achieved, the wheel-rail contact relation can be improved, the service life of the steel rail is prolonged, and the safety and stability of vehicle running are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of rail surface disease treatment engineering, and relates to a rail corrugation disease treatment method combining milling and grinding with polishing. Background Art

[0002] Rail surface fatigue disease is a disease that mainly occurs on the surface of the rail head. It mainly occurs in areas with busy lines and insufficient track lubrication. It is usually caused by the repeated pressure and friction of heavy-loaded vehicles on the line, which leads to contact fatigue damage on the rail surface. Its main manifestations include: fish scale cracks, peeling, abrasions, corrugation and rail head fat edge. If these diseases are not handled and maintained in time, they will gradually expand and eventually lead to rail breakage, posing a threat to train operation safety.

[0003] At present, the methods for treating surface fatigue diseases such as rail corrugation include rail grinding and rail milling. The grinding device of the rail grinding car drives the grinding wheel to rotate through an electric motor or a hydraulic motor, and the grinding wheel and the rail are tightly fitted through a constant pressure control system, so that the grinding wheel can adjust the inclination angle, pressure and grinding amount of the rail, and the ideal rail geometry can be achieved by controlling the amount of rail grinding at different angles. However, because the grinding stone is in contact with the rail surface alone, it is easy to vibrate up and down, making the grinding car operation unit unstable, resulting in problems such as longitudinal unevenness of the rail surface caused by abnormal wear marks on the rail surface during rail corrugation grinding. At the same time, since the grinding amount of the rail grinding car is small, it has no obvious advantage in treating more serious rail corrugation diseases.

[0004] Rail milling and grinding vehicles use several groups of milling cutter discs to remove defects on the surface of rails by forming milling. The milling and grinding vehicles can repair rails efficiently and accurately, with a milling amount of 0.3-1.5mm per pass. The milling cutter embedded in the circumferential surface of the cutter disc simultaneously mills the top surface, gauge angle and outer angle of the rail through the axial rotation of the milling cutter disc. The cutter disc is a contoured circumferential cutter disc, so the rail milling operation has high accuracy and is almost unaffected by the original state of the rail. Therefore, rail milling is very suitable for treating fat edges, corrugation, stripping blocks, fish scale cracks, surface scratches, joint diseases, etc. However, since the cutter disc of the milling and grinding equipment is fixed, personalized milling cannot be performed. Although the disease situation is improved after milling, the wheel-rail contact relationship is not improved. Therefore, the rail will quickly develop fatigue diseases again after milling. Moreover, milling is relatively slow compared to grinding, so it is not suitable to use milling alone to treat rail corrugation diseases. Summary of the invention

[0005] In view of the problems existing in the above-mentioned existing rail corrugation disease treatment technology, the present invention studies a comprehensive rail corrugation disease treatment method combining milling and grinding, which achieves high-efficiency and high-quality treatment of rail corrugation disease treatment, and solves the problems that grinding cannot treat heavier corrugation diseases and track unevenness after grinding, and the problem that milling cannot improve the wheel-rail contact relationship. At the same time, it can ensure that the service life of the rails is extended, the safety and stability of vehicle operation are improved, and the maintenance costs of engineering equipment are reduced.

[0006] The rail corrugation disease treatment method combining milling and grinding of the present invention comprises the following steps:

[0007] Step 1: Detect the representative profile of the rail in each section of the grinding line, as well as the rail surface corrugation position, corrugation parameters, representative profile of the corrugation point and rail surface straightness information.

[0008] Step 2: Based on the test results obtained in step 1, formulate rail corrugation disease treatment plans for different wavelength corrugation sections, including:

[0009] A. Use milling and grinding operations to process each corrugation and remove surface fatigue damage.

[0010] B. Use a grinding vehicle to grind the rails in the area where corrugation damage is planned to be repaired based on the milling operation.

[0011] Among them, the milling and grinding operation plan is designed as follows:

[0012] Given milling parameters, including milling speed, rail surface cutting depth, rail side cutting depth 0, maximum cutting amount of track gauge angle, minimum operating curve radius, and milling angle range.

[0013] According to the given milling parameters, the milling amount of the milling car at each milling angle is determined according to the deviation value between the representative profile at the wave grinding before milling and the rail profile after milling determined in step 1; the milling mode that the milling car needs to execute is further matched according to the milling amount, and the number of milling passes is determined by the milling mode; after determining the milling mode and the number of milling passes, the execution order of the milling mode is arranged accordingly to ensure that all grinding operations can be completed within the skylight time.

[0014] The grinding car operation plan is designed as follows:

[0015] Given the operating speed and current of the grinding car, the operating angle and the average cutting amount per pass; at the corrugated grinding position, determine the grinding amount of the grinding head at each grinding angle according to the aforementioned given operating speed and angle arrangement of the grinding car, as well as the deviation value between the rail profile after milling and the target profile after grinding; then, match the grinding mode that the grinding car needs to execute according to the grinding amount, and determine the number of grinding passes through the grinding mode; after determining the grinding mode and the number of grinding passes, arrange the execution order of the grinding mode accordingly to ensure that all grinding operations can be completed within the skylight time.

[0016] Step 3: Design an operation plan and perform milling and grinding operations on the areas where the corrugation damage is planned to be remedied.

[0017] Refine the operating mileage and operating position of the milling and grinding vehicles in the operating area, so that the milling and grinding vehicles can only perform milling and grinding in the corrugated grinding area, and obtain the corresponding relationship between the operating mode and each corrugated grinding position according to the operating mode determined in step 2, so that continuous corrugated grinding positions in the same grinding interval are ground using the same grinding mode; then, the operation is performed by milling first and then grinding.

[0018] Step 4: Quality inspection after grinding.

[0019] The advantages of the present invention are:

[0020] (1) The rail corrugation disease treatment method combining milling and grinding of the present invention has a scientific and reasonable treatment process for rail corrugation disease. The actual situation of rail corrugation disease is understood through pre-grinding detection, and the deviation of milling and grinding amount and profile is clarified, thus giving full play to the operating performance and advantages of milling and grinding.

[0021] (2) The rail corrugation defect treatment method combining milling and grinding of the present invention realizes the treatment of corrugation defects in different wavelengths and different wave depth sections. The corrugation defects are first removed by milling, and then the profile is corrected by grinding to improve the rail profile quality and wheel-rail contact relationship, thereby improving the stability and safety of train operation.

[0022] (3) The present invention combines milling and grinding to correct rail corrugation defects. The method can quickly eliminate rail surface fatigue defects through milling, and can correct the rail profile and improve the wheel-rail contact state through grinding. This method avoids the problem of longitudinal unevenness of the rail surface due to a small amount of grinding and a large number of grinding passes, and also avoids the problem of no improvement in the wheel-rail relationship due to the fixed cutter head and no personalized milling of the milling machine.

[0023] (4) The rail corrugation treatment method combining milling and grinding of the present invention can provide effective guidance for the treatment of rail corrugation. The method of the present invention can formulate a treatment plan and arrange a grinding plan according to the actual situation of the corrugation disease, provide a basis for the treatment work, and avoid blind operation.

[0024] (5) The rail corrugation disease treatment method combining milling and grinding of the present invention realizes high-efficiency, high-quality and high-economic treatment of rail corrugation diseases, can improve the wheel-rail contact relationship, extend the service life of the rails, and improve the safety and stability of vehicle operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the overall process of the rail corrugation disease treatment method combining milling and grinding according to the present invention;

[0026] Figure 2 A schematic diagram for marking the location of rail corrugation damage;

[0027] Figure 3 It is a schematic diagram of the grinding range of the grinding stone of the grinding machine;

[0028] Figure 4 It is a schematic diagram of the milling range of the milling cutter head. DETAILED DESCRIPTION

[0029] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0030] In order to accurately grasp the actual situation of rail corrugation diseases on the line and ensure the treatment effect of the diseases, the rail corrugation disease treatment method combining milling and grinding is proposed in the present invention. The rails are tested before treatment to understand the relevant information of the line, the wavelength and wave depth of the rail corrugation are clarified, the rail profile, surface state, etc. are mastered, and then a treatment plan for rail corrugation diseases is formulated in a targeted manner according to the test results, and then milling and grinding are carried out in coordination, and finally quality acceptance is carried out.

[0031] like Figure 1 As shown, the rail corrugation disease treatment method combining milling and grinding of the present invention comprises the following specific steps:

[0032] Step 1: Rail inspection before grinding.

[0033] (1) Initial inspection: Conduct on-foot measurement of the entire line in the area where the corrugation damage is planned to be remedied. Use a rail profiler and camera to detect the rail profile in the planned grinding section and the rail surface condition (whether corrugation exists and whether the rail surface flatness is qualified).

[0034] For the straight section of the conventional line, every 600m is regarded as a grinding section; at the end of each grinding section (i.e. every 600m), the rail profiles of the rails on both sides are detected as the representative profiles of each grinding section; at the same time, the surface conditions of the rails at the end of each grinding section are detected.

[0035] For the curved sections of conventional lines, the profile data of the rails on both sides at the five major pile points of straight-gradient, gradual-circular, mid-curve, gradual-circular-gradient, and gradual-straight are detected as the representative profiles of each section. At the same time, the surface conditions of the rails at each pile point are detected.

[0036] For high-speed lines, every 400 meters is regarded as a grinding section; at the end of each grinding section (i.e. every 400 meters), the rail profiles of the rails on both sides are detected as the representative profiles of each grinding section; at the same time, the surface conditions of the rails at the end of each grinding section are detected.

[0037] (2) Re-inspection: Intensive inspection is carried out on sections where rail corrugation is severe and affects passenger comfort, so as to obtain more detailed information on the corrugation locations, corrugation parameters and rail profile changes in the continuous sections with severe corrugation.

[0038] Firstly, some trains in the area where corrugation damage is planned to be remedied are randomly selected for artificial addition of passengers, and the sections with poor physical sensation are screened out through the addition of passengers.

[0039] Then, the rail profiler, electronic straight ruler, corrugation trolley and other equipment are used to determine the corrugation positions, profile information and corrugation parameters (corrugation wavelength, wave depth and over-limit rate, etc.) of the bad position. At the same time, the same inspection is carried out on the corrugation positions existing in the initial inspection.

[0040] During the initial inspection and re-inspection, the rail profile at the corrugation position needs to be inspected more frequently. At least two pairs of rail profiles at the crest and trough of the same corrugation position should be measured, and the rail waist should be marked to indicate that the position is the profile measurement position. Take photos and record the start and end range of corrugation on the rail survey form, such as Figure 2 The rail profiles at each trough position of the measured corrugation are further compared, and the lowest pair of profiles are selected as the representative profiles of the corrugation.

[0041] Step 2: Based on the rail inspection results obtained in step 1, formulate rail corrugation disease control plans for rail corrugation sections with different wavelengths.

[0042] First, the milling machine is used to process each corrugation, remove surface fatigue damage, preliminarily trim the rail profile, and improve the smoothness of the line.

[0043] The milling and grinding operation plan is designed as follows:

[0044] The SF03 milling machine used has a milling speed of 0.6-1.5 km / h, a cutting depth of 0.3-1.5 mm for rail surface operation, a cutting depth of 0.3-3.0 mm for rail side operation, a maximum cutting amount of 5.0 mm for track gauge angle, a minimum operating curve radius of 180 m, and a milling angle range of -40° to 70°. Figure 3As shown in the figure, its main operating device consists of two milling units and one grinding unit, which are respectively equipped with milling cutter discs and grinding wheels. Rail milling and grinding operations include two major operating procedures: rail milling and rail grinding.

[0045] According to the above-given milling speed and milling angle arrangement of the milling car, the milling amount of the milling car at each milling angle is determined according to the deviation value between the representative profile of the wave grinding before milling and the rail profile after milling (determined according to the characteristics of the milling car cutter disc), which is determined in step 1. It is required that there is a grindable amount of not less than 0.1mm between the rail profile after milling and the rail profile after milling. Subsequently, the milling mode that the milling car needs to execute is matched according to the milling amount, and the number of milling passes is determined by the milling mode. After determining the milling mode and the number of milling passes, the execution order of the milling mode is arranged accordingly, with the aim of ensuring that all grinding operations can be completed within the skylight time. The parameters obtained above are input into the control system of the milling car to perform rail milling operations, which are unidirectional operations.

[0046] Subsequently, based on the milling operation, the rails in the area where the corrugation disease is planned to be remedied are ground to correct the rail profile, improve the wheel-rail contact relationship, increase the service life of the rails, and ensure the smoothness and safety of train operation.

[0047] The grinding car operation plan is designed as follows:

[0048] The Speno96 grinding machine used has an operating speed of 10-12 km / h, a common operating current of 26-28A, and an operating angle of -10° to 50°. Figure 4 As shown. The average cutting amount of a single pass is 0.2mm on the active edge, 0.1mm on the rail top, and 0.15mm on the non-active edge. The grinding car has 6 working cars, and each control unit of each working car needs to input an angle to control the grinding motor.

[0049] At the corrugation position, the grinding amount of the grinding head at each grinding angle is determined according to the given grinding vehicle operating speed, angle arrangement, and the deviation between the rail profile after milling and the target profile after grinding; then, the grinding mode to be executed by the grinding vehicle is matched according to the grinding amount, and the number of grinding passes is determined by the grinding mode. After determining the grinding mode and the number of grinding passes, the execution order of the grinding mode is arranged accordingly, with the aim of ensuring that all grinding operations can be completed within the skylight time.

[0050] At the remaining positions, the grinding amount of the grinding head at each grinding angle is determined according to the given grinding vehicle operating speed, angle arrangement, and the deviation value between the representative profile initially detected in step 1 and the target profile after grinding; then, the grinding mode to be executed by the grinding vehicle is matched according to the grinding amount, and the number of grinding passes is determined by the grinding mode and the grinding amount at each grinding angle. After determining the grinding mode and the number of grinding passes, the execution order of the grinding mode is arranged accordingly to ensure that all grinding operations can be completed within the skylight time.

[0051] Step 3: Design an operation plan and perform milling and grinding operations on the areas where the corrugation damage is planned to be remedied.

[0052] According to the milling and grinding operation plan designed in step 2, the operation plan is arranged. The operation plan must be milled first and then polished; and because the wave grinding sections in the area where the disease needs to be renovated are discontinuous, and the skylight time of each wave grinding section is discontinuous, it is necessary to determine the operation plan of each section of the wave grinding according to the position of each wave grinding section and the skylight time of each section; the milling mileage of the milling car is less than the grinding mileage of the grinding car in the same skylight time, so it is necessary to plan the operation position of the milling car and the grinding car. Therefore, in this step, the operation mileage and operation position of the milling car and the grinding car in the operation section are refined, so that the milling car and the grinding car only perform milling and grinding in the wave grinding section, and the corresponding relationship between the working mode and each wave grinding position is obtained according to the working mode determined in step 3, so that the continuous wave grinding positions in the same grinding interval are ground using the same grinding mode. In this way, the cost of rail maintenance is saved, and the accurate and effective implementation of the operation plan is ensured.

[0053] Step 4: Quality inspection after grinding.

[0054] All grinding intervals determined in step 1 are inspected and accepted, with emphasis on the corrugation treatment, rail surface condition, profile treatment, etc.

[0055] The post-grinding acceptance indicators include rail GQI (grinding quality index), roughness, grinding surface width, width of the light band after grinding, bluing of the grinding surface, periodic wear marks on the rail surface, etc.

[0056] Inspection and acceptance items include: grinding depth, grinding surface roughness, blue band, etc.

[0057] After grinding, the over-limit rate in the wavelength range of 10 to 300mm must be completely eliminated, and the rail wave depth must be controlled below 0.03mm. After grinding, the over-limit rate in the wavelength range greater than 300mm must be completely eliminated, and the rail wave depth must be controlled below 0.05mm. The surface rail block falling should be eliminated as completely as possible.

[0058] Except for the technical features described in the specification, all of them are known technologies to those skilled in the art. The present invention omits the description of known components and known technologies to avoid redundancy and unnecessary limitation of the present invention. The implementation methods described in the above embodiments do not represent all implementation methods consistent with the present application. On the basis of the technical solution of the present invention, various modifications or variations that can be made by those skilled in the art without creative labor are still within the protection scope of the present invention.

Claims

1. A method for treating rail corrugation by combining milling and grinding, characterized in that: The specific steps are: Step 1: Detect the representative profile of the rails in each section of the grinding line, as well as the corrugation position, corrugation parameters, representative profile of the corrugation location and rail surface straightness information; Step 2: Based on the test results obtained in step 1, formulate rail corrugation disease treatment plans for different wavelength corrugation sections, including: A. Use milling and grinding operations to process each corrugation and remove surface fatigue damage; B. Grinding the rails in the area where the corrugation damage is planned to be treated by using a grinding vehicle on the basis of milling operations; Among them, the milling and grinding operation plan is designed as follows: Given milling parameters, including milling speed, cutting depth of rail surface operation, rail side operation cutting depth 0, maximum cutting amount of track gauge angle, minimum operation curve radius, and milling angle range; According to the given milling parameters, the milling amount of the milling car at each milling angle is determined according to the deviation value between the representative profile of the wave grinding before milling and the rail profile after milling determined in step 1; the milling mode to be executed by the milling car is further matched according to the milling amount, and the number of milling passes is determined by the milling mode; after determining the milling mode and the number of milling passes, the execution order of the milling mode is arranged accordingly to ensure that all grinding operations can be completed within the skylight time; The grinding car operation plan is designed as follows: Given the operating speed and current of the grinding vehicle, the operating angle and the average cutting amount per pass; at the corrugation position, according to the operating speed and angle arrangement of the given grinding vehicle, and the deviation between the rail profile after milling and the target profile after grinding, determine the grinding amount at each grinding angle of the grinding head; then, match the grinding mode that the grinding vehicle needs to execute according to the grinding amount, and determine the number of grinding passes through the grinding mode; after determining the grinding mode and the number of grinding passes, arrange the execution order of the grinding mode accordingly to ensure that all grinding operations can be completed within the skylight time; Step 3: Design an operation plan and perform milling and grinding operations on the area where the corrugation damage is planned to be remedied; The operation mileage and operation position of the milling and grinding vehicles and the grinding vehicles in the operation area are refined, so that the milling and grinding vehicles and the grinding vehicles can only perform milling and grinding in the corrugation area, and the corresponding relationship between the operation mode and each corrugation position is obtained according to the operation mode determined in step 2, so that the continuous corrugation positions in the same grinding interval are ground using the same grinding mode; then the operation is performed by milling first and then grinding; Step 4: Quality inspection after grinding.

2. A rail corrugation treatment method combining milling and grinding as claimed in claim 1, characterized in that: In step 1, firstly, the whole line of the area where the corrugation disease is planned to be treated is measured on foot, and the representative profile of the rail in the planned grinding section, as well as the corrugation and straightness of the rail surface at the representative profile position are detected by using a rail profiler and a camera. Subsequently, some trains in the area where the corrugation disease is planned to be remedied are selected for artificial addition of passengers, and sections with poor body sensation are screened out by adding passengers; further, measuring equipment is used to detect the corrugation existing in sections with poor body sensation and at the representative profile positions of the aforementioned grinding intervals, to determine each corrugation position, the representative profile at the corrugation position, and the corrugation parameters.

3. A rail corrugation treatment method combining milling and grinding as claimed in claim 2, characterized in that: For the straight section of the conventional line, every 600m is regarded as a grinding section; at the end of each grinding section, the rail profiles of the rails on both sides are detected as the representative profiles of each grinding section; For the curved sections of conventional lines, the profile data of the rails on both sides at the five major stake points of straight-slow, slow-round, mid-curve, round-slow, and slow-straight are detected as the representative profiles of each section; For high-speed lines, every 400m is regarded as a grinding section; at the end of each grinding section, the rail profiles of the rails on both sides are detected as the representative profiles of each grinding section.

4. A rail corrugation treatment method combining milling and grinding as claimed in claim 1, characterized in that: In step 2, in the design of the grinding vehicle operation plan: at the remaining positions except the corrugated grinding positions, determine the grinding amount at each grinding angle of the grinding head according to the given grinding vehicle operation speed, angle arrangement, and the deviation value between the representative profile measured in step 1 and the target profile after grinding; then, match the grinding mode that the grinding vehicle needs to execute according to the grinding amount, and determine the number of grinding passes through the grinding mode and the grinding amount at each grinding angle; after determining the grinding mode and the number of grinding passes, arrange the execution order of the grinding mode accordingly to ensure that all grinding operations can be completed within the skylight time.

5. A rail corrugation treatment method combining milling and grinding as claimed in claim 1, characterized in that: In step 4, all sections are inspected and accepted, with a focus on corrugation treatment, rail surface condition, and profile treatment; The post-grinding acceptance indicators include rail GQI, roughness, grinding surface width, light band width after grinding, grinding surface bluing, and rail surface periodic wear mark indicators; Inspection and acceptance items include grinding depth, grinding surface roughness, and blue band; After grinding, the over-limit rate of wavelengths within the range of 10 to 300 mm must be completely eliminated, and the rail wave depth must be controlled below 0.03 mm. After grinding, the over-limit rate of wavelengths greater than 300 mm must be completely eliminated, and the rail wave depth must be controlled below 0.05 mm. Surface rail block falling needs to be eliminated.

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