Cooling water flow control method and system in railway wheel quenching process

Abstract

The invention discloses a cooling water flow control method and system in the railway wheel quenching process, and relates to the technical field of wheel heat treatment. According to the cooling water flow set value of the quenching process and the predetermined optimal pipeline structure corresponding to different cooling water flow ranges, the optimal pipeline structure is determined and put into use; inquiring a preset value buffer page table according to a cooling water flow set value of a quenching process, if the preset value buffer page table is hit, acquiring a corresponding proportional valve opening value as a proportional valve opening initial value, and if the preset value buffer page table is not hit, acquiring a corresponding proportional valve opening value as a proportional valve opening initial value from a pipeline flow page table according to a flow deviation minimum principle; storing the obtained opening value of the proportional valve and the flow value corresponding to the opening value into a preset value buffer page table; and the opening degree of the proportional valve is adjusted to the opening degree initial value of the proportional valve, quenching is started, and PID closed-loop control is conducted. According to the invention, rapid and accurate control of the cooling water flow in the wheel quenching process can be realized.

Description

Technical Field

[0001] The present invention relates to the technical field of wheel heat treatment, and in particular to a method and system for controlling cooling water flow in a railway wheel quenching process. Background Art

[0002] Under high-speed, heavy-load transportation conditions, the quality requirements for railway train wheels are constantly increasing. Heat treatment, as a key step in railway wheel production, directly affects the performance of railway wheels. In traditional heat treatment quenching processes, the cooling water flow during quenching is controlled solely by a proportional valve, lacking closed-loop control and feedback. This imprecise control of cooling water flow cannot ensure that the quenching effect meets process requirements, resulting in unstable quenching results that are far from the actual process requirements, seriously affecting the quality and performance of the wheels. Summary of the Invention

[0003] In order to solve some or all of the technical problems existing in the above-mentioned prior art, the present invention provides a method and system for controlling the flow rate of cooling water during the quenching process of railway wheels.

[0004] The technical solutions of the present invention are as follows:

[0005] In a first aspect, a method for controlling the flow of cooling water during a railway wheel quenching process is provided, comprising the following steps:

[0006] Step 1: Acquire quenching process parameters, wherein the quenching process parameters include a cooling water flow setting value and a quenching time for each quenching step;

[0007] Step 2: According to the cooling water flow rate setting value of the current quenching process and the optimal piping structure corresponding to different predetermined cooling water flow rate ranges, the optimal piping structure is determined from all preset piping structures and put into use;

[0008] Step 3: query the preset value buffer page table according to the cooling water flow setting value of the current quenching process. If a hit is found, the corresponding proportional valve opening value is obtained as the proportional valve opening initial value. If a hit is found, the corresponding proportional valve opening value is obtained from the pipeline flow page table according to the principle of minimum flow deviation as the proportional valve opening initial value, and the obtained proportional valve opening value and its corresponding flow value are stored in the preset value buffer page table. The preset value buffer page table includes multiple cache data, each cache data includes a proportional valve opening value and a corresponding flow value. The pipeline flow page table includes multiple debugging data, each debugging data includes a proportional valve opening value and a corresponding flow value.

[0009] Step 4: Adjust the opening of the proportional valve in the pipeline structure to the initial value of the proportional valve opening, start quenching, maintain the first set time, and then perform PID closed-loop control until the current quenching process is completed. The PID closed-loop control uses the cooling water flow set value of the current quenching process and the actual value of the cooling water flow output by the pipeline structure as input, and uses the proportional valve as the actuator;

[0010] Step 5: Take the next quenching process as the current quenching process, and repeat steps 2 to 4 until all quenching processes are completed.

[0011] In some optional implementations, the quenching process parameters are obtained through a host computer.

[0012] In some optional embodiments, the optimal piping structure corresponding to different cooling water flow ranges is predetermined by:

[0013] The cooling water flow range of the quenching process is divided into segments. According to the relationship curve between the proportional valve opening and the cooling water flow under different pipeline structures, the pipeline structure with the slope of the relationship curve between the proportional valve opening and the cooling water flow in all preset pipeline structures closest to the set slope under the cooling water flow range corresponding to the segment is taken as the optimal pipeline structure corresponding to the segment, and the optimal pipeline structure corresponding to each segment is determined.

[0014] In some optional embodiments, when obtaining the corresponding proportional valve opening value from the pipeline flow page table according to the principle of minimum flow deviation, the proportional valve opening value corresponding to the flow value in the pipeline flow page table with the smallest deviation from the cooling water flow setting value of the current quenching process is selected.

[0015] In some optional embodiments, when the obtained proportional valve opening value and its corresponding flow value are stored in the preset value buffer page table, if the available cache data rows in the preset value buffer page table are insufficient, the cache data row that has not been used for the longest time is selected for information replacement.

[0016] In some optional embodiments, for each pipeline structure, an experiment is conducted by gradually increasing the opening of the proportional valve and recording the corresponding flow value, obtaining multiple debugging data including the proportional valve opening value and the corresponding flow value, and generating a pipeline flow page table corresponding to the pipeline structure.

[0017] In some optional implementations, a flow meter installed at the output end of the pipeline structure is used to measure the actual value of the cooling water flow output by the pipeline structure.

[0018] In some optional embodiments, when performing PID closed-loop control, if a deviation between a cooling water flow set value of a current quenching process and an actual cooling water flow value output by the pipeline structure is less than a preset deviation threshold and is maintained for more than a second set time period, an updated value of the proportional valve opening is calculated based on the proportional valve opening value output by the current PID closed-loop control, and the preset value buffer page table is updated using the updated value of the proportional valve opening and the cooling water flow set value of the current quenching process;

[0019] The updated value of the proportional valve opening is calculated using the following formula:

[0020] S1=S0*(1-α)+N*α;

[0021] Among them, S1 represents the updated value of the proportional valve opening, S0 represents the initial value of the proportional valve opening corresponding to the cooling water flow setting value of the current quenching process, N represents the proportional valve opening value output by the current PID closed-loop control, α represents the learning rate, and 0<α<1.

[0022] In a second aspect, a cooling water flow control system for a railway wheel quenching process is also provided, the system comprising:

[0023] Host computer, used to store quenching process parameters;

[0024] A proportional valve is provided in the cooling water piping structure to open or close the piping structure;

[0025] A flow meter is provided at the output end of the cooling water pipeline structure and is used to measure the cooling water flow output by the pipeline structure in real time;

[0026] A control unit is connected to the host computer, the proportional valve, and the flow meter, respectively. The control unit stores a preset value buffer page table, a pipeline flow page table, optimal pipeline structure information corresponding to different cooling water flow ranges, and first set time information. The control unit is used to execute the cooling water flow control method in the railway wheel quenching process as described in claim 1.

[0027] In some optional embodiments, the control unit includes a PLC.

[0028] The main advantages of the technical solution of the present invention are as follows:

[0029] The cooling water flow control method and system during the railway wheel quenching process of the present invention determines the optimal piping structure corresponding to each quenching step based on acquired quenching process parameters and pre-configured optimal piping structure information corresponding to different cooling water flow ranges. Furthermore, the system determines the initial value of the proportional valve opening when the piping structure is put into use based on pre-configured preset value buffer pages and pipeline flow pages, and performs PID closed-loop control on the proportional valve opening. This method and system can achieve rapid and precise control of the cooling water flow during the railway wheel quenching process, ensuring that the actual quenching effect more closely meets process requirements and improving the heat treatment performance and quality of the railway wheel. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The drawings described herein are used to provide a further understanding of the embodiments of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0031] Figure 1 A schematic flow chart of a method for controlling cooling water flow during railway wheel quenching provided by an embodiment of the present invention;

[0032] Figure 2 A schematic diagram of a water spraying process for quenching railway wheels provided by an embodiment of the present invention;

[0033] Figure 3 A schematic diagram of a cooling water pipeline for railway wheel quenching provided by an embodiment of the present invention, which includes various pipeline structures;

[0034] Figure 4 A schematic structural diagram of a cooling water flow control system during railway wheel quenching provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0035] To make the objectives, technical solutions, and advantages of the present invention more clear, the technical solutions of the present invention will be clearly and completely described below in conjunction with specific embodiments of the present invention and corresponding drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0036] The technical solutions provided by the embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0037] refer to Figure 1-3 In a first aspect, an embodiment of the present invention provides a method for controlling the flow of cooling water during a railway wheel quenching process, the method comprising the following steps:

[0038] Step 1, obtaining quenching process parameters;

[0039] In an embodiment of the present invention, the quenching process parameters include a cooling water flow setting value and a quenching time for each quenching step.

[0040] Specifically, the quenching process parameters are determined according to actual needs.

[0041] Step 2: According to the cooling water flow rate setting value of the current quenching process and the optimal piping structure corresponding to different predetermined cooling water flow rate ranges, the optimal piping structure is determined from all preset piping structures and put into use;

[0042] In the embodiment of the present invention, the pipeline structure is determined according to actual conditions.

[0043] Step 3: Based on the cooling water flow setting value of the current quenching process, query the preset value buffer page table. If a match is found, obtain the corresponding proportional valve opening value as the proportional valve initial opening value. If a match is not found, obtain the corresponding proportional valve opening value from the pipeline flow page table according to the principle of minimum flow deviation as the proportional valve initial opening value, and store the obtained proportional valve opening value and its corresponding flow value in the preset value buffer page table.

[0044] In the embodiment of the present invention, the minimum flow deviation principle indicates selecting the proportional valve opening corresponding to the flow value with the minimum deviation from the cooling water flow setting value of the current quenching process in the pipeline flow page table.

[0045] In an embodiment of the present invention, the preset value buffer page table and the pipeline flow page table are pre-configured and stored, the preset value buffer page table includes multiple cache data, each cache data includes a proportional valve opening value and a corresponding flow value, and the pipeline flow page table includes multiple debugging data, each debugging data includes a proportional valve opening value and a corresponding flow value.

[0046] It should be noted that each pipeline structure has a corresponding preset value buffer page table and pipeline flow page table.

[0047] Step 4: Adjust the opening of the proportional valve in the pipeline structure to the initial value of the proportional valve opening, start quenching, maintain the first set time, and then perform PID closed-loop control until the current quenching process is completed;

[0048] In the embodiment of the present invention, the PID closed-loop control takes the cooling water flow set value of the current quenching process and the actual value of the cooling water flow output by the pipeline structure as input, and uses the proportional valve as the actuator;

[0049] Specifically, the actual value of the cooling water flow output by the pipeline structure is collected in real time, the error between the cooling water flow set value and the actual cooling water flow is calculated, the PID output is generated according to the error, and the proportional valve opening is dynamically adjusted according to the PID output, thereby accurately controlling the cooling water flow output by the pipeline structure.

[0050] In the embodiment of the present invention, the first set duration is specifically set according to actual conditions to avoid initial flow fluctuations.

[0051] Step 5: Take the next quenching process as the current quenching process, and repeat steps 2 to 4 until all quenching processes are completed.

[0052] Specifically, after the current quenching process is completed, the next quenching process is used as the current quenching process, and steps 2 to 4 are continued until all quenching processes in the quenching process are completed in sequence.

[0053] The cooling water flow control method for railway wheel quenching provided in an embodiment of the present invention determines the optimal piping structure corresponding to each quenching step based on acquired quenching process parameters and pre-configured optimal piping structure information corresponding to different cooling water flow ranges. The method also determines the initial value of the proportional valve opening when the piping structure is put into use based on pre-configured preset value buffer pages and pipeline flow pages, and performs PID closed-loop control on the proportional valve opening. This method can achieve rapid and precise control of the cooling water flow during the railway wheel quenching process, ensuring that the actual quenching effect more closely meets process requirements and improving the heat treatment performance and quality of the railway wheel.

[0054] Furthermore, in an embodiment of the present invention, in order to facilitate the acquisition of the quenching process parameters, the quenching process parameters are directly acquired from a host computer storing the quenching process parameters.

[0055] Furthermore, in an embodiment of the present invention, the optimal pipeline structure corresponding to different cooling water flow ranges is predetermined by:

[0056] The cooling water flow range of the quenching process is divided into segments. According to the relationship curve between the proportional valve opening and the cooling water flow under different pipeline structures, the pipeline structure with the slope of the relationship curve between the proportional valve opening and the cooling water flow in all preset pipeline structures closest to the set slope under the cooling water flow range corresponding to the segment is taken as the optimal pipeline structure corresponding to the segment, and the optimal pipeline structure corresponding to each segment is determined.

[0057] In an embodiment of the present invention, by segmenting the cooling water flow range of the quenching process and adopting a corresponding pipeline structure for each segment, it is possible to ensure that the control curve of the proportional valve opening-cooling water flow of each segment is within the optimal control curve range of the corresponding pipeline structure, thereby achieving rapid and accurate control of the cooling water flow.

[0058] In an embodiment of the present invention, the set slope is set according to actual conditions, but the set slope cannot be too large or too small. When the set slope is too large or too small, it is difficult to achieve fast and accurate control when performing closed-loop control of the cooling water flow.

[0059] In the embodiment of the present invention, the relationship curves between the opening of the proportional control valve and the cooling water flow rate under different pipeline structures are determined by performing actual experiments on each pipeline structure.

[0060] In the embodiment of the present invention, all pipeline structures are determined according to actual conditions. Figure 2-3 For example, a pipeline configuration consisting of three pipelines of different diameters (WF1-WF3-WF2 or WF4-WF6-WF5 or WF7-WF9-WF8) connected in parallel, with independent on / off valves installed in each of the three pipelines, can be created by changing the open / closed states of the three on / off valves to create pipeline structures with different flow capacities. For this pipeline configuration consisting of three pipelines of different diameters connected in parallel, seven different pipeline structures with different flow capacities can be created by adjusting the on / off valve states.

[0061] Furthermore, in an embodiment of the present invention, based on the above-mentioned set principle of minimum flow deviation, when obtaining the corresponding proportional valve opening value from the pipeline flow page table according to the principle of minimum flow deviation, the proportional valve opening value corresponding to the flow value in the pipeline flow page table with the smallest deviation from the cooling water flow setting value of the current quenching process is selected.

[0062] Furthermore, considering that the cache space of the preset value buffer page table is limited, in order to improve the utilization rate of the information recorded in the preset value buffer page table, thereby reducing the number of pipeline flow page table traversals and improving the quenching processing efficiency, in an embodiment of the present invention, when the acquired proportional valve opening value and its corresponding flow value are stored in the preset value buffer page table, if the available cache data rows in the preset value buffer page table are insufficient, the cache data row that has not been used for the longest time is selected for information replacement.

[0063] Furthermore, in an embodiment of the present invention, for each pipeline structure, an experiment is conducted by gradually increasing the opening of the proportional valve and recording the corresponding flow value, obtaining multiple debugging data including the proportional valve opening value and the corresponding flow value, and generating a pipeline flow page table corresponding to the pipeline structure.

[0064] Among them, the number of items of debugging data recorded in the pipeline flow page table is determined according to the capacity of the pipeline flow page table, and the flow value in the recorded debugging data is required to include multiple flow value data within different cooling water flow ranges corresponding to the corresponding pipeline structure, so as to ensure that the flow value corresponding to the initial value of the proportional valve opening obtained through the pipeline flow page table can be as close as possible to the cooling water flow set value of the quenching process.

[0065] Furthermore, in an embodiment of the present invention, in order to facilitate the acquisition of the actual value of the cooling water flow output by the pipeline structure and ensure the accuracy of the acquired data, a flow meter installed at the output end of the pipeline structure is used to measure the actual value of the cooling water flow output by the pipeline structure.

[0066] Furthermore, in an embodiment of the present invention, when performing PID closed-loop control, if the deviation between the cooling water flow setting value of the current quenching process and the actual cooling water flow value output by the pipeline structure is less than a preset deviation threshold and is maintained for more than a second set time, then the updated value of the proportional valve opening is calculated based on the proportional valve opening value output by the current PID closed-loop control, and the preset value buffer page table is updated using the updated value of the proportional valve opening and the cooling water flow setting value of the current quenching process.

[0067] The updated value of the proportional valve opening is calculated using the following formula:

[0068] S1=S0*(1-α)+N*α;

[0069] S1 represents the updated value of the proportional valve opening, S0 represents the initial value of the proportional valve opening corresponding to the cooling water flow setting value of the current quenching process, N represents the proportional valve opening value output by the current PID closed-loop control, α represents the learning rate, 0<α<1.

[0070] In an embodiment of the present invention, by performing learning and updating of a preset value buffer page table according to a preset learning rate during a PID closed-loop control process, the initial value of the proportional valve opening can be optimized, thereby reducing the PID convergence time and improving the response speed. This can adapt to quenching equipment aging and environmental changes, achieve rapid and precise control of the cooling water flow rate during the railway wheel quenching process, make the actual quenching effect more in line with process requirements, and improve the heat treatment performance and quality of the railway wheel.

[0071] The second set duration is set according to actual conditions to avoid accidental traffic fluctuations.

[0072] refer to Figure 4 In a second aspect, an embodiment of the present invention further provides a cooling water flow control system for a railway wheel quenching process, the system comprising:

[0073] Host computer, used to store quenching process parameters;

[0074] A proportional valve is provided in the cooling water piping structure to open or close the piping structure;

[0075] A flow meter is provided at the output end of the cooling water pipeline structure and is used to measure the cooling water flow output by the pipeline structure in real time;

[0076] A control unit is connected to the host computer, the proportional valve, and the flow meter, respectively. The control unit stores a preset value buffer page table, a pipeline flow page table, optimal pipeline structure information corresponding to different cooling water flow ranges, and first set time information. The control unit is used to execute the above-mentioned cooling water flow control method during the railway wheel quenching process.

[0077] Furthermore, in an embodiment of the present invention, the control unit includes a PLC (Programmable Logic Controller).

[0078] The cooling water flow control system for the railway wheel quenching process provided in an embodiment of the present invention is a device corresponding to the above-mentioned control method, and is used to implement all processes of the cooling water flow control method described in any of the above-mentioned embodiments. The specific working principle, function and technical effects achieved by the cooling water flow control system can refer to the cooling water flow control method described in the above-mentioned embodiment, and will not be repeated here.

[0079] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In addition, "front", "back", "left", "right", "upper" and "lower" in this document are all referenced to the placement states shown in the accompanying drawings.

[0080] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for controlling the cooling water flow rate during railway wheel quenching, characterized in that: The following steps are involved: Step 1: Acquire quenching process parameters, wherein the quenching process parameters include a cooling water flow setting value and a quenching time for each quenching step; Step 2: According to the cooling water flow rate setting value of the current quenching process and the optimal piping structure corresponding to different predetermined cooling water flow rate ranges, the optimal piping structure is determined from all preset piping structures and put into use; Step 3: query the preset value buffer page table according to the cooling water flow setting value of the current quenching process. If a hit is found, the corresponding proportional valve opening value is obtained as the proportional valve opening initial value. If a hit is found, the corresponding proportional valve opening value is obtained from the pipeline flow page table according to the principle of minimum flow deviation as the proportional valve opening initial value, and the obtained proportional valve opening value and its corresponding flow value are stored in the preset value buffer page table. The preset value buffer page table includes multiple cache data, each cache data includes a proportional valve opening value and a corresponding flow value. The pipeline flow page table includes multiple debugging data, each debugging data includes a proportional valve opening value and a corresponding flow value. Step 4: Adjust the opening of the proportional valve in the pipeline structure to the initial value of the proportional valve opening, start quenching, maintain the first set time, and then perform PID closed-loop control until the current quenching process is completed. The PID closed-loop control uses the cooling water flow set value of the current quenching process and the actual value of the cooling water flow output by the pipeline structure as input, and uses the proportional valve as the actuator; Step 5: Take the next quenching process as the current quenching process, and repeat steps 2 to 4 until all quenching processes are completed.

2. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: Obtain quenching process parameters through the host computer.

3. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: The optimal piping structure for different cooling water flow ranges is predetermined by: The cooling water flow range of the quenching process is divided into segments. According to the relationship curve between the proportional valve opening and the cooling water flow under different pipeline structures, the pipeline structure with the slope of the relationship curve between the proportional valve opening and the cooling water flow in all preset pipeline structures closest to the set slope under the cooling water flow range corresponding to the segment is taken as the optimal pipeline structure corresponding to the segment, and the optimal pipeline structure corresponding to each segment is determined.

4. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: When obtaining the corresponding proportional valve opening value from the pipeline flow page table according to the principle of minimum flow deviation, the proportional valve opening value corresponding to the flow value with the minimum deviation from the cooling water flow setting value of the current quenching process in the pipeline flow page table is selected.

5. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: When the acquired proportional valve opening value and its corresponding flow value are stored in the preset value buffer page table, if the available cache data rows in the preset value buffer page table are insufficient, the cache data row that has not been used the longest is selected for information replacement.

6. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: For each pipeline structure, experiments are conducted by gradually increasing the opening of the proportional valve and recording the corresponding flow values. Multiple debugging data including the proportional valve opening value and the corresponding flow value are obtained to generate a pipeline flow page table corresponding to the pipeline structure.

7. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: The flow meter installed at the output end of the pipeline structure is used to measure the actual value of the cooling water flow output by the pipeline structure.

8. The method for controlling cooling water flow rate during railway wheel quenching according to claim 1, characterized in that: When performing PID closed-loop control, if the deviation between the cooling water flow rate set value of the current quenching process and the actual value of the cooling water flow rate output by the pipeline structure is less than a preset deviation threshold and is maintained for more than a second set time period, then based on the proportional valve opening value output by the current PID closed-loop control, an updated value of the proportional valve opening is calculated, and the updated value of the proportional valve opening and the cooling water flow rate set value of the current quenching process are used to update the preset value buffer page table; The updated value of the proportional valve opening is calculated using the following formula: S1=S0*(1-α)+N*α; Among them, S1 represents the updated value of the proportional valve opening, S0 represents the initial value of the proportional valve opening corresponding to the cooling water flow setting value of the current quenching process, N represents the proportional valve opening value output by the current PID closed-loop control, α represents the learning rate, and 0<α<1.

9. A cooling water flow control system for railway wheel quenching process, characterized in that: The system comprises: Host computer, used to store quenching process parameters; A proportional valve is provided in the cooling water piping structure to open or close the piping structure; A flow meter is provided at the output end of the cooling water pipeline structure and is used to measure the cooling water flow output by the pipeline structure in real time; A control unit is connected to the host computer, the proportional valve, and the flow meter, respectively. The control unit stores a preset value buffer page table, a pipeline flow page table, optimal pipeline structure information corresponding to different cooling water flow ranges, and first set time information. The control unit is used to execute the cooling water flow control method in the railway wheel quenching process as described in claim 1.

10. The cooling water flow control system in the railway wheel quenching process according to claim 9, characterized in that: The control unit includes a PLC.

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