Turnout small machine grinding acceptance evaluation method

Abstract

The invention discloses an acceptance evaluation method for grinding of a small turnout machine, and belongs to the field of turnout profile grinding. Further analyzing each piece of test mark data of the turnout according to the collected turnout data, and judging a turnout grinding result according to an analysis result. According to the method, the statistics theory is applied, the grinding acceptance evaluation method for the small turnout machine is innovatively provided, the grinding acceptance evaluation model for the small turnout machine is established, comprehensive acceptance evaluation is carried out on the grinding effect of the small turnout machine in an omnibearing and multi-angle mode, and an acceptance method is provided for grinding acceptance of a turnout using small machine grinding equipment on site.

Description

Technical Field

[0001] The invention relates to the field of profile grinding of turnouts, and is an acceptance and evaluation method for grinding of turnouts by a small machine, and in particular is an evaluation method for acceptance of grinding results of turnouts by using a small machine grinding device. Background Art

[0002] As the service time of the turnout increases, the shape and condition of the turnout gradually deteriorate, causing fatigue damage or even serious damage to components such as the point rail and switch core, which greatly affects the service life of the turnout.

[0003] Rail profile grinding is one of the effective means to repair the rail profile and eliminate rail surface defects. The rail profile grinding technology of large grinding vehicles has been fully applied in the railway system. However, due to the operating conditions of large turnout grinding vehicles and the power of the grinding vehicles, it still cannot meet the on-site operation needs. At this time, a small machine can be used to grind the turnout to solve this problem. At present, some railway bureaus have carried out relevant turnout small machine grinding operations, but have not judged the quality of the turnout after grinding, and the quality after grinding is difficult to control. Summary of the invention

[0004] In view of the lack of acceptance methods for the grinding of small turnout machines, the present invention proposes an acceptance and evaluation method for the grinding of small turnout machines, which is an acceptance and evaluation method for the grinding of small turnout machines on conventional speed lines from eight aspects: rail profile, rail surface defects, wheel-rail contact light band, joint, weld and rise and fall cutter point smoothness, reduction value, rail surface roughness, grinding surface width and grinding surface blue band, filling the gap in the domestic conventional speed line turnout machine grinding acceptance standards.

[0005] The inspection and evaluation method for the grinding of a small turnout machine of the present invention is implemented by the following steps:

[0006] Step 1: Collect basic data on the turnouts that have been polished by small machines, including rail profile, rail surface defects, wheel-rail contact light band, rail joints, welds, smoothness of the rise and fall points, reduction value, roughness, polished surface width and blue band on the polished surface.

[0007] Step 2: Score the turnout data collected in step 1;

[0008] 1) Rail profile scoring is weighted by mean and standard deviation, which is:

[0009]

[0010] In the formula, G i GQI is the comprehensive score of the silhouette index; i is the average GQI value of the turnouts in this group tested; S is the sample standard deviation of the GQI values ​​of the turnouts in this group tested.

[0011] 2) The scoring method for rail surface diseases is:

[0012] Rail surface disease score = 100 - number of rail surface diseases / total number of measuring points * 100.

[0013] 3) The wheel-rail contact light band score is obtained by weighting the light band width score and the light band position score, which is:

[0014] Light band score = light band width score × 0.6 + light band position score × 0.4.

[0015] 4) The scoring method for the smoothness of joints, welds and cutting points is as follows:

[0016] Smoothness score = 100 - number of smoothness violations / total number of inspections*100.

[0017] 5) The scoring method for reducing the value is the average value:

[0018] Point rail 20mm reduction score

[0019] Point rail 50mm reduction score

[0020] Gap between point rail, movable center rail and slide bed

[0021] Fixed frog reduction value

[0022] Lower value

[0023] Where, d and e are the deviations between the actual reduction value and the standard reduction value at the 20mm and 50mm sections of the point rail, in mm; f i is the clearance between the slide plate of the point rail and the movable heart rail at different sections, in mm; j i It is the deviation between the actual reduction value and the standard reduction value at different cross-section positions of the fixed frog, in mm.

[0024] 6) Roughness score R is:

[0025]

[0026] 7) The grinding surface width is scored by the average value. The scoring method for the grinding surface width in each area of ​​the rail surface is:

[0027]

[0028] Where W1 is the grinding surface width in the 10mm area on both sides of the rail top centerline, W2 is the grinding surface width in the area 10mm to 25mm from the rail top centerline, W3 is the grinding surface width in the remaining areas, W4 is the maximum change of adjacent grinding surfaces, ∑Y i It represents the sum of the scores of the width variation of different areas of the rail top centerline and adjacent grinding surfaces.

[0029] 8) The scoring method for blue ribbon on rail surface is:

[0030] The blue band score of the polished surface = 100 - the number of blue bands on the polished surface / the total number of measuring points * 100.

[0031] Step 3: Evaluation of turnout grinding results.

[0032] The evaluation indexes of ordinary speed turnout grinding include rail profile, rail surface disease, wheel-rail contact light band, joint and weld start-stop smoothness, reduction value, rail surface roughness, grinding surface width and grinding surface blue band, and the full score is 100 points. Among the scores, the GQI score of rail profile accounts for 30%, rail surface disease 20%, wheel-rail contact light band 15%, joint and weld start-stop smoothness 10%, reduction value 10%, rail surface roughness 5%, grinding surface width 5%, grinding surface blue band 5%. The comprehensive score of turnout grinding after GQI is 30%, rail surface disease 20%, wheel-rail contact light band 15%, joint and weld start-stop smoothness 10%, reduction value 10%, rail surface roughness 5%, grinding surface width 5%, grinding surface blue band 5%. z The sum of each verification score multiplied by the weight coefficient is:

[0033] G z =∑(score of each verification score×weight coefficient).

[0034] Step 4: Based on the conventional line turnout small machine grinding quality assessment results obtained by the above evaluation model, a test report is formed in combination with the test data.

[0035] The advantages of the present invention are:

[0036] 1. Acceptance and evaluation of the grinding of small turnout machines from multiple angles. Based on the reference to relevant existing inspection standards and documents, the patent of this invention uses statistical theory to innovatively propose a method for acceptance and evaluation of the grinding of small turnout machines, establishes a model for acceptance and evaluation of the grinding of small turnout machines, and comprehensively accepts and evaluates the grinding effect of small turnout machines from all directions and multiple angles, providing an acceptance method for the on-site acceptance of turnout grinding using small machine grinding equipment.

[0037] 2. Strong applicability and wide application scenarios. The patent of this invention can be applied to most of the turnout equipment on conventional lines in my country, and can be used for comprehensive acceptance and evaluation of turnout straight strands, turnout curved strands, complete sets of turnouts, and fixed-core and movable-core turnouts, with a wide range of application scenarios.

[0038] 3. Support the acceptance and evaluation of turnouts on conventional lines after operation by different grinding equipment. The patent of this invention supports the use of various types of small machine grinding equipment such as vertical grinders, turnout grinders and belt grinders, and can provide acceptance methods for their grinding acceptance. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 The present invention is a general flow chart of the acceptance and evaluation method for the grinding of a small turnout machine;

[0040] Figure 2 This is a diagram of the rail area division method. DETAILED DESCRIPTION

[0041] The present invention will be further described in detail below in conjunction with the accompanying drawings.

[0042] The present invention proposes an acceptance and evaluation method for the grinding of a small turnout machine based on the conventional speed turnout machine grinding acceptance standard given in Table 1 below.

[0043] Table 1 Acceptance criteria for grinding of small turnout machines for ordinary speed railway

[0044]

[0045]

[0046]

[0047] Based on Table 1, the acceptance evaluation method of the turnout small machine grinding of the present invention is as follows: Figure 1 As shown, the specific steps are:

[0048] Step 1: Collect basic data on the turnouts that have been polished by small machines.

[0049] The turnout data collected include: rail profile, rail surface defects, wheel-rail contact light band, rail joints, welds, smoothness of the rise and fall points, reduction value, roughness, grinding surface width and grinding surface blue band; the details are as follows:

[0050] (1) Rail profile

[0051] Detect the profile of MP1~MP10 rails, the profile of the 20, 50mm section of the pointed base rails and the profile of the 20, 40mm section of the frogs; mark the key section positions and use the rail profiler, section caliper, 5m steel tape measure and 20cm steel ruler for detection;

[0052] (2) Rail surface damage

[0053] Use depth gauge, hardness tester and 20cm steel ruler to detect surface defects of straight rails, curved rails or whole rails;

[0054] (3) Wheel-rail contact light zone

[0055] Measure one point on each of the four rails at the connection part of the entire set of turnouts for inspection; within the inspection range, use a 20cm steel ruler to visually inspect the width and position of the light band; if necessary, spray white self-spray paint (about 100mm along the rail length) at the inspection position after grinding for marking;

[0056] (4) Smoothness of joints, welds, and cutting points

[0057] Each type of joint and weld in the turnout is randomly inspected at one location; an electronic ruler, a 1m straight ruler, and a feeler gauge are used to visually check whether the light strip is abnormal and whether the joint has misaligned teeth;

[0058] (5) Reduce the value

[0059] Detect the 20 and 50mm section reduction values ​​of the point rail and the 20 and 40mm section reduction values ​​of the frog; mark the key section positions and use rail profiler, reduction ruler, 1m straight ruler, feeler gauge, section caliper, and 5m steel tape measure for detection;

[0060] (6) Roughness

[0061] At any position of each set of turnouts, the roughness of the rail grinding surface shall be tested at least twice using a roughness testing tool. During the test, the test shall be conducted on the same rail grinding surface within a range of 10 mm, in a direction perpendicular to the rail grinding marks, and at least 6 points shall be tested continuously.

[0062] (7) Grinding surface width

[0063] After the grinding operation of the turnout machine is completed, the maximum width of the rail grinding surface is measured using a steel ruler at any position in the turnout area.

[0064] (8) Polished surface with blue stripe

[0065] Use a 5m steel tape measure and a 20cm steel ruler to visually inspect the blue band on the polished surface of the turnout rail.

[0066] Step 2: Score the turnout data collected in step 1.

[0067] 1) Rail profile scoring

[0068] GQI (Grinding Quality Index) is the rail grinding quality index, which is currently widely used to evaluate the quality of rail profile. It represents the degree of fit between the measured profile and the designed profile. The higher the fit, the higher the GQI value, and its value ranges from 0-100.

[0069] The GQI comprehensive score is weighted by mean and standard deviation. The scoring formula is as follows:

[0070]

[0071] In the formula, G i GQI is the comprehensive score of the profile index (the value is between 0 and 100). The larger the value, the better the rail profile matches the design profile, the smaller the fluctuation, and the higher the profile quality. i is the average GQI value of the group of turnouts tested; i=1,2,.....,10 corresponds to the rail profiles of MP1~MP10; S is the sample standard deviation of the GQI value of the group of turnouts tested.

[0072] 2) Rail surface disease scoring

[0073] There are many types of rail surface diseases, the most common of which are scale damage, peeling and abrasion, which are important indicators affecting the service status of rails. Scoring is performed based on the damage ratio of each measuring point in each group of turnouts. The higher the value, the better the rail surface condition. The calculation formula is as follows:

[0074] Rail surface disease score = 100 - number of rail surface diseases / total number of measuring points * 100 (2)

[0075] 3) Wheel-rail contact light band scoring

[0076] The width of the light band on conventional railways should be maintained at 25-35mm, and the width of the light band from the inside should be 10-20mm. The higher the light band score, the more reasonable the width and distribution of the light band on the rail surface. The light band score is obtained by weighting the light band width score and the light band position score, as follows:

[0077] Light band score = light band width score × 0.6 + light band position score × 0.4 (3) For the light band analysis of conventional turnouts, it can be divided into straight strands, curved strands and the grinding of the entire group of turnsouts.

[0078] A. Straight stock

[0079]

[0080] Among them, the scoring method for the width and position of the left and right lateral light bands is:

[0081]

[0082] In the formula, a is the width of the light band, and b is the distance between the light band and the inner working edge. The light band of the straight point rail gradually transitions from the 20 to 50 mm section, and a complete light band is formed above the 50 mm section.

[0083] Then, the left and right thigh light band scores can be obtained through formula (3).

[0084] B. Qugu

[0085]

[0086] Scoring of the light band on the guide bend: The width of the light band on the guide bend is about 2 / 3 of the rail head area. The contact light band position of the upper rail on the curve is biased to the inside. The contact light band extends from the inside of the rail to the rail top area. The scoring method is:

[0087]

[0088] The n is the number of light band mutations or unreasonable distributions.

[0089] Scoring of the subthigh light band under the guide:

[0090] The position of the rail contact light band under the guide curve is centered or slightly outside the center. The scoring method is:

[0091]

[0092] C. Rating of the entire set of turnout light bands:

[0093]

[0094] 4) Smoothness score of joints, welds and cutting points

[0095] The smoothness requirement for joints, welds and cutting points is that the straightness of the rail top surface is 0 to -0.3, and "-" indicates a depression. The evaluation index for the smoothness of joints, welds and cutting points is the proportion of measuring points that meet the requirements. The higher the value, the better the straightness. The calculation formula is:

[0096] Smoothness score = 100 - number of smoothness violations / total number of inspections*100.

[0097] 5) Reduce the value score

[0098] The reduction value is an important parameter that affects the wheel-rail contact in the switch area. Reasonable reduction values ​​of the point rail and heart rail can achieve a smooth transition of loads in the switch and frog areas. The reduction value of the point rail relative to the basic rail is: -2mm / +3mm for a 20mm section, ±2mm for a 50mm section; the gap between the point rail, movable heart rail and slide bed is ≤2mm, and the reduction value of the fixed frog is <4mm.

[0099] The score of the reduced value acceptance project is calculated by the average value. The scoring formula is as follows:

[0100] Point rail 20mm reduction score

[0101] Point rail 50mm reduction score

[0102] Gap between point rail, movable center rail and slide bed

[0103] Fixed frog reduction value

[0104] Lower value

[0105] Where, d and e are the deviations between the actual reduction value and the standard reduction value at the 20mm and 50mm sections of the point rail, in mm, and f i is the clearance between the slide plate of the point rail and the movable heart rail at different sections, in mm, j i It is the deviation between the actual reduction value and the standard reduction value at different cross-section positions of the fixed frog, in mm.

[0106] 6) Roughness score

[0107] The roughness of the rail grinding surface should not be greater than 10μm. The roughness score is expressed by R. The roughness R score formula is as follows:

[0108]

[0109] 7) Grinding surface width

[0110] The grinding surface width score is calculated using the average value. The scoring formula for each area of ​​the rail surface is as follows:

[0111]

[0112] Where W1 is the grinding surface width in the 10mm area on both sides of the rail top centerline, W2 is the grinding surface width in the area 10mm to 25mm from the rail top centerline, W3 is the grinding surface width in the remaining areas, W4 is the maximum change of adjacent grinding surfaces, ΣY i It represents the sum of the scores of the width variation of different areas of the rail top centerline and adjacent grinding surfaces.

[0113] 8) Blue band on the rail surface

[0114] After the grinding operation is completed, the blue band on the rail grinding surface of each set of turnouts shall be checked. There should be no continuous blue band. The score is calculated based on the proportion of blue bands at each measuring point of each set of turnouts. The higher the value, the higher the grinding quality. The calculation formula is as follows:

[0115] The blue band score of the polished surface = 100 - the number of blue bands on the polished surface / the total number of measuring points * 100.

[0116] Step 3: Evaluation of turnout grinding results.

[0117] Since the wheel-rail relationship is one of the key indicators affecting the service life of rails, the GQI score of rail profile accounts for 30%, rail surface diseases 20%, wheel-rail contact light band 15%, joint and weld rise and fall point smoothness 10%, reduction value 10%, rail surface roughness 5%, polished surface width 5%, and polished surface blue band 5%.

[0118]

[0119] The evaluation indexes of ordinary speed turnout grinding machine are rail profile, rail surface disease, wheel-rail contact light band, joint and weld rise and fall cutter point smoothness, reduction value, rail surface roughness, grinding surface width and grinding surface blue band. The full score of 8 evaluation indexes is 100 points. The comprehensive score of each turnout machine after grinding is G z The sum of each verification score multiplied by the weight coefficient. That is:

[0120] G z =∑(score of each verification score×weight coefficient).

[0121] Step 4: Based on the quality assessment results of the grinding of small turnout machines on conventional lines obtained by the above evaluation model, a test report is formed in combination with the test data. At the same time, reasonable suggestions are provided for the grinding operation plan based on the actual situation, the operating capacity of the grinding equipment, the number of skylights, etc.

[0122] The acceptance and evaluation method for the grinding of turnouts by small machines of the present invention, for the turnouts that have completed the grinding by small machines, collects the data of various acceptance indicators, and refers to the "Acceptance Standards for Rail Grinding of Conventional Railways" (TJ / GW170-2021), "Rail Grinding Manual" (China Railway Group Industrial and Electrical Department 2020), "Conventional Railway Line Repair Rules" (TG / GW102-2019), "High-speed Railway Ballasted Track Line Maintenance Rules (Trial)" (TG / GW116-2013) and other standards combined with relevant statistical principles, and comprehensively evaluates the turnout status from multiple angles of wheelset, frame, and full-section of the car body, so as to achieve accurate judgment of the grinding quality of turnouts by small machines on conventional lines, thereby scientifically guiding the grinding and correction operations of turnouts, thereby reducing ineffective labor, avoiding excessive repairs as much as possible, and improving labor efficiency.

Claims

1. A method for acceptance and evaluation of the grinding of a small turnout machine, characterized in that: The specific steps are: Step 1: Collect basic data of the turnouts that have been polished by small machines, including rail profile, rail surface defects, wheel-rail contact light band, rail joints, welds, smoothness of the rise and fall points, reduction value, roughness, polished surface width and blue band on the polished surface; Step 2: Score the turnout data collected in step 1; 1) Rail profile scoring adopts the weighted method of mean and standard deviation, which is: In the formula, G i GQI is the comprehensive score of the silhouette index; i is the average GQI value of the turnouts in this group tested; S is the sample standard deviation of the GQI value of the turnouts in this group tested; 2) The scoring method for rail surface diseases is: Rail surface disease score = 100-number of rail surface diseases / total number of measuring points*100 3) The wheel-rail contact light band score is obtained by weighting the light band width score and the light band position score, which is: Light band score = light band width score × 0.6 + light band position score × 0.4 4) The scoring method for the smoothness of joints, welds and cutting points is as follows: Smoothness score = 100 - number of smoothness violations / total number of inspections * 100 5) The scoring method for reducing the value is the average value: Point rail 20mm reduction score Point rail 50mm reduction score Gap between point rail, movable center rail and slide bed Fixed frog reduction value Lower value Where, d and e are the deviations between the actual reduction value and the standard reduction value at the 20mm and 50mm sections of the point rail, in mm; f i is the clearance between the slide plate of the point rail and the movable heart rail at different sections, in mm; j i It is the deviation between the actual reduction value and the standard reduction value at different cross-section positions of the fixed frog, in mm; 6) Roughness score R is: 7) The grinding surface width is scored by the average value. The scoring method for the grinding surface width in each area of ​​the rail surface is: Where W1 is the grinding surface width in the 10mm area on both sides of the rail top centerline, W2 is the grinding surface width in the area 10mm to 25mm from the rail top centerline, W3 is the grinding surface width in the remaining areas, W4 is the maximum change of adjacent grinding surfaces, ∑Y i The sum of the scores representing the width variation of different areas of the rail top centerline and adjacent grinding surfaces; 8) The scoring method for blue ribbon on rail surface is: Blue belt score of polished surface = 100 - number of blue belts on polished surface / total number of measuring points * 100 Step 3: Evaluation of turnout grinding results; The full score of the eight evaluation indicators of ordinary speed turnout machine grinding is 100 points, including rail profile, rail surface disease, wheel-rail contact light band, joint and weld rise and fall cutter smoothness, reduction value, rail surface roughness, grinding surface width and grinding surface blue band. Among the scores, the GQI score of rail profile accounts for 30%, rail surface disease 20%, wheel-rail contact light band 15%, joint and weld rise and fall cutter smoothness 10%, reduction value 10%, rail surface roughness 5%, grinding surface width 5%, grinding surface blue band 5%; the comprehensive score of turnout machine after grinding GQI score is 30%, rail surface disease 20%, wheel-rail contact light band 15%, joint and weld rise and fall cutter smoothness 10%, reduction value 10%, rail surface roughness 5%, grinding surface width 5%, grinding surface blue band 5%. z The sum of each verification score multiplied by the weight coefficient is: G z =∑(each verification score×weight coefficient); Step 4: Based on the conventional line turnout small machine grinding quality assessment results obtained by the above evaluation model, a test report is formed in combination with the test data.

2. The inspection and evaluation method for grinding a small turnout machine as claimed in claim 1, characterized in that: The specific data collection location and method in step 1 are: (1) Rail profile Detect the profile of MP1~MP10 rails, the profile of the 20, 50mm section of the pointed base rails and the profile of the 20, 40mm section of the frogs; mark the key section positions and use the rail profiler, section caliper, 5m steel tape measure and 20cm steel ruler for detection; (2) Rail surface damage Use depth gauge, hardness tester and 20cm steel ruler to detect surface defects of straight rails, curved rails or whole rails; (3) Wheel-rail contact light zone Measure one point on each of the four rails at the connection of the entire turnout set for testing; within the testing range, use a 20cm steel ruler to visually test the width and position of the light band; (4) Smoothness of joints, welds, and cutting points Each type of joint and weld in the turnout is randomly inspected at one location; an electronic ruler, a 1m straight ruler, and a feeler gauge are used to visually check whether the light strip is abnormal and whether the joint has misaligned teeth; (5) Reduce the value Detect the 20 and 50mm section reduction values ​​of the point rail and the 20 and 40mm section reduction values ​​of the frog; mark the key section positions and use rail profiler, reduction ruler, 1m straight ruler, feeler gauge, section caliper, and 5m steel tape measure for detection; (6) Roughness Use a roughness detection tool to perform at least 2 rail grinding surface roughness tests at any position of each set of turnouts; during the test, the same rail grinding surface shall be tested in a direction perpendicular to the rail grinding marks within a range of 10mm, and at least 6 points shall be tested continuously; (7) Grinding surface width After the turnout machine grinding operation is completed, use a steel ruler to measure the maximum width of the rail grinding surface at any position in the turnout area; (8) Polished surface with blue stripe Use a 5m steel tape measure and a 20cm steel ruler to visually inspect the blue band on the polished surface of the turnout rail.

3. The inspection and evaluation method for grinding a small turnout machine as claimed in claim 1, characterized in that: In step 2, in the wheel-rail contact light band scoring, the light band of the conventional turnout can be divided into the straight strand, curved strand and the whole set of turnout polished light band scoring, which are: A. Straight stock In the formula, a is the width of the light band, and b is the distance between the light band and the inner working edge; B. Qugu Scoring of the light band on the guide bend: The width of the light band on the guide bend is about 2 / 3 of the rail head area. The contact light band position of the upper rail on the curve is biased to the inside, and the contact light band extends from the inside of the rail to the rail top area; The n is the number of light band mutations or unreasonable distributions; Scoring of the light band under the guide curve: The position of the rail under the guide curve contacting the light band is in the center or slightly outside the center; C. Rating of the entire set of turnout light bands:

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