Split type steel rail induction heating device

Abstract

The invention provides a split type steel rail induction heating device, and belongs to the technical field of railway steel rail welding. The split type steel rail induction heating device comprises a heating power supply used for converting a three-phase power frequency alternating current into a single-phase intermediate frequency alternating current; the induction heating machine head comprises a machine head frame and two heating modules arranged on the machine head frame, a heating space capable of containing a steel rail is formed between the two heating modules, each heating module comprises a resonant capacitor and a resonant inductor which are electrically connected, and the two resonant capacitors are electrically connected with a heating power source. According to the split type steel rail induction heating device provided by the invention, by adopting a split type design, the light weight and portability of the device are realized, so that field operators can operate by one person, and the operation efficiency is remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of railway rail welding, and in particular to a split rail induction heating device. Background Art

[0002] Heat treatment of rail welds is one of the key technologies for seamless railways and plays an important role in the development of seamless railways. Especially in the case of high-speed and heavy-loaded trains, the quality requirements for seamless line joints are also higher. At present, the welding of seamless line rails is basically carried out by contact welding. Because the melting process and high-temperature heating have occurred on the weld fusion line, the so-called overheating zone will appear near the fusion line, which will coarsen the metal structure, especially the austenite grains, and significantly reduce the toughness and plasticity. According to the test, the impact toughness near the welding fusion line is only 30-40% of the parent material, and the plasticity is 50-60% of the parent material. The drop hammer test reflecting the comprehensive performance of the welded joint is difficult to pass the requirements in the current standards, which seriously affects the safe use of seamless lines. At the same time, for full-length quenched rails, the original quenching layer in the weld area after contact welding disappears and a wider low-hardness area appears, which is easy to produce joint depression and induce wavy wear during use, which will shorten the service life of the full-length quenched rail seamless line. In order to solve the above problems, post-weld heat treatment must be carried out.

[0003] The most widely used post-weld heat treatment method is electromagnetic induction heat treatment. However, the mobile post-weld heat treatment equipment in service is bulky and has low stability. The heat treatment system needs to be equipped with generators, power supplies, chillers, hydraulic pump stations and other related equipment, and the front end of the heat treatment machine head needs to be equipped with a medium-frequency transformer, which makes the induction heating system bloated and cannot be operated in a handheld manner. In addition, the induction heating coils currently in use are mostly designed with left and right halves separated, and the passage of high-frequency current is ensured by mechanical clamping. This clamping method requires a flat contact surface and appropriate external loading, which poses a hidden danger when applied to complex field environments. The transformers configured in the in-service equipment are heavy, which makes it impossible to reduce the working weight and volume of the machine head. It can only be fixed and moved mechanically, limiting its possibility of use in different scenarios.

[0004] In view of this, the inventor has designed a split rail induction heating device based on many years of production design experience in this field and related fields and after repeated experiments, in order to solve the problems existing in the prior art. Summary of the invention

[0005] The object of the present invention is to provide a split rail induction heating device, which reduces the weight of the equipment and facilitates the operation of on-site operators.

[0006] In order to achieve the above-mentioned invention object, the present invention provides a split rail induction heating device, wherein the heating power supply is used to convert three-phase industrial frequency alternating current into single-phase medium frequency alternating current;

[0007] The induction heating head includes a head frame and two heating modules arranged on the head frame, and a heating space capable of accommodating a rail is formed between the two heating modules. The heating module includes an electrically connected resonant capacitor and a resonant inductor, and the two resonant capacitors are electrically connected to a heating power supply respectively.

[0008] Compared with the prior art, the present invention has the following characteristics and advantages:

[0009] The present invention proposes a split rail induction heating device, which realizes the lightness and portability of the equipment by adopting a split design, so that on-site operators can operate it alone, which significantly improves the working efficiency.

[0010] The present invention proposes a split rail induction heating device. The full water cooling heat dissipation system effectively solves the heat dissipation problem of the equipment under high current and high frequency working conditions. The DC power supply with IGBT as the core provides a stable and adjustable power supply, which not only improves the heat treatment quality and reduces labor intensity and safety risks, but also enhances the applicability and flexibility of the equipment, providing a new efficient, convenient and safe solution for the rail welding field in the railway industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The accompanying drawings described herein are only for explanation purposes and are not intended to limit the scope of the present invention in any way. In addition, the shapes and proportional dimensions of the various components in the figures are only schematic, used to help understand the present invention, and are not specifically limited to the shapes and proportional dimensions of the various components of the present invention. Those skilled in the art can select various possible shapes and proportional dimensions to implement the present invention according to the teachings of the present invention.

[0012] Figure 1 It is a schematic structural diagram of the portable split rail induction heating device of the present invention;

[0013] Figure 2 It is the principle diagram of the DC power supply of the present invention;

[0014] Figure 3 It is a front view of the induction heating head structure of the present invention;

[0015] Figure 4 It is a top view of the induction heating head structure of the present invention;

[0016] Figure 5 It is a side view of the induction heating head structure of the present invention.

[0017] Description of the accompanying drawings:

[0018] 10. Resonant capacitor; 20. Resonant inductor; 30. Headstock;

[0019] 31. Bracket; 32. Mounting plate; 33. Hinge;

[0020] 40. Heating power supply; 50. Cooling system; 60. Generator or grid power. DETAILED DESCRIPTION

[0021] The details of the present invention can be more clearly understood with reference to the accompanying drawings and the description of the specific embodiments of the present invention. However, the specific embodiments of the present invention described herein are only used for the purpose of explaining the present invention and cannot be understood as limiting the present invention in any way. Under the guidance of the present invention, technicians can conceive of any possible variations based on the present invention, which should all be considered to belong to the scope of the present invention.

[0022] The present invention proposes a split rail induction heating device, wherein a heating power supply 40 is used to convert three-phase industrial frequency alternating current into single-phase medium frequency alternating current; an induction heating head includes a head frame 30 and two heating modules arranged on the head frame, and a heating space capable of accommodating the rail is formed between the two heating modules. The heating module includes an electrically connected resonant capacitor 10 and a resonant inductor 20, and the two resonant capacitors 10 are electrically connected to the heating power supply 40 respectively.

[0023] The split induction heating device proposed by the present invention has an overall structure as follows: Figure 1 As shown, it includes a heating power supply and an induction heating head. The input of the heating power supply is a three-phase industrial frequency AC power provided by an external generator or grid power, and the output is a single-phase medium frequency AC power. The induction heating head includes two resonant circuits composed of two independent resonant inductors and resonant capacitors. The rail is placed in the middle of the resonant inductor, and the electromagnetic induction principle is applied to perform induction heating.

[0024] In the split type induction heating device proposed by the present invention, the specific structure of the head is as follows Figure 3-Figure 5 As shown. Two independent resonant circuits are placed on both sides of the rail. When the split induction heating device is in operation, the two resonant circuits are in an overlapped state, but they still maintain two independent resonant circuits. The two resonant circuits act on both sides of the rail joint respectively to perform post-weld induction heating on the rail joint. When the heating process is completed, the induction heating head is removed. The overall weight of the induction heating head does not exceed 20kg, which can be operated by a single operator on site.

[0025] The invention proposes a split rail induction heating device, which heats the rail joints by means of two resonant circuits of a split design, thereby achieving lightweight and portability of the equipment, enabling on-site operators to operate it alone, and significantly improving operating efficiency.

[0026] In an optional embodiment of the present invention, the resonant inductor 20 is an induction heating coil, the bending curvature of the induction heating coil is adapted to the profile of the rail, and the two induction heating coils enclose a heating space, and the cross-sectional shape of the heating space is the same as the cross-sectional shape of the rail.

[0027] Specifically, the induction heating coil is designed to have a specific bending arc, which corresponds precisely to the cross-sectional shape of the rail, ensuring that the induction heating coil can fit tightly against the side of the rail. The two induction heating coils are symmetrically arranged on both sides of the rail to enclose a closed heating space, and the cross-sectional shape of the heating space matches the cross-sectional shape of the rail, so that the rail joint can be evenly affected by the induction heating coil during the entire heating process. During operation, the single-phase medium-frequency alternating current output by the heating power supply is transmitted to the induction heating coil. Based on the principle of electromagnetic induction, eddy currents are generated inside the rail, thereby achieving rapid and uniform heating of the rail joint.

[0028] The structural design of the split rail induction heating device proposed in the present invention not only ensures the high efficiency of the heat treatment process, but also the precise adaptation of the induction heating coil to the rail profile ensures the uniformity of the heating process, avoids the problem of local overheating or insufficient heating, can improve the quality of the welded joint, and extend its service life. In addition, the symmetrically arranged induction heating coils and the closed heating space design reduce heat loss and improve energy efficiency. Finally, this design also simplifies the assembly and operation process of the equipment, because the induction heating coil can be quickly and accurately placed around the rail without complicated adjustment or fixation, which not only improves the convenience of the operation, but also reduces the complexity of the operation, making the equipment more suitable for on-site working environments. In general, the above structure not only improves the effect of heat treatment, but also enhances the flexibility and practicality of the equipment, providing an efficient, reliable and easy-to-operate rail induction heating solution.

[0029] In an optional example of this embodiment, when enclosing a heating space, there is a gap between the induction heating coil and the rail. The existence of this gap not only avoids damage that may be caused by physical contact, but also allows heat to be evenly distributed inside the rail by induction. In the working state, the alternating current inside the induction heating coil generates an alternating magnetic field, which passes through the gap and interacts with the rail, generating eddy currents inside the rail, thereby achieving rapid heating of the rail. The above-mentioned gap design allows the magnetic field generated by the induction heating coil to penetrate the rail more effectively, making the eddy current distribution inside the rail more even, thereby improving the heating efficiency and the quality of the welded joint.

[0030] In an optional embodiment of the present invention, the head frame 30 includes a bracket 31 and two mounting plates 32, and the two mounting plates 32 are symmetrically arranged on opposite sides of the bracket 31. One side of each mounting plate 32 is hinged to the bracket 31, and the other side of each mounting plate 32 can swing up and down, and the heating module is correspondingly arranged on the lower surface of the mounting plate 32.

[0031] The design of the head frame 30 in the split rail induction heating device of the present invention can ensure the balance and symmetry of the device. One side of each mounting plate 32 is connected to the bracket 31 through a hinge structure, so that the mounting plate 32 can swing up and down within a certain range, thereby adapting to rails of different sizes or providing necessary flexibility during installation and disassembly. In addition, the mounting plate 32 can swing up and down, and the heating module can also be accurately docked with the upper surface of the rail. The heating module is correspondingly arranged on the lower surface of the mounting plate 32. When the mounting plate 32 is swung into place, the heating module forms a closed heating space with the rail, so that the heating module can fit the rail and achieve efficient induction heating.

[0032] The split rail induction heating device of the present invention has a head frame 30 designed so that the heating module can flexibly adapt to rails of different sizes, and the hinged and swinging design of the mounting plate 32 allows the heating module to be quickly and accurately positioned above the rail, thereby simplifying the installation and adjustment process of the equipment.

[0033] In an optional example of this embodiment, the mounting plate 32 is hinged to the bracket 31 through two or more hinges 33, so that the mounting plate 32 can swing freely on the axis of the hinge 33, thereby achieving adaptive contact with the rail. The use of the hinge 33 not only provides a stable connection point, but also allows the mounting plate 32 to be adjusted within a certain angle range to adapt to rails of different sizes or to be fine-tuned under different working conditions. The provision of the hinge 33 enhances the structural stability and durability of the entire device, so that the mounting plate 32 can maintain a stable position even under heavy loads or long-term use, reducing the problem of uneven heating caused by deformation or displacement of the mounting plate 32.

[0034] In an optional example of this embodiment, the resonant capacitor 10 is fixedly connected to the mounting plate 32, and the resonant inductor 20 is fixedly connected to the resonant capacitor 10. In the split rail induction heating device of the present invention, efficient induction heating is achieved by fixedly connecting the resonant capacitor 10 and the resonant inductor 20 (i.e., the induction heating coil). The resonant capacitor 10 and the resonant inductor 20 together constitute a resonant circuit, wherein the resonant capacitor 10 is responsible for storing electrical energy, and the resonant inductor 20, as an inductor element, forms a resonant loop together with the resonant capacitor 10. When the single-phase medium-frequency alternating current output by the power supply is transmitted to the resonant inductor 20, the current and voltage in the resonant loop reach a resonant state, generating a strong electromagnetic field, thereby achieving efficient induction heating of the rail. The design of the split rail induction heating device of the present invention simplifies the assembly and maintenance process of the split rail induction heating device by fixing all key components in one position, and is convenient for operators to quickly check and maintain, and its fixed connection can also reduce the risk of component displacement or damage due to vibration or impact during operation, and this layout can greatly improve the stability and reliability of the device.

[0035] In an optional example of this embodiment, a handle is provided on the mounting plate 32. The specific position of the handle is preferably to ensure that the best gripping point is provided during transportation and operation. The handle is fixed to the mounting plate 32 and coordinated with the positions of the resonant capacitor 10 and the resonant inductor 20 to ensure the balance and symmetry of the overall design. In actual use, the operator can easily lift or move the entire induction heating device by the handle without directly contacting the induction heating coil or other sensitive components. The material and structure of the handle also take into account durability and impact resistance so as to be able to adapt to various environmental conditions that may be encountered in field operations. The handle provides a safe gripping point for the split rail induction heating device, reduces the risk of electric shock or burns that the operator may suffer during transportation, and improves the safety of the operation.

[0036] In an optional example of this embodiment, a flipping drive mechanism (not shown in the figure) is also provided on the mounting plate 32, so that the mounting plate 32 can flip around the hinge point. The flipping drive mechanism can be manual or electric, including but not limited to a gear system, a hydraulic cylinder or a pneumatic cylinder, etc., to adapt to different operating requirements and environmental conditions. The setting of the flipping drive mechanism enables the mounting plate 32 to move from a vertical position to a position in contact with the rail, achieving precise docking between the resonant inductor 20 and the rail, improving the flexibility and adaptability of the split rail induction heating device, and simplifying the installation and adjustment process, so that the operator can quickly position the induction heating device to the desired position even in different working scenarios and rail specifications.

[0037] In an optional embodiment of the present invention, the heating power supply is connected to the resonant capacitor 10 via a water-cooled cable, thereby ensuring efficient energy transmission between the heating power supply 40 and the heating module, while solving the heat dissipation problem under high current working conditions.

[0038] In the split rail induction heating device of the present invention, the connection between the heating power supply 40 and the resonant capacitor 10 is achieved through a water-cooled cable, which ensures efficient energy transmission between the heating power supply 40 and the heating module, and solves the heat dissipation problem under high current working conditions. The water-cooled cable not only serves as a transmission medium for the current, but also serves as a channel for the coolant, effectively transferring the heat energy generated by the current from the power supply to the cooling system 50, thereby keeping the temperature of the heating power supply 40 and the induction heating head within a safe working range. In practical applications, the design of the water-cooled cable allows the induction heating head to maintain a certain distance from the heating power supply 40, while ensuring a stable connection between the heating power supply 40 and the resonant capacitor 10, so that the induction heating process can be carried out continuously and efficiently. The use of water-cooled cables significantly improves the thermal management efficiency between the heating power supply 40 and the heating module, prevents overheating problems caused by long-term high current operation, and thus improves the stability and reliability of the equipment.

[0039] In an optional embodiment of the present invention, the heating power supply 40 is a DC power supply, which includes: a rectifier circuit, which converts three-phase industrial frequency AC power into fixed DC power; a voltage regulator circuit, which converts fixed DC power into stable and adjustable DC power; and an inverter circuit, which converts stable and adjustable DC power into single-phase medium frequency AC power. The DC power supply schematic diagram of the portable split induction heating device is shown in FIG. Figure 2 As shown, a DC-DC voltage regulation circuit and an inverter circuit are used. The rectifier circuit adopts an uncontrolled rectifier mode to convert the three-phase industrial frequency AC power from the generator or the grid 60 into DC power, which is input into the DC-DC voltage regulation circuit. The DC-DC voltage regulation circuit adopts a circuit structure based on the BUCK-BOOST principle, and converts the DC power from the rectifier circuit into a stable and adjustable DC power through step-up and step-down, and outputs it to the inverter circuit. The inverter circuit is based on the power device IGBT, and converts the stable and adjustable DC power from the DC-DC voltage regulation circuit into a single-phase medium frequency AC power through the inverter process, and outputs it to the resonant circuit of the induction heating machine head through the medium frequency transformer placed in the power cabinet. Through the combination of the rectifier circuit, the voltage regulation circuit and the inverter circuit, a highly controllable power supply is provided for the split rail induction heating device, which can maintain stable performance and accurately adjust the output according to different heating requirements and different working conditions, and can provide uniform and consistent heating regardless of grid voltage fluctuations or rail size changes.

[0040] The detailed explanation of the above-mentioned embodiments is only intended to explain the present invention so as to facilitate a better understanding of the present invention. However, these descriptions cannot be interpreted as limitations on the present invention for any reason. In particular, the various features described in different embodiments may also be arbitrarily combined with each other to form other embodiments. Unless there is a clear description to the contrary, these features should be understood to be applicable to any embodiment and are not limited to the described embodiments.

Claims

1. A split rail induction heating device, characterized in that: The split rail induction heating device at least comprises: A heating power supply is used to convert three-phase industrial frequency AC power into single-phase medium frequency AC power; The induction heating head includes a head frame and two heating modules arranged on the head frame, and a heating space capable of accommodating a rail is formed between the two heating modules. The heating module includes an electrically connected resonant capacitor and a resonant inductor, and the two resonant capacitors are electrically connected to the heating power supply respectively.

2. The split rail induction heating device according to claim 1, characterized in that: The resonant inductor is an induction heating coil, the bending curvature of the induction heating coil is adapted to the profile of the rail, two induction heating coils enclose the heating space, and the cross-sectional shape of the heating space is the same as the cross-sectional shape of the rail.

3. The split rail induction heating device according to claim 2, characterized in that: When the heating space is enclosed, there is a gap between the induction heating coil and the rail.

4. The split rail induction heating device according to claim 1, characterized in that: The head frame includes a bracket and two mounting plates, the two mounting plates are symmetrically arranged on opposite sides of the bracket, one side of each mounting plate is hinged to the bracket, and the other side of each mounting plate can swing up and down, and the heating module is correspondingly arranged on the lower surface of the mounting plate.

5. The split rail induction heating device according to claim 4, characterized in that: The mounting plate is hinged on the bracket through two or more hinges.

6. The split rail induction heating device according to claim 4, characterized in that: The resonant capacitor is fixedly connected to the mounting board, and the resonant inductor is fixedly connected to the resonant capacitor.

7. The split rail induction heating device according to claim 4, characterized in that: A handle is provided on the mounting plate.

8. The split rail induction heating device according to claim 4, characterized in that: The mounting plate is provided with a turning drive mechanism.

9. The split rail induction heating device according to claim 1, characterized in that: The heating power supply is connected to the resonant capacitor through a water-cooling cable.

10. The split rail induction heating device according to claim 1, characterized in that: The heating power supply comprises: The rectifier circuit will convert the three-phase industrial frequency AC power into fixed DC power in the future; A voltage regulating circuit converts the fixed direct current into a stable and adjustable direct current; The inverter circuit converts the stable and adjustable direct current into single-phase medium-frequency alternating current.

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