Method for automatically generating steel rail grinding mode

Abstract

The invention provides a method for automatically generating a steel rail polishing mode, which comprises the following steps of: aligning an actual measurement profile of a steel rail with a target profile of the steel rail by taking the target profile of the steel rail as a reference; forming a designed and polished target profile of the steel rail based on the target profile of the steel rail; the designed and polished target profile is formed by connecting a plurality of line segments which are connected in sequence; according to the aligned actual measurement profile and the designed polished target profile, the position and the area of a to-be-polished area of the steel rail are calculated and determined; establishing a relationship between the grinding power and the grinding area of a single grinding wheel of the steel rail grinding wagon; and aiming at eliminating the area of the to-be-polished area of the steel rail, automatically generating a polishing mode based on the relationship between the polishing power of a single grinding wheel of the steel rail polishing wagon and the polishing area of the single grinding wheel. The technical problem that according to traditional steel rail grinding, the to-be-ground area needs to be manually confirmed, and the grinding mode needs to be determined according to grinding experience is solved.

Description

Technical Field

[0001] This application relates to the field of rail grinding technology, and more specifically, to a method for automatically generating rail grinding patterns. Background Technology

[0002] As a key component in the railway transportation system, rails play a crucial role in guiding vehicle movement and transmitting loads to the roadbed. During operation, rails are subjected to complex and varied loads and stresses from rail vehicles, leading to surface and even internal defects and damage. This causes wear and deformation of the rail profile, affecting the smoothness and comfort of the ride.

[0003] As an effective means of repairing rail surface damage and profile defects, rail grinding machines have become indispensable tools for rail maintenance and extending rail lifespan, especially with the increasing speed, density, and weight of rail trains. The working principle of a rail grinding machine is to use a grinding wheel to remove the required amount of metal from the rail surface to eliminate damage or repair its profile. This controls the generation and development of defects at their source, improves wheel-rail contact, extends rail service life, and enhances the comfort of railway operation.

[0004] Rail grinding operations require different grinding schemes to determine the specific grinding mode based on the actual condition of the rail, in order to achieve the purpose of profile repair or rail surface defect repair. If the grinding mode is not designed properly, it will directly affect the grinding quality and grinding effect.

[0005] Traditional rail grinding suffers from the technical problem of low efficiency in generating grinding patterns due to the need for manual confirmation of the area to be ground and determination of the grinding mode based on grinding experience.

[0006] The information disclosed in the background section is only intended to enhance the understanding of the background of this application, and therefore may contain information that is not part of the prior art known to those skilled in the art. Summary of the Invention

[0007] This application provides a method for automatically generating rail grinding patterns to solve the technical problem that traditional rail grinding requires manual confirmation of the area to be ground and determination of the grinding pattern based on grinding experience.

[0008] This application provides a method for automatically generating rail grinding patterns, including the following steps: Step S1: Using the target profile of the rail as a reference, align the measured profile of the rail with the target profile of the rail; Step S2: Based on the grinding mechanism of the rail grinding machine, the designed target profile of the rail after grinding is formed based on the target profile of the rail; wherein, the designed target profile after grinding is formed by connecting multiple sequentially connected line segments; Step S3: Based on the actual measured profile after alignment and the target profile after grinding, calculate and determine the location and area of ​​the area to be ground on the rail. Step S4: Establish the relationship between the grinding power p of a single grinding wheel of the rail grinding machine and the grinding area S of a single grinding wheel.

[0009] Step S5: With the goal of eliminating the area of ​​the rail to be ground, a grinding mode is automatically generated based on the relationship between the grinding power p of a single grinding wheel and the grinding area S of a single grinding wheel on the rail grinding vehicle.

[0010] This application, by adopting the above technical solution, has the following technical effects: In the method for automatically generating rail grinding patterns in this application embodiment: In step S1, the measured profile 2 of the rail is aligned with the target profile 1 to ensure the accuracy of the determination of the location of the area to be ground and the calculation of the area to be ground in the subsequent rail.

[0011] Step S2 combines the grinding mechanism of the rail grinding vehicle to generate the target profile after grinding, which is formed by the sequential connection of multiple line segments. This not only takes into account the theoretical requirements of conforming to the target profile of the rail, but also takes into account the processing capabilities of the actual grinding equipment (such as the limitations of the grinding wheel movement trajectory), thus avoiding infeasible grinding paths caused by idealized design and improving the feasibility of the solution.

[0012] Step S3 accurately locates the area to be ground based on the aligned measured profile and the designed target profile after grinding, calculates and determines the location and area to be ground, that is, accurately calculates the location and area to be ground of the rail to be ground, and realizes the quantitative analysis of the amount of material removed.

[0013] Step S4 refines the relationship between the precise grinding amount, grinding power, grinding speed, and grinding angle for each grinding head under different grinding conditions in different areas of the rail head, providing a decision-making data basis for the refined control of grinding operation quality.

[0014] Step S5 establishes a control algorithm based on quantitative grinding area automatic closed-loop elimination to realize the automatic generation of grinding mode based on target profile repair.

[0015] The method for automatically generating rail grinding patterns in this application, which designs the target profile after grinding by sequentially connecting multiple line segments, takes into account both the theoretical requirements for conforming to the target profile of the rail and the processing capacity of the actual grinding equipment. It accurately calculates and determines the location and area to be ground, and realizes quantitative analysis of material removal, which can significantly improve the accuracy, efficiency and resource utilization of rail grinding. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 The method steps and flowchart for automatically generating the rail grinding mode of this application; Figure 2 This is a schematic diagram comparing the silhouette after alignment and target silhouette design with the actual measured silhouette. Figure 3 This is a diagram illustrating the change in the area to be sanded at each step during the sanding process, starting from the right and proceeding sequentially to the left. Figure 4 Flowchart of the overall method for automatically generating grinding patterns based on grinding area deviation; Figure 5 A flowchart illustrating the process of automatically generating polishing patterns based on a strategy of sequential polishing from one side to the other; Figure 6 The algorithm implementation process for calculating the grinding angle using the bisection method with known grinding points and target grinding area is as follows: Figure 7 The algorithm implementation process for solving the grinding line equation using the bisection method with known grinding angle and target grinding area; Figure 8 A simulation diagram illustrating the effect of automatically generating a polishing pattern based on a strategy of polishing sequentially from one side to the other.

[0017] Figure label: Target profile 1, measured profile 2, designed target profile after polishing 3, area to be polished 4, intersection point 5, polishing line 6. Detailed Implementation

[0018] To make the technical solutions and advantages of this application clearer, the exemplary embodiments of this application will be described in further detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not an exhaustive list of all embodiments. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. Example 1

[0019] like Figures 1 to 3 As shown, the method for automatically generating rail grinding patterns according to this application includes the following steps: Step S1: Using the target profile 1 of the rail as a reference, align the measured profile 2 of the rail with the target profile 1 of the rail.

[0020] Step S2: Based on the grinding mechanism of the rail grinding machine, the designed post-grinding target profile 3 of the rail is formed based on the target profile 1 of the rail; wherein, the designed post-grinding target profile 3 is formed by connecting multiple sequentially connected line segments; Step S3: Based on the aligned measured profile 2 and the designed target profile 3 after grinding, calculate and determine the location of the area to be ground and the area to be ground of the rail.

[0021] Step S4: Establish the relationship between the grinding power p of a single grinding wheel of the rail grinding machine and the grinding area S of a single grinding wheel; Step S5: With the goal of eliminating the area of ​​the rail to be ground, a grinding mode is automatically generated based on the relationship between the grinding power p of a single grinding wheel and the grinding area S of a single grinding wheel on the rail grinding vehicle.

[0022] In the method for automatically generating rail grinding patterns in this application embodiment: In step S1, the measured profile 2 of the rail is aligned with the target profile 1 to ensure the accuracy of the determination of the location of the area to be ground and the calculation of the area to be ground in the subsequent rail.

[0023] Step S2 combines the grinding mechanism of the rail grinding vehicle to generate the designed grinding target profile 3, which is formed by sequentially connecting multiple line segments. This not only considers the theoretical requirements of conforming to the rail target profile, but also the processing capabilities of the actual grinding equipment (such as the limitations of the grinding wheel movement trajectory), avoiding infeasible grinding paths caused by idealized design and improving the feasibility of the solution.

[0024] Step S3 accurately locates the area to be ground based on the aligned measured profile 2 and the designed target profile 3 after grinding, calculates and determines the location and area to be ground of the area to be ground, that is, accurately calculates the location and area to be ground of the rail to be ground, and realizes the quantitative analysis of the amount of material removed.

[0025] Step S4 refines the relationship between the precise grinding amount, grinding power, grinding speed, and grinding angle for each grinding head under different grinding conditions in different areas of the rail head, providing a decision-making data basis for the refined control of grinding operation quality.

[0026] Step S5 establishes a control algorithm based on quantitative grinding area automatic closed-loop elimination to realize the automatic generation of grinding mode based on target profile repair.

[0027] The method for automatically generating rail grinding patterns in this application, which designs the target profile 3 after grinding by sequentially connecting multiple line segments, takes into account both the theoretical requirements of conforming to the target profile of the rail and the processing capacity of the actual grinding equipment; it accurately calculates and determines the location and area to be ground, and realizes quantitative analysis of material removal, which can significantly improve the accuracy, efficiency and resource utilization of rail grinding.

[0028] The method for automatically generating rail grinding patterns in this application, in steps S1 to S3, accurately calculates and determines the location and area to be ground of the rail's grinding area based on the target profile of the rail, the area deviation of the measured profile of the rail, and the designed target profile after grinding, thereby quickly and accurately determining the location and area to be ground of the rail's grinding area. Steps S4 to S5, with the goal of eliminating the grinding area of ​​the rail's grinding area, automatically generate a grinding pattern based on the relationship between the grinding area and grinding power of a single grinding wheel on the rail grinding vehicle. This grinding pattern can be directly and effectively used for profile repair grinding operations, with high efficiency and a high degree of automation.

[0029] Specifically, the target profile of a rail refers to the ideal geometric shape set for the rail head during the design and maintenance of railway tracks. This ideal shape design is based on a variety of considerations, including but not limited to the safety, stability, comfort of train operation, and reduction of wear and noise.

[0030] Specifically, the measured profile of a rail refers to the data on the geometry of the rail head obtained directly from a track in actual operation using specific measuring tools and techniques. This data reflects the actual changes in the rail's shape after a period of use, caused by repeated rolling by train wheelsets, environmental factors, and potential maintenance work.

[0031] Specifically, the target profile of a rail after grinding refers to the ideal rail head geometry that is desired to be achieved after the rail has been ground and maintained. This target profile is designed based on multiple considerations, aiming to optimize wheel-rail contact, extend the service life of the rail and wheels, reduce noise, and ensure the safety and comfort of train operation.

[0032] The target profile of a rail refers to the ideal shape that the rail should maintain throughout its entire service life, serving as a general guiding principle for new rail installation and maintenance. The post-grinding target profile, on the other hand, specifically refers to the exact geometric shape the rail should achieve after maintenance (such as grinding), representing a more specific, operational goal set to restore rail performance. Both work together to ensure the efficient operation and safety of the railway system.

[0033] The following is a detailed explanation of steps S1 to S5.

[0034] like Figure 2 As shown, step S1 specifically includes: Step S11: Using the target profile 1 ( Figure 2 Using the solid red line in the middle as a reference, the measured profile 2 ( Figure 2 (Use a solid black line in the middle) Align it vertically with the target outline 1 at the center point of the top of the track; Step S12: Align the measured profile 2 with the target profile 1 horizontally; the horizontal alignment method is as follows: For the measured profile 2 where the working edge (i.e., the inner edge of the rail, which is the side directly in contact with the train wheel tread) is not severely worn, align the left and right sides at the unworn and undeformed area at and below the working edge gauge point; the effect after alignment is as follows. Figure 2 The target profile 1 and the measured profile 2 are shown.

[0035] For the measured profile 2 with severe wear on the working edge, align the unworn and undeformed parts of the non-working edge (i.e. the outer edge of the rail) with the left and right sides.

[0036] Specifically, if the wear on the working edge extends beyond the gauge angle, it can be considered as severe wear. In this case, the non-working edge can be selected as the left and right alignment edge.

[0037] Step S12 employs a wear-adaptive left-right alignment strategy: For measured profiles with minimal wear on the working edge, the working edge gauge point and the unworn area below it are aligned left and right to preserve the reference value of the original gauge parameters of the rail and avoid lateral errors introduced by unnecessary coordinate system translation. For measured profiles with severe wear on the working edge, switch to the unworn area on the non-working edge for alignment to avoid interference from the worn area on the reference point and ensure the reliability of left and right positioning.

[0038] like Figure 2 As shown, the measured profile 2 deviates from the target profile 1, indicating that the measured profile 2 has undergone significant wear and deformation during use, resulting in a reduction in profile quality. It is necessary to repair it by grinding.

[0039] For measured profiles with severe wear on the working edge, the unworn and undeformed parts of the non-working edge can be aligned left and right.

[0040] For measured profiles with severe wear on the working edge, such as the upper part of a long-serving curve where there may be significant wear at or below the gauge angle, using the working edge for alignment can easily lead to a large lateral displacement deviation after alignment. Therefore, for such profiles, the non-working edge that is not worn or deformed can be selected for left-right alignment.

[0041] Among them, the working edge gauge point is a standardized position at a specific depth (such as 16 mm) below the inner top surface of the rail, serving as a reference point for gauge measurement and profile alignment.

[0042] like Figure 2 As shown, step S2 specifically includes: Step S21: Move the target profile 1 (red solid line) down as a whole; where the depth of the downward movement is the displacement of the expected grinding depth of the rail top.

[0043] Step S22: Based on the grinding mechanism of the rail grinding machine, the target profile (i.e. the target profile after downward movement) within the target grinding range is segmented and linearized.

[0044] The segmented linearization process refers to the segmented linearization of the target profile after it has been moved down, based on a preset length for the width of the profile surface in different areas after polishing.

[0045] Step S23: Form the target profile 3 after design and polishing; The target profile, after being shifted downwards from a complex curve, is decomposed into a multi-segment connected design. The resulting target profile 3 after grinding has a higher compatibility with the grinding wheels of the rail grinding vehicle. The actual grinding process performed by the rail grinding vehicle's grinding wheels is more efficient, and the actual ground profile more closely resembles the ground target profile 3.

[0046] like Figure 2 and Figure 3 As shown, step S3 specifically includes: Step S31: Extend the outermost left and right lines of the target profile 3 after design and polishing outwards to intersect with the measured profile 1, and calculate the intersection points 5 on both sides (e.g., Figure 2 (The dot marked with a central asterisk).

[0047] Step S32: When the outermost line segment cannot be found to intersect with the measured profile 2 after being extended outward, the next line segment of the target profile 3 after design and polishing is gradually extended outward to calculate the intersection with the actual profile 2 to be polished, until the outer intersection point or the intersection point with the line segment range is found.

[0048] Step S33: The area enclosed by the target profile 3 after design and the measured profile 2 after polishing is the area to be polished 4. Figure 2 (The area is represented by a shaded area with diagonal lines), and the area to be sanded is calculated and determined. Step S34: Extend each line segment of the target profile 3 after sanding outwards to the intersection with the measured profile 2 to form a sanding line 6. The area above the sanding line 6 in the area to be sanded 4 is the area to be sanded along that sanding line. Figure 3 As shown.

[0049] In steps S31 and S32, the intersection point 5 is the intersection of the designed target profile 3 after grinding and the measured profile 1, which is the starting point and the ending point of the area to be ground on the rail.

[0050] Thus, steps S33 and S34 achieve the goal of dividing the larger area to be polished 4 into multiple smaller polishing lines to be polished areas.

[0051] like Figure 3 The demonstration showed the change in the area to be ground at each step of the grinding strategy, which involves grinding from the right side of the rail sequentially to the left.

[0052] When different grinding strategies are employed, such as grinding from both sides of the rail towards the middle, grinding from the middle of the rail towards both sides, or other feasible sequential methods, the change in the area to be ground at each step corresponds to... Figure 3 There are differences.

[0053] To facilitate understanding and explanation of the method of the present invention, the following description focuses only on the grinding strategy of grinding sequentially from one side of the rail to the other. However, this grinding strategy is merely one application embodiment of the present invention and does not limit the invention. The method of the present invention can also be applied to different grinding strategies, such as grinding from both sides of the rail towards the middle, grinding from the middle of the rail towards both sides, or other sequential methods that can be implemented.

[0054] Meanwhile, for cases with a large amount of sanding, the present invention can also apply the overall coverage method to sand one to N layers first, and finally implement the sanding strategy according to the segment lines in the sanding design outline as the sanding lines. These will not be listed in detail here.

[0055] Step S5 automatically generates a polishing mode, which includes a polishing strategy. The polishing strategy includes: Grinding can be done sequentially from one side of the rail to the other, or from both sides of the rail to the middle, or from the middle of the rail to both sides. For cases with a large amount of grinding, in order to avoid grinding too many times continuously at a single angle, the grinding depth can be divided into multiple operations, covering the grinding layer by layer until the grinding is completed.

[0056] Step S4: Establish the relationship between the grinding power p of a single grinding wheel of the rail grinding machine and the grinding area S of a single grinding wheel.

[0057] The grinding efficiency of a rail grinding machine is related to many factors such as the characteristics of the grinding wheel, the control of the grinding head (i.e., the grinding wheel), and the characteristics of the rail. When faced with a specific rail grinding machine, the factors of the grinding wheel, the rail, and the grinding control are usually relatively certain. The factors that have a greater impact on the grinding power p are the grinding speed and the grinding angle.

[0058] Therefore, based on the fundamental equivalent coefficient λ between the grinding area S and grinding power p of a single grinding wheel, introducing compensation factors such as grinding speed v and grinding angle θ can better reflect the relationship between the grinding area S and grinding power p during the grinding operation. That is, the grinding power p and grinding area S of the rail grinding vehicle have a corresponding relationship.

[0059] The specific method for establishing the relationship between the grinding power p of a single grinding wheel and the grinding area S of a single grinding wheel on a rail grinding machine is as follows: Step S41: Obtain the basic equivalent coefficient λ between the grinding area S of a single grinding wheel of the rail grinding machine and the grinding power p of a single grinding wheel; Step S42: Establish the equivalent relationship between the grinding power p and the grinding area S of a single grinding wheel of the rail grinding machine: S = p λ (k) V + k θ );in: S represents the grinding area of ​​a single grinding wheel; p represents the grinding power of a single grinding wheel; k V is the grinding speed compensation coefficient, used to compensate for the difference in grinding efficiency between grinding area S and grinding power p under different grinding speeds, and v is the grinding speed of a single grinding wheel; k θ θ is the grinding angle compensation coefficient, used to compensate for the grinding efficiency deviation between the grinding area S and the grinding power p under different grinding angles, where θ is the grinding angle of a single grinding wheel.

[0060] The basic equivalent coefficient λ and the compensation coefficient, as well as the grinding speed compensation coefficient k, are all based on the principle of equality and equality. V Grinding angle compensation coefficient k θ All of these can be obtained through refinement experiments or machine learning methods, and can be adjusted and revised during use.

[0061] The grinding mode includes a grinding strategy. When the grinding strategy adopts a grinding strategy that grinds sequentially from one side of the rail to the other, step S5: Based on the relationship between the grinding power and grinding area of ​​the rail grinding vehicle, and with the goal of eliminating the area of ​​the rail to be ground, a grinding mode is automatically generated. The main implementation process is as follows: Figure 4 As shown, it includes: (1) Extend the line segment of the target outline after design and polishing to polishing line 6 ( Figure 3 The purple line segment is the polishing line 6). Calculate the effective polishing area enclosed by the actual outline 1 to be polished. The effective polishing area refers to the area enclosed above the polishing line 6.

[0062] (2) Based on the grinding speed and grinding angle parameters of the rail grinding vehicle, and the equivalent relationship between the grinding area and grinding power of the rail grinding vehicle, calculate the effective grinding power of the rail grinding vehicle.

[0063] (3) The maximum grinding power of the rail grinding car is used as the constraint judgment condition. If the grinding power exceeds the maximum grinding power of the grinding car, the outer end point of the target profile 3 after grinding is used as the fixed point, and the grinding angle and grinding line are continuously adjusted. Steps (1) and (2) are repeated to ensure that the grinding power does not exceed the limit.

[0064] (4) Output the grinding angle and grinding power of a single grinding head, and replace the actual profile 1 to be ground with the profile formed after simulation grinding according to the grinding parameters.

[0065] (5) After updating the actual profile to be polished, perform the polishing parameter calculation for the next polishing head.

[0066] (6) Execute the next line segment of the target profile 3 after design grinding, repeat (1) to (5) until all line segments of the target profile 3 after design grinding are executed. A series of grinding parameters of the grinding head, including grinding angle and grinding power, will be generated in sequence, that is, the grinding mode based on the repair of the target profile 3 after design grinding is automatically generated.

[0067] (7) The generated grinding mode can be entered into the grinding car in sequence to guide the grinding operation, or a grinding file can be generated according to the number of grinding car heads and the grinding direction, so as to import the grinding car to guide the operation.

[0068] To facilitate understanding, the following example illustrates the process of automatically generating rail grinding patterns using a strategy that grinds rails sequentially from one side to the other. Figure 5 A flowchart illustrating the process of automatically generating a polishing pattern based on a strategy of polishing sequentially from one side to the other. Figure 8 A simulation diagram illustrating the effect of automatically generating a polishing pattern based on a strategy of polishing sequentially from one side to the other.

[0069] like Figure 5 and Figure 8 As shown, under the preset constraints, the maximum grinding power of a single grinding wheel of the rail grinding machine is p_max, the maximum grinding angle of a single grinding wheel is θ_max, and the minimum grinding angle of a single grinding wheel is θ_min.

[0070] Step S51: Select the i-th (starting from the first) line segment of the target profile 3 after design and polishing, and denote it as line segment i; Step S52: Calculate the equation of the straight line i of the grinding line i of line segment i; Step S53: Calculate the grinding angle of grinding line i based on the straight line equation of grinding line i. Step S54: Determine whether the grinding angle of grinding line i exceeds the limit of the grinding angle of a single grinding wheel of the rail grinding car. The maximum grinding angle of the grinding wheel is θ_max and the minimum grinding angle of the grinding wheel is θ_min. If the grinding angle of grinding line i does not exceed the limit of the grinding angle of the grinding wheel of the rail grinding vehicle, proceed to step S54-1. If the grinding angle of grinding line i exceeds the grinding angle limit of the grinding wheel of the rail grinding vehicle, it indicates that the grinding line exceeds the grinding capacity of the grinding vehicle, and the calculation is transferred to the next grinding line, and step S55 is executed. Step S55: Proceed to the next line segment of the target profile 3 after design and polishing; wherein, the method used is to assign a value to i, i=i+1; Step S56: Determine whether all line segments of the target profile 3 after design and polishing have been selected; If all line segments of the target profile 3 after design and polishing have been selected, it means that the entire polishing profile has been completed, and the polishing mode generation program ends directly. If not all line segments of the target profile 3 after design and polishing have been selected, proceed to step S51.

[0071] In practice, the grinding mode includes a grinding strategy. When the grinding strategy adopts a grinding strategy that grinds sequentially from one side of the rail to the other, the method for automatically generating the grinding mode in step S5 includes: Step S54-0: Design the target profile 3 after grinding, and the profile to be ground formed after grinding with the previous (n-1) grinding parameters, as the profile to be ground n; Step S54-1: Calculate the effective grinding area required between the grinding line i and the profile n to be ground; Step S54-2: Combine the grinding speed and grinding angle of the rail grinding vehicle to calculate the grinding area S and grinding power equivalence coefficient of the rail grinding vehicle, and then calculate the effective grinding power corresponding to the effective grinding area. Step S54-3: Determine whether the effective grinding power exceeds the maximum grinding power p_max of the rail grinding vehicle: If the effective grinding power does not exceed the maximum grinding power p_max of the rail grinding vehicle, it indicates that grinding line i can be completed by a single grinding head. Step S54-3-1 is executed: output the grinding angle and grinding power of that grinding head as the grinding parameters for the nth grinding head. The next grinding parameter calculation should proceed to grinding line i+1.

[0072] When the effective grinding power exceeds the maximum grinding power p_max of the rail grinding vehicle, it indicates that the i-th grinding line cannot be completed under the current grinding parameters. The grinding parameters need to be adjusted, and step S54-4 should be executed.

[0073] Step S54-4: Using the outer endpoint (near the start edge) of grinding line i as a fixed point, the grinding angle is adjusted using the bisection method to quickly find the grinding line corresponding to the maximum grinding area S_max; wherein, the bisection method is used to calculate the grinding line by adjusting the grinding angle based on the known grinding point and the target grinding area S_max, and the process is as follows. Figure 6 As shown.

[0074] Step S54-5: Calculate the grinding angle of the nth grinding wheel corresponding to the grinding line corresponding to the maximum grinding area S_max. Step S54-6: Determine whether the grinding angle of the nth grinding wheel corresponding to the grinding line corresponding to the maximum grinding area S_max exceeds the grinding angle range of the rail grinding vehicle. If the grinding angle does not exceed the limit of the rail grinding vehicle, proceed to step S54-3-1: output the grinding angle and grinding power of the grinding head as the grinding parameters for the nth grinding head. The next grinding parameter calculation is still performed on the i-th grinding line, so the value of i does not change.

[0075] If the grinding angle exceeds the limit of the rail grinding machine, the grinding angle strategy needs to be adjusted, and step S54-7 should be executed: Step S54-7: Grind according to the grinding angle of the i-segment grinding line; Step S54-8: Use the bisection method to quickly find the grinding line with a grinding area of ​​S_max at the given grinding angle, then jump to step S54-3-1: Output the grinding angle and grinding power of the grinding head as the grinding parameters for the nth grinding head. The bisection method calculates the grinding line by adjusting the grinding intercept based on the known grinding angle and target grinding area S_max, as shown in the following process. Figure 7 As shown.

[0076] The grinding mode includes a grinding strategy. When the grinding strategy adopts a grinding strategy that grinds sequentially from one side of the rail to the other, the method for automatically generating the grinding mode in step S5 includes: Step S54-3-1: Output the grinding angle and grinding power of the nth grinding wheel; Step S54-3-2: Simulate grinding the profile n to be ground according to the grinding angle and grinding power of the nth grinding wheel. The profile formed after grinding is used as the profile to be ground in the next grinding mode. Step S54-3-3: Update the profile after simulated grinding using the grinding angle and grinding power of the nth grinding wheel to a new profile segment n to be ground, where n = n + 1; continue to calculate the grinding parameters for the i-th grinding line that has not yet been ground, and proceed to step S52.

[0077] It is worth noting that the target profile in this method can be a standard profile or any other profile based on improving the wheel-rail relationship, making it suitable for the automatic design of grinding modes for different target profiles. It is also applicable to applications that do not change the current measured profile but only perform uniform surface grinding on the rail; in this case, the measured profile can be used as the target grinding profile.

[0078] Figure 6 The algorithm implementation flow uses the bisection method to calculate the grinding angle based on known grinding points and the target grinding area. That is... Figure 6 The process is Figure 5 This paper presents a specific implementation method for quickly finding the grinding line using the binary search method.

[0079] Step S61: Obtain the profile to be polished; Step S62: Import the maximum grinding area S_max, and select the grinding point according to the grinding line i; Step S63: Obtain the maximum grinding angle θ_max and the minimum grinding angle θ_min of the rail grinding vehicle; Step S64: The grinding angle θ of the grinding machine = (θ_max + θ_min) / 2; Step S65: Use the point-slope method to find the straight line equation of the grinding line; Step S66: Select the area where the grinding line intersects with the profile to be ground; Step S67: Determine if the intersecting data is greater than or equal to 2? If there are 2 or more intersecting data, proceed to step S68: determine whether the intersecting data are discontinuous. When the intersecting data is discontinuous, calculate the intersecting area S by region; When the intersecting data is continuous, the intersection area S is calculated directly; Step S610: Determine whether the deviation between the intersection area S and S_max is less than or equal to e; If the deviation between the intersection area S and S_max is less than or equal to e, proceed to step S611; Step S611: Output polishing line.

[0080] In step S67: Determine whether the intersecting data is greater than or equal to 2? If the number of intersecting data is less than 2, proceed to step S610-3: Step S67-1: θ_max = θ.

[0081] In step S610: Determine whether the deviation between the intersection area S and S_max is less than or equal to e; If the deviation between the intersection area S and S_max is greater than e, proceed to step S610-1. Step S610-1: Determine the intersection area S 相交 Is it greater than the maximum grinding area S_max of the rail grinding vehicle? In the intersection area S 相交 If the area is greater than the maximum grinding area S_max of the rail grinding vehicle, proceed to step S610-2: θ_min = θ; If the intersection area S is not greater than the maximum grinding area S_max of the rail grinding vehicle, proceed with step S610-3.

[0082] After steps S610-3 and S610-2, step S610-4 is executed: update θ; then step S64 is executed.

[0083] Figure 7 The algorithm implementation flow for solving the grinding line equation using the bisection method with known grinding angles and target grinding area is as follows: Figure 7 The process is Figure 5 The binary search method is used to quickly find another specific implementation of the grinding line.

[0084] Step S71: Obtain the profile to be polished; Step S72: Import the maximum grinding area S_max and grinding angle θ; Step S73: Initialize the maximum intercept b_max = 140mm and the minimum intercept b_min = 0mm; Step S74: The intercept of the grinding machine is b = (b_max + b_min) / 2; Step S75: Use the oblique intercept method to find the straight line equation of the grinding line; Step S76: Select the area where the grinding line intersects with the measured profile 2; Step S77: Determine if the intersecting data is greater than or equal to 2? If there are 2 or more intersecting data, proceed to step S78: determine whether the intersecting data are discontinuous. When the intersecting data is discontinuous, calculate the intersecting area S by region; When the intersecting data is continuous, the intersection area S is calculated directly; Step S710: Determine whether the deviation between the intersection area S and S_max is less than or equal to e; If the deviation between the intersection area S and S_max is less than or equal to e, proceed to step S711; Step S711: Output polishing line.

[0085] In step S77: Determine whether the intersecting data is greater than or equal to 2? If the number of intersecting data is less than 2, proceed to step S710-3: Step S77-1: b_max = b.

[0086] In step S710: Determine whether the deviation between the intersection area S and S_max is less than or equal to e; If the deviation between the intersection area S and S_max is greater than e, proceed to step S710-1. Step S710-1: Determine whether the intersection area S is greater than the maximum grinding area S_max of the rail grinding machine; If the intersection area S is greater than the maximum grinding area S_max of the rail grinding vehicle, execute step S710-2: b_min = b; If the intersection area S is not greater than the maximum grinding area S_max of the rail grinding vehicle, proceed with step S710-3.

[0087] After steps S710-3 and S710-2, step S710-4 is executed: update b; then step S74 is executed.

[0088] The advantages of this invention are: 1. The polishing pattern automatically generated by the method of the present invention is a precise repair method based on the target profile.

[0089] In the method of this invention, the target profile can be any profile. It can automatically generate the corresponding grinding pattern based on the deviation between the measured profile and the target profile. It has high design efficiency, fast calculation speed, and can be directly and effectively used for profile repair grinding operations.

[0090] 2. Based on the target silhouette design, the final polished silhouette can be customized, and the width of the polished silhouette surface can be controlled.

[0091] 3. Facilitates programmed calculations and enables programmed grinding patterns. This invention provides a programmed calculation flow, which is easy to implement and facilitates the design of batch rail profile repair and grinding patterns.

[0092] It can automatically generate modes and grinding schemes based on the characteristics of different grinding machines (such as 16 heads, 20 heads, 48 ​​heads, 96 heads, etc.), different grinding speeds, grinding directions, etc., and has strong application scalability.

[0093] It is compatible with a variety of grinding strategies, such as automatic generation of grinding modes based on profile repair, or automatic generation of grinding modes based on the elimination of surface fatigue layer or microcrack layer without changing the current profile, and has broad application prospects.

[0094] The following is a standardized explanation of the technical terms used in this application: Specifically, the railhead center point refers to the geometric center of the top of the rail. In railway engineering and related technical fields, this point is commonly used to define some key characteristics of the track and to perform precise measurements. For example, on the cross-section of the track, the railhead center point is the midpoint of the top surface of the rail head, and in some cases it is used to determine the track's orientation, height, and relative position to other structures (such as vehicle wheelsets).

[0095] Specifically, the working side and non-working side of a rail refer to the two sides of the contact surface between the rail and the wheel, each with different meanings and functions: Working edge: This refers to the inner edge of the rail, which is the side that directly contacts the tread of the train wheels. Because this side directly bears the pressure and friction when the train passes, it is called the working edge.

[0096] Non-working edge: In contrast, the outer edge of the rail is called the non-working edge.

[0097] Specifically, the working edge gauge point is a specific reference point used in railway track surveying to determine the track gauge (i.e., the distance between the inner edges of the heads of two rails). This point is located on the working edge of the rail, specifically 16 millimeters below the top surface of the inner edge of the rail. This is an internationally accepted standard measurement location.

[0098] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0099] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 a process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0100] These computer program instructions may also be stored in a computer readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 a process or multiple processes and / or boxes Figure 1 The function specified in one or more boxes.

[0101] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing the instructions executed on the computer or other programmable device for implementing the process. Figure 1 a process or multiple processes and / or boxes Figure 1 A step that specifies a function in one or more boxes.

[0102] Although preferred embodiments of this application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of this application.

[0103] Obviously, those skilled in the art may make various changes and modifications to this application without departing from the spirit and scope of this application. Thus, if these modifications and variations of this application fall within the scope of the claims of this application and their equivalents, this application is intended to include these modifications and variations.

Claims

1. A method for automatically generating rail grinding patterns, characterized in that, Includes the following steps: Step S1: Using the target profile (1) of the rail as a reference, align the measured profile (2) of the rail with the target profile (1) of the rail; Step S2: Based on the grinding mechanism of the rail grinding machine, the designed target profile (3) of the rail after grinding is formed based on the target profile (1) of the rail; wherein, the designed target profile (3) after grinding is formed by connecting multiple sequentially connected line segments; Step S3: Based on the actual measured profile (2) after alignment and the target profile (3) after grinding, calculate and determine the location and area of ​​the rail to be ground; Step S4: Establish the relationship between the grinding power p of a single grinding wheel of the rail grinding machine and the grinding area S of a single grinding wheel; Step S5: With the goal of eliminating the area of ​​the rail to be ground, a grinding mode is automatically generated based on the relationship between the grinding power p of a single grinding wheel and the grinding area S of a single grinding wheel on the rail grinding vehicle.

2. The method according to claim 1, characterized in that, Step S1 specifically includes: Step S11: Using the target profile (1) as a reference, align the measured profile (2) with the target profile (1) vertically at the center point of the rail top; Step S12: Align the measured profile (2) with the target profile (1) left and right; the alignment method is as follows: For the measured profile (2) where the working edge is not severely worn, align the left and right sides at the working edge gauge point and below where there is no wear or deformation. For the measured profile (2) with severe wear on the working edge, align the left and right sides of the non-working edge that is not worn or deformed.

3. The method according to claim 1, characterized in that, Step S2 specifically includes: Step S21: Move the target profile (1) down as a whole; where the depth of the downward movement is the displacement of the expected grinding depth of the rail top; Step S22: Based on the grinding mechanism of the rail grinding machine, the target profile after being moved down is segmented and linearized. The segmented linearization process refers to the segmented linearization process of the target profile after the downward movement, based on a preset length of the width of different areas after grinding. Step S23: Form the target profile after design and polishing (3).

4. The method according to claim 1, characterized in that, Step S3 specifically includes: Step S31: Extend the outermost left and outermost right line segments of the target profile (3) after grinding to intersect with the measured profile (1), and calculate the position of the intersection point (5) on both sides; where the intersection point (5) is the starting point and ending point of the area to be ground on the rail. Step S32: When the outermost line segment extends outward and cannot find an intersection with the measured profile (2), then gradually look inward for the next line segment of the target profile (3) after design and polishing and execute step S31 until an outer intersection point or an intersection point that intersects with the line segment range of the target profile (3) after design and polishing is found. Step S33: The area enclosed by the target profile (3) after design and the measured profile (2) is the area to be polished (4), and the area of ​​the area to be polished is calculated and determined; Step S34: Design each line segment of the target profile (3) after polishing to extend to both sides to the intersection with the measured profile (2) to form a polishing line (6). The area above the polishing line (6) in the area to be polished (4) is the polishing area of ​​the polishing line (6).

5. The method according to claim 1, characterized in that, Step S4 specifically includes: Step S41: Obtain the basic equivalent coefficient λ between the grinding area S of a single grinding wheel of the rail grinding machine and the grinding power p of a single grinding wheel; Step S42: Establish the equivalent relationship between the grinding power p of a single grinding wheel and the grinding area S of a single grinding wheel of the rail grinding machine: S = p λ (k) V + k θ ); Where S is the grinding area of ​​a single grinding wheel; p is the grinding power of a single grinding wheel; k V k is the grinding speed compensation coefficient, used to compensate for the difference in grinding efficiency between the grinding area S and the grinding power p at different grinding speeds; θ θ is the grinding angle compensation coefficient, used to compensate for the grinding efficiency deviation between the grinding area S and the grinding power p under different grinding angles, v is the grinding speed of a single grinding wheel, and θ is the grinding angle of a single grinding wheel.

6. The method according to claim 1, characterized in that, Step S5 automatically generates a polishing mode, which includes a polishing strategy. The polishing strategy includes: Grinding can be done sequentially from one side of the rail to the other, or from both sides of the rail to the middle, or from the middle of the rail to both sides. For cases with a large amount of grinding, in order to avoid grinding too many times continuously at a single angle, the grinding depth can be divided into multiple operations, covering the grinding layer by layer until the grinding is completed.

7. The method according to claim 1, characterized in that, The grinding mode includes a grinding strategy. When the grinding strategy adopts a grinding strategy that grinds sequentially from one side of the rail to the other, the method for automatically generating the grinding mode in step S5 includes: Step S51: Select the i-th line segment of the target profile 3 after design and polishing, and represent it as line segment i; Step S52: Calculate the point-slope equation of the grinding line i of line segment i; Step S53: Calculate the grinding angle of grinding line i based on the slope of the point-slope equation of grinding line i. Step S54: Determine whether the grinding angle of grinding line i exceeds the grinding angle limit of the grinding wheel of the rail grinding vehicle. The maximum grinding angle is θ_max and the minimum grinding angle is θ_min. If the grinding angle of grinding line i does not exceed the range of the maximum grinding angle θ_max and the minimum grinding angle θ_min, then proceed to step S54-1. If the grinding angle of grinding line i exceeds the limit of the grinding angle of the rail grinding vehicle, proceed to step S55. Step S55: Proceed to the next line segment of the target profile 3 after design and polishing; wherein, the method used is to assign a value to i, i=i+1; Step S56: Determine whether all line segments of the target profile 3 after design and polishing have been selected; If all line segments of the target silhouette 3 after design and refinement have been selected, the process ends directly. If not all line segments of the target profile 3 after design and polishing have been selected, proceed to step S51.

8. The method according to claim 1, characterized in that, The grinding mode includes a grinding strategy. When the grinding strategy adopts a grinding strategy that grinds sequentially from one side of the rail to the other, the method for automatically generating the grinding mode in step S5 includes: Step S54-0: Design the actual profile part corresponding to the nth line segment of the target profile 3 after polishing, as the profile segment n to be polished; the profile segment n to be polished is the profile to be polished formed after n-1 polishing. Step S54-1: Calculate the effective grinding area of ​​grinding line i and profile n to be ground; Step S54-2: Combining the grinding speed v and grinding angle θ of the grinding wheel of the rail grinding vehicle, the basic equivalent coefficient λ between the grinding area S and grinding power p of the grinding wheel of the rail grinding vehicle is obtained by grinding test and simulation calculation or by combining AI, and then the effective grinding power corresponding to the effective grinding area is calculated. Step S54-3: Determine whether the effective grinding power exceeds the maximum grinding power p_max of the rail grinding vehicle: When the effective grinding power exceeds the maximum grinding power p_max of the rail grinding vehicle, proceed to step S54-4. When the effective grinding power does not exceed the maximum grinding power p_max of the rail grinding vehicle, it means that the grinding meets the grinding conditions of the grinding vehicle. Jump to S54-3-1: Output the grinding angle and grinding power corresponding to the grinding line, which is recorded as the grinding mode of the nth grinding head. Step S54-4: Using the outer endpoint of the i-th grinding line as a fixed point, use the bisection method to quickly find the grinding line corresponding to the maximum grinding area S_max of the grinding wheel; Step S54-5: Calculate the grinding angle of the grinding wheel corresponding to the grinding line corresponding to the maximum grinding area S_max of the grinding wheel; Step S54-6: Determine whether the grinding angle of the grinding wheel corresponding to the grinding line corresponding to the maximum grinding area S_max of the grinding wheel exceeds the grinding angle of the rail grinding vehicle. If the grinding angle of the grinding wheel corresponding to the grinding line corresponding to the maximum grinding area S_max of the grinding wheel exceeds the limit of the grinding angle of the rail grinding vehicle, proceed to step S54-7. If the grinding angle of the grinding wheel corresponding to the grinding line corresponding to the maximum grinding area S_max of the grinding wheel does not exceed the limit of the grinding angle of the rail grinding vehicle, execute step S54-3-1: output the grinding angle and grinding power corresponding to the grinding line, and record it as the grinding mode of the nth grinding head. Step S54-7: Grind according to the grinding angle of the i-segment grinding line; Step S54-8: Use the binary search method to quickly find the grinding line with a grinding area of ​​S_max of the grinding wheel at the grinding angle, and jump to step S54-3-1: Output the grinding angle and grinding power corresponding to the grinding line, and record it as the grinding mode of the nth grinding head.

9. The method according to claim 1, characterized in that, The grinding mode includes a grinding strategy. When the grinding strategy adopts a grinding strategy that grinds sequentially from one side of the rail to the other, the method for automatically generating the grinding mode in step S5 includes: Step S54-3-1: Output the grinding angle and grinding power of the nth grinding wheel; Step S54-3-2: Simulate grinding based on the grinding angle and grinding power of the nth grinding wheel to be ground profile n; Step S54-3-3: Update the grinding angle and grinding power of the nth grinding wheel. The profile to be ground after simulation grinding is used as the new profile segment n to be ground. The count of n is incremented by 1, i.e., n = n + 1. After completing the output of the grinding mode and updating the profile to be ground, continue to solve the grinding mode of the next grinding head and execute step S52; until all grinding lines have been ground, the output of the grinding mode ends, the grinding mode output is completed, and the grinding mode output program ends.

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