A method for automatically generating a rail grinding pattern

Abstract

The application provides a method for automatically generating a rail grinding mode, comprising the following steps: aligning a measured profile of a rail with a target profile of the rail based on the target profile of the rail; forming a design post-grinding target profile of the rail based on the target profile of the rail; the design post-grinding target profile is connected by a plurality of sequentially connected line segments; determining the position and area of a to-be-ground region of the rail according to the aligned measured profile and the design post-grinding target profile; establishing a relationship between the grinding power of a single grinding wheel of a rail grinding vehicle and the grinding area of the single grinding wheel; and automatically generating a grinding mode based on the relationship between the grinding power of the single grinding wheel of the rail grinding vehicle and the grinding area of the single grinding wheel, with the goal of eliminating the area of the to-be-ground region of the rail. The application solves the technical problem of the traditional rail grinding, which needs manual confirmation of the to-be-ground region and determination of the grinding mode according to grinding experience.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of rail grinding, in particular to a method for automatically generating a rail grinding mode. BACKGROUND

[0002] As a key component of railway transportation system, the rail plays a role of bearing and transferring load to the roadbed. In the operation process, the rail surface and even the internal damage and injury occur due to the complex and variable load and stress of the track vehicle, and the rail profile is worn and deformed, which affects the smoothness and comfort of the train.

[0003] The rail grinder is an effective means for repairing the rail surface damage and profile, and has become an indispensable tool for rail maintenance and improving the service life of the rail with the increase of the speed of the track train, the increase of the train density and the increase of the carrying weight. The working principle of the rail grinder is to complete the required metal grinding amount by grinding the rail with the grinding wheel to achieve the purpose of eliminating the rail surface damage or repairing the profile, thereby controlling the generation and development of the disease and improving the wheel-rail contact relationship, prolonging the service life of the rail and improving the comfort of the railway operation.

[0004] The rail grinding operation needs to specify different grinding schemes to determine the specific grinding mode according to the actual situation of the rail, so as to achieve the effect of profile repair or rail surface disease repair. If the design of the grinding mode is unreasonable, it will directly affect the grinding quality and effect.

[0005] The traditional rail grinding needs to manually confirm the grinding area and determine the grinding mode according to the grinding experience, which has the technical problem of low efficiency of the grinding mode generation.

[0006] The above information disclosed in the background is only used to strengthen the understanding of the background of the present application, and therefore it may contain information which is not formed into the prior art known by those skilled in the art. SUMMARY

[0007] The present application provides a method for automatically generating a rail grinding mode to solve the technical problem of the traditional rail grinding which needs to manually confirm the grinding area and determine the grinding mode according to the grinding experience.

[0008] The present application provides a method for automatically generating a rail grinding mode, comprising the following steps:

[0009] Step S1: aligning the measured profile of the rail and the target profile of the rail based on the target profile of the rail;

[0010] Step S2: According to the grinding wheel grinding mechanism of the rail grinding vehicle, a design post-grinding target profile of the rail is formed based on a target profile of the rail; wherein the design post-grinding target profile is connected by a plurality of sequentially connected line segments;

[0011] Step S3: According to the aligned measured profile and the design post-grinding target profile, the position of the to-be-ground area of the rail and the area of the to-be-ground area are calculated and determined;

[0012] Step S4: The relationship between the grinding power p of a single grinding wheel of the rail grinding vehicle and the grinding area S of the single grinding wheel is established.

[0013] Step S5: Taking the elimination of the area of the to-be-ground area of the rail as the target, a grinding mode is automatically generated based on the relationship between the grinding power p of a single grinding wheel of the rail grinding vehicle and the grinding area S of the single grinding wheel.

[0014] The present application has the following technical effects due to the use of the above technical solutions:

[0015] In the rail grinding mode automatic generation method of the present application:

[0016] The measured profile 2 of the rail of step S1 is aligned with the target profile 1, which ensures the accuracy of the subsequent determination of the position of the to-be-ground area of the rail and the calculation of the to-be-ground area of the to-be-ground area.

[0017] Step S2 combines the grinding wheel grinding mechanism of the rail grinding vehicle to generate a design post-grinding target profile formed by sequentially connecting a plurality of line segments, which not only considers the theoretical requirements of the target profile of the rail, but also considers the processing capacity of the actual grinding equipment (such as the movement trajectory limitation of the grinding wheel), avoiding unfeasible grinding paths caused by idealized design, and improving the implementability of the scheme.

[0018] Step S3 accurately positions based on the aligned measured profile and the design post-grinding target profile, and calculates and determines the position of the to-be-ground area and the to-be-ground area thereof, i.e. accurately calculates the position of the to-be-ground area of the rail and the to-be-ground area thereof, and realizes quantitative analysis of the material removal amount.

[0019] Step S4 refines the establishment of the relationship between the accurate grinding amount and the grinding power, grinding speed and grinding angle under different grinding operation conditions of each grinding head for different areas of the rail head, providing a decision data basis for fine control of grinding operation quality.

[0020] Step S5 establishes a quantitative-based grinding area automatic closed-loop elimination control algorithm, which realizes automatic generation of the grinding mode based on the target profile repair.

[0021] The rail grinding mode automatic generation method of the application, the design grinding target profile formed by sequentially connecting multiple line segments, not only considers the theoretical requirements of conforming to the rail target profile, but also considers the processing capacity of the actual grinding equipment; The position of the area to be ground and the area to be ground are accurately calculated and determined, the quantitative analysis of the material removal amount is realized, and the precision, efficiency and resource utilization of the rail grinding can be significantly improved. BRIEF DESCRIPTION OF DRAWINGS

[0022] The drawings described herein are used to provide further understanding of the application, and form a part of the application. The illustrative embodiments of the application and their descriptions are used to explain the application, and do not constitute an improper limitation on the application. In the drawings:

[0023] Figure 1 The steps and flowchart of the rail grinding mode automatic generation method of the application;

[0024] Figure 2 The profile alignment, target profile design and measured profile comparison schematic diagram;

[0025] Figure 3 The schematic diagram of the area change required to be ground in each step of the right-to-left step-by-step grinding process;

[0026] Figure 4 The overall method flowchart of automatically generating the grinding mode based on the grinding area deviation;

[0027] Figure 5 The flowchart of automatically generating the grinding mode based on the one-side sequential grinding to the other side strategy;

[0028] Figure 6 The algorithm implementation process of using the known grinding point and target grinding area to solve the grinding angle by using the bisection method;

[0029] Figure 7 The algorithm implementation process of using the known grinding angle and target grinding area to solve the grinding line equation by using the bisection method;

[0030] Figure 8 The simulation effect schematic diagram of automatically generating the grinding mode based on the one-side sequential grinding to the other side strategy.

[0031] REFERENCE NUMERALS:

[0032] Target profile 1, measured profile 2, design grinding target profile 3, area to be ground 4, intersection point 5, grinding line 6. DETAILED DESCRIPTION

[0033] 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

[0034] like Figures 1 to 3 As shown, the method for automatically generating rail grinding patterns according to this application includes the following steps:

[0035] 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.

[0036] 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;

[0037] 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.

[0038] 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;

[0039] 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.

[0040] In the method for automatically generating rail grinding patterns in this application embodiment:

[0041] 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.

[0042] 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.

[0043] Step S3 is based on the aligned measured profile 2 and the designed post-grinding target profile 3 to accurately position and calculate the position of the area to be ground and the area to be ground, that is, to accurately calculate the position of the area to be ground and the area to be ground of the steel rail, and to realize quantitative analysis of the material removal amount.

[0044] Step S4 refines the relationship between the accurate grinding amount and the grinding power, grinding speed and grinding angle of each grinding head under different grinding operation conditions of different areas of the rail head, providing decision data basis for fine control of grinding operation quality.

[0045] Step S5 establishes a quantitative grinding area automatic closed-loop elimination control algorithm to realize automatic generation of the grinding mode based on the target profile repair.

[0046] The steel rail grinding mode automatic generation method of the present application, the designed post-grinding target profile 3 formed by sequentially connecting multiple line segments, not only considers the theoretical requirements of the steel rail target profile, but also considers the processing capacity of the actual grinding equipment; the position of the area to be ground and the area to be ground are accurately calculated and determined, and quantitative analysis of the material removal amount is realized, which can significantly improve the precision, efficiency and resource utilization rate of steel rail grinding.

[0047] The steel rail grinding mode automatic generation method of the present application, steps S1 to S3, based on the target profile of the steel rail, the area deviation of the measured profile of the steel rail, and the designed post-grinding target profile of the steel rail, accurately calculate and determine the position of the area to be ground of the steel rail and the area to be ground of the area to be ground, thereby quickly and accurately determining the position of the area to be ground of the steel rail and the area to be ground of the area to be ground. Steps S4 to S5, with the goal of eliminating the area to be ground of the steel rail, automatically generate a grinding mode through the relationship between the grinding area and the grinding power of the single grinding wheel of the steel rail grinding car, which can be directly and effectively used for profile repair grinding operation, with high efficiency and high automation degree.

[0048] Specifically, the target profile of the steel rail refers to the ideal geometric shape set for the head of the steel rail in the design and maintenance of the railway track. This ideal shape design is based on various considerations, including but not limited to the safety, stability, comfort of train operation, and reduction of wear and noise, etc.

[0049] Specifically, the measured profile of the steel rail refers to the data of the geometric shape of the head of the steel rail directly obtained on the track in actual operation through specific measurement tools and techniques. This data reflects the actual shape changes of the steel rail after a period of use due to repeated rolling of train wheelsets, environmental factors and possible maintenance operations, etc.

[0050] Specifically, the design post-grinding target profile of the rail refers to the ideal rail head geometry that is expected to be achieved after grinding maintenance of the rail. This target profile is designed based on various considerations, aiming to optimize the wheel-rail contact state, prolong the service life of the rail and the wheel, reduce noise, and ensure the safety and comfort of train operation.

[0051] The target profile of the rail refers more to the ideal shape that the rail should maintain throughout its service life, serving as a general guideline for rail installation and maintenance. The design post-grinding target profile of the rail, on the other hand, specifically refers to the specific geometry that the rail should achieve after maintenance (such as grinding), which is a more specific and operational level target set to restore the performance of the rail. The two work together to ensure the efficient operation and safety of the railway system.

[0052] The steps S1 to S5 will be described in detail below.

[0053] As shown in Figure 2 , step S1 specifically includes:

[0054] Step S11: Align the measured profile 2 (shown in black solid line) with the target profile 1 at the top center point of the rail (shown in red solid line) up and down. Figure 2 Figure 2 Step S12: Align the measured profile 2 with the target profile 1 left and right; the left and right alignment method is as follows:

[0055] For the measured profile 2 with less wear on the working side (i.e. the edge of the inner side of the rail, which is directly in contact with the train wheel tread), align it left and right at the gage point and below the non-wear deformed area on the working side; the effect after alignment is shown in

[0056] For the measured profile 2 with severe wear on the working side, choose the non-working side (i.e. the edge of the outer side of the rail) non-wear deformed area for left and right alignment. Figure 2

[0057] Specifically, if the wear position on the working side has exceeded the gage corner position, it can be considered as severe wear, and at this time, the non-working side can be considered as the left and right alignment edge.

[0058] Step S12 adopts a left and right alignment strategy that adapts to the degree of wear:

[0059] For the measured profile with less wear on the working side, choose the gage point and below the non-wear area on the working side for left and right alignment, which preserves the reference nature of the original gage parameter of the rail, avoiding the introduction of transverse errors by unnecessary coordinate system translation.

[0060]

[0061] ​​​For the measured profile with serious wear on the working edge, switch to the non-working edge without wear area for alignment, avoid the interference of the wear area on the reference point, and ensure the reliability of left and right direction positioning.

[0062] As shown in Figure 2 , the measured profile 2 deviates from the target profile 1, indicating that the measured profile 2 has undergone significant wear deformation during use, resulting in a decrease in profile quality, and it is necessary to repair it by grinding.

[0063] For the measured profile with serious wear on the working edge, the non-working edge without wear deformation can be selected for left and right alignment.

[0064] For the measured profile with serious wear on the working edge, such as the curve of the long-term service upper rail, there may be significant wear at the gauge corner and the lower part. If the working edge is used for alignment, it is easy to cause a large transverse deviation after the profile alignment. Therefore, for such profiles, the non-working edge without wear deformation can be selected for left and right alignment.

[0065] Among them, the working edge gauge point is the standardized position of the inner top surface of the steel rail at a certain depth (such as 16 mm), which is used as the reference point for gauge measurement and profile alignment.

[0066] As shown in Figure 2 , step S2 specifically includes:

[0067] Step S21: move the target profile 1 (red solid line) downward as a whole; wherein the depth of the downward movement is the displacement amount of the expected grinding depth of the rail head.

[0068] Step S22: based on the grinding mechanism of the rail grinding vehicle, the target profile in the target grinding range (i.e. the target profile after moving down) is segmented and linearly processed.

[0069] Among them, the segmented linear processing refers to segmented linear processing of the target profile after moving down according to the preset length of the profile width of different regions after grinding.

[0070] Step S23: form a designed target profile 3 after grinding;

[0071] The target profile of the complex curve after moving down is decomposed into a designed target profile 3 after grinding connected by multiple line segments, which has a higher degree of adaptation to the grinding of the rail grinding vehicle. The actual grinding of the grinding wheel of the rail grinding vehicle is completed to a higher degree, and the profile after actual grinding is closer to the target profile 3 after grinding.

[0072] As shown in Figure 2 and Figure 3 , step S3 specifically includes:

[0073] Step S31: Extend the line segments of the left and right outermost sides of the design polished target profile 3 outwards to intersect with the measured profile 1, and calculate the intersection points 5 on both sides (as shown in Figure 2 the points marked with an asterisk).

[0074] Step S32: When the outermost line segment is extended outwards and no intersection point is found with the measured profile 2, then gradually extend the next line segment of the design polished target profile 3 inwards 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.

[0075] Step S33: The area enclosed by the design polished target profile 3 and the measured profile 2 is the area to be polished 4 (as shown in Figure 2 the shaded area with diagonal lines), and the area of the area to be polished is calculated and determined;

[0076] Step S34: Each line segment of the design polished target profile 3 is extended outwards to the intersection position with the measured profile 2 to form a polishing line 6, and the area above the polishing line 6 in the area to be polished 4 is the polishing area of the polishing line, as shown in Figure 3 .

[0077] Step S31 and Step S32, the intersection point 5 is the intersection point of the design polished target profile 3 and the measured profile 1, which is the starting point and the ending point of the position of the area to be polished on the rail.

[0078] In this way, Step S33 and Step S34, the larger area to be polished 4 is divided into a plurality of smaller polishing line polishing areas.

[0079] As Figure 3 demonstrated in the figure, the polishing strategy is to polish from the right side of the rail to the left side step by step, and the area to be polished at each step changes.

[0080] When the polishing strategy is to polish from both sides of the rail to the middle, from the middle of the rail to both sides, or other sequential methods that can be implemented, the area to be polished at each step is different from Figure 3 .

[0081] For the convenience of understanding and explaining the method of the present application, the following content only selects the polishing strategy of polishing from one side of the rail to the other side step by step to explain the method of the present application, but this polishing strategy is only one application example of the present application, and does not limit the present application. The method of the present application can also be applied to different polishing strategies such as polishing from both sides of the rail to the middle, polishing from the middle of the rail to both sides, or other sequential methods that can be implemented.

[0082] Meanwhile, for the case of large polishing amount, the polishing strategy of polishing one to N layers by the whole covering method first and then polishing according to the polishing design profile section line as the polishing line is also applicable, and this will not be enumerated one by one.

[0083] The automatically generated polishing mode in step S5 comprises a polishing strategy, and the polishing strategy comprises:

[0084] The polishing is sequentially performed from one side of the rail to the other side, or from both sides of the rail to the middle, or from the middle of the rail to both sides; for the case of large polishing amount, the polishing depth can also be executed in multiple times to polish layer by layer until the polishing is completed.

[0085] Step S4: establishing the relationship between the polishing power p of the single grinding wheel of the rail polishing vehicle and the polishing area S of the single grinding wheel.

[0086] The polishing efficiency of the rail polishing vehicle is related to the grinding wheel characteristics, the polishing head (i.e. the grinding wheel) control, the rail characteristics and many other factors. When facing a certain rail polishing vehicle, the factors of the grinding wheel, the rail and the polishing control are relatively certain, and the factors that mainly affect the polishing power p are the polishing speed and the polishing angle.

[0087] Therefore, on the basis of obtaining the basic equivalent coefficient λ between the polishing area S and the polishing power p of the single grinding wheel, the compensation factors of the polishing speed v and the polishing angle θ can better reflect the relationship between the polishing area S and the polishing power p in the polishing process. That is, the polishing power p and the polishing area S of the rail polishing vehicle have a corresponding relationship.

[0088] The specific method for establishing the relationship between the polishing power p of the single grinding wheel of the rail polishing vehicle and the polishing area S of the single grinding wheel is as follows:

[0089] Step S41: obtaining the basic equivalent coefficient λ between the polishing area S of the single grinding wheel of the rail polishing vehicle and the polishing power p of the single grinding wheel;

[0090] Step S42: establishing the equivalent relationship between the polishing power p of the single grinding wheel of the rail polishing vehicle and the polishing area S of the single grinding wheel: S=p λ (k V + k θ ); wherein:

[0091] S is the polishing area of the single polishing grinding wheel;

[0092] p is the polishing power of the single grinding wheel;

[0093] k VA polishing speed compensation coefficient is used to compensate for the polishing efficiency difference between the polishing area S and the polishing power p at different polishing speeds, and v is the polishing speed of a single grinding wheel.

[0094] k θ A polishing angle compensation coefficient is used to compensate for the polishing efficiency deviation between the polishing area S and the polishing power p at different polishing angles, and θ is the polishing angle of a single grinding wheel.

[0095] The basic equivalent coefficient λ and the compensation coefficient polishing speed compensation coefficient k V , and the polishing angle compensation coefficient k θ can be obtained by polishing test or machine learning method, and can be adjusted and revised during use.

[0096] The polishing mode includes a polishing strategy, and when the polishing strategy is a polishing strategy of sequentially polishing from one side of the rail to the other side, step S5: based on the relationship between the polishing power and the polishing area of the rail polishing vehicle, a polishing mode is automatically generated to eliminate the area of the to-be-polished region of the rail. The main implementation process is as shown in Figure 4 , which includes:

[0097] (1) The line segment of the designed target profile after polishing is extended as a polishing line 6 (the purple line segment in Figure 3 is the polishing line 6), and the effective polishing area surrounded by the actual profile 1 to be polished and the polishing line 6 is calculated. The effective polishing area refers to the area surrounded above the polishing line 6.

[0098] (2) The effective polishing power of the rail polishing vehicle is calculated based on the equivalent relationship between the polishing area and the polishing power of the rail polishing vehicle in combination with the polishing speed and the polishing angle parameters of the rail polishing vehicle.

[0099] (3) The maximum polishing power of the rail polishing vehicle is used as a constraint judgment condition, and for the polishing power exceeding the maximum polishing power of the rail polishing vehicle, the outer endpoint of the designed target profile 3 after polishing is used as a fixed point, and the polishing angle and the polishing line are adjusted repeatedly, and steps (1) and (2) are repeated to make the polishing power not exceed the limit.

[0100] (4) The polishing angle and the polishing power of a single polishing head are output, and the profile formed after polishing is simulated according to the polishing parameters to replace the actual profile 1 to be polished.

[0101] (5) The polishing parameter calculation of the next polishing head is performed after updating the actual profile to be polished.

[0102] (6) Execute the next line segment of the design polished target profile 3, repeat (1) ~ (5), until all the line segments of the design polished target profile 3 are executed, a series of polishing parameters of polishing heads including polishing angle and polishing power are generated in sequence, that is, the polishing mode based on the design polished target profile 3 is automatically generated.

[0103] (7) The generated polishing mode can be input into the polishing car to guide the polishing operation, or a polishing file can be generated according to the number of polishing heads and the polishing direction to guide the operation.

[0104] For the convenience of understanding, the following lists a strategy of polishing from one side to the other to specifically explain the process of the method of automatically generating the programmed rail polishing mode. Figure 5 Flowchart of automatically generating the polishing mode based on the strategy of polishing from one side to the other. Figure 8 Schematic diagram of the simulation effect of automatically generating the polishing mode based on the strategy of polishing from one side to the other.

[0105] As shown in Figure 5 and Figure 8 , the preset limit conditions are that the maximum polishing power of a single grinding wheel of the rail polishing car is p_max, the maximum polishing angle of a single grinding wheel is θ_max, and the minimum polishing angle of a single grinding wheel is θ_min.

[0106] Step S51: Select the i-th (from the first) line segment of the design polished target profile 3, denoted as line segment i;

[0107] Step S52: Calculate the straight line equation of the polishing line i of the line segment i;

[0108] Step S53: Calculate the polishing angle of the polishing line i according to the straight line equation of the polishing line i;

[0109] Step S54: Determine whether the polishing angle of the polishing line i exceeds the limit of the polishing angle of a single grinding wheel of the rail polishing car, the maximum polishing angle of the grinding wheel is θ_max, and the minimum polishing angle of the grinding wheel is θ_min;

[0110] In the case where the polishing angle of the polishing line i does not exceed the limit of the polishing angle of the grinding wheel of the rail polishing car, step S54-1 is executed;

[0111] In the case where the polishing angle of the polishing line i exceeds the limit of the polishing angle of the grinding wheel of the rail polishing car, it means that the polishing line exceeds the polishing capacity of the polishing car, and the calculation of the next polishing line is transferred, and step S55 is executed;

[0112] Step S55: Go to the next line segment of the design polished target profile 3; wherein the adopted way is to assign i, i = i + 1;

[0113] Step S56: judging whether all line segments of the design post-grinding target profile 3 are selected;

[0114] In the case that all line segments of the design post-grinding target profile 3 are selected, it means that the whole grinding profile execution is completed, and the grinding mode generation program is directly ended;

[0115] In the case that all line segments of the design post-grinding target profile 3 are not selected, it jumps to step S51.

[0116] In the implementation, the grinding mode includes a grinding strategy, and when the grinding strategy is to sequentially grind from one side of the rail to the other side, the method for automatically generating the grinding mode in step S5 includes:

[0117] Step S54-0: the to-be-ground profile formed after the design post-grinding target profile 3 is ground by the previous (n-1) grinding parameters, as the to-be-ground profile n;

[0118] Step S54-1: calculating the effective grinding area required between the grinding line i and the to-be-ground profile n;

[0119] Step S54-2: combining the grinding speed and the grinding angle of the rail grinding vehicle, calculating the grinding area S of the rail grinding vehicle and the grinding power equivalent coefficient, and then calculating the effective grinding power corresponding to the effective grinding area;

[0120] Step S54-3: judging whether the effective grinding power exceeds the maximum grinding power p_max of the rail grinding vehicle:

[0121] When the effective grinding power does not exceed the maximum grinding power p_max of the rail grinding vehicle, it means that the grinding line i can be executed by a single grinding head, and step S54-3-1 is executed to output the grinding angle and the grinding power of the grinding head as the grinding parameter of the nth grinding head. The next grinding parameter calculation should enter i+1 grinding lines.

[0122] When the effective grinding power exceeds the maximum grinding power p_max of the rail grinding vehicle, it means that the i-th grinding line cannot be executed under the current grinding parameter, and the grinding parameter needs to be adjusted, and step S54-4 is executed.

[0123] Step S54-4: taking the outer endpoint (near the starting side) of the grinding line i as the fixed point, and using the bisection method to adjust the grinding angle to quickly find the grinding line corresponding to the maximum grinding area S_max; wherein the bisection method is used to solve the grinding line by adjusting the grinding angle based on the known grinding point and the target grinding area S_max, and the implementation process is as shown in Figure 6

[0124] ​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 according to the grinding line corresponding to the maximum grinding area S_max;

[0125] 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;

[0126] In the case where the grinding angle does not exceed the limit of the grinding angle of the rail grinding vehicle, step S54-3-1 is executed: the grinding angle and the grinding power of the grinding head are output as the grinding parameters of the nth grinding head. The next grinding parameter calculation is still the i-th grinding line, so the value of i does not change.

[0127] In the case where the grinding angle exceeds the limit of the grinding angle of the rail grinding vehicle, the grinding angle strategy needs to be adjusted, and step S54-7 is executed:

[0128] Step S54-7: Grind according to the grinding angle of the i-th grinding line;

[0129] Step S54-8: Use the bisection method to quickly find the grinding line with a grinding area of S_max at this grinding angle, and jump to step S54-3-1: output the grinding angle and the grinding power of the grinding head as the grinding parameters of the nth grinding head. The bisection method is used to solve the grinding line based on the known grinding angle and the target grinding area S_max by adjusting the grinding intercept, and the implementation process is as shown in Figure 7 .

[0130] The grinding mode includes a grinding strategy, and when the grinding strategy adopts a grinding strategy of sequentially grinding from one side of the rail to the other side, the method for automatically generating the grinding mode in step S5 includes:

[0131] Step S54-3-1: Output the grinding angle of the nth grinding wheel and the grinding power of the nth grinding wheel;

[0132] Step S54-3-2: Simulate grinding the n-th grinding profile according to the grinding angle of the n-th grinding wheel and the grinding power of the n-th grinding wheel, and the profile formed after grinding is used as the grinding profile to be ground for the next grinding mode generation;

[0133] Step S54-3-3: Update the profile after simulating grinding of the n-th grinding wheel with the grinding angle of the n-th grinding wheel and the grinding power of the n-th grinding wheel to a new grinding profile segment n, n = n + 1; continue to execute the grinding parameter calculation of the i-th grinding line which is not yet ground, and execute step S52.

[0134] It is worth noting that the target profile in the method can be a standard profile or any other profile based on improving the wheel-rail relationship, and the automatic design of the grinding mode is applicable to different target profiles. At the same time, it is applicable to the application requirement of not changing the current measured profile and only implementing the balanced surface grinding of the rail, at this time, the measured profile can be taken as the target grinding profile.

[0135] Figure 6 The algorithm implementation process of using the bisection method to solve the grinding angle with the known grinding point and the target grinding area is as follows. Figure 6 The process is Figure 5 In the bisection method, a specific implementation way of quickly finding the grinding line is adopted.

[0136] Step S61: Obtain the profile to be ground;

[0137] Step S62: Import the maximum grinding area S_max, and select the grinding point according to the grinding line i;

[0138] Step S63: Obtain the maximum grinding angle θ_max and the minimum grinding angle θ_min of the rail grinding vehicle;

[0139] Step S64: The grinding angle θ of the grinding vehicle is (θ_max + θ_min) / 2;

[0140] Step S65: Use the point-slope form to solve the straight line equation of the grinding line;

[0141] Step S66: Select the area intersected by the grinding line and the profile to be ground;

[0142] Step S67: Determine whether the intersection data is greater than or equal to 2?

[0143] In the case that the intersection data is greater than or equal to 2, step S68 is executed: determine whether the intersection data is discontinuous?

[0144] In the case that the intersection data is discontinuous, the intersection area S is calculated by region;

[0145] In the case that the intersection data is continuous, the intersection area S is directly calculated;

[0146] Step S610: Determine whether the deviation of the intersection area S and S_max is less than or equal to e;

[0147] In the case that the deviation of the intersection area S and S_max is less than or equal to e, step S611 is executed;

[0148] Step S611: Output the grinding line.

[0149] In step S67: determine whether the intersection data is greater than or equal to 2?

[0150] In the case of intersection data less than 2, step S610-3 is performed:

[0151] Step S67-1: θ_max = θ.

[0152] In step S610, it is determined whether the deviation of the intersection area S from S_max is less than or equal to e;

[0153] In the case where the deviation of the intersection area S from S_max is greater than e, step S610-1 is performed;

[0154] Step S610-1: it is determined whether the intersection area S 相交 is greater than the maximum grinding area S_max of the rail grinding car;

[0155] In the case where the intersection area S 相交 is greater than the maximum grinding area S_max of the rail grinding car, step S610-2 is performed: θ_min = θ;

[0156] In the case where the intersection area S is not greater than the maximum grinding area S_max of the rail grinding car, step S610-3 is performed.

[0157] After step S610-3 and step S610-2, step S610-4 is performed: updating θ; and then step S64 is performed.

[0158] Figure 7 The algorithm implementation process for solving the grinding line equation with known grinding angle and target grinding area by using the dichotomy method. That is Figure 7 The process is Figure 5 Another specific implementation of the dichotomy method for quickly finding the grinding line in

[0159] Step S71: obtaining the profile to be ground;

[0160] Step S72: importing the maximum grinding area S_max and the grinding angle θ;

[0161] Step S73: initializing the maximum intercept b_max = 140 mm and the minimum intercept b_min = 0 mm;

[0162] Step S74: the intercept b of the grinding car = (b_max + b_min) / 2;

[0163] Step S75: using the oblique intercept method to solve the straight line equation of the grinding line;

[0164] Step S76: selecting the area where the grinding line intersects the measured profile 2;

[0165] Step S77: determining whether the intersection data is greater than or equal to 2?

[0166] In the case of intersection data greater than or equal to 2, step S78 is performed: whether the intersection data is discontinuous?

[0167] In the case of discontinuous intersection data, the intersection area S is calculated by region;

[0168] In the case of continuous intersection data, the intersection area S is directly calculated;

[0169] Step S710: whether the deviation of intersection area S and S_max is less than or equal to e;

[0170] In the case of the deviation of intersection area S and S_max less than or equal to e, step S711 is performed;

[0171] Step S711: output the polishing line.

[0172] In step S77: whether the intersection data is greater than or equal to 2?

[0173] In the case of intersection data less than 2, step S710-3 is performed:

[0174] Step S77-1: b_max = b.

[0175] In step S710: whether the deviation of intersection area S and S_max is less than or equal to e;

[0176] In the case of the deviation of intersection area S and S_max greater than e, step S710-1 is performed;

[0177] Step S710-1: whether the intersection area S is greater than the maximum polishing area S_max of the rail polishing car;

[0178] In the case of whether the intersection area S is greater than the maximum polishing area S_max of the rail polishing car, step S710-2 is performed: b_min = b;

[0179] In the case of whether the intersection area S is not greater than the maximum polishing area S_max of the rail polishing car, step S710-3 is performed.

[0180] After step S710-3 and step S710-2, step S710-4 is performed: updating b; and then step S74 is performed.

[0181] The advantages of the present application are:

[0182] 1. The polishing mode generated by the method of the present application is an accurate repair method based on target profile.

[0183] The target profile in the method can be any profile, and the corresponding grinding mode can be automatically generated according to the deviation between the measured profile and the target profile, the design efficiency is high, the calculation speed is fast, and the profile repair grinding operation can be directly and effectively used.

[0184] 2. The target profile is designed after the final grinding, and the width of the profile after grinding can be customized and designed, and the width of the profile after grinding can be controlled.

[0185] 3. The programmatic calculation is facilitated, and the grinding mode is realized. The programmatic calculation process is given, which is convenient for programming and beneficial to complete the design of batch rail profile repair grinding mode.

[0186] The mode and grinding scheme can be automatically generated according to the characteristics of different grinding cars (such as 16 heads, 20 heads, 48 heads, 96 heads, etc.), different grinding speeds, grinding directions, etc., and the application is strong in expansion.

[0187] It can be compatible with multiple grinding strategies, such as automatically generating grinding mode based on profile repair, or automatically generating grinding mode based on balanced grinding for eliminating surface fatigue layer or micro-crack layer without changing the current profile, and has broad application prospects.

[0188] The technical terms used in the present application are uniformly explained as follows:

[0189] Specifically, the rail top center point refers to the geometric center position of the top of the rail. In the field of railway engineering and related technologies, this point is often used to define some key characteristics of the track and to make precise measurements. For example, on the cross section of the track, the rail top center point is the middle point of the top surface of the rail head, which is used to determine the direction, height and relative position of the track to other structures (such as vehicle wheelsets) in some cases.

[0190] Specifically, the working edge and the non-working edge of the rail refer to the two sides of the rail contact surface, each of which has different meanings and functions:

[0191] Working edge: This refers to the inner side edge of the rail, which is directly in contact with the train wheel tread. Since this side directly bears the pressure and friction force when the train passes through, it is called the working edge.

[0192] Non-working edge: In contrast, the outer side edge of the rail is called the non-working edge.

[0193] Specifically, the working edge gauge point refers to a specific reference point used to determine the gauge (i.e. the distance between the inner sides of the heads of two rails) in railway track measurement. This point is located on the working edge of the rail, which is 16 mm below the top surface of the inner side edge of the rail, which is the internationally accepted standard measurement position.

[0194] Those skilled in the art will appreciate that embodiments of the application can be readily used as software, hardware, or a combination of software and hardware. In one

[0195] The embodiments of methods, apparatuses (systems) and computer program products are described herein with reference to flowchart illustrations and / or block diagrams of the methods, apparatuses (systems) and computer program products according to embodiments of the 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, create means for implementing the functions specified in the flowchart Figure 1 one or more functions specified in the flowchart block or blocks. Figure 1 one or more functions specified in the flowchart block or blocks.

[0196] These computer program instructions can also be stored in a computer- readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instructions which implement the Figure 1 one or more functions specified in the flowchart block or blocks. Figure 1 one or more functions specified in the flowchart block or blocks.

[0197] These computer program instructions can also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks. Figure 1 one or more functions specified in the flowchart block or blocks. Figure 1 one or more functions specified in the flowchart block or blocks.

[0198] While preferred embodiments of the application have been described, modifications and alterations thereto will occur to those skilled in the art upon reading the preceding description. In particular, it will be apparent to those skilled in the art that parts can be added to, or substituted for, parts of the described embodiments of the application. Therefore, it is intended that the application not be limited to the particular embodiments disclosed, but will include all embodiments falling within the scope of the application as broadly interpreted by the appended claims.

[0199] Obviously, many modifications and variations of the present application are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims and their equivalents, the application can be practiced otherwise than as specifically described.

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. 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 in 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.

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 the unworn and deformed area. 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 segments of the target profile (3) after grinding to intersect with the measured profile (2), 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 S5 automatically generates a polishing mode, which includes a polishing strategy. The polishing strategy includes: Grind 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.

6. 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.

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 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.

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 S54-3-1: 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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