Steel rail defect maintenance method and system

Abstract

The invention provides a steel rail disease maintenance method and system, and the method comprises the steps: carrying out the disease detection of a steel rail, and obtaining the disease data of the steel rail; if the disease data is larger than a disease milling and polishing threshold value, working parameters of the steel rail are obtained; determining the milling and grinding amount of disease milling and grinding based on the disease data; on the basis of the disease data and the working parameters, the number of times of disease polishing and the milling and polishing operation interval between disease milling and polishing are determined; and carrying out the disease milling and grinding and the disease grinding on the steel rail based on the milling and grinding amount of the disease milling and grinding, the number of times of the disease grinding and the interval of the milling and grinding operation. The purposes of reducing the grinding times, saving the grinding machine force, repairing the profile of the steel rail in a personalized manner, saving the maintenance cost and prolonging the service life of the steel rail can be achieved.

Description

Technical Field

[0001] The present invention relates to the field of railway technology, and in particular to a rail disease repair method and system. Background Art

[0002] Rails are the main components of railway tracks. Their function is to guide the wheels of locomotives and vehicles forward, bear the huge pressure of the wheels, and transfer it to the sleepers. Rails are affected by the combined influence of factors such as track conditions, line conditions and vehicles. During service, they will gradually deteriorate, resulting in fatigue block falling, rail corrugation and other diseases, which seriously affect the safety of train passage.

[0003] Rail milling and rail grinding are common means of rail maintenance, which can effectively remove rail fatigue block loss and corrugation, improve wheel-rail contact, and improve rail surface smoothness. However, rail grinding maintenance has the problems of small single-pass grinding volume, large number of grinding passes, long operation time, high maintenance cost, and easy recurrence of diseases. Rail milling has the disadvantages of low operation efficiency, inability to remove block loss and corrugation diseases at the track gauge angle on curved rails, inability to repair rail profile in an individualized manner, and poor wheel-rail relationship after operation. Summary of the invention

[0004] The embodiments of the present application provide a rail defect repair method and system, which can solve the problems of small single-pass grinding amount, large number of grinding passes, long operation time, high maintenance cost, and easy recurrence of defects in existing rail grinding and repair; the problems of low operation efficiency in rail milling, inability to remove block drop and corrugation defects at the track gauge angle on curved rails, inability to personalize the repair of rail profile, and poor wheel-rail relationship after operation.

[0005] In a first aspect, an embodiment of the present application provides a rail disease repair method, comprising:

[0006] Performing a defect detection on the rail to obtain defect data of the rail;

[0007] If the disease data is greater than the disease milling and grinding threshold, the working parameters of the rail are obtained;

[0008] Determining a milling amount for performing disease milling based on the disease data;

[0009] Determine the number of defect grinding operations and the interval between the defect milling and the defect grinding based on the defect data and the working parameters;

[0010] The defect milling and the defect grinding are performed on the rail based on the milling amount of the defect milling, the number of defect grinding times and the milling and grinding operation interval.

[0011] In some embodiments, the disease detection includes fatigue block drop detection, corrugation detection and wear detection;

[0012] The step of performing a defect detection on the rail to obtain defect data of the rail includes:

[0013] Performing fatigue block drop detection on the rail to obtain fatigue block drop data of the rail;

[0014] Performing corrugation detection on the rail to obtain corrugation data of the rail;

[0015] The wear of the rail is detected to obtain the wear data of the rail.

[0016] In some embodiments, the disease milling and grinding threshold includes a fatigue chipping milling and grinding threshold, a corrugated milling and grinding threshold, and a wear milling and grinding threshold;

[0017] If the damage data is greater than the damage milling and grinding threshold, obtaining the working parameters of the rail includes:

[0018] If the fatigue block loss data is greater than the fatigue block loss milling and grinding threshold, and / or the corrugation data is greater than the corrugation milling and grinding threshold, and / or the wear data is greater than the wear milling and grinding threshold, the working parameters of the rail are obtained.

[0019] In some embodiments, the milling amount includes an upper strand milling amount and a lower strand milling amount;

[0020] The step of determining the milling amount for the defect milling based on the defect data comprises:

[0021] Determining the upper strand milling amount for disease milling based on the disease data;

[0022] The milling amount of the lower strand for disease milling is determined based on the disease data.

[0023] In some embodiments, determining the upper strand milling amount for disease milling based on the disease data comprises:

[0024] Acquiring a real-time profile of the rail, and aligning the real-time profile with a designed profile of the rail in a side grinding alignment manner;

[0025] Obtaining a cutter head profile of a milling cutter head;

[0026] The cutterhead profile is brought into contact with the real-time profile and tangent thereto, and the upper vertical distance between the center point of the cutterhead profile and the center point of the design profile is measured;

[0027] The upper strand milling amount is obtained based on the upper strand vertical distance.

[0028] In some embodiments, obtaining the upper strand milling amount based on the upper strand vertical distance includes:

[0029] If the corrugation data is smaller than the upper strand vertical distance, the upper strand vertical distance is determined to be the upper strand milling amount;

[0030] If the corrugation data is greater than or equal to the upper strand vertical distance, the corrugation data is determined to be the upper strand milling amount.

[0031] In some embodiments, determining the milling amount of the lower strand for disease milling based on the disease data comprises:

[0032] Acquiring the real-time profile of the rail and the profile of the milling cutter head;

[0033] Vertically aligning the center of the real-time profile with the center of the cutter head profile, and making the cutter head profile abut and tangent to the real-time profile;

[0034] Measuring the lower vertical distance between the center point of the real-time profile and the center point of the cutterhead profile;

[0035] The lower strand milling amount is obtained based on the lower strand vertical distance.

[0036] In some embodiments, the lower strand milling amount is obtained based on the lower strand vertical distance, specifically:

[0037] Based on the formula of lower strand milling amount d max =d h +d f +d j , the lower strand vertical distance, the disease data and experience value to obtain the lower strand milling amount;

[0038] Among them, d max is the milling amount of the lower strand, d h is the disease data, d f is the vertical distance of the lower strand, d j For experience value.

[0039] In some embodiments, the operating parameters include the arc radius of the rail;

[0040] The determining the number of defect grinding operations and the interval between the defect milling and the defect grinding based on the defect data and the working parameters includes:

[0041] Determining the amount of defect to be ground for the defect grinding based on the milling amount of the defect milling and the defect data;

[0042] Determining the number of times to grind the defect based on the amount of defect to be grinded;

[0043] The milling and grinding operation interval between the defect milling and the defect grinding is determined based on the arc radius.

[0044] In some embodiments, determining the milling and grinding interval between the defect milling and the defect grinding based on the arc radius includes:

[0045] Obtaining the total passing weight of the rail after the defect milling;

[0046] The milling and grinding operation interval between the defect milling and the defect grinding is determined based on the arc radius and the total weight.

[0047] In a second aspect, an embodiment of the present application provides a rail defect repair system, comprising:

[0048] Detection module: used to detect the defects of the rail and obtain the defect data of the rail;

[0049] Acquisition module: used for acquiring the working parameters of the rail if the damage data is greater than the damage milling and grinding threshold;

[0050] Calculation module: used to determine the milling amount of the defect milling based on the defect data; determine the number of defect grindings and the milling and grinding interval between the defect milling and the defect grinding based on the defect data and the working parameters;

[0051] Instruction module: used for performing the defect milling and the defect grinding on the rail based on the milling amount of the defect milling, the number of defect grinding and the milling and grinding operation interval.

[0052] Compared with the prior art, the advantages of the embodiments of the present application are that, by performing defect detection on the rail, the defect data of the rail is obtained; if the defect data is greater than the defect milling and grinding threshold, the working parameters of the rail are obtained; the milling amount for defect milling is determined based on the defect data; the number of defect grinding and the milling and grinding interval between the defect milling and the defect grinding are determined based on the defect data and the working parameters; the defect milling and the defect grinding are performed on the rail based on the milling amount of the defect milling, the number of defect grinding and the milling and grinding interval, which can reduce the number of grinding times, save grinding machine power, personalize the repair of the rail profile, save maintenance costs, and extend the service life of the rail. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Hereinafter, the present invention will be described in more detail based on embodiments and with reference to the accompanying drawings.

[0054] Figure 1is a flow chart of a rail disease repair method provided by an embodiment of the present invention;

[0055] Figure 2 It is a schematic diagram of rail surface fatigue block falling provided by one embodiment of the present invention;

[0056] Figure 3 is a schematic diagram of wear detection positions provided by an embodiment of the present invention;

[0057] Figure 4 is a schematic diagram of upper strand milling amount calculation provided by an embodiment of the present invention;

[0058] Figure 5 is a schematic diagram of calculating the lower strand milling amount provided by another embodiment of the present invention;

[0059] Figure 6 It is a schematic diagram of the development of diseases after milling provided by another embodiment of the present invention. DETAILED DESCRIPTION

[0060] The present invention will be further described below in conjunction with the accompanying drawings.

[0061] Rails, as important track equipment for heavy-duty railways, bear huge train loads. Under the combined influence of factors such as track status, line conditions and vehicles, they will gradually deteriorate during service, resulting in fatigue block falling, rail corrugation and other defects. The rail profile also undergoes significant changes during plastic flow, leading to the deterioration of the wheel-rail relationship. With the annual increase in railway freight, rail surface defects are becoming more and more serious. Severe rail defects lead to basic defects such as loose bolts, broken rails and whitening of the ballast bed, which seriously affect the safety of train passage.

[0062] Rail milling and rail grinding are common means of rail maintenance, which can effectively remove rail fatigue block loss and corrugation, improve wheel-rail contact, and improve rail surface smoothness. Among them, the rail grinding vehicle uses a constant pressure system to make the grinding wheel and rail fit closely, and the motor drives the grinding wheel to rotate and grind the rail. The rail top grinding amount of the 96-head rail grinding vehicle is 0.1-0.15mm / pass. Through grinding, fatigue block loss and part of the corrugation on the rail surface can be removed, and the rail profile can be repaired in a personalized manner. However, due to the small amount of single-pass grinding of rail grinding, it usually takes 8-16 passes to treat serious diseases (such as fatigue block loss with a depth of more than 1mm), which leads to a significant increase in maintenance costs. In addition, the disease cannot be completely removed when the machine power is insufficient or time is limited. When the wavelength of the rail surface corrugation is greater than 300mm, the pressure of the grinding wheel (diameter 250mm) remains unchanged at the peak and valley, which also makes it impossible to completely eliminate the rail surface corrugation disease.

[0063] Rail milling machines use the rotation of the cutter disc to drive the cutter grains to mill rails. The milling precision is high, and the milling volume can reach 0.5-1.5mm / pass. One pass can completely remove the fatigue block disease on the rail surface. However, the milling machine has a slow operating speed (0.6-1.2km / h) and low work efficiency. Milling is limited by rail wear, resulting in the inability to remove corrugation and block disease at the track gauge angle on the curve. In addition, due to the fixed shape of the cutter disc, the rail profile cannot be repaired in an individualized manner. The poor wheel-rail relationship after milling will cause new diseases to appear on the rail surface again soon.

[0064] In summary, the amount of rail grinding per pass is small, and it takes many passes to treat severe fatigue chipping, the operation time is long, the maintenance cost is high, and it can only handle corrugation within a wavelength of 300mm. Rail diseases are prone to reappear within a short time after grinding. The rail milling operation is inefficient, and it cannot remove chipping and corrugation diseases at the track gauge angle on the curve, and it is impossible to repair the rail profile in an individualized manner, and the wheel-rail relationship is poor after the operation.

[0065] First, as Figure 1 As shown, in view of the above technical problems, the embodiment of the present application provides a rail disease repair method, comprising:

[0066] S101: performing a defect detection on the rail to obtain defect data of the rail;

[0067] In some embodiments, the disease detection includes fatigue block drop detection, corrugation detection and wear detection;

[0068] The step of performing a defect detection on the rail to obtain defect data of the rail includes:

[0069] Performing fatigue block drop detection on the rail to obtain fatigue block drop data of the rail;

[0070] Performing corrugation detection on the rail to obtain corrugation data of the rail;

[0071] The wear of the rail is detected to obtain the wear data of the rail.

[0072] It should be noted that when repairing the rail, the condition of the rail must first be detected in order to carry out targeted repairs. The fatigue block detection of the rail can be carried out by using a depth gauge to measure the fatigue block depth on the surface of the rail and take the average value. For example, the fatigue block depth at each point is calculated as a. i , the average block drop depth is In this way, the fatigue block drop data can be obtained.

[0073] It should be noted that after obtaining the fatigue block loss data, the fatigue block loss data can be classified, such as Figure 2As shown, the rails are divided into four grades, namely "A", "B", "C" and "D", according to the chipping situation on the rail surface. The surface of the "A" grade rail has no fatigue chipping disease; the surface of the "B" grade rail has fatigue pitting and discontinuous fatigue chipping, with a depth of about 0.3-0.5mm, which can be completely removed by grinding 3-4 times; the surface of the "C" grade rail has formed continuous fatigue chipping, with a depth of less than 0.6mm, but a small area, which can be completely removed by grinding 4-6 times; the surface of the "D" grade rail has formed continuous and large-area fatigue chipping, with a depth of more than 0.6mm, and it takes more than 8 times of grinding to completely remove it. By classifying the fatigue chipping data (i.e., the rails with fatigue chipping disease), subsequent maintenance and processing can be facilitated.

[0074] It should be noted that, when performing corrugation detection on the rail, a rail corrugation trolley or a rail profiler can be used to detect corrugation defects on the rail surface to obtain corrugation detection data. If corrugation exists on the rail in the section, the maximum corrugation depth (i.e., the corrugation data) can be determined based on the corrugation detection data. When performing wear detection on the rail, the profiles of the upper rail and the lower rail at the three points of the upper slow circle, the middle of the curve, and the slow circle of the rail curve can be measured (e.g., Figure 3 As shown), the wear data is obtained.

[0075] S102: If the damage data is greater than the damage milling and grinding threshold, obtaining the working parameters of the rail;

[0076] In some embodiments, the disease milling and grinding threshold includes a fatigue chipping milling and grinding threshold, a corrugated milling and grinding threshold, and a wear milling and grinding threshold;

[0077] If the damage data is greater than the damage milling and grinding threshold, obtaining the working parameters of the rail includes:

[0078] If the fatigue block loss data is greater than the fatigue block loss milling and grinding threshold, and / or the corrugation data is greater than the corrugation milling and grinding threshold, and / or the wear data is greater than the wear milling and grinding threshold, the working parameters of the rail are obtained.

[0079] It should be noted that when the fatigue block loss data is less than or equal to the fatigue block loss milling grinding threshold, and / or the corrugation data is less than or equal to the corrugation milling grinding threshold, and / or the wear data is less than or equal to the wear milling grinding threshold, the rail can be repaired by grinding alone to improve maintenance efficiency.

[0080] It should be noted that when the fatigue block-falling data is greater than the fatigue block-falling milling grinding threshold, and / or the corrugation data is greater than the corrugation milling grinding threshold, and / or the wear data is greater than the wear milling grinding threshold, a maintenance method combining milling and grinding is used to repair the rail to improve maintenance efficiency. The fatigue block-falling grinding threshold may be 0.5 mm, that is, the "C" and "D" grade rails mentioned above, and the corrugation milling grinding threshold may be 0.5 mm (for rails with a speed of 120 km and below). Road, when the rail valley depth exceeds 0.5mm, it reaches the standard of minor injury. The single-pass grinding amount of the rail top is 0.1-0.15mm. When the valley depth is less than 0.5mm, rail grinding can be used. When the valley depth exceeds 0.5mm, a combined maintenance method of first milling and then grinding is required. The wear milling threshold can be 0.5mm, and the specific values ​​of the fatigue block milling threshold, the corrugated milling threshold and the wear milling threshold can be set according to actual conditions, and the embodiments of this application do not make specific limitations.

[0081] It should be noted that if there are scratches, bruises or other defects on the surface of the rail, a combined maintenance method of first milling and then grinding can be used.

[0082] S103: Determine the milling amount for the defect milling based on the defect data;

[0083] The milling amount includes the upper strand milling amount and the lower strand milling amount;

[0084] The step of determining the milling amount for the defect milling based on the defect data comprises:

[0085] Determining the upper strand milling amount for disease milling based on the disease data;

[0086] The milling amount of the lower strand for disease milling is determined based on the disease data.

[0087] It should be noted that, when determining to mill the rail, the milling amount can be determined first in order to calculate the subsequent grinding amount of the rail. The rail can be a curved rail, which includes an upper stock (i.e., an outer ring of the curved rail) and a lower stock (i.e., an inner ring of the curved rail). Usually, the degree of damage of the upper stock of the rail is different from that of the lower stock, so they need to be calculated separately.

[0088] In some embodiments, determining the upper strand milling amount for disease milling based on the disease data comprises:

[0089] Acquiring a real-time profile of the rail, and aligning the real-time profile with a designed profile of the rail in a side grinding alignment manner;

[0090] Obtaining a cutter head profile of a milling cutter head;

[0091] The cutterhead profile is brought into contact with the real-time profile and tangent thereto, and the upper vertical distance between the center point of the cutterhead profile and the center point of the design profile is measured;

[0092] The upper strand milling amount is obtained based on the upper strand vertical distance.

[0093] It should be noted that the upper strand of the rail usually has greater side wear (i.e., wear), so the side wear alignment method is used to align the rail for subsequent milling. Figure 4 As shown, the side grinding alignment method is to align the center point of the real-time profile vertically with the center point of the design profile, and when the cutter head profile moves from below to above the real-time profile and contacts the real-time profile at the first contact point A (i.e., abutting and tangent), measure or calculate the distance between the center point of the cutter head profile (i.e., point B) and the center point of the design profile (i.e., point C), which is the upper strand vertical distance d f1 .

[0094] In some embodiments, obtaining the upper strand milling amount based on the upper strand vertical distance includes:

[0095] If the corrugation data is smaller than the upper strand vertical distance, the upper strand vertical distance is determined to be the upper strand milling amount;

[0096] If the corrugation data is greater than or equal to the upper strand vertical distance, the corrugation data is determined to be the upper strand milling amount.

[0097] It should be noted that when there is no corrugation disease, the vertical distance d of the upper strand is f1 That is, the upper strand milling amount H. When corrugation damage exists, it is necessary to convert the corrugation damage depth (i.e., the corrugation data) into the upper strand vertical distance d. f1 The comparison shows that the corrugation damage depth is less than the upper strand vertical distance d f1 When the vertical distance d of the upper strand is determined f1 is the milling amount H of the upper strand; when the depth of the corrugated disease is greater than or equal to the vertical distance d of the upper strand f1 , determine the depth of the corrugation disease as the upper strand milling amount H.

[0098] In some embodiments, determining the milling amount of the lower strand for disease milling based on the disease data comprises:

[0099] Acquiring the real-time profile of the rail and the profile of the milling cutter head;

[0100] Vertically aligning the center of the real-time profile with the center of the cutter head profile, and making the cutter head profile abut and tangent to the real-time profile;

[0101] Measuring the lower vertical distance between the center point of the real-time profile and the center point of the cutterhead profile;

[0102] The lower strand milling amount is obtained based on the lower strand vertical distance.

[0103] It should be noted that the lower strand of the rail usually has a larger fatigue block fall disease, so a different calculation method is used from the side wear disease, that is, Figure 5 As shown, the center points of the cutter head profile and the real-time profile are aligned on the same vertical line. When the cutter head profile and the real-time profile are in contact at the first contact point a (the initial contact point between the cutter head profile and the real-time profile, or the abutment tangent), the vertical distance between the real-time profile and the center point of the cutter head profile is measured and calculated, that is, the vertical distance d between the center point b of the cutter head profile and the center point c of the real-time profile (or the profile before milling, the representative profile). f (i.e. the profile deviation caused by concave grinding of the rail surface), the profile deviation must be removed during milling before milling to the rail top; if there is no concave grinding on the rail surface, the center point of the cutter head profile is approximately coincident with the center point of the profile before milling, d f is 0.

[0104] In some embodiments, the lower strand milling amount is obtained based on the lower strand vertical distance, specifically:

[0105] Based on the formula of lower strand milling amount d max =d h +d f +d j , the lower strand vertical distance, the disease data and experience value to obtain the lower strand milling amount;

[0106] Among them, d max is the milling amount of the lower strand, d h is the disease data, d f is the vertical distance of the lower strand, d j For experience value.

[0107] It should be noted that in order to ensure that the lower strand of the rail can meet the maintenance requirements after milling, the disease data d h (or disease depth), the disease data d h Usually it is fatigue block falling data. The milling amount of the lower rail can be determined by the lower rail milling amount formula to determine whether the milling amount of the lower rail meets the maintenance requirements, wherein the d j Usually 0-3mm is used.

[0108] It should be noted that when calculating the grinding amount, the real-time profile of all rails to be measured should be aligned with the standard profile (or design profile) according to the outer non-working edge and the outer bottom angle, and the vertical wear H should be measured at 1 / 3 of the width of the top surface of the rail (from the working edge of the standard profile), and the maximum wear value H should be taken. max .

[0109] It should be noted that for railways with a speed of 120 km / h or less, when the vertical wear of the rails reaches the light damage standard, the rails need to be replaced. When the vertical wear of the rails approaches the light damage standard, rail milling or rail grinding operations are no longer performed to save rail maintenance costs.

[0110] It should be noted that the rail milling amount is 0.5-1.5 mm / pass. To prevent the milling operation from accelerating to the minor injury standard, H max When the rail surface fatigue block disease is completely removed by rail grinding (grinding more than 8 times), the rail top grinding amount usually reaches 1mm. In order to prevent the milling operation from accelerating to the light damage standard, H max No more grinding is required when the diameter is ≥8mm.

[0111] S104: Determine the number of defect grinding operations and the interval between the defect milling and the defect grinding based on the defect data and the working parameters;

[0112] S105: performing the defect milling and the defect grinding on the rail based on the milling amount of the defect milling, the number of defect grinding times and the milling and grinding operation interval.

[0113] In some embodiments, the operating parameters include the arc radius of the rail;

[0114] The determining the number of defect grinding operations and the interval between the defect milling and the defect grinding based on the defect data and the working parameters includes:

[0115] Determining the amount of defect to be ground for the defect grinding based on the milling amount of the defect milling and the defect data;

[0116] Determining the number of times to grind the defect based on the amount of defect to be grinded;

[0117] The milling and grinding operation interval between the defect milling and the defect grinding is determined based on the arc radius.

[0118] It should be noted that after milling the rails, corrugation and block falling defects at the track gauge angle on the rail curve cannot usually be removed; and since the shape of the cutter disc is fixed, the rail profile cannot be repaired in an individualized manner. Poor wheel-rail relationship after milling will cause new defects to appear on the rail surface soon, so the rails need to be ground and repaired. Since the grinding amount of the rails is usually 0.1 to 0.15 mm, the number of times (or passes) to grind the defects can be determined by the amount of defect to be ground and the grinding amount, so as to repair the rails in an individualized manner.

[0119] It should be noted that under the same total weight, different radius curves are divided into three categories according to the development rate of rail surface diseases: R<500m, 500m≤R<800m, and R≥800m. For example, the surface fatigue disease of the rail in the curve R<500m develops fastest. In order to repair the rail profile in a personalized way to ensure the best wheel-rail relationship, it is necessary to arrange subsequent rail grinding operations as soon as possible; while the surface disease of the rail in the curve R≥800m develops slowly, and it is not necessary to complete the grinding within a specific time interval after milling.

[0120] It should be noted that, in order to minimize the number of grinding times and control maintenance costs, grinding is usually carried out before the "B" grade fatigue block loss disease appears on the rail surface after milling (grinding up to 4 times). According to the observation of the development of fatigue disease on the rail surface after milling, if Figure 6 As shown in Table 1, "B" grade fatigue disease appears 0.5 months after milling of the curve with R<500m, "B" grade fatigue disease appears 1.5 months after milling of the curve with 500m≤R<800m, and the surface disease of the curve rail with R≥800m develops slowly. Therefore, the milling and grinding operation interval between the disease milling and the disease grinding can be determined according to the arc radius, wherein the milling and grinding operation time interval is the FTF time interval (i.e., the interval from the milling completion time to the grinding completion time).

[0121] In some embodiments, determining the milling and grinding interval between the defect milling and the defect grinding based on the arc radius includes:

[0122] Obtaining the total passing weight of the rail after the defect milling;

[0123] The milling and grinding operation interval between the defect milling and the defect grinding is determined based on the arc radius and the total weight.

[0124] It should be noted that the time when fatigue damage reappears after rail milling is not only related to the arc radius, but also to the total weight of the rail, as shown in Table 1. Figure 6 As shown, the greater the total weight, the greater the arc radius, and the smaller the milling and grinding operation interval.

[0125] Table 1 Statistical example of curve milling + grinding combined with maintenance grinding passes

[0126]

[0127] It should be noted that the operation interval can also be determined according to the number of grinding times after milling. To ensure the efficiency of the grinding operation, the curve should be ground at most 4 times after milling to repair the rail profile. Table 1 shows the statistics of the number of grinding times when the curve is milled and ground in combination with maintenance in actual situations. The requirements can be met by grinding 4 times for the R<500m curve 0.5 months after milling and grinding 4 times for the 500m≤R≤800m curve 1.5 months after milling. The grinding times of the curves with a time interval greater than this cannot meet the requirements. In summary, the R<500m curve needs to be ground within 0.5 months after milling, and the 500m≤R≤800m curve needs to be ground within 1.5 months after milling.

[0128] It should be noted that a maintenance plan combining milling and grinding can be designed. When the conditions for the combined maintenance of milling and grinding are met, firstly, severe surface defects of the rail are removed by milling, and then the profile is repaired by grinding within the determined interval of the milling and grinding operations. When the conditions for the combined maintenance operations are not met, rail milling or rail grinding operations are performed according to the actual situation of the rail defects.

[0129] A. Rail Milling Solution

[0130] 1) Determine the milling section, stock type, and rail model based on the inspection results of the maintenance section;

[0131] 2) The upper rail profile and the lower rail profile of the curve are respectively Figure 4 and attached Figure 4 Align as shown;

[0132] 3) Calculate the vertical distance between the rail profile (or real-time profile) under the curve and the center point of the cutterhead profile;

[0133] 4) Calculate the milling amount of the upper rail and the lower rail of the curve;

[0134] 5) The feed amount of the milling cutter each time is 0.1mm, and the number of feeds of each milling cutter is determined according to the milling amount of the upper rail and the milling amount of the lower rail;

[0135] 6) After milling, measure the profiles of the upper and lower rails at the curve gentle circle, the middle of the curve, and the circle gentle position for the subsequent rail grinding plan design.

[0136] B. Rail Grinding Solution

[0137] The rail grinding plan requires a given operating current, speed, and angle arrangement, and the grinding plan is designed based on the deviation between the measured rail profile and the target profile.

[0138] The embodiment of the present invention uses a GMC-48K rail grinding vehicle, with a common operating current of 28 to 29A, an operating speed of 10 to 12 km / h, a grinding angle range of -10 to 50 degrees, a single-pass active edge grinding amount of 0.3 to 0.4 mm, a rail top grinding amount of 0.1 to 0.15 mm, and a non-active edge grinding amount of 0.15 to 0.2 mm. Rail fatigue block drop and corrugation diseases are usually at the rail top position, with a single-pass grinding amount of 0.1 to 0.15 mm, wherein the rail grinding mode: when grinding the rail, cut from the inner large angle to the outer large angle in sequence to ensure that the trace of the previous cut is covered by the next cut, thereby improving the smoothness of the cut. The modes used for rail grinding of the present invention are shown in Tables 2 to 5 below.

[0139] Table 2 Rail top grinding mode

[0140]

[0141] Table 3 Grinding pattern of inner side of profile after milling

[0142]

[0143] Table 4 Grinding mode of outer side of profile

[0144]

[0145] Table 5 Grinding pattern of the inner side of the unmilled profile

[0146]

[0147] Tables 2 to 5 show the angles input to the control unit of each grinding trolley of each work vehicle to control the operation of the grinding motor, where the negative angle is the inner working edge and the positive angle is the outer non-working edge. The maintenance area is divided into milling and non-milling sections, and appropriate grinding modes are arranged in different sections according to the deviation distribution between the measured rail profile and the target profile.

[0148] Compared with the prior art, the advantages of the embodiments of the present application are that, by performing defect detection on the rail, the defect data of the rail is obtained; if the defect data is greater than the defect milling and grinding threshold, the working parameters of the rail are obtained; the milling amount for defect milling is determined based on the defect data; the number of defect grinding and the milling and grinding interval between the defect milling and the defect grinding are determined based on the defect data and the working parameters; the defect milling and the defect grinding are performed on the rail based on the milling amount of the defect milling, the number of defect grinding and the milling and grinding interval, which can reduce the number of grinding times, save grinding machine power, personalize the repair of the rail profile, save maintenance costs, and extend the service life of the rail.

[0149] It should be noted that 1) the present invention proposes a heavy-duty railway curved rail maintenance method combining milling and grinding, which innovatively combines rail grinding and rail milling in the repair of rail defects, transforming the previous extensive and single-form maintenance into maintenance in which milling and grinding cooperate with each other, giving full play to the advantages of the two maintenance methods and making up for the disadvantages of the two maintenance methods, thereby improving the quality and efficiency of maintenance operations and reducing maintenance operation costs; 2) the present invention proposes a heavy-duty railway curved rail maintenance method combining milling and grinding, which is not limited by operating conditions and rail defects, and can customize maintenance operation plans according to construction needs. Through process optimization, the problem of overheating of the grinding motor caused by too many grinding times of the rail grinding vehicle in a long tunnel is effectively avoided. The invention provides a complete rail grinding and milling combined maintenance process, which can guide the operation by following the process, and is easy to promote and use; 3) The present invention proposes a heavy-duty railway curved rail maintenance method combining milling and grinding, which achieves efficient and high-quality treatment of rail fatigue block falling, corrugation and other diseases, can effectively improve the wheel-rail relationship, extend the service life of the rail, and improve the safety and stability of heavy-duty vehicle operation; 4) The heavy-duty railway curved rail maintenance method combining milling and grinding of the present invention can form effective guidance for the maintenance of heavy-duty railway rail surface diseases, and can formulate grinding and milling maintenance plans according to the actual situation of rail surface diseases to avoid blind operations on site.

[0150] In a second aspect, an embodiment of the present application provides a rail defect repair system, comprising:

[0151] Detection module: used to detect the defects of the rail and obtain the defect data of the rail;

[0152] Acquisition module: used for acquiring the working parameters of the rail if the damage data is greater than the damage milling and grinding threshold;

[0153] Calculation module: used to determine the milling amount of the defect milling based on the defect data; determine the number of defect grindings and the milling and grinding interval between the defect milling and the defect grinding based on the defect data and the working parameters;

[0154] Instruction module: used for performing the defect milling and the defect grinding on the rail based on the milling amount of the defect milling, the number of defect grinding and the milling and grinding operation interval.

[0155] Although the present invention has been described with reference to preferred embodiments, various modifications may be made thereto and parts thereof may be replaced by equivalents without departing from the scope of the present invention. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there are no structural conflicts. The present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A rail disease repair method, characterized in that: include: Performing a defect detection on the rail to obtain defect data of the rail; If the disease data is greater than the disease milling and grinding threshold, the working parameters of the rail are obtained; Determining a milling amount for performing disease milling based on the disease data; Determine the number of defect grinding operations and the interval between the defect milling and the defect grinding based on the defect data and the working parameters; The defect milling and the defect grinding are performed on the rail based on the milling amount of the defect milling, the number of defect grinding times and the milling and grinding operation interval.

2. The rail defect repair method according to claim 1, characterized in that: The disease detection includes fatigue block drop detection, corrugation detection and wear detection; The step of performing a defect detection on the rail to obtain defect data of the rail includes: Performing fatigue block drop detection on the rail to obtain fatigue block drop data of the rail; Performing corrugation detection on the rail to obtain corrugation data of the rail; The wear of the rail is detected to obtain the wear data of the rail.

3. The rail defect repair method according to claim 2, characterized in that: The disease milling and grinding thresholds include fatigue chipping milling and grinding thresholds, corrugated milling and grinding thresholds and wear milling and grinding thresholds; If the damage data is greater than the damage milling and grinding threshold, obtaining the working parameters of the rail includes: If the fatigue block loss data is greater than the fatigue block loss milling grinding threshold, and / or the corrugation data is greater than the corrugation milling grinding threshold, and / or the wear data is greater than the wear milling grinding threshold, the working parameters of the rail are obtained.

4. The rail defect repair method according to claim 2, characterized in that: The milling amount includes the upper strand milling amount and the lower strand milling amount; The step of determining the milling amount for the defect milling based on the defect data comprises: Determining the upper strand milling amount for disease milling based on the disease data; The milling amount of the lower strand for disease milling is determined based on the disease data.

5. The rail defect repair method according to claim 4, characterized in that: The step of determining the upper strand milling amount for performing disease milling based on the disease data comprises: Acquiring a real-time profile of the rail, and aligning the real-time profile with a designed profile of the rail in a side grinding alignment manner; Obtaining a cutter head profile of a milling cutter head; The cutterhead profile is brought into contact with the real-time profile and tangent thereto, and the upper vertical distance between the center point of the cutterhead profile and the center point of the design profile is measured; The upper strand milling amount is obtained based on the upper strand vertical distance.

6. The rail defect repair method according to claim 5, characterized in that: The obtaining the upper strand milling amount based on the upper strand vertical distance comprises: If the corrugation data is smaller than the upper strand vertical distance, the upper strand vertical distance is determined to be the upper strand milling amount; If the corrugation data is greater than or equal to the upper strand vertical distance, the corrugation data is determined to be the upper strand milling amount.

7. The rail defect repair method according to claim 4, characterized in that: The step of determining the milling amount of the lower strand for disease milling based on the disease data comprises: Acquiring the real-time profile of the rail and the profile of the milling cutter head; Vertically aligning the center of the real-time profile with the center of the cutter head profile, and making the cutter head profile abut and tangent to the real-time profile; Measuring the lower vertical distance between the center point of the real-time profile and the center point of the cutterhead profile; The lower strand milling amount is obtained based on the lower strand vertical distance.

8. The rail defect repair method according to claim 7, characterized in that: The milling amount of the lower strand is obtained based on the vertical distance of the lower strand, specifically: Based on the formula of lower strand milling amount d max =d h +d f +d j , the lower strand vertical distance, the disease data and experience value to obtain the lower strand milling amount; Among them, d max is the milling amount of the lower strand, d h is the disease data, d f is the vertical distance of the lower strand, d j For experience value.

9. The rail defect repair method according to claim 1, characterized in that: The working parameters include the arc radius of the rail; The determining the number of defect grinding operations and the interval between the defect milling and the defect grinding based on the defect data and the working parameters includes: Determining the amount of defect to be ground for the defect grinding based on the milling amount of the defect milling and the defect data; Determining the number of times to grind the defect based on the amount of defect to be grinded; The milling and grinding operation interval between the defect milling and the defect grinding is determined based on the arc radius.

10. The rail defect repair method according to claim 9, characterized in that: The determining of the milling and grinding operation interval between the defect milling and the defect grinding based on the arc radius includes: Obtaining the total passing weight of the rail after the defect milling; The milling and grinding operation interval between the defect milling and the defect grinding is determined based on the arc radius and the total weight.

11. A rail defect repair system, characterized in that: include: Detection module: used to detect the defects of the rail and obtain the defect data of the rail; Acquisition module: used for acquiring the working parameters of the rail if the damage data is greater than the damage milling and grinding threshold; Calculation module: used to determine the milling amount of the defect milling based on the defect data; determine the number of defect grindings and the milling and grinding interval between the defect milling and the defect grinding based on the defect data and the working parameters; Instruction module: used for performing the defect milling and the defect grinding on the rail based on the milling amount of the defect milling, the number of defect grinding and the milling and grinding operation interval.

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