Rail-changing high-low joint milling device and high-low joint processing method

Abstract

The invention provides a rail-changing high-low joint milling device, which belongs to the technical field of railway engineering machinery, and comprises a main frame, an inclination adjusting mechanism, a milling mechanism, a milling mechanism, a control mechanism and a control mechanism, and is characterized in that the inclination adjusting mechanism is arranged on the main frame and is used for adjusting the inclination of the main frame to carry out downslope milling operation; the rail clamping mechanism is used for clamping and positioning the steel rail so as to mill; the machining unit is used for milling the joint of the steel rail; and the guide unit is used for guiding the machining unit to move along the downslope track so as to carry out downslope milling. A cutter forming face of the machining unit is matched with a steel rail working face, a rail top and a steel rail non-working face. The method effectively solves the problems of high labor intensity and poor precision of on-site new and old rail height difference downslope grinding, can realize downslope transition milling operation in a sufficient range, meets the requirement that the high gradient is less than 0.1%, and has the advantages of high joint treatment efficiency, good quality and the like.

Description

Technical Field

[0001] The invention belongs to the technical field of railway engineering machinery, and in particular relates to a rail-changing high and low joint milling device. Background Art

[0002] In the field of high-speed railway line maintenance, according to railway line maintenance regulations, rails should be replaced when the vertical wear of the base rail exceeds 6mm, and the welded joints between the new and old rails should be sloped. Currently, slope treatment at the joints of the new and old rails is mainly done manually using small grinding devices. This is labor-intensive and inefficient for operators. The slope is determined by a combination of experience and visual inspection, which has poor accuracy, relies on the operator's personal experience, is highly subjective, and is difficult to ensure quality. Summary of the Invention

[0003] The purpose of the present invention is to overcome the above-mentioned shortcomings of the prior art and provide a rail changing high and low joint milling device with high joint processing efficiency and good quality, which can effectively achieve the purpose of reducing manpower and labor in the on-site high and low joint grinding of new and old rails and improving quality and efficiency.

[0004] The technical solution of the present invention is as follows: A track-changing high and low joint milling device includes a main frame and a device provided on the main frame: A slope adjustment mechanism for adjusting the inclination of the main frame to facilitate down-slope milling operations; A rail clamping mechanism for clamping and positioning rails for milling; Machining unit for milling rail joints; A guide unit used to guide the machining unit to move along a slope trajectory for slope milling.

[0005] The inclination adjustment mechanism includes a plurality of adjustable leg mechanisms arranged at the lower part of the main frame; the adjustable leg mechanisms include hydraulic legs and a servo valve for controlling the extension and retraction of the hydraulic legs.

[0006] The guide unit includes one or more guide rails arranged on the main frame, a sliding sleeve slidably connected to each guide rail, a processing unit mounting seat connected to the sliding sleeve for mounting the processing unit, and a gear slide rail for cooperating with the processing unit; the gear slide rail includes a rack installed on the main frame and a gear meshing with the rack for transmission.

[0007] The processing unit mounting seat is connected to the sliding sleeve via the sliding sleeve mounting seat.

[0008] The machining unit includes a guide drive element provided on a machining unit mounting seat for driving the gear to rotate so that the gear reciprocates along the rack, a tool for milling the rail, a tool drive element for driving the tool to rotate, and a vertical feed drive element for driving the tool to vertically lift and lower.

[0009] The tool is a profiling tool, and the tool forming surface is adapted to the working surface, rail top and non-working surface of the rail.

[0010] The tool profiling surface is inlaid with tool grains.

[0011] The tool is a concave arc milling cutter, and the milling cutter forming surface is adapted to the working surface, rail top and non-working surface of the rail.

[0012] The guide drive element, tool drive element, and vertical feed drive element are servo motors or servo hydraulic motors or other power sources.

[0013] The tool driving element is connected to the machining unit mounting seat via a vertical feed driving element.

[0014] The rail clamping mechanism comprises a fixed rail clamping block and a movable rail clamping block which cooperate with each other to clamp and position the rail; The clamping surfaces of the fixed rail clamping block and the movable rail clamping block are adapted to the rails; The movable rail clamping block is connected to the main frame via a servo hydraulic cylinder, a servo actuator used to drive the movable rail clamping block to clamp / release the rail.

[0015] It also includes a control system for controlling the slope adjustment mechanism, the guide unit, and the processing unit to perform slope milling on the rails according to the height difference between the new rail and the old rail.

[0016] The main frame is more than 3m long; the main frame is a double-layer frame structure, and each layer of the frame includes two longitudinal side beams and one or more transverse side beams; the upper frame also includes one or more middle cross beams connected between the two longitudinal side beams; a plurality of longitudinal beams for connecting the upper and lower frames are provided between the opposite longitudinal side beams on the upper and lower frames.

[0017] Another aspect of the present invention provides a method for processing a track-swap joint, comprising the following steps: Step SF1. Position the rail-changing high-low joint milling device at the work point to be milled, with the machining unit on one side of the mainframe positioned above the lower rail at the high-low joint to be processed, and the hydraulic legs of the milling device resting on the trackbed. Step SF2. Oil and power the milling device via a railcar or other power source. Step SF3. The control system controls the inclination adjustment mechanism to adjust the mainframe inclination based on the height difference between the new and old rails to facilitate downslope milling. The control system detects the joint position using an optical detection device and fine-tunes the machining unit position for tool alignment. Step SF4. Clamp the milling device to the rail using the rail clamping mechanism to form a rigid connection. Step SF5. The control system sets the milling unit's machining depth based on the height difference between the new and old rails. The downslope distance is calculated based on the height difference between the new and old rails, and the milling unit performs the milling operation. Step SF6. After the milling operation is completed, the milling device is recovered; Step SFL. Polishing the sloped working surface. The process also includes: step SV, welding the sections of the new and old rails; grinding the entire section of the weld after welding to ensure a smooth transition between the new and old rails; The step SV is located before the step SF1 or between the step SF6 and the step SFL.

[0018] The beneficial effects of the present invention are as follows: the rail-changing high and low joint milling device provided by the present invention is simple and easy to operate, and has low requirements for operators. Before or after welding the new and old rails, the device can achieve a sufficient range of slope transition milling operations in conjunction with the main frame through the profiling tool that can process the working surface, rail top and non-working surface of the rail, meeting the requirement of high slope less than 1‰. It has the advantages of high precision, high operating efficiency, good dynamic slope-following ability, high level of automation, and a dust-free working environment using milling instead of grinding. Compared with existing manual grinding, it has higher efficiency, better working quality and lower labor intensity. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a structural schematic diagram of the present invention; Figure 2 It is a schematic diagram of the operation of the present invention (top view); Figure 3 This is a schematic diagram of the operation of the present invention (front view); Figure 4 This is a schematic diagram of the main frame structure of the present invention; Figure 5 for Figure 4 BB cross-sectional view; Figure 6 This is a schematic diagram of the processing unit structure of the present invention; Figure 7 This is a schematic structural diagram of the guide unit of the present invention; Figure 8 This is a schematic diagram of the high and low rail operation of the present invention; Figure 9 This is the second schematic diagram of the high and low rail operation of the present invention; Figure 10 Schematic diagram of rail profile.

[0020] Figure markings: main frame; 2-machining unit; 3-guide unit; 4-rail clamping mechanism; 5-inclination adjustment mechanism; 6-rack; 7-tool; 8-guide drive element; 9-ear plate; 10-machining unit mounting seat; 11-hydraulic support leg; 12-vertical feed drive element; 13-longitudinal side beam; 131, longitudinal beam; 14-transverse side beam; 15-fixed rail clamping block; 16-movable rail clamping block; 17-middle crossbeam; 18-servo hydraulic cylinder; 19-sleeve; 20-sleeve mounting seat; 21-guide rail; 22-gear; 23-tool drive element; 24-hydraulic support leg; 25-high rail; 26-low rail; 27-rail; 701-cutter; 901-rail top; 902-rail working surface; 903-rail non-working surface. DETAILED DESCRIPTION

[0021] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements with the same or similar functions.

[0022] In the description of the present invention, it should be noted that, for directional words, such as the terms "center", "horizontal (X)", "longitudinal (Y)", "vertical (Z)", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like, indicating directions and positional relationships, are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and should not be understood as limiting the specific scope of protection of the present invention.

[0023] The following description of the embodiments of the present invention is provided in conjunction with the accompanying drawings to further describe the specific embodiments of the present invention so that the technical solutions and beneficial effects of the present invention will be more clearly understood. The following description of the embodiments with reference to the accompanying drawings is illustrative and intended to explain the present invention, but is not to be construed as limiting the present invention.

[0024] Technologies, methods, and apparatus known to ordinary technicians in the relevant field may not be discussed in detail, but where appropriate, such technologies, methods, and apparatus should be considered part of the authorization specification.

[0025] Part 1: Structural composition.

[0026] like Figures 1 to 9 As shown, the track-changing high and low joint milling device provided by the present invention mainly includes a main frame 1, a processing unit 2, a guide unit 3, a track clamping mechanism 4, and an inclination adjustment mechanism 5.

[0027] The main frame 1 is more than 3 meters long and is composed of a transverse side beam 14, a longitudinal side beam 13, and a central cross beam 17 to form an installation frame.

[0028] The main frame 1 is a double-layer frame structure, and each layer of the frame includes two longitudinal side beams 13 and one or more transverse side beams 14; the upper frame also includes one or more middle cross beams 17 connected between the two longitudinal side beams 13; and a plurality of longitudinal beams 131 for connecting the upper and lower frames are provided between the opposite longitudinal side beams 13 on the upper and lower frames.

[0029] The rail clamping mechanism 4, used to clamp and position the rail for milling, includes a fixed clamping block 15 and a movable clamping block 16, which cooperate to hold the rail in place. The clamping surfaces of the fixed and movable clamping blocks 15, 16 mate with the rail. The movable clamping block 16 is connected to the mainframe 1 via a servo hydraulic cylinder 18, a servo actuator that drives the movable clamping block 16 to clamp and release the rail.

[0030] The fixed rail clamping block 15 and the movable rail clamping block 16 of the rail clamping mechanism 4 are fixed to the bottom of the main frame 1 and are installed in three sets respectively. The servo hydraulic cylinder 18 that controls the rail clamping mechanism 4 is installed on the side of the transverse side beam 13.

[0031] The tilt adjustment mechanism 5, used to adjust the inclination of the mainframe 1 for downhill milling operations, includes multiple adjustable outrigger mechanisms located at the bottom of the mainframe 1. These adjustable outrigger mechanisms include hydraulic outriggers 24 and servo valves that control their extension and retraction. The hydraulic outriggers 24 of the tilt adjustment mechanism 5 are located at the four corners of the mainframe 1 and are equipped with servo valves that control their extension and retraction.

[0032] The guide unit 3, used to drive the machining unit 2 along a sloped trajectory, consists of guide rails 21, a sliding sleeve 19, a sliding sleeve mounting seat 20, a machining unit mounting seat 10, a rack 6, and a gear 22. Two guide rails 21 are mounted on the main frame 1. Each guide rail 21 is slidably connected to a sliding sleeve 19, which is connected to the sliding sleeve mounting seat 20. The machining unit mounting seat 10 is connected to the sliding sleeve 19 via the sliding sleeve mounting seat 20, and the machining unit mounting seat 10 cooperates with the machining unit 2. The guide drive element 8 meshes with the rack 6 and gear 22 to achieve the purpose of driving the entire machining unit.

[0033] The machining unit 2 for milling rail joints comprises a guide drive element 8 mounted on a machining unit mounting base 10, which drives a gear 22 for rotation and reciprocation along a rack 6; a tool 7 for milling the rails; a tool drive element 23 for rotating the tool 7; and a vertical feed drive element 12 for vertically raising and lowering the tool 7. The vertical feed drive element 12 controls the feed rate of the tool 7, while the tool drive element 23 controls the rotational speed of the tool 7 and can be adjusted based on the feed rate of the tool 7.

[0034] The tool 7 can be a concave arc milling cutter or a milling cutter with inlaid blades. The milling cutter forming surface is in contact with the rail working surface 901, the rail top 901 and the rail non-working surface 903 ( Figure 10 shown) adaptation.

[0035] The system also includes a control system that controls the slope adjustment mechanism 5, guide unit 3, and processing unit 2 to mill the rails along the slope based on the height difference between the new and old rails. The control system calculates the along-slope distance and inclination based on the height difference between the new and old rails, as measured by the external rail profile detection system. The control system then controls the slope adjustment mechanism 5, guide unit 3, and processing unit 2 to mill the rails along the slope accordingly.

[0036] Part 2: Working principle and description.

[0037] First, the parameters and working mode of the track-changing high and low joint milling device are described, taking the present invention as an example: Parameters: The design standard of the inclined transition section is 1:1000, that is, the slope length for a 1mm height difference is 1000mm.

[0038] The operating principle is as follows: When there is a weld height difference between the upper rail 25 and the lower rail 26, the rail profile is scanned by the external rail profile detection system. The control system calculates the downslope distance and inclination based on the height difference between the new and old rails collected by the external rail profile detection system. For example, when the height difference is 3mm in actual operation, the downslope distance is set to 3000mm. Based on this, the slope adjustment mechanism 5, the guide unit 3, and the processing unit 2 are controlled to mill the rails downslope. The downslope motion is controlled by controlling the servo hydraulic cylinder 18 to control the clamping force, the hydraulic support leg 24 to adjust the horizontality, the vertical feed drive element 12 to adjust the vertical feed amount, and the speed of the tool 7. The speed control amount can be adjusted according to the single milling amount of the tool 7 to prevent the chipping of the embedded tool chip 701.

[0039] An optical detection device can be installed at the machining unit to detect the joint position. This detection is based on the height difference between the upper rail 25 and the lower rail 26. The control system transmits the signal to the machining unit, which then moves along the guide rail 21 for tool positioning. Tool 7 replaces grinding with milling, enabling a single-step milling operation for the entire cross-section of the rail weld.

[0040] Part 3: Treatment methods for rail change joints The track-changing joint processing method provided by the present invention comprises the following steps: Step SF1. Transport the rail-changing high-low joint milling device to the work site via a railcar. Use a crane or other device to position the milling device at the work site, ensuring that the machining unit on one side of the mainframe is positioned over the lower rail at the high-low joint to be processed and that the hydraulic legs of the inclination adjustment mechanism are positioned on the trackbed. Step SF2. Oil and power the milling device via a railcar or other power source. Step SF3. The control system controls the inclination adjustment mechanism to adjust the mainframe inclination based on the height difference between the new and old rails to facilitate downslope milling. The control system uses an optical detection device located at the machining unit to detect the joint position and fine-tune the machining unit position for tool alignment. Step SF4. Clamp the milling device to the rail using the rail clamping mechanism to form a rigid connection. Step SF5. The control system sets the milling unit's machining depth based on the height difference between the new and old rails. The downslope distance is calculated based on the height difference between the new and old rails, and the milling unit performs the milling operation. Step SF6. After the milling operation is completed, the milling device is recovered; Step SFL. Polishing the sloped working surface. The process also includes: step SV, welding the sections of the new and old rails; grinding the entire section of the weld after welding to ensure a smooth transition between the new and old rails; The step SV is located before the step SF1 or between the step SF6 and the step SFL.

[0041] In the description of the specification, reference to the terms "one embodiment," "preferably," "example," "specific example," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. The schematic expressions of the above terms in this specification do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any appropriate manner in any one or more embodiments or examples.

[0042] The present invention is not limited to the above-described embodiments. Persons skilled in the art may make various improvements and modifications without departing from the principles of the present invention, and such improvements and modifications are deemed to be within the scope of protection of the present invention. Any matters not described in detail in this specification constitute prior art known to those skilled in the art.

Claims

1. A track-changing high and low joint milling device, characterized in that: It comprises a main frame (1) and the following components arranged on the main frame (1): A slope adjustment mechanism (5) for adjusting the inclination of the main frame (1) to facilitate downslope milling operations; A rail clamping mechanism (4) for clamping and positioning the rail for milling; a machining unit (2) for milling rail joints; A guide unit (3) for guiding the machining unit (2) to move for down-slope milling.

2. The track-changing high-low joint milling device according to claim 1, characterized in that: The inclination adjustment mechanism (5) comprises a plurality of adjustable leg mechanisms arranged at the lower part of the main frame (1); the adjustable leg mechanisms comprise hydraulic legs (24) and a servo valve for controlling the extension and retraction of the hydraulic legs.

3. The track-changing high-low joint milling device according to claim 1, characterized in that: The guide unit (3) includes one or more guide rails (21) arranged on the main frame (1), a sliding sleeve (19) slidably connected to each guide rail (21), a processing unit mounting seat (10) connected to the sliding sleeve (19) for mounting the processing unit (2), and a gear slide rail for cooperating with the processing unit (2); the gear slide rail includes a rack (6) installed on the main frame (1) and a gear (22) meshing with the rack (6) for transmission.

4. The track-changing high-low joint milling device according to claim 3, characterized in that: The processing unit mounting seat (10) is connected to the sliding sleeve (19) via the sliding sleeve mounting seat (20).

5. The track-changing high-low joint milling device according to claim 1, characterized in that: The machining unit (2) comprises a guide drive element (8) provided on a machining unit mounting seat (10) for driving a gear (22) to rotate so that the gear (22) reciprocates along a rack (6), a tool (7) for milling a rail, a tool drive element (23) for driving the tool (7) to rotate, and a vertical feed drive element (12) for driving the tool (7) to vertically ascend and descend; the tool forming surface is adapted to the working surface, rail top, and non-working surface of the rail.

6. The track-changing high-low joint milling device according to claim 5, characterized in that: The guide drive element (8), the tool drive element (23), and the vertical feed drive element (12) are servo motors or servo hydraulic motors.

7. The track-changing high-low joint milling device according to claim 5, characterized in that: The rail clamping mechanism (4) comprises a fixed rail clamping block (15) and a movable rail clamping block (16) which cooperate with each other to clamp and position the steel rail; The clamping surfaces of the fixed rail clamping block (15) and the movable rail clamping block (16) are adapted to the rail; The movable rail clamping block (16) is connected to the main frame (1) via a servo hydraulic cylinder (18), a servo actuator element, which is used to drive the movable rail clamping block (16) to clamp / release the rail.

8. The track-changing high-low joint milling device according to claim 1, characterized in that: It also includes a control system for controlling the slope adjustment mechanism (5), the guide unit (3), and the processing unit (2) to perform slope milling on the rails according to the height difference between the new rail and the old rail.

9. The track-changing high-low joint milling device according to claim 1, characterized in that: The main frame (1) is more than 3 m in length; the main frame (1) is a double-layer frame structure, and each layer of the frame includes two longitudinal side beams (13) and one or more transverse side beams (14); the upper frame also includes one or more middle cross beams (17) connected between the two longitudinal side beams (13); and a plurality of longitudinal beams (131) for connecting the upper and lower frames are provided between the longitudinal side beams (13) facing each other on the upper and lower frames.

10. A rail-changing joint processing method, characterized in that: The following steps are involved: Step SF1. Place the rail-changing high-low joint milling device at the work point to be milled, with the machining unit on one side of the mainframe positioned above the lower rail at the high-low joint to be processed and the inclination adjustment mechanism resting on the trackbed. Step SF2. Oil and power the milling device via a railcar or other power source. Step SF3. The control system controls the inclination adjustment mechanism to adjust the mainframe inclination based on the height difference between the new and old rails to facilitate downslope milling. The control system detects the joint position using an optical detection device and fine-tunes the machining unit position for tool alignment. Step SF4. Clamp the milling device to the rail using the rail clamping mechanism to form a rigid connection. Step SF5. The control system sets the milling unit's machining depth and downslope distance based on the height difference between the new and old rails, and performs milling operations using the machining unit. Step SF6. After the milling operation is completed, the milling device is recovered; Step SFL. Polishing the sloped working surface. The process also includes: step SV, welding the sections of the new and old rails; grinding the entire section of the weld after welding to ensure a smooth transition between the new and old rails; The step SV is located before the step SF1 or between the step SF6 and the step SFL.

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