Ground rail straightening equipment and method
Through the cooperation of the hydraulic press-driven straightening frame, laser spotlights and scanning cameras, an efficient, accurate and controllable process of ground rail straightening is achieved, and the problems of low efficiency and uncontrollable parameters in the existing technology are solved.
Patent Information
- Application Number
- CN202411845326.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-26
- Publication Date
- 2025-02-07
AI Technical Summary
The existing ground rail straightening technology has problems such as low efficiency, uncontrollable straightening parameters, and easy to cause reflux, which affects production progress.
The straightening frame driven by a hydraulic press is used, combined with laser spotlights and scanning cameras for real-time shooting and fine adjustment, and the ground rail bending degree is calculated through industrial computers and the pressurizer is adjusted to achieve efficient straightening.
It improves the work efficiency and calibration accuracy of ground rail straightening, ensures the safety and controllability of the straightening process, and reduces the complexity of manual operations.
Smart Images
Figure CN119387358A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of ground rail production, and in particular to a ground rail straightening device and method. Background Art
[0002] The floor rail is a kind of equipment used for the assembly, testing, welding and inspection of large equipment. It is also called T-slot floor rail, floor beam, floor slot iron, foundation slot iron, cast iron floor rail, strip platform, etc. The floor rail is mainly designed and spliced into a cast beam platform according to the fixed points of the equipment, and is used for the assembly, testing, welding and inspection of large equipment. In this way, it does not need to be made into a large platform, which not only saves material costs, but also takes up very little space, and has a high cost performance.
[0003] After the installation of the ground rail, the horizontal deviation is no more than 1mm within any 1m length, and the horizontal deviation of the entire length is no more than 2mm; the horizontal deviation of the corresponding points between the rails is no more than 1mm, and the parallelism deviation between each two rails is less than 2mm. In order to ensure the quality of the ground rail, the ground rail needs to be straightened after welding to eliminate the bending and twisting of the metal parts of the ground rail during the production or processing process, and improve its straightness and surface quality. During the straightening process, it is usually necessary to repeat the operation on the metal parts many times until the expected straightening accuracy is achieved.
[0004] In the prior art, the ground rail is pressurized by heavy objects, which is simple to operate. However, after the heavy objects are removed, it is easy to cause rebound, and the straightening parameters are uncontrollable, which is inefficient and affects the production progress. Summary of the invention
[0005] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a ground rail straightening device and method.
[0006] In order to achieve the above object, the present invention adopts the following technical solutions: A floor rail straightening device comprises a base and a gantry, wherein a base is provided on the upper side of the base, a straightening frame is provided on the upper side of the base, a hydraulic press is provided on the upper side of the gantry, the hydraulic press and the straightening frame are arranged correspondingly, an adjustment frame is provided on one side of the base, a laser spotlight is provided on the adjustment frame, the laser spotlight emits a laser beam as a reference line for alignment, and scanning cameras are provided on both sides of the gantry; the straightening frame comprises a load frame, a pressurizer and a screw, the pressurizer is arranged on the upper side of the load frame, a floor rail is provided on the straightening frame, the load frame, the pressurizer and the floor rail are alternately stacked in multiple layers from bottom to top, through holes are provided at both ends of the load frame, the screw passes through the through holes, and the bottom end is connected to the base, a nut and a pad are provided on the top of the screw, and the pressurizer is vertically raised and lowered to change the distance between the floor rail and the load frame to straighten the floor rail.
[0007] Preferably, an industrial computer is provided on one side of the adjustment frame, the laser spotlight and the scanning camera are electrically connected to the industrial computer, an electric-controlled lifting frame is provided on the outside of the scanning camera, an electric-controlled telescopic rod is provided on the adjustment frame, and a control component is connected to the pressurizer.
[0008] Preferably, the electrically-controlled lifting frame is used to control the up and down movement of the scanning camera, the adjusting frame includes a vertical rod group and a horizontal rod group, and the electrically-controlled telescopic rods are provided with multiple groups, which are respectively used to drive the vertical rod group and the horizontal rod group to work, and control the vertical or horizontal movement of the laser spotlight.
[0009] Preferably, the base is slidably connected to the pedestal, a position sensor is provided on the base, the gantry is fixedly connected to the pedestal, at least three groups of gantry are provided, and the multiple groups of gantry are arranged in parallel to form a straightening station.
[0010] Preferably, an execution unit is provided between the pressurizer and the load frame, and the control component is connected to the execution unit, and the pressurizer is driven by hydraulic pressure or pneumatic pressure to achieve lifting.
[0011] Preferably, the laser spotlight is provided with an angle adjustment device for correcting the angle of the laser spotlight to ensure that the laser beam is in a horizontal direction.
[0012] Preferably, the straightening method comprises: Step S1, the construction personnel install the screw on the base and arrange the load racks, at least three load racks are evenly arranged on the same horizontal plane and are arranged corresponding to the hydraulic press; Step S2, arranging a pressurizer on the load frame according to the structure of the ground rail to ensure stable support of the ground rail, and then alternately stacking the load frame, the pressurizer, and the ground rail from bottom to top in multiple layers, and temporarily fixing them with nuts and spacers; Step S3, adjust the ground rails to ensure neat stacking, the laser spotlight emits a laser beam, shining it on the side of the ground rail as a reference line, and at the same time, the scanning camera works to take photos of the side of the ground rails, and records the deformation and warping degree of each side of the ground rails. The hydraulic press starts working to pressurize the straightening frame; Step S4: During the pressurization process, tighten the nut in time, fix the straightening frame, and the industrial computer calculates the bending degree of the ground rail according to the picture taken by the scanning camera, and adjusts the pressurizer and the ground rail spacing accordingly, so that the center line of the ground rail in the deformed state is pressed to a distance below the center line of the normal state, and the ground rail is bent in the reverse direction, so that the ground rail produces plastic deformation; Step S5, the hydraulic press maintains pressure for 1 to 2 minutes, the preliminary straightening is completed, the pressurizer is reset, the ground rail releases pressure, elastically resets, and the scanning camera takes pictures of the ground rail shape again to record the status; Step S6, determine whether the residual bending amount of each part of the rail after rebounding exceeds the allowable value. If it still exceeds the allowable value, repeat steps S4 and S5 until the bending amount of the rail is within the allowable value, adjust all pressurizers to the same height, pressurize the hydraulic press, tighten the nut, and retain a part of the pressure on the straightening frame to straighten the rail and put it in a straight state; Step S7, the base platform removes the straightening frame and allows the straightened rail to stand still. The standing time is determined according to the size, quantity and material of the rail. After the standing time is completed, the straightening frame is removed, the rail is inspected, and qualified and unqualified products are screened. Qualified products are sent out for subsequent processes, and unqualified products are re-straightened until they are qualified.
[0013] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention adopts a base to carry the ground rail, which slides on the base to realize the straightening of the assembly line and improve the work efficiency. At the same time, a hydraulic press is used for straightening, which is efficient and convenient, and the straightening force is controllable, which greatly ensures the safety of the straightening work; 2. The present invention provides a straightening frame, which takes real-time photos of the ground rails through laser spotlights and scanning cameras, and cooperates with a pressurizer to perform fine adjustments, reversely correct the ground rails, promote plastic deformation of the ground rails, and improve the operability, reliability and correction accuracy of ground rail straightening. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 A schematic diagram of the three-dimensional assembly structure of a ground rail straightening device proposed by the present invention; Figure 2 for Figure 1 A schematic diagram of the local enlarged structure at point A in the middle; Figure 3 This is a schematic diagram of a partial structure of a ground rail straightening device proposed by the present invention in a front view and a cross-section; Figure 4 A schematic diagram of the main structure of a straightening frame of a ground rail straightening device proposed by the present invention; Figure 5 A schematic diagram of a top view of the structure of a straightening frame of a ground rail straightening device proposed by the present invention; Figure 6 The present invention is a schematic diagram of the working process of a ground rail straightening method proposed in the present invention.
[0015] In the figure: 1. Straightening frame; 11. Load frame; 12. Pressurizer; 13. Pad; 14. Screw; 2. Scanning camera; 3. Gantry; 4. Hydraulic press; 5. Adjustment frame; 6. Laser spotlight; 7. Base; 8. Electric lifting frame; 9. Base; 10. Ground rail. DETAILED DESCRIPTION
[0016] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is by no means intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0017] Reference Figure 1-6 A floor rail straightening device comprises a base 7 and a gantry 3. A base 9 is provided on the upper side of the base 7. The base 9 is slidably connected to the base 7. The workstation is switched by a driving device or manual pushing. A position sensor is provided on the base 9 to determine the position of the base 9, so as to facilitate the cooperation with other equipment. The gantry 3 is fixedly connected to the base 7. At least three groups of gantry 3 are provided. The multiple groups of gantry 3 are arranged in parallel to form a straightening workstation. The floor rail is straightened by pressurizing at least three positions. A straightening frame 1 is provided on the upper side of the base 9, and a ground rail 10 is provided on the straightening frame 1. A hydraulic press 4 is provided on the upper side of the gantry 3, and the hydraulic press 4 is arranged corresponding to the straightening frame 1. An adjustment frame 5 is provided on one side of the base 7, and a laser spotlight 6 is provided on the adjustment frame 5. The laser spotlight 6 emits a laser beam as a reference line for alignment. An electrically controlled telescopic rod is provided on the adjustment frame 5. The adjustment frame 5 includes a vertical rod group and a horizontal rod group. The vertical rod group controls the horizontal rod group to move up and down, and the horizontal rod group controls the laser spotlight 6 to move horizontally. There are multiple groups of electrically controlled telescopic rods, which are respectively used to drive the vertical rod group and the horizontal rod group to work, so as to realize the vertical or horizontal movement of the laser spotlight 6. At the same time, an angle adjustment device is provided on the laser spotlight 6 for fine-tuning the angle of the laser spotlight 6 to ensure that the laser beam is in a horizontal direction and to ensure a horizontal straight line reference line. Scanning cameras 2 are provided on both sides of the gantry 3, an industrial computer is provided on one side of the adjustment frame 5, the laser spotlight 6 and the scanning camera 2 are electrically connected to the industrial computer, and an electric control lifting frame 8 is provided on the outside of the scanning camera 2, and the electric control lifting frame 8 is used to control the scanning camera 2 to move up and down to shoot the status of the ground rail 10; The straightening frame 1 includes a load frame 11, a pressurizer 12 and a screw 14. The pressurizer 12 is arranged on the upper side of the load frame 11. The pressurizer 12 is connected to a control component. The load frame 11, the pressurizer 12 and the ground rail 10 are stacked alternately from bottom to top. Figure 4As shown, the pressurizer 12 is lifted and lowered vertically to change the distance between the ground rail 10 and the load frame 11 to straighten the ground rail 10. An execution unit is provided between the pressurizer 12 and the load frame 11. The execution unit adopts a micro hydraulic cylinder or an air bag. The control component is connected to the execution unit. The pressurizer 12 is driven by hydraulic or pneumatic pressure to achieve lifting and lowering, pressurize the ground rail 10, adjust the spacing of the ground rail 10, and perform bending and straightening. Through holes are provided at both ends of the load frame 11, and the screw 14 passes through the through holes, and the bottom end is connected to the base 9. A nut and a pad 13 are provided on the top of the screw 14, so as to fix the straightening frame 1 and apply partial pressure to the ground rail 10 at the same time.
[0018] Straightening methods include: Step S1, the construction personnel install the screw rod 14 on the base 9, and arrange the load frame 11, at least three load frames 11 are evenly arranged on the same horizontal plane, which are divided into 11A, 11B, and 11C, and are arranged corresponding to the hydraulic press 4; Step S2, a pressurizer 12 is arranged on the load frame 11 according to the structure of the ground rail 10 to ensure stable support of the ground rail 10, and then the load frame 11, the pressurizer 12, and the ground rail 10 are alternately stacked in multiple layers from bottom to top. The multi-layer ground rail 10 is divided into 10a, 10b, 10c, 10d, and 10e, and temporarily fixed by nuts and spacers 13; Step S3, adjust the ground rail 10 to ensure neat stacking, the laser spotlight 6 emits a laser beam, shining on the side of the ground rail 10 as a reference line, and at the same time, the scanning camera 2 works to take a side photo of the ground rail 10, and records the deformation and warping degree of each side of the ground rail 10, and the hydraulic press 4 starts to work to pressurize the straightening frame 1, and initially pressurizes; Step S4, during the pressurization process, tighten the nut in time to fix the straightening frame 1. Based on the straightness of the base 9, 10e and 10a are straightened by the screw 14 during pressurization. If necessary, the load frame 11 on the upper side of 10a can be installed in reverse, and the pressurizer 12 is used to align and fine-tune the ground rail 10; The industrial computer calculates the bending degree of the ground rail 10 according to the pictures taken by the scanning camera 2, and adjusts the pressurizer 12 accordingly, and adjusts the spacing of the ground rail 10 layer by layer. For example, if the middle part of 10b bulges upward, then 11B on the upper side of 10b is pressurized, and 11B on the lower side is contracted, and 11A and 11C on both sides remain unchanged, so that the middle part of 10b is bent downward, and the center line of the ground rail 10 in the deformed state is pressed to a distance below the center line of the normal state, and the ground rail 10 is bent in the reverse direction, and the ground rail 10 undergoes plastic deformation; Step S5, the hydraulic press 4 maintains pressure for 1 to 2 minutes, the preliminary straightening is completed, and the pressurizer 12 is reset, the ground rail 10 releases pressure and resets elastically, and the scanning camera 2 takes pictures of the shape of the ground rail 10 again to record the status; The longer the holding time is, the greater the plastic deformation of the metal part is, which helps to achieve a better straightening effect; however, it should be noted that the holding time should not be too long to avoid excessive deformation of the floor rail 10 and other quality problems; Step S6, determine whether the residual bending amount of each part of the ground rail 10 after rebounding exceeds the allowable value. If it still exceeds the allowable value, repeat steps S4 and S5 until the bending amount of the ground rail 10 is within the allowable value, adjust the heights of all pressurizers 12 to be consistent, pressurize the hydraulic press 4, tighten the nut, and retain a part of the pressure on the straightening frame 1 to straighten the ground rail 10 to a straight state; Step S7, the base 9 removes the straightening frame 1, and allows the ground rail 10 in the straightened state to stand still. The standing time is determined according to the size, quantity and material of the ground rail. After the standing time is completed, the straightening frame 1 is removed, the ground rail 10 is inspected, and qualified and unqualified products are screened. Qualified products are sent out for subsequent processes, and unqualified products are manually inspected in detail to avoid excessive straightening, which may cause metal cracks or fractures. Products with problems are recycled and scrapped. Products with qualified strength are determined and re-straightened until they are qualified.
[0019] In addition, the straightening process also involves a series of straightening parameters, which play a vital role in the straightening process. They directly affect the straightening effect and quality. Reasonable control of pressure, tension, temperature and other parameters in the straightening process can ensure the straightening quality and efficiency.
[0020] For example, the straightening coefficient is a parameter used by the straightening machine to correct the curvature of the material. Its calculation method is mainly based on the curvature of the material and the straightening force of the straightening machine.
[0021] The formula is: straightening coefficient = straightening force / bending degree; Among them, the straightening force refers to the force applied by the straightening machine, and the curvature refers to the degree of curvature of the material before straightening; generally, the larger the straightening coefficient, the smaller the straightening force required by the straightening machine and the better the straightening effect; the size of the straightening coefficient is affected by many factors, including the hardness, elastic modulus, thickness of the material, the straightening force of the straightening machine, the shape and size of the straightening roller, etc.
[0022] In addition to the straightening factor, there are other key straightening parameters that usually vary depending on the specific straightening machine and the object being straightened; among them: Straightening force: The force applied during straightening is used to correct the curvature of the material; the magnitude of the straightening force directly affects the straightening effect and material performance.
[0023] Straightening speed: the speed at which the material moves during the straightening process; the choice of straightening speed needs to take into account the properties of the material, the capacity of the straightening machine and the requirements for straightening quality.
[0024] Straightening temperature: For some heat-treated materials, the choice of straightening temperature is also very important; appropriate straightening temperature can help the material recover its shape better and improve the straightening quality.
[0025] Number of straightening times: How many times the material needs to be straightened to achieve the desired straightening effect; the number of straightening times should be determined based on the degree of bending of the material and the capacity of the straightening machine.
[0026] In actual operation, the selection and adjustment of straightening parameters need to be carried out according to the specific straightening task, material properties and the capabilities of the straightening machine.
[0027] Before selecting the straightening parameters, it is necessary to fully understand the material's hardness, elastic modulus, yield strength and other performance parameters in order to better select the appropriate straightening parameters.
[0028] Before actual operation, experimental straightening can be carried out. By observing the straightening effect and changes in material performance, the straightening parameters can be gradually adjusted to achieve the best straightening effect.
[0029] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.
[0030] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.
[0031] Unless otherwise specifically stated, the relative arrangement of the parts and steps described in these embodiments, numerical expressions and numerical values do not limit the scope of the present invention. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to the actual proportional relationship. The technology, method and equipment known to ordinary technicians in the relevant field may not be discussed in detail, but in appropriate cases, the technology, method and equipment should be regarded as a part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once a certain item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.
Claims
1. A ground rail straightening device, comprising a base (7) and a gantry (3), characterized in that: A base (9) is provided on the upper side of the base (7), a straightening frame (1) is provided on the upper side of the base (9), a hydraulic press (4) is provided on the upper side of the portal (3), the hydraulic press (4) and the straightening frame (1) are arranged correspondingly, an adjustment frame (5) is provided on one side of the base (7), a laser spotlight (6) is provided on the adjustment frame (5), the laser spotlight (6) emits a laser beam as a reference line for alignment, and scanning cameras (2) are provided on both sides of the portal (3); The straightening frame (1) comprises a load frame (11), a pressurizing device (12) and a screw (14); the pressurizing device (12) is arranged on the upper side of the load frame (11); a ground rail (10) is arranged on the straightening frame (1); the load frame (11), the pressurizing device (12) and the ground rail (10) are alternately stacked in multiple layers from bottom to top; through holes are arranged at both ends of the load frame (11); the screw (14) passes through the through holes and the bottom end is connected to the base (9); a nut and a spacer (13) are arranged at the top of the screw (14); the pressurizing device (12) is vertically raised and lowered to change the distance between the ground rail (10) and the load frame (11) so as to straighten the ground rail (10).
2. A ground rail straightening device according to claim 1, characterized in that: An industrial computer is provided on one side of the adjustment frame (5); the laser spotlight (6) and the scanning camera (2) are electrically connected to the industrial computer; an electric-controlled lifting frame (8) is provided on the outside of the scanning camera (2); an electric-controlled telescopic rod is provided on the adjustment frame (5); and a control component is connected to the pressurizer (12).
3. A ground rail straightening device according to claim 2, characterized in that: The electrically controlled lifting frame (8) is used to control the scanning camera (2) to move up and down. The adjusting frame (5) comprises a vertical rod group and a horizontal rod group. The electrically controlled telescopic rods are provided in a plurality of groups, which are respectively used to drive the vertical rod group and the horizontal rod group to work and control the vertical or horizontal movement of the laser spotlight (6).
4. A ground rail straightening device according to claim 1, characterized in that: The base (9) is slidably connected to the base (7), a position sensor is provided on the base (9), the door frame (3) is fixedly connected to the base (7), at least three groups of the door frames (3) are provided, and the multiple groups of the door frames (3) are arranged in parallel to form a straightening station.
5. A ground rail straightening device according to claim 3, characterized in that: An execution unit is provided between the pressurizer (12) and the load frame (11), and the control component is connected to the execution unit, and the pressurizer (12) is driven by hydraulic pressure or pneumatic pressure to achieve lifting.
6. A ground rail straightening device according to claim 1, characterized in that: The laser spotlight (6) is provided with an angle adjustment device for correcting the angle of the laser spotlight (6) to ensure that the laser beam is in a horizontal direction.
7. A method for straightening a ground rail according to any one of claims 1 to 6, characterized in that: The straightening method comprises: Step S1, a construction worker installs a screw rod (14) on a base (9) and arranges a load frame (11), wherein at least three load frames (11) are evenly arranged on the same horizontal plane and are arranged corresponding to the hydraulic press (4); Step S2, arranging a pressurizer (12) on the load frame (11) according to the structure of the ground rail (10) to ensure stable support of the ground rail (10), and then alternately stacking the load frame (11), the pressurizer (12), and the ground rail (10) in multiple layers from bottom to top, and temporarily fixing them by nuts and spacers (13); Step S3, adjusting the ground rails (10) to ensure neat stacking, the laser spotlight (6) emits a laser beam to illuminate the side of the ground rail (10) as a reference line, and at the same time, the scanning camera (2) works to take a side photo of the ground rail (10) and record the deformation and warping degree of each side of the ground rail (10), and the hydraulic press (4) starts to work to pressurize the straightening frame (1); Step S4, during the pressurization process, the nut is tightened in time to fix the straightening frame (1), and the industrial computer calculates the bending degree of the ground rail (10) according to the image taken by the scanning camera (2), and adjusts the pressurizer (12) accordingly, adjusts the spacing of the ground rail (10), presses the center line of the ground rail (10) in the deformed state to a distance below the center line of the normal state, and reversely presses and bends the ground rail (10), so that the ground rail (10) undergoes plastic deformation; Step S5, the hydraulic press (4) maintains pressure for 1 to 2 minutes, the preliminary straightening is completed, and the pressurizer (12) is reset at the same time, the ground rail (10) releases pressure and resets elastically, and the scanning camera (2) takes another picture of the shape of the ground rail (10) and records the state; Step S6, determining whether the residual bending amount at each location of the floor rail (10) after rebounding exceeds the allowable value; if it still exceeds the allowable value, repeating steps S4 and S5 until the bending amount of the floor rail (10) is within the allowable value, adjusting the heights of all pressurizers (12) to be consistent, applying pressure with the hydraulic press (4), locking the nuts, and retaining a portion of pressure on the straightening frame (1), so as to straighten the floor rail (10) and put it in a straight state; Step S7, the base (9) removes the straightening frame (1), and allows the straightened ground rail (10) to rest for a period of time determined according to the size, quantity and material of the ground rail. After the resting period is completed, the straightening frame (1) is removed, and the ground rail (10) is inspected to select qualified and unqualified products. The qualified products are sent out for subsequent processes, and the unqualified products are re-straightened until they are qualified.