Lithium battery full-automatic steel rail grinding machine

Abstract

The invention discloses a lithium battery full-automatic steel rail grinding machine which is used for solving the problem that an existing grinding machine is not high in grinding precision. Comprising a grinding head, a main motor, a motor mounting frame, a lifting mechanism, a rotating mechanism, a translation mechanism and a rack, the rack is provided with a door-shaped mounting frame through the translation mechanism, and the two sides of the lower end of a portal frame are mechanically connected with longitudinal beams of the door-shaped mounting frame through the rotating mechanism in an angle-adjustable mode; linear bearings are installed on two linear guide columns on the portal frame, the two linear bearings are fixedly connected with a motor installation frame, a main motor is fixed to the motor installation frame, a polishing head is installed on a power shaft of the main motor, and the rotating structure is innovatively designed. According to the device, the motor mounting frame with the rectangular frame is adopted, and the portal frame, the door-shaped mounting frame and other good-rigidity designs are matched, so that the rigidity degree of the grinding head is improved, flexible deformation is relieved, and the stability of the grinding head is improved.

Description

Technical Field

[0001] The invention relates to the technical field of rail grinding machines. Background Art

[0002] Railway engineering departments mainly use rail grinding to improve the wheel-rail relationship and extend the service life of rails. Due to the constraints of window time and construction costs, vertical rail grinders have become the main equipment for daily rail profile repair. At present, they are mainly used to grind fish scales on the top and side of the rails, peel off blocks, wave-shaped wear, and repair rail profiles. Figure 1 .

[0003] At present, the vertical rail grinders used in the bureau are all driven by internal combustion gasoline engines. The vertical rail grinders driven by internal combustion gasoline engines have the following problems: the exhaust emissions of internal combustion engines are serious, which endangers the health of operators and causes environmental pollution; the gap between transmission running parts is large, the rigidity of the grinding wheel is poor, and it produces self-vibration, resulting in poor grinding accuracy; grinding iron chips are easily inhaled into the engine, causing damage to the engine cylinder and a high failure rate; engine noise pollution harms human health and disturbs residential areas; it is difficult to start at low temperatures; it is difficult to supply imported accessories and the maintenance cost is high. Among them, traditional grinders are mostly driven by internal combustion and all use mechanical adjustment mechanisms. The minimum division of the mechanical adjustment mechanism depends on the fixed limit on the circumference or straight line, and the minimum adjustment angle is 1°. Therefore, the minimum division of lifting and angular rotation is greatly limited, and the grinding quality depends on the grinding experience of employees. Summary of the invention

[0004] In order to solve the above problems, it is very urgent and necessary to carry out the research and development of lithium-ion vertical rail grinders, which is of great significance to improving equipment quality and ensuring driving safety and stability.

[0005] The technical solution adopted by the present invention to solve the technical problem is: A lithium battery fully automatic rail grinding machine, comprising a grinding wheel, a main motor, a motor mounting frame, a lifting mechanism, a rotating mechanism, a translation mechanism and a frame, a gantry, a door-shaped mounting frame, and an electric control system, characterized in that: four rail wheels are arranged on the frame, and flanges and lateral limit wheels are arranged on the edges of the rail wheels, and insulating sleeves are arranged on the surfaces of the rail wheels, and brake assemblies are arranged at one or two of the rail wheels, and the frame is pushed forward along the rails, and the grinder is stopped at any position of the rails by operating the brake assemblies; The rack is mounted with a door-shaped mounting frame via a translation mechanism; The lower ends of the gantry are mechanically connected to the longitudinal beams of the gantry-shaped mounting frame at adjustable angles through a rotating mechanism; the rotating structure includes a servo motor II, a worm gear, a large gear, a small gear, a rotating shaft I, and a rotating shaft II, wherein the rotating shaft I is mechanically installed on the longitudinal beams of the gantry-shaped mounting frame, the rotating shaft II is fixedly connected to the gantry and movably cooperates with the gantry-shaped mounting frame, the rotating shaft I is fixedly connected to the small gear, the large gear is fixedly installed on the rotating shaft II, the small gear is meshed with the large gear, the rotating shaft I is key-connected with the worm gear, and the worm is mechanically connected to the motor shaft of the servo motor II; the servo motor II is electrically connected to the electronic control system, and the grinding rotation angle is adjusted under the command of the electronic control system. If the parallel position of the rail is set to zero, the grinding wheel can rotate within a range of ±90° in the vertical direction on both sides of the rail; A lifting guide assembly and a lifting mechanism are installed between the gantry and the motor mounting frame, wherein the lifting mechanism includes a lead screw, a thread sleeve, a bevel gear and a servo motor I, wherein the lead screw and the thread sleeve are mechanically matched, the thread sleeve is rotatably mounted on the crossbeam of the gantry through a bearing, the lead screw is movably connected to the motor mounting frame, the thread sleeve is mechanically connected to the bevel gear, the bevel gear is matched with a bevel gear, the bevel gear is mounted on the motor shaft of the servo motor I, and the servo motor I is mounted on the crossbeam of the gantry, the servo motor I is electrically connected to the electric control system, and the motor mounting frame is lifted or lowered in the height direction under the command of the electric control system, and the lifting range is between 0-190mm; The main motor with a grinding wheel installed is fixed in the frame of the motor mounting frame, and the motor shaft of the main motor is arranged downward and has an inclination angle β in the vertical plane of the vertical rail.

[0006] Furthermore, within the range of the lifting action, the height of the grinding wheel can be raised or lowered by manually pressing a button, and the zero position can be locked during the lifting process. After the zero position is locked, the grinding wheel can only rise or fall above the zero position.

[0007] Furthermore, the large gear is an incomplete gear with a one-third sector-shaped profile.

[0008] Furthermore, the translation mechanism includes a linear slide rail assembly and a screw transmission mechanism. The lower end of the gate-shaped mounting frame is mechanically connected to the frame through four groups of linear slide rail assemblies. The screw in the screw transmission mechanism is rotatably mounted on the frame through a bearing assembly and is longitudinally arranged. The screw sleeve in the screw transmission mechanism is fixedly mounted on the gate-shaped mounting frame.

[0009] Furthermore, a sprocket is installed at the end of the lead screw and is connected to a handwheel through a chain transmission. The handwheel is installed on a bracket, which is a cantilever bracket extended from the subframe and fixed by welding, and a chain transmission mechanism is installed inside.

[0010] Furthermore, the lifting guide assembly includes two linear guide columns installed on the gantry and a linear bearing installed on the motor mounting frame, and the linear guide columns and the linear bearing are slidably matched.

[0011] Furthermore, the touch screen is provided above the door-shaped mounting frame.

[0012] Furthermore, the motor mounting frame is a rectangular frame formed by combining steel plates.

[0013] Furthermore, the frame includes two left and right sub-frames, which are detachably connected by steel pipe plugging and bolt fixing.

[0014] Furthermore, a lithium battery, a storage platform and a control box are fixedly installed on the frame.

[0015] The beneficial effects of the present invention are: In this technology, by introducing servo motors and their precision servo control systems into grinding machinery, the intelligent electronic control integration of the grinding machine is greatly improved, and automation transformation is realized. For example, the common operations of the machine's grinding head lifting and angle rotation are all driven by servo motors, and in conjunction with the use of PLC controllers, all grinding operations are concentrated on the control panel for touch screen operation, which reduces the difficulty of machine operation and improves the level of automation.

[0016] High degree of intelligence: The machine display screen integrates many functions. It can not only accurately display the "real-time angle" and "feed amount" in pictures and numbers, but also has many functions such as "zero return", "low position lock", "fast and slow speed" and "battery display". It also has the function of automatic execution by digital input, which further enhances its intelligence.

[0017] The grinder has good stability: In order to match the high precision of the servo motor, the grinder adopts mechanical design methods such as linear slide rail assemblies, linear bearings, worm gears, and screw drives to reduce the assembly gap and the shaking degree of the grinding wheel.

[0018] This technology uses a rectangular frame motor mounting frame, which makes the installation of the main motor more secure and stable, and realizes the rigid installation of the main motor. In combination with designs with good rigidity such as the gantry and door-shaped mounting frame, the rigidity of the grinding wheel is improved, the flexible deformation is reduced, and the stability of the grinding wheel of the whole machine is improved to a higher level.

[0019] This technology changes the rotating mechanism into a worm gear transmission combined with a servo motor drive, which has a high-precision and high-stability mechanical transmission. The self-locking effect of the worm gear improves the rigidity of the practice gantry, allowing the gantry to rotate relatively and quickly maintain its position after the rotation is adjusted into place, thus solving the problem of main motor shaking. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 Schematic diagram of grinding the top and side surfaces of the rail.

[0021] Figure 2 This is a three-dimensional diagram of a grinding machine.

[0022] Figure 3 for Figure 2 A partial enlarged view of point A in the middle.

[0023] Figure 4 for Figure 2 A partial enlarged view of point B in the middle.

[0024] Figure 5 for Figure 2 A partial enlarged view of point C in the middle.

[0025] Figure 6 It is a longitudinal full section view.

[0026] Figure 7 This is the control schematic diagram of this device.

[0027] Figure 8 This is a physical display diagram of the electronic control system screen.

[0028] Fig. 9 This is a physical display diagram of the electronic control system screen.

[0029] In the figure: 100 rack, 110 rail wheel, 111 insulating sleeve, 112 manual brake assembly, 113 flange, 120 limit wheel, 130 bolt, 140 insert, 200 lithium battery, 210 storage platform, 300 door-shaped mounting frame, 310 linear guide rail assembly, 320 touch screen, 330 screw drive mechanism, 331 bracket, 332 handwheel, 340 longitudinal beam, 400 gantry, 410 rotating mechanism, 430 linear guide column, 420 linear bearing, 411 servo motor II, 412 worm gear, 413 large gear, 415 small gear, 414 rotating shaft I, 416 rotating shaft II, 500 motor mounting frame, 510 main motor, 520 bottom frame plate, 530 grinding wheel, 540 protective cover, 600 lifting mechanism, 610 lead screw, 620 thread sleeve, 630 bevel gear, 640 servo motor I. DETAILED DESCRIPTION

[0030] This embodiment discloses a vertical rail grinder powered by lithium battery and capable of rapid disassembly. By optimizing the frame structure, the walking structure, the rotation, lifting, translation and other structural designs, and installing a PLC touch screen operating system, high precision and intelligent improvement are achieved. The equipment adopts a modular design method, and the whole machine can be quickly disassembled and assembled, which is convenient for on- and off-road and transportation, improves the intelligence level of the vertical rail grinder, realizes automation, improves grinding accuracy, improves operating efficiency, reduces the labor intensity of employees, and reduces environmental pollution. The equipment can be used for preventive and repair grinding operations on the top and inner sides of different types of rails.

[0031] The understanding of this embodiment requires full reference to the attached manual Figure 1 To Attachment Fig. 9 conduct.

[0032] refer to Figure 2 The grinder can be divided into several parts, including grinding wheel, main motor, lifting mechanism, rotating mechanism, translation mechanism, frame, touch screen, control box, control box and lithium battery. The driving motors in the lifting mechanism and rotating mechanism are controlled by servo motors, which are controlled by the program of the electronic control system and have the advantage of closed-loop control.

[0033] The rack 100 is designed as a four-track wheel along the track and is manually pushed. The rack includes four track wheels 110, each of which is provided with and covered with an insulating sleeve 111, which can ensure that each track wheel is insulated from the rack, prevent static electricity or weak current interference between the two, and ensure the safe operation of the automatic control.

[0034] A lateral limiting wheel 120 is arranged on the frame corresponding to each rail wheel for lateral limiting, which limits the lateral position of the rail to avoid derailment. The four rail wheels are placed on the rail so that the frame has the ability to move linearly on the rail.

[0035] On one side corresponding to each rail wheel 110, refer to Figure 5 In the middle, that is, on the other side away from the lateral limiting wheel 120, a flange 113 is provided on the rail wheel, and the flange limits and guides the rail on the inner side.

[0036] Furthermore, a manual brake assembly 112 is disposed at one or both rail wheels 110. The manual brake assembly is operated by a wrench to temporarily lock the rail wheel 110 to prevent it from slipping, which is crucial when working on a non-horizontal rail section.

[0037] Furthermore, an insert 140 is provided at each of the four corners of the frame 100. The insert is an optional function, for example, a sunshade can be built, which is very important for outdoor construction, especially in the hot summer.

[0038] The frame 100 can be split into two sections, including two left and right sub-frames, and can be quickly assembled by plugging steel pipes and fixing with bolts 130. The assembled frame is arranged in a stretcher shape. It can be quickly disassembled and assembled. When transporting, the nuts are loosened, the bolts are pulled out, and the machine is split into two for easy transportation. When grinding is required, the two split frames are plugged in, the holes of the two halves of the frame are aligned, the bolts are inserted, and the nuts are tightened to achieve quick assembly.

[0039] A lithium battery 200 is fixedly installed on one of the sub-frames, and a storage platform 210 is provided. The storage platform can be used to place temporary tools, etc. in the working state. The storage platform 210 is fixed to the steel pipe of the sub-frame by a clamp, and other methods such as welding can also be used. The existence of the storage platform 210 can also enhance the overall rigidity of the frame and resist deformation of the frame.

[0040] A door-shaped installation frame 300 is installed on another sub-frame through a translation mechanism. Specifically, a square steel pipe 150 is sleeved and welded or bolted on the crossbeam of the sub-frame, that is, the square steel pipe is fixed outside the circular steel pipe to form an installation platform for the linear slide rail assembly, and the strength of this part is locally strengthened.

[0041] The door-shaped mounting frame 300 spans across two rails (not shown in the figure), and the length direction of the rails extends in the longitudinal direction. Figure 2 The longitudinal marking is shown. Specifically, the gate-shaped mounting frame 300 is formed by bending and welding a steel pipe, and is mounted on the square steel pipe 150 at the bottom end of the gate-shaped mounting frame 300 through four sets of linear guide rail assemblies 310. That is, the linear guide rails are fixedly mounted on the two square steel pipes of the sub-frame, and the linear slider is mounted on the gate-shaped mounting frame. The linear slider and the linear guide rail are matched to achieve high-precision linear sliding matching, wherein the linear slider and the linear guide rail together constitute the linear guide rail assembly 310.

[0042] A space for a gantry 400 is formed inside the door-shaped installation frame 300 for installing the gantry, a touch screen and other functional components.

[0043] The above-mentioned door-shaped mounting frame 300 is composed of two sub-frames and a crossbeam, and has a three-dimensional structural rigid frame, and is movably mounted at the lower end of the door-shaped mounting frame through four sets of linear guide rail assemblies. The touch screen 320 is fixed at the upper position of the door-shaped mounting frame, which is convenient for the operator's operating position.

[0044] Furthermore, a set of screw transmission mechanism 330 is installed between the bottom end of the door-shaped mounting frame 300 and the sub-frame of the frame, wherein the screw in the screw transmission mechanism is rotatably mounted on the sub-frame through a bearing assembly, and is arranged longitudinally, wherein the thread sleeve sleeve in the screw transmission mechanism 330 is fixedly mounted on the bottom of the door-shaped mounting frame 300, and the door-shaped mounting frame is driven to move in the lateral direction through the screw transmission mechanism. A sprocket is also installed at the end of the screw in the screw transmission mechanism, and a hand wheel is connected through a chain drive, and the hand wheel 332 is installed on a bracket 331, which is a cantilever bracket extending from the sub-frame and welded and fixed, and a chain transmission mechanism is installed inside, and the screw is manipulated by the hand wheel to control the lateral displacement of the above-mentioned door-shaped mounting frame. This operation is used to adjust the relative position of the grinding head and the rail to be polished.

[0045] The above-mentioned four sets of linear slide rail assemblies 310 use commonly used slide rails in machine tool equipment as linear slide rails, linear sliders as support, and use professional high-precision screw transmission structure as the control drive rod, which effectively eliminates the longitudinal gap, and the transmission is smooth and high-precision, meeting the requirements of various grinding positions on the rails to be ground.

[0046] The frame 100 is only used as a supporting component, and two linear guide rails are installed on the upper part. The linear guide rails are assembled using a vernier caliper for measurement, and the parallelism can be controlled within 0.2 mm. The precision linear slider that matches the linear guide rail eliminates the longitudinal gap after installation, and the overall longitudinal gap is basically eliminated. The machine has no longitudinal fluctuation, and the grinding accuracy is improved.

[0047] The mounting frame of the main motor 510 is located in the internal space of the gantry, and a lifting mechanism 600 is installed between the gantry and the motor mounting frame. The motor mounting frame 500 is driven to be lifted or lowered in the height direction by the lifting mechanism, and the lifting process should be smooth and reliable.

[0048] The lower ends of the gantry 400 are mechanically connected to the longitudinal beams 340 of the door-shaped mounting frame at adjustable angles through the rotating mechanism 410. Figure 6, the two vertical rods on the gantry 400 serve as vertical linear guide columns 430, and a linear bearing 420 is installed on the linear guide column 430, and the two linear bearings are fixedly installed on the motor mounting frame 500 at the same time, and together they constitute a lifting guide assembly. The motor mounting frame 500 is a rectangular frame formed by a combination of steel plates, and the main motor 510 is fixedly installed in the rectangular frame, that is, the motor mounting frame 500 has a vertical sliding ability under the sliding assembly of the linear bearing 420. The main motor 510 is vertically arranged, and the main motor shaft is arranged downward, and has a certain inclination angle design. Specifically, the bottom frame plate 520 of the above-mentioned motor mounting frame 500 is not horizontally arranged, but has an inclination angle design in the horizontal direction. For example, in this embodiment, the inclination angle β is about 6°, and a grinding wheel 530 (generally a grinding wheel) is installed on the power shaft of the main motor 510. The grinding wheel is a grinding wheel of a specially customized size for grinding and correcting rails.

[0049] In this technical solution, the motor mounting frame 500 is designed as a rectangular frame, which is enclosed by vertical plates on both sides and upper and lower top frame plates and bottom frame plates. It is CNC-processed and assembled with thick steel plates for fixed installation, and has higher installation accuracy.

[0050] Furthermore, a protective cover 540 is provided on the outside of the grinding wheel 530 , and the protective cover is fixed to the motor mounting seat by butterfly bolts, and the protective cover is used to ensure safety during the grinding operation.

[0051] The design features of the above-mentioned motor mounting frame 500 and the installation method of the main motor can effectively meet the installation strength requirements of the main motor and the grinding wheel. Even when the main motor and the grinding wheel rotate at high speed and effectively grind the rails, resonance or vibration between the grinding wheel and the rails will not occur.

[0052] The reliability of the installation is greatly improved by this specially designed main motor installation method.

[0053] The grinding wheel and its driving motor of the traditional grinder mostly adopt a fixed cantilever structure. Due to the large size of the head component, the grinding wheel is far away from the rotation axis (about 300mm). When the grinding wheel contacts the rail, the grinding wheel applies force vertically downward to the rail, and the rail gives the grinding wheel a large upward reaction force. When the rail has corrugation or other defects or the grinding wheel is unbalanced, the force on the grinding wheel changes at any time, and the grinding wheel vibrates slightly up and down, affecting the grinding quality. Therefore, the design is improved to adopt a gantry frame structure, and by making the main motor and the main rotation line of the grinding wheel non-perpendicular to the surface of the rail, the rotation center axis of the grinding wheel is no longer perpendicular to the grinding table, which can improve the rigidity of the grinding wheel, eliminate the slight vibration of the grinding wheel, and improve the grinding accuracy.

[0054] In this embodiment, a combination of linear sliding bearings and linear guide rails is used between the motor mounting frame and the gantry, thereby improving the stability and accuracy of the linear motion of the motor and the grinding wheel.

[0055] The lifting mechanism 600 is driven by a motor. Specifically, the lifting mechanism 600 includes a lead screw 610, a thread sleeve 620, a bevel gear 630 and a servo motor I 640, wherein the lead screw and the thread sleeve are mechanically matched, the thread sleeve 620 is rotatably mounted on the cross beam of the gantry through a bearing, and the bottom end of the lead screw 610 is movably connected to the motor mounting frame 500 through a rotatable hinge structure 611, and the lead screw 610 can be raised or lowered in height by rotating the thread sleeve, and the motor mounting frame 500 is driven to be raised or lowered in height, and further drive the position adjustment of the grinding wheel in height direction. A bevel gear 630 is fixedly mounted on the thread sleeve, and the bevel gear is matched with a bevel gear, which is mounted on the motor shaft of the servo motor I 640, and the servo motor I 640 is horizontally mounted on the cross beam of the gantry 400, and the bevel gear transmission is driven by the servo motor I, and the movement of the lead screw thread sleeve drives the lifting and lowering of the motor mounting frame.

[0056] The function of the servo motor I640 is to control the lifting and lowering of the motor mounting frame, so it is also called a lifting motor.

[0057] The lifting stroke range of the grinding wheel is 180mm. Within the stroke range, the grinding wheel can be manually raised or lowered by pressing the button, and the minimum scale of the lifting is 0.01mm. When the button is pressed, the current position of the grinding wheel is displayed in real time. In order to facilitate reading, there is also a "zero" button, which can quickly return to zero with one button. There are also fast mode and slow mode, which can adjust the speed of the grinding wheel lifting and lowering, and set text prompts to remind the user of the current speed mode. The lifting value can also be achieved through manual input. For example, if you enter 30 in the lifting box and press the execute button, the rising indicator light will light up, the grinding wheel will rise 30mm, and the change in the rising amplitude will be displayed at the current position. The physical picture of the electronic control system screen is as follows Figure 8 shown.

[0058] The rotating mechanism 410 is installed between the gantry and the door-shaped installation frame, and is located at the low point of the two. The rotating structure 410 includes a servo motor II 411, a worm gear 412, a large gear 413, a small gear 415, a rotating shaft I 414, and a rotating shaft II 416, wherein the rotating shaft 414 is a short shaft, which is installed at the longitudinal beam 340 of the door-shaped installation frame through a bearing, and the rotating shaft I 414 is rotatably pivotally connected to the door-shaped installation frame, and the small gear 415 and the worm gear are respectively installed at both ends of the rotating shaft. At the same time, the rotating shaft II 416 is fixedly connected to the lower end of the gantry, and is rotatably mechanically connected to the door-shaped installation frame 300, and this connection enables the gantry to have a rotating pivot axis relative to the door-shaped installation frame 300. A large gear 413 is fixedly mounted on the rotating shaft II 416. The large gear 413 has a one-third sector profile and is an incomplete gear. The large gear 413 is fixedly mounted on the rotating shaft II 416 through a flat key and the two rotate synchronously. A small gear 415 is meshed with the large gear. The small gear 415 is mounted on the door-shaped mounting frame through the rotating shaft I. The rotating shaft I of the small gear is synchronously connected to the worm wheel in the worm gear through a flat key, and the worm is connected to the motor. The servo motor II 411 drives the worm gear and the gear assembly to achieve the adjustment of the inclination angle of the electric grinding head. At the same time, the worm gear has a position self-locking function, which can achieve stable docking at any position while adjusting. The design of the rotating mechanism 410 makes the position angle of the grinding wheel in the horizontal vertical plane adjustable, meeting the working requirements of the grinding wheel rotation range of -20 degrees to 80 degrees.

[0059] The function of servo motor II411 is to control the angle adjustment of the motor mounting frame, so it is also called a rotary motor. Figure 7 .

[0060] In order to achieve the accuracy of display and control, a worm gear transmission mechanism is designed to complete the rotation of the main motor to the grinding wheel. Its advantages are that the input angle and the output angle are in a fixed ratio, and the display and control are relatively simple. The specific design is a set of worm gear transmission, with a transmission ratio of 1:40 and a transmission efficiency of 0.4; with a set of spur gear transmission, its transmission ratio is 1:2.5 and the transmission efficiency is 0.95.

[0061] In this embodiment, in the horizontal vertical plane, for example, Figure 1 The grinding wheel has a rotation range of -20 to 80 degrees. Within the range, the grinding wheel can be manually rotated left or right by pressing a button. The minimum rotation scale is 0.1 degrees. When the button is pressed, the screen displays the current position of the grinding wheel in real time. To facilitate understanding of the grinding wheel position, the display not only displays the value, but also lights up near the grinding wheel outline. The rotation angle of the electronic control system screen and the wheel-type rotation structure of the grinder are shown in the figure. Figure 7 shown.

[0062] The rotation angle can also be manually input. If you enter 30 in the rotation box and press the execute button, the clockwise rotation indicator will light up, and the device will stop after rotating 30° clockwise. The rotation amplitude change will be displayed on the current angle. Similarly, the manual input of the rotation angle of the electronic control system screen is as follows: Fig. 9 shown.

[0063] Traditional rotary mechanisms mostly use a push rod to push a certain point on the circumference to complete the angle change of the grinding wheel. The structure is relatively simple, but the movement of the push rod on the circumference is not linear motion, resulting in the machine angle adjustment input and output being disproportionate, unable to set the input value, and inaccurate electric control.

[0064] Therefore, the rotating structure 410 is specially designed, and a worm gear is introduced to quantify the input. At the same time, the worm gear transmission is relatively large, and the rotation input is more labor-saving. At the same time, the worm gear transmission has a position self-locking function and can be docked at any position without other program settings.

[0065] The control box 700 contains a controller, relays and control switches. The integrated functions and simple panel, with two switches for start and stop, facilitate the on-site operation of the operator. The controller also has an overcurrent protection function to further protect the components in the system. After actual grinding tests, the average current of the motor in daily construction is 60-70A, so the first condition of the first-level overcurrent protection is set to a current exceeding 80A. In order to prevent the activation of instantaneous high-load overcurrent protection, the second condition of the first-level overcurrent protection is set to a duration of more than 3 seconds. Only when both conditions are met at the same time can the overcurrent protection be activated.

[0066] The control box is controlled by PLC, please refer to the control schematic diagram Figure 7 During actual grinding operation, the lifting position and rotation angle of the grinder are adjusted according to different grinding ranges and grinding requirements to remove defects on the rail surface and repair the rail profile.

[0067] The main grinding area of ​​this equipment is the non-working surface of the rail top and the 0-60° part of the working surface. It can also grind the part below 60° of the working surface of non-turnout lines (the main working area of ​​the turnout grinder).

[0068] The electronic control is specially designed with a low-position locking function. After determining the lowest point for grinding, press the button to lock the lowest point of the grinding wheel. At this time, the lifting and lowering operations can only be performed above this set value. If it is locked downward, it cannot be operated. The operation can only be continued after manual locking. There are text prompts after operating the buttons.

[0069] The program function settings of the equipment's electronic control system are as follows: During grinding operation, the grinding wheel of the grinder is started and stopped by an independent switch.

[0070] The grinding wheel can be raised or lowered in height direction and can be rotated at an angle within the numerical plane perpendicular to the rail.

[0071] The lifting and rotating angles are set to manual control mode.

[0072] One-button emergency stop during operation.

[0073] 1. Grinding wheel zero position locking (1) The grinding wheel lifting stroke range is 0-190mm. During the grinding wheel lifting process, the zero position can be manually locked at any position; (2) Once the zero position is manually locked, the grinding wheel can only rise and fall in the space above the zero position (for example, after locking the zero position at 30mm, the grinding wheel can only rise and fall between 30-70mm). Once the grinding wheel reaches the zero position, it must stop and cannot continue to fall; (3) After the zero position is locked, the scale is counted upward from the zero position to display the distance scale from the zero position. For example, if the zero position is locked at a stroke of 30 mm, if it rises 1 mm, it will display 1 mm, and if it rises 10 mm, it will display 10 mm, with an accuracy of 0.01 mm.

[0074] Grinding wheel lifting and rotation angle control program interface reference Figure 8 and Fig. 9 .

[0075] (1) Grinding. Press the manual button to start or stop the grinding wheel head.

[0076] (2) Raising and lowering the grinding wheel. Within the travel range, the grinding wheel can be raised or lowered manually by pressing the button (press and hold the switch to continue to rise or fall, and release to stop); the zero position can be locked during the raising and lowering process. After the zero position is locked, the grinding wheel can only rise or fall above the zero position; (3) The grinding wheel lifting speed is divided into two levels: fast and slow.

[0077] (4) Grinding rotation angle. When the parallel position between the grinder and the rail is zero (no locking is required), the grinding wheel of the grinder can rotate clockwise ±90° and counterclockwise ±90° along the vertical direction on both sides of the rail. The rotation angle has an automatic rotation function (relative to the zero position, after manually entering a specific angle value, the circuit controls the grinding wheel to automatically rotate to the specified angle and then stop. For example: if you enter 30° or -30° on the screen, the grinding wheel will automatically rotate to 3 / 0° or -30° and stop.) Button Settings There are two start and stop buttons to control the grinding wheel head (1 to control start, 1 to control stop), and the reset button can be used to control the start and stop of the grinding wheel.

[0078] There are two buttons to control the raising and lowering of the grinding wheel, one for raising and one for lowering, which respectively control the raising and lowering of the grinding wheel (press and hold the switch to raise or lower it all the time, and release it to stop).

[0079] There are two buttons to control the rotation angle, one +90 and one -90, which control the grinding wheel to rotate +-90 degrees respectively (press and hold the switch to rotate counterclockwise or clockwise, and stop when you release it).

[0080] 1 zero position locking button, which can lock the zero position at any time during operation. The button adopts a self-locking switch (press the button once to drop it, press it again to pop it up); 1 power (emergency stop) switch, which controls the power supply of the grinder and can be stopped at any time during operation; The main power switch controls the on and off of the main circuit.

[0081] There is a button for switching between fast and slow gears for lifting the grinding wheel to switch the lifting speed of the grinding wheel.

[0082] Touch screen interface design and display content: 1. Real-time travel scale of grinding wheel lifting (after zero position is locked, the scale starts from the zero position and moves upwards to display the distance scale from the zero position. For example, if the zero position is locked at the travel position of 30mm, if it rises 1mm, it will display 1mm, and if it rises 10mm, it will display 10mm), accurate to 0.01mm, and there are icons for rising or falling, such as up and down arrows (two scale displays, one scale display in the non-zero position locked state, and the other scale display in the zero position locked state.) 2. The real-time angle and status of the rotation angle, clearly indicating whether the status is clockwise or counterclockwise (refer to the car speed display dashboard); 5. Remaining power and low power prompts; 6. Over-current, over-temperature, over-voltage, under-voltage and phase loss prompts; 7. The controller is equipped with lighting.

[0083] This equipment uses lithium batteries as its power source. To meet the requirements of skylight point construction, its capacity must ensure that the whole machine can work continuously for 3 hours. According to actual tests, a single 72V45Ah battery is selected. Each battery can meet the requirements of continuous construction for more than 1.5 hours. Each machine is equipped with two batteries to meet the requirements of continuous construction for 3 to 4 hours. The battery is a quick-change structure, and the battery can be replaced within one minute, which does not delay normal construction and can share the weight of the battery.

[0084] The battery not only has a hardware protection board to balance the power supply of the battery cells inside and protect real-time use, but also has an integrated battery management system to monitor battery parameters through software and provide real-time protection.

[0085] The daily battery display contents include: current, voltage, remaining battery power, cumulative battery usage time, etc.

[0086] Five major functions of battery hardware protection: high and low temperature protection during charging, single-cell overcharge / over-discharge voltage protection, charge / discharge overcurrent protection, cell balancing function, short circuit protection, etc.

[0087] Another advantage of this embodiment is that the stability of the grinding machine movement is improved through the mechanical structure design: The use of linear guide rails as the main body of the grinding wheel translation structure effectively eliminates the longitudinal gap, and the transmission is smooth and high-precision, meeting the requirements of various grinding positions. With the screw drive, the overall longitudinal gap is basically eliminated, the machine has no longitudinal fluctuation, and the grinding accuracy is improved.

[0088] The gantry frame structure is used in the lifting mechanism to improve the rigidity of the grinding wheel. Two rotating mechanisms are used as rotating support points to improve the rigidity of the grinding wheel, eliminate slight vibration of the grinding wheel, reduce flexible deformation, and improve grinding accuracy.

[0089] The lifting and rotating mechanisms of the grinder are all changed to servo motor control. The motor rotation is controlled by PLC, and the step angle of a single rotation is subdivided, and its accuracy is improved by more than ten times.

[0090] The screen displays the angle and up and down position of the grinding wheel in real time. When the button is operated, the movement of the grinding wheel is displayed by arrows on the screen.

[0091] In summary, this embodiment also has the advantages of improved grinding quality, convenient operation and low use cost.

[0092] The grinding data is quantified and all concentrated on the control panel, making the whole grinding process visible and controllable. The feed and angle adjustment are driven by servo motors, which improves the accuracy of the grinding position and the precision of the grinding feed, and the overall grinding efficiency is increased by more than 20%, saving precious "window time".

[0093] The whole machine uses lithium batteries as the power source, avoiding the problem of internal combustion engine starting difficulties due to factors such as temperature or altitude. Secondly, all operating actions are displayed on the operation panel, which is convenient for operators to identify and read, so that operators have a comprehensive data grasp of the grinding work and the operation is easier.

[0094] Improve the working environment for employees and enhance their comfort: It uses lithium battery clean energy, has no tail gas emissions, the motor runs smoothly, and the ear noise is low, which improves the working comfort of employees.

[0095] It is driven by electric energy, which saves significant fuel consumption and has low cumulative operating costs.

[0096] The embodiments described above are merely descriptions of preferred implementations of the present invention and are not intended to limit the scope of the present invention. Without departing from the spirit of the present invention, various modifications and improvements to the present invention by relevant technical personnel in the field should fall within the scope of protection determined by the claims of the present invention.

Claims

1. A lithium battery fully automatic rail grinding machine, comprising a grinding wheel, a main motor, a motor mounting frame, a lifting mechanism, a rotating mechanism, a translation mechanism and a frame, a gantry, a door-shaped mounting frame, and an electric control system, characterized in that: Four rail wheels (110) are arranged on the frame, and flanges and lateral limiting wheels (120) are arranged on the edges of the rail wheels, and insulating sleeves (111) are arranged on the surfaces of the rail wheels, and a brake assembly is arranged at one or two of the rail wheels (110), so that the frame is pushed forward along the steel rail, and the grinder is stopped at any position of the steel rail by operating the brake assembly; The frame (100) is mounted with a door-shaped mounting frame (300) via a translation mechanism; The two sides of the lower end of the gantry (400) are mechanically connected to the longitudinal beam (340) of the gate-shaped installation frame (300) via a rotating mechanism (410) with adjustable angles; the rotating structure (410) comprises a servo motor II (411), a worm gear (412), a large gear (413), a small gear (415), a rotating shaft I (414), and a rotating shaft II (416), wherein the rotating shaft I (414) is mechanically mounted on the longitudinal beam (340) of the gate-shaped installation frame, and the rotating shaft II (416) is fixedly connected to the gantry and is connected to the gate-shaped installation frame ( 300) is movably matched, the rotating shaft I (414) is fixedly connected to the pinion (415), the large gear (413) is fixedly installed on the rotating shaft II (416), the pinion (415) is meshed with the large gear, the rotating shaft I (414) is key-connected with the worm gear, and the worm is mechanically connected to the motor shaft of the servo motor II (411); the servo motor II is electrically connected to the electronic control system, and the grinding rotation angle is adjusted under the command of the electronic control system. If the parallel position of the rail is set to zero, the grinding wheel can rotate within a range of ±90° in the vertical direction on both sides of the rail; A lifting guide assembly and a lifting mechanism (600) are installed between the gantry and the motor mounting frame, wherein the lifting mechanism (600) comprises a lead screw (610), a thread sleeve (620), a bevel gear (630) and a servo motor I (640), wherein the lead screw and the thread sleeve are mechanically matched, the thread sleeve (620) is rotatably mounted on the crossbeam of the gantry via a bearing, the lead screw (610) is movably connected to the motor mounting frame (500), the thread sleeve is mechanically connected to the bevel gear (630), the bevel gear is matched with a bevel gear, the bevel gear is mounted on the motor shaft of the servo motor I (640), and the servo motor I is mounted on the crossbeam of the gantry (400), the servo motor I is electrically connected to an electric control system, and under the command of the electric control system, the motor mounting frame (500) is lifted or lowered in the height direction, and the lifting range is between 0 and 190 mm; The main motor (510) equipped with a grinding wheel is fixed in the frame of the motor mounting frame (500), and the motor shaft of the main motor is arranged downward and has an inclination angle β in the vertical plane of the vertical rail.

2. A lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: Within the range of the lifting action, the height of the grinding wheel can be raised or lowered by manually pressing the button. The zero position can be locked during the lifting process. After the zero position is locked, the grinding wheel can only rise or fall above the zero position.

3. A lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The large gear is an incomplete gear with a one-third sector profile.

4. The lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The translation mechanism includes a linear slide rail assembly and a screw transmission mechanism. The lower end of the door-shaped mounting frame is mechanically connected to the frame through four sets of linear slide rail assemblies. The screw in the screw transmission mechanism is rotatably mounted on the frame through a bearing assembly and is longitudinally arranged. The wire sleeve in the screw transmission mechanism is fixedly mounted on the door-shaped mounting frame.

5. A lithium battery fully automatic rail grinding machine according to claim 4, characterized in that: A sprocket is also installed at the end of the lead screw and is connected to a handwheel through a chain transmission. The handwheel is installed on a bracket, which is a cantilever bracket extended from the subframe and fixed by welding, and a chain transmission mechanism is installed inside.

6. The lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The lifting guide assembly comprises two linear guide columns (430) mounted on the gantry (400) and a linear bearing mounted on the motor mounting frame (500), wherein the linear guide columns and the linear bearing are in sliding cooperation.

7. The lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The touch screen is arranged above the door-shaped installation frame.

8. The lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The motor mounting frame is a rectangular frame formed by combining steel plates.

9. The lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The frame comprises two left and right sub-frames, which are detachably connected by steel pipe plugging and bolt fixing.

10. The lithium battery fully automatic rail grinding machine according to claim 1, characterized in that: The lithium battery, storage platform and control box are fixedly installed on the rack.

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