Extrusion grinding device for steel rail welding seam shaping and control method of extrusion grinding device

Abstract

The embodiment of the invention provides an extruding and grinding device for steel rail welding seam shaping and a control method thereof, and belongs to the technical field of railway track maintenance. The extruding and polishing device for shaping the steel rail welding seam comprises a follow-up frame, an extruding and polishing device and a polishing device, the extrusion forming unit is arranged on the follow-up frame and used for performing continuous extrusion on the weld reinforcement; the grinding unit comprises a grinding head and a driving part and is used for grinding the surface of the welding seam after extrusion forming; the detection unit is mounted on the follow-up frame and is used for acquiring contour information of the surface of the welding seam and outputting a flatness index; the control unit is in signal connection with the extrusion forming unit, the grinding unit and the detection unit and used for receiving the contour information output by the detection unit and issuing execution instructions to the extrusion forming unit and the grinding unit. According to the scheme, through linkage control of extrusion and grinding, efficient removal of steel rail weld reinforcement and stable improvement of rail surface flatness are achieved.

Description

Technical Field

[0001] This invention relates to the field of railway track maintenance technology, specifically to an extrusion grinding device for shaping rail welds and a control method for the extrusion grinding device for shaping rail welds. Background Technology

[0002] After welding, railway rails often exhibit issues such as excess weld height, ripples, and uneven surfaces in the weld area. If these defects are not corrected promptly, they can affect the smoothness and safety of train operation and accelerate the wear of the rails and wheels. Therefore, after rail weld construction is completed, a shaping process is typically used to repair and grind the weld to restore the geometry of the rail surface.

[0003] Existing weld shaping methods mainly fall into two categories: one is a simple grinding process, which involves grinding the weld surface using a handheld or vehicle-mounted grinder; the other is a simple extrusion process, which involves plastically deforming the weld reinforcement using a pressure roller or pressure head. While these two methods can improve rail surface smoothness to some extent in engineering applications, they still have significant shortcomings.

[0004] Simple grinding processes often rely on manual operation or single fixed parameter control. When the weld reinforcement is large or there are significant differences in material hardness, uneven removal can easily occur, leading to unevenness in the rail surface or over-grinding. In addition, prolonged dry grinding conditions may cause excessive temperature rise in the weld area, resulting in a burn layer or cracks, further reducing the service performance of the rail.

[0005] The simple extrusion process lacks coordination with subsequent grinding. Although it can quickly reduce weld reinforcement, it easily forms a hardened layer and accumulates plastic deformation on both sides of the weld, requiring secondary adjustments to the rail surface geometry. Without a matching grinding process, it is often difficult to achieve the flatness and surface quality required for long-term service.

[0006] In summary, existing technologies have not yet been able to achieve an efficient combination of extrusion and grinding during the weld shaping process. At the same time, they lack real-time perception and control of differences in hardness and temperature rise in the weld area, resulting in limited accuracy in controlling rail surface flatness and unstable work quality. Summary of the Invention

[0007] The purpose of this invention is to provide an extrusion and grinding device and its control method for rail weld shaping, so as to at least solve the problems of separation of grinding and extrusion processes and insufficient accuracy of rail surface flatness control in the existing weld shaping process.

[0008] To achieve the above objectives, the first aspect of the present invention provides an extrusion and grinding device for shaping rail welds, comprising: a follower frame for moving along the weld direction on the rail; an extrusion forming unit disposed on the follower frame, including a pressure shoe and a drive component, for continuously extruding the weld excess height; a grinding unit disposed on the follower frame, including a grinding head and a drive component, for grinding the weld surface after extrusion forming; a detection unit mounted on the follower frame for acquiring contour information of the weld surface and outputting a flatness index; and a control unit connected to the extrusion forming unit, the grinding unit, and the detection unit respectively, for receiving the contour information output by the detection unit and issuing execution commands to the extrusion forming unit and the grinding unit.

[0009] Optionally, the press shoe is a replaceable end face module structure; the end face module structure is installed at the front end of the extrusion forming unit by means of fasteners and positioning pins, and corresponds to the rail section template in the preset rail type library.

[0010] Optionally, the extrusion forming unit is equipped with a six-axis force sensor and a linear displacement sensor; the force sensor is fixed between the press shoe and the drive component for real-time acquisition of extrusion force signals; the displacement sensor is connected to the stroke section of the drive component for acquisition of displacement information; the extrusion force signal and displacement information are combined to generate force-position monitoring data for the extrusion process.

[0011] Optionally, the grinding unit includes an electric spindle grinding head, a feed mechanism, and a swing mechanism; the electric spindle grinding head is equipped with a grinding wheel and is driven by a motor to generate an adjustable speed; the feed mechanism is connected to the follower frame for feeding along the track; the swing mechanism is connected to the grinding head for generating track-oriented swing.

[0012] Optionally, the grinding unit is equipped with a spray cooling nozzle and a temperature detection unit; the nozzle is arranged upstream of the grinding contact area and connected to the liquid supply module; the temperature detection unit is used to collect the temperature and temperature rise rate of the grinding area, and when the temperature exceeds a preset threshold, the spray cooling is activated based on the trigger signal output by the control unit, and the target pressure value of the contact pressure loading component is reduced in conjunction with the control unit.

[0013] Optionally, the extrusion grinding device for rail weld shaping further includes a hardness detection unit; the hardness detection unit includes an eddy current probe and an acoustic emission sensor; the eddy current probe is installed at the front end of the follower frame to maintain a preset gap with the rail surface and collect the signal of change in the conductivity of the metal in the weld area; the acoustic emission sensor is fixed on the bracket of the extrusion forming unit to collect the stress wave signal generated by the weld during the extrusion process; the output signal of the hardness detection unit is transmitted to the control unit and fused and processed in the control unit to generate hardness proxy parameters for distinguishing the weld center area and the heat-affected zone, thereby realizing the partitioned configuration of the extrusion forming unit and the grinding unit in different hardness areas.

[0014] Optionally, the detection unit includes a dual-line laser profilometer arranged in front of the weld and an image acquisition device set on the follower frame; the dual-line laser profilometer is used to acquire the profile of the rail head section and calculate the weld reinforcement height and flatness index; the image acquisition device is used to acquire the weld surface texture information; the control unit determines whether the weld shaping meets the standard based on the weld reinforcement height, flatness index and weld surface texture information.

[0015] Optionally, the follower frame is provided with a pair of guide wheels at the top of the rail and a pair of limiting wheels at the web of the rail. The guide wheels and limiting wheels are respectively attached to the surface of the top of the rail and the web of the rail to ensure that the device maintains a stable posture and suppresses lateral sway during the feeding process along the weld seam.

[0016] Optionally, the extrusion and grinding device for shaping rail welds further includes a pressure shoe compliance adjustment unit; the pressure shoe compliance adjustment unit is disposed between the rail and the pressure shoe, and includes an elastic layer and a variable damping component; the variable damping component adjusts the contact compliance between the pressure shoe and the weld surface by controlling the pressure of magnetorheological fluid or air bladder, and is used to maintain uniform extrusion pressure distribution and suppress high-frequency vibration when the weld reinforcement change is greater than a preset change threshold.

[0017] A second aspect of the present invention provides a control method for an extrusion grinding device for shaping rail welds. The method is applied to the aforementioned extrusion grinding device for shaping rail welds. The method includes: acquiring weld surface contour information collected by a detection unit and calculating the weld reinforcement height and initial flatness index within a control unit; generating an extrusion pressure adjustment command within the control unit and issuing it to the extrusion forming unit based on the weld reinforcement height and initial flatness index to drive the pressure shoe to continuously extrude the weld reinforcement height; and generating a grinding parameter adjustment command within the control unit and issuing it to the grinding unit based on the weld reinforcement height and initial flatness index. The unit drives the grinding head to grind the weld surface after extrusion forming. During the extrusion and grinding process, it acquires the hardness proxy parameters output by the hardness detection unit in the extrusion and grinding device for rail weld shaping and the temperature information output by the temperature detection unit in the extrusion and grinding device for rail weld shaping, and corrects the extrusion pressure adjustment command and grinding parameter adjustment command in the control unit. Based on the corrected extrusion pressure adjustment command and grinding parameter adjustment command, it drives the extrusion forming unit and the grinding unit to operate in coordination until the flatness index output by the detection unit reaches the preset criterion.

[0018] Through the above technical solution, the present invention can stably move along the rail weld direction under the support of the moving frame, sequentially completing the continuous extrusion and surface grinding of the weld excess height. The detection unit acquires the contour information of the weld surface in real time and outputs a flatness index. Based on this index, the control unit dynamically adjusts the execution status of the extrusion forming unit and the grinding unit, thereby realizing the linkage control of the extrusion and grinding processes. This not only improves the continuity and accuracy of weld shaping operations, but also avoids the uneven removal problem caused by a single process, making the rail surface flatness and service quality after weld shaping more stable and reliable.

[0019] Other features and advantages of the embodiments of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0020] The accompanying drawings are provided to further illustrate embodiments of the present invention and form part of the specification. They are used together with the following detailed description to explain the embodiments of the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a structural diagram of an extrusion and grinding device for shaping rail welds according to one embodiment of the present invention. Figure 2 This is a schematic diagram of the extrusion and grinding device for shaping rail welds according to one embodiment of the present invention. Figure 3 This is a schematic diagram of the structure of an extrusion forming unit provided in one embodiment of the present invention; Figure 4This is a schematic diagram of the structure of a grinding unit provided in one embodiment of the present invention; Figure 5 This is a flowchart of the control method steps for an extrusion and grinding device for shaping rail welds according to one embodiment of the present invention.

[0021] Explanation of reference numerals in the attached figures 10 - Follow-up frame; 20 - Extrusion forming unit; 30 - Grinding unit; 201-Shoe press; 202-Drive component; 301 - Electric spindle grinding head; 302 - Feed mechanism; 303 - Oscillating mechanism. Detailed Implementation

[0022] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0023] Figure 1 This is a structural diagram of the decoration of an extrusion grinding device for shaping rail welds according to one embodiment of the present invention. Figure 1 As shown, this invention provides an extrusion and grinding device for shaping rail welds. The device includes: a follower frame 10 for moving along the weld direction on the rail; an extrusion forming unit 20 mounted on the follower frame 10, including a pressure shoe 201 and a drive component 202, for continuously extruding the weld excess height; a grinding unit 30 mounted on the follower frame 10, including a grinding head and a drive component 202, for grinding the weld surface after extrusion forming; a detection unit mounted on the follower frame 10 for acquiring the contour information of the weld surface and outputting a flatness index; and a control unit connected to the extrusion forming unit 20, the grinding unit 30, and the detection unit, for receiving the contour information output by the detection unit and issuing execution commands to the extrusion forming unit 20 and the grinding unit 30.

[0024] like Figure 2In one specific embodiment, a pressing and grinding device for shaping rail welds includes a follower frame 10, a grinding unit 30, and an extrusion forming unit 20. The follower frame 10 is arranged above the rail and is in contact with the rail surface through guide wheels on the rail top and limit wheels on the rail web, allowing the device to move smoothly along the weld direction. The grinding unit 30 is fixed at the front of the follower frame 10 and has an electric spindle grinding head 301, a feed mechanism 302, and a swing mechanism 303 inside, which can grind and trim the weld surface after extrusion forming. The extrusion forming unit 20 is located at the rear of the follower frame 10 and includes a drive component 202 and a pressure shoe 201 connected to the drive component 202, used to continuously extrude the weld excess height. In the specific working process, the follower frame 10 feeds at a uniform speed along the weld direction, and the extrusion forming unit 20 first performs dynamic pressure adjustment extrusion on the weld excess height under the guidance of the output parameters of the detection unit, so that the weld protrusion is gradually flattened. Subsequently, the grinding unit 30, driven by an electric spindle, rotates the grinding wheel and, through a combination of feed and oscillation, further grinds the surface of the extruded weld to ensure that the flatness of the rail surface meets the preset standard. Through this structural configuration, the device achieves continuous and integrated extrusion and grinding processes, significantly improving the efficiency and quality of weld shaping.

[0025] In this embodiment of the invention, the extrusion and grinding device for shaping rail welds is integrally equipped with a follower frame 10. The follower frame 10 is a load-bearing foundation structure straddling the rail, capable of smooth movement along the weld direction, and providing fixed installation positions for each functional unit. Relying on the stable support of the follower frame 10, the device can avoid shaping deviations caused by lateral swaying or irregular displacement during operation, thereby providing a geometric reference for subsequent extrusion and grinding operations. The follower frame 10 is typically equipped with guide wheels and limit wheel sets, which cooperate with the rail top and rail web to ensure that the feed path along the rail direction remains linear and stable.

[0026] like Figure 3 An extrusion forming unit 20 is provided on the follower frame 10. This unit specifically includes a pressure shoe 201 and a drive component 202 connected to the pressure shoe 201. The drive component 202 can be a hydraulic cylinder, an electric push rod, or other actuation mechanism capable of providing stable loading force. The pressure shoe 201 is configured with an end face matching the rail cross-section, and through loading cooperation with the drive component 202, it continuously extrudes the weld excess height. In this way, the protruding portion of the weld can be gradually plastically deformed and approach the height of the base rail surface, thereby macroscopically reducing the weld excess height and decreasing the amount of material removed during subsequent grinding.

[0027] Downstream of the extrusion forming unit 20, a grinding unit 30 is installed. This unit mainly includes an electrically driven grinding head and a matching feed and oscillation mechanism 303. The grinding head uses a high-speed rotating grinding wheel to finely finish the surface of the extruded weld. The feed mechanism 302 pushes the grinding head to move longitudinally along the rail, while the oscillation mechanism 303 provides small-amplitude oscillations within the rail direction or lateral range, ensuring that the grinding process evenly covers the weld surface. This combination ensures further surface finishing based on extrusion forming, resulting in a smooth connection between the weld transition area and the base material rail surface.

[0028] A detection unit is also installed at the front end or a suitable location of the follow-up frame 10. This unit can be a laser profilometer, image acquisition device, or other non-contact measuring equipment, used to collect the geometric contour information of the weld surface in real time and calculate the excess height value and flatness index. These detection results are transmitted to the control unit in real time. The control unit maintains a signal connection with the extrusion forming unit 20, the grinding unit 30, and the detection unit, and can receive the data output by the detection unit, and generate corresponding control commands based on the preset flatness requirements, and issue them to the extrusion forming unit 20 and the grinding unit 30 to achieve dynamic adjustment.

[0029] With the cooperation of the above structures, the device can complete the entire process from the extrusion and reduction of weld excess height to the grinding and finishing of weld surface under the guidance of the moving frame 10. Under the closed-loop action of the detection unit and the control unit, the execution parameters can be dynamically corrected according to the actual rail surface condition, thereby ensuring that the flatness of the shaped rail surface meets the expected standard.

[0030] Preferably, the press shoe 201 is a replaceable end face module structure; the end face module structure is installed on the front end of the extrusion forming unit 20 by means of fasteners and positioning pins, and corresponds to the rail surface section template in the preset rail type library.

[0031] In this embodiment of the invention, the pressure shoe 201 is designed as a replaceable end-face module structure. The main consideration for this is that rails vary in type across different lines and regions, with significant differences in rail head cross-sectional shapes. If a fixed pressure shoe 201 is used, it cannot be compatible with different rail types, limiting its application range. Constructing the pressure shoe 201 as an end-face module allows for flexible replacement of different shaped end-face modules on the same extrusion forming unit 20, thus maintaining consistency with the cross-sectional profile of the rail to be shaped. The end-face module is installed using a combination of snap-fit ​​components and positioning pins. The snap-fit ​​components quickly lock the end-face module, while the positioning pins ensure that the module does not shift during installation, accurately aligning with the rail surface. This mechanical quick-connect structure enables rapid replacement under field conditions while ensuring the stability and repeatability of the pressure shoe 201 under stress.

[0032] Specifically, the end face module is typically made of high-strength wear-resistant alloy steel or a material with a hardened surface. Its end face shape is processed according to a pre-defined rail profile library. The rail profile library is a database of rail surface cross-section templates established according to different rail models. Designers retrieve the corresponding cross-section data from the library based on the rail model to be shaped, and then process the contour shape matching that data on the module's end face. In this way, the pressure shoe 201 can fully conform to the rail surface cross-section where the weld is located during loading and compression, achieving uniform stress and efficient shaping. When changing to a different rail model, simply disassemble the original module and install the new corresponding module; the process is simple and intuitive, and can meet the weld shaping needs of multiple rail specifications on site.

[0033] The advantages of this replaceable end-face module structure are significantly improved adaptability and efficiency, avoiding the matching problem of pressure shoe 201 caused by differences in rail type. Simultaneously, the cooperation of the clips and positioning pins not only ensures the convenience of replacement operations but also improves positioning accuracy, resulting in a more stable force distribution during the pressing process, thereby effectively improving the shaping quality of the weld reinforcement. Overall, this design approach reduces the maintenance and modification costs of the device and provides a universal solution for weld shaping on multiple lines and with multiple rail types.

[0034] Preferably, the extrusion forming unit 20 is equipped with a six-axis force sensor and a linear displacement sensor; The force sensor is fixed between the pressure shoe 201 and the drive component 202 to collect the extrusion force signal in real time; the displacement sensor is connected to the stroke section of the drive component 202 to collect displacement information; the extrusion force signal and displacement information are combined to generate force and position monitoring data for the extrusion process.

[0035] In this embodiment of the invention, the extrusion forming unit 20 is equipped with a six-axis force sensor and a linear displacement sensor for real-time monitoring of the loading state during weld shaping. The six-axis force sensor is positioned between the pressure shoe 201 and the drive component 202, its location designed to completely cover the force path of the pressure shoe 201. This installation method allows the sensor to simultaneously acquire the main axial force in the extrusion direction and the additional force components that may appear in the lateral and torsional directions, thus providing a comprehensive characterization of the actual stress state of the pressure shoe 201 during extrusion. Compared to single-axis or triaxial sensors, the six-axis force sensor offers higher accuracy and completeness in multi-dimensional mechanical response monitoring, effectively avoiding monitoring errors caused by off-center loading, eccentric force, etc.

[0036] The linear displacement sensor is directly connected to the stroke component of the drive component 202 to collect displacement data generated by the drive component 202 during loading. This displacement data is highly consistent with the movement trajectory of the front end of the pressure shoe 201, and can accurately reflect the change in the amount of compression over time. The displacement sensor typically employs high-precision solutions such as grating rulers or inductive linear displacement gauges to ensure reliable measurement results even under strong vibration and high load environments.

[0037] In actual operation, the extrusion pressure signal output by the six-axis force sensor and the displacement information output by the linear displacement sensor are synchronously collected and combined to generate force-position monitoring data. This monitoring data includes the real-time magnitude and direction distribution of the extrusion pressure, as well as the corresponding displacement range. By fusing the two types of data, a coupling relationship curve between force and displacement during the extrusion process can be obtained. This curve can reflect the material's plastic deformation characteristics when the weld reinforcement is compressed, such as the elasto-plastic transition point and hardness change trend.

[0038] The combined use of a six-axis force sensor and a linear displacement sensor makes the extrusion process not only a simple mechanical loading process, but also provides a quantifiable feedback mechanism. Through the accumulation and analysis of monitoring data, an experience database for weld shaping can be gradually established for subsequent control parameter adjustments. This invention achieves real-time monitoring and traceability of the extrusion process, avoiding the uncertainties of traditional experience-based operations and improving the stability and repeatability of the shaping operation. Simultaneously, the force and position monitoring data also provides a reference for adjusting the processing parameters of the subsequent grinding unit 30, forming a closed-loop control logic for the entire weld shaping process.

[0039] Preferred, such as Figure 4 The grinding unit 30 includes an electric spindle grinding head 301, a feed mechanism 302, and a swing mechanism 303. The electric spindle grinding head 301 is equipped with a grinding wheel and is driven by a motor to generate an adjustable speed. The feed mechanism 302 is connected to the follower frame 10 for feeding along the track. The swing mechanism 303 is connected to the grinding head for generating track swing.

[0040] In this embodiment of the invention, the grinding unit 30 specifically includes an electric spindle grinding head 301, a feed mechanism 302, and a oscillating mechanism 303. The electric spindle grinding head 301 is the core execution component for grinding operations. A grinding wheel is mounted at its front end. The grinding wheel typically uses wear-resistant ceramic-bonded or resin-bonded materials, enabling it to maintain a sharp cutting edge under high-speed rotation. The electric spindle is directly driven by a motor, and its speed is adjustable via a built-in or external frequency converter. The speed range covers from low-speed rough grinding to high-speed fine grinding, thus adapting to the removal requirements under different weld reinforcement heights and surface hardness conditions. The electric spindle typically contains high-precision bearings to ensure low radial runout and high grinding accuracy during high-speed operation. Simultaneously, the operating temperature of the electric spindle is maintained stable through cooling grease or air cooling.

[0041] The feed mechanism 302 provides longitudinal displacement for the electric spindle grinding head 301. Its structure typically consists of a lead screw drive, a guide rail slider, and a servo motor. The feed mechanism 302 is connected to the follow-up frame 10, enabling the grinding unit 30 to move smoothly along the longitudinal direction of the rail. Through precise control of the servo motor, the feed speed of the grinding head can be set, ensuring that the contact between the grinding wheel and the weld surface remains within a reasonable cutting depth range. Excessive feed speed can easily cause surface burns or grinding wheel overload, while insufficient speed affects work efficiency. Therefore, the controllability of the feed mechanism 302 is crucial to the shaping quality.

[0042] The oscillating mechanism 303 is positioned between the grinding head and the feed mechanism 302. Its function is to generate minute oscillations in the directional or lateral direction during the grinding process. The specific structure can be an eccentric wheel driven linkage, a crank-slider, or an electrically servo-driven swing arm. Through the periodic movement of the oscillating mechanism 303, the grinding wheel forms a machining trajectory with a wider coverage on the weld surface, avoiding local overcutting caused by a fixed grinding wheel entry point. The oscillation amplitude and frequency can be adjusted through preset parameters, ensuring both flatness and maintaining surface roughness within an acceptable range during the grinding process.

[0043] Through the coordinated operation of the electric spindle grinding head 301, the feed mechanism 302, and the oscillating mechanism 303, the grinding unit 30 can achieve efficient finishing of the weld surface after extrusion forming. The electric spindle provides high-speed rotational power, and the grinding wheel removes material; the feed mechanism 302 controls the uniform movement of the grinding head along the rail direction; the oscillating mechanism 303 increases the grinding coverage and improves surface uniformity. Ultimately, the combination of the three not only ensures that the excess weld surface is fully eliminated, but also forms a smooth transition between the rail surface and the base material. Its technical effect is to improve the uniformity and stability of weld shaping, avoid local defects caused by single-point processing, thereby extending the service life of the rail and improving the smoothness of train operation.

[0044] Preferably, the grinding unit 30 is equipped with a spray cooling nozzle; the nozzle is arranged upstream of the grinding contact area and connected to the liquid supply module; the temperature detection unit is used to collect the temperature and temperature rise rate of the grinding area, and when the temperature exceeds the preset threshold, the spray cooling is activated based on the trigger signal output by the control unit, and the target pressure value of the contact pressure loading component is reduced in conjunction with the control unit.

[0045] In this embodiment of the invention, the grinding unit 30 is further equipped with a spray cooling nozzle. This nozzle is positioned upstream of the grinding contact area, specifically in front of the contact point between the grinding wheel and the weld surface. The upstream position is chosen because the grinding wheel, rotating at high speed, carries airflow and grinding debris. If the nozzle were positioned behind or directly below, the coolant would not easily enter the effective cutting zone, significantly reducing cooling efficiency. By fixing the nozzle to the grinding head support frame, the spray angle is made at a certain angle to the grinding wheel's rotation direction, ensuring that the coolant atomizes and directly covers the grinding point, thereby achieving simultaneous cooling and lubrication of the grinding wheel and the weld surface. The nozzle is connected to a coolant supply module, which typically includes a liquid storage tank, a pressurizing pump, and a flow regulating valve, providing a continuous and controllable coolant supply. The coolant is usually water-based or an emulsion containing rust-inhibiting and lubricating components to reduce temperature rise and prevent rail surface corrosion.

[0046] To avoid energy waste or negative impact on grinding performance caused by indiscriminate spraying, this embodiment also includes a temperature detection unit in the grinding area. The temperature detection unit can be a non-contact infrared temperature sensor or a thermocouple array positioned near the grinding head. The collected temperature signal includes not only absolute temperature values ​​but also the temperature rise rate, which can be calculated differentially. The temperature rise rate is crucial for determining whether abnormal friction or grinding wheel passivation occurs in the grinding area, as sudden localized temperature increases are often precursors to burns or cracks on the grinding surface.

[0047] When the temperature output by the temperature detection unit exceeds a preset threshold, the control logic immediately triggers the spray cooling device to activate. The coolant, atomized through the nozzles, quickly covers the grinding area, carrying away the heat generated by friction and preventing the formation of a white layer or micro-cracks on the guide surface. Simultaneously, while triggering spray cooling, the control logic also adjusts the grinding contact pressure, reducing the target pressure value of the loaded components. This aims to further reduce the heat source by decreasing the grinding force, while restoring the contact state between the grinding wheel and the guide surface to a safe range.

[0048] By combining spray cooling nozzles, temperature detection units, and pressure regulation logic, the grinding process achieves dynamic thermal management and adaptive protection, ensuring that rail surface quality is maintained while grinding with high efficiency. This is reflected not only in effectively suppressing overheating and surface burns, but also in improving grinding wheel life and processing stability, ultimately resulting in a significant improvement in the flatness of the rail surface and its service reliability after weld seam shaping.

[0049] Preferably, the extrusion grinding device for shaping rail welds further includes a hardness detection unit; the hardness detection unit includes an eddy current probe and an acoustic emission sensor; the eddy current probe is installed at the front end of the follower frame 10 to maintain a preset gap with the rail surface and collect the signal of change in the conductivity of the metal in the weld area; the acoustic emission sensor is fixed on the bracket of the extrusion forming unit 20 to collect the stress wave signal generated by the weld during the extrusion process; the output signal of the hardness detection unit is transmitted to the control unit and fused and processed in the control unit to generate a hardness proxy parameter for distinguishing the weld center area and the heat-affected zone, thereby realizing the partitioned configuration of the extrusion forming unit 20 and the grinding unit 30 in different hardness areas.

[0050] In this embodiment of the invention, the extrusion and grinding device for shaping rail welds further includes a hardness detection unit for real-time monitoring and judgment of the hardness state of the material region during weld shaping. Specifically, the hardness detection unit consists of an eddy current probe and an acoustic emission sensor, which complement each other and can reflect the hardness information of the weld from two dimensions: the electromagnetic properties of the material and the stress acoustic properties. The eddy current probe is installed at the front end of the follower frame 10 and fixed by a bracket, so that its probe end face maintains a preset gap value with the surface of the rail weld. This gap is usually in the range of 0.5 to 2 mm to ensure that it can stably sense changes in conductivity without damaging the probe due to mechanical interference. By continuously acquiring the metal conductivity change signal during the scanning process of the weld area, an electromagnetic response curve related to the microstructure and hardness distribution can be obtained. Generally, the central area of ​​the weld is dense due to rapid solidification, and its conductivity is higher than that of the surrounding heat-affected zone. Therefore, the eddy current signal can sensitively reflect the difference between the two.

[0051] Meanwhile, an acoustic emission sensor is mounted on a support of the extrusion forming unit 20, allowing it to be in close contact with the stressed component and capture high-frequency stress wave signals generated by the weld during the extrusion forming process in real time. Due to significant differences in the plastic deformation capacity of different hardness regions, the frequency and amplitude of acoustic emission events generated in the weld center region during extrusion differ significantly from those in the heat-affected zone. The acoustic signal output by the sensor, after filtering and feature extraction, can complement the eddy current signal. Both types of signals are simultaneously transmitted to the control logic, where fusion processing is performed to extract key feature parameters and generate hardness proxy parameters to distinguish between the weld center region and the heat-affected zone.

[0052] Based on this hardness proxy parameter, the extrusion forming unit 20 and the grinding unit 30 can achieve regionalized zoning configuration. For example, in the weld center region with higher hardness, the control logic can increase the extrusion pressure and decrease the grinding feed to ensure the forming effect; while in the heat-affected zone with lower hardness, the extrusion pressure is reduced and the grinding feed is appropriately increased, thereby avoiding excessive damage to the material or excessive material removal. Through this intelligent zoning adjustment, not only can the overall uniformity of weld shaping be improved, but the service life of the grinding wheel can also be effectively extended, avoiding premature wear.

[0053] Preferably, the detection unit includes a dual-line laser profilometer arranged in front of the weld and an image acquisition device set on the follower frame 10; the dual-line laser profilometer is used to acquire the rail head cross-sectional profile and calculate the weld reinforcement height and flatness index; the image acquisition device is used to acquire weld surface texture information; the control unit determines whether the weld shaping meets the standard based on the weld reinforcement height, flatness index and weld surface texture information.

[0054] In this embodiment of the invention, the detection unit employs dual detection methods to achieve a comprehensive characterization of the weld formation effect. Specifically, the detection unit includes a dual-line laser profilometer positioned in front of the weld and an image acquisition unit mounted on the follower frame 10, which complement each other. The dual-line laser profilometer works by projecting two parallel laser lines onto the weld surface to form an optical reference for intercepting the rail head cross-section. As the follower frame 10 moves along the weld direction, the geometric relationship between the laser lines and the weld reinforcement height continuously changes. The receiver of the profilometer records these changes in real time and generates a corresponding height distribution curve. By performing analytical calculations on the curve, not only can the numerical value of the weld reinforcement height be obtained, but also the flatness index of the rail head cross-section can be derived, thereby quantitatively reflecting the forming effect.

[0055] Meanwhile, the image acquisition unit supplements the analysis from the perspective of surface features. Fixed to the side or top of the moving frame 10, the image acquisition unit uses an industrial camera lens to capture high-resolution images of the weld surface. After preprocessing, the image data reflects the texture features of the weld surface, such as irregular textures like stripes, ripples, or cracks. Since surface texture is often closely related to microscopic defects and material fluctuations in the heat-affected zone, relying solely on weld height and flatness is insufficient to fully cover this information. Therefore, the texture information provided by the image acquisition unit is crucial for quality evaluation.

[0056] After receiving multi-source data from the dual-line laser profilometer and image acquisition unit, the control unit performs data fusion processing. Specifically, the weld height and flatness indicators are used as geometric evaluation parameters, and the weld surface texture is used as an appearance quality parameter. The control logic uses threshold discrimination or pattern recognition algorithms to comprehensively determine whether the current weld meets the preset shaping standard. When the weld height is lower than the target range, the flatness fluctuation is controlled within the allowable error, and there are no obvious abnormalities in the surface texture, the weld shaping can be determined to be up to standard. If any parameter does not meet the requirements, the control unit will generate a correction command and feed it back to the extrusion forming unit 20 or the grinding unit 30 for further adjustment.

[0057] This inspection method, which combines geometric measurement with surface imaging, avoids the limitations of single inspection methods. For example, relying solely on a laser profilometer may overlook surface cracks, while relying solely on image acquisition cannot accurately quantify geometric flatness. The combination of the two enables both macroscopic flatness control and surface defect identification, thereby improving the comprehensiveness and reliability of weld seam shaping inspection.

[0058] Preferably, the follower frame 10 is provided with a pair of guide wheels at the top of the rail and a pair of limiting wheels at the waist of the rail. The guide wheels and limiting wheels are respectively attached to the surface of the top of the rail and the surface of the waist of the rail to ensure that the device maintains a stable posture and suppresses lateral sway during the feeding process along the weld seam.

[0059] In this embodiment of the invention, the follower frame 10 is provided with a pair of guide wheels at the top of the rail and a pair of limiting wheels at the web of the rail. Both types of wheel sets are directly in contact with the corresponding surfaces of the rail. The guide wheels are installed on the upper structure of the frame, and their roller surfaces are in precise contact with the top of the rail, providing longitudinal guidance when the frame moves along the weld direction to ensure that the frame does not deviate. At the same time, the limiting wheels are fixed in the middle or lower part of the frame, and their rims are in contact with both sides of the web of the rail, forming a lateral limit to prevent the device from swinging left and right during movement. To ensure fitting accuracy, the installation positions of the guide wheels and limiting wheels are geometrically calibrated so that they match the top of the rail and the web of the rail, thereby maintaining a stable fitting state even when there is weld excess or slight unevenness on the rail surface.

[0060] This structural arrangement creates bidirectional constraints on the moving frame 10 during the feeding process, both vertically and horizontally, effectively providing a stable trajectory for the device's operation. Even if slight fluctuations occur on the rail surface in the weld area due to welding repair or grinding, the combination of guide wheels and limit wheels effectively offsets the resulting attitude deviations, preventing positional errors in the detection or processing units. In other words, this design ensures that the entire extrusion and grinding process always proceeds along the weld direction, improving the straightness of the operation and reducing the risk of uneven weld treatment caused by lateral swaying. The final technical effect is a significant improvement in the stability of the processing path, thus providing a reliable guarantee for the quality of weld shaping.

[0061] Preferably, the extrusion and grinding device for shaping rail welds further includes a pressure shoe compliance adjustment unit; the pressure shoe compliance adjustment unit is disposed between the rail and the pressure shoe 201, and includes an elastic layer and a variable damping component; the variable damping component adjusts the contact compliance between the pressure shoe 201 and the weld surface by controlling the pressure of magnetorheological fluid or airbag, and is used to maintain uniform extrusion pressure distribution and suppress high-frequency vibration when the weld reinforcement change is greater than a preset change threshold.

[0062] In this embodiment of the invention, the extrusion grinding device for shaping rail welds further includes a compliance adjustment unit for the pressure shoe 201. This unit is positioned between the rail and the pressure shoe 201, effectively creating a smooth transition layer between the pressure shoe 201 and the rail weld surface. The basic structure of this compliance adjustment unit is a combination of an elastic layer and a variable damping component. The elastic layer typically uses a rubber-based composite material or a polymer elastomer resistant to high-frequency impacts. Its thickness and hardness parameters can be preset according to the weld type and rail cross-section, thereby absorbing minor impacts from localized irregularities when the pressure shoe 201 is loaded. This avoids localized stress concentration caused by rigid loading and allows the extrusion pressure to be transmitted more smoothly to the weld metal surface.

[0063] In addition to the elastic layer, a variable damping component is also provided. This component can take the form of a cavity structure filled with magnetorheological fluid, or a pneumatic mechanism that adjusts stiffness and damping by regulating the pressure of the air bladder. Magnetorheological fluid has the characteristic of rapidly adjustable viscosity under the action of an external magnetic field. By adjusting the current intensity of the electromagnetic coil, the damping state can be changed within milliseconds, thus allowing the contact characteristics between the pressure shoe 201 and the weld surface to switch between rigidity and flexibility. If an air bladder structure is used, the pressure inside the air bladder is adjusted through a valve-controlled circuit to achieve dynamic control of contact compliance. This design allows the pressure shoe 201 to maintain high stiffness in flat areas to ensure forming efficiency, while providing a certain degree of buffering compliance in areas with abrupt changes in excess height or surface undulations, avoiding localized over-extrusion.

[0064] The adaptive adjustment unit works by actively intervening when the weld reinforcement height exceeds a preset threshold to maintain a uniform distribution of extrusion pressure on the contact surface. To put it simply, if the press shoe 201 directly encounters a protrusion, without a buffer mechanism, high stress will form at the contact point. However, through adaptive adjustment, a certain degree of "yield" can be made during the contact process, distributing the impact over a larger area, thereby improving the overall forming quality. Simultaneously, the variable damping component can effectively suppress high-frequency vibrations that occur during extrusion, preventing vibrations from superimposing on the extrusion process and causing fine ripples or secondary unevenness on the weld surface.

[0065] This structural configuration not only ensures the working stability of the press shoe 201 under different weld reinforcement height conditions, but also significantly improves the adaptability and quality consistency of the forming operation. Firstly, it achieves automatic adaptation to fluctuations in different reinforcement heights, eliminating the need for manual adjustment during the extrusion process. Secondly, it effectively controls high-frequency vibration, improving the flatness and structural uniformity of the weld after forming, providing more stable benchmark conditions for subsequent grinding processes.

[0066] like Figure 5 As shown, an embodiment of the present invention provides a control method for an extrusion grinding device for shaping rail welds, the method comprising: Step S10: Obtain the weld surface contour information collected by the detection unit, and calculate the excess height and initial flatness index in the control unit.

[0067] Specifically, the detection unit consists of a dual-line laser profilometer positioned in front of the weld and an image acquisition unit on the moving frame. The dual-line laser profilometer projects two parallel laser lines across the rail head cross-section and, combined with the receiver's high-resolution displacement sampling function, acquires the height difference data between the weld cross-section and the reference rail surface. As the moving frame advances along the weld direction, the detection unit continuously scans the rail head surface at a fixed sampling frequency, thereby obtaining the three-dimensional profile data of the weld's longitudinal section. Simultaneously, the image acquisition unit records the texture image of the weld surface, providing auxiliary data for subsequent judgment through grayscale distribution and edge information.

[0068] After the collected contour data enters the control unit, it first undergoes outlier removal and filtering to eliminate noise points caused by dust, light spot vibration, or rail surface contamination. Subsequently, the control unit calculates the weld reinforcement height (the height difference between the weld metal and the standard rail surface) based on a predefined rail profile template. The reinforcement height is typically calculated by establishing a difference function between the weld center region and the base metal reference surfaces on both sides, then using least-squares fitting to obtain a continuous curve, thus yielding the reinforcement height parameters for each sampling point.

[0069] Based on the obtained weld height distribution, the control unit further extracts the flatness index. The flatness index refers to the root mean square error or peak-to-valley difference of the weld surface height variation relative to the reference plane, used to quantify the degree of rail surface unevenness. The calculation of the flatness index not only depends on the longitudinal weld height but also incorporates the cross-sectional geometry to comprehensively measure the overall geometric deviation of the weld area. Ultimately, the control unit outputs two key parameters: the weld height distribution curve and the initial flatness numerical index. These data will serve as the core input for subsequent extrusion and grinding.

[0070] Step S20: Based on the excess height and initial flatness index, generate an extrusion pressure adjustment command in the control unit and send it to the extrusion forming unit to drive the press shoe to continuously extrude the excess height of the weld.

[0071] Specifically, after the control unit obtains the excess height curve and initial flatness index calculated in step S10, it first segments the data. Specifically, the system divides the weld area into several continuous segments according to the excess height variation at the track-direction sampling points. For example, if the excess height curve fluctuates less than a preset threshold within a certain segment, that segment is determined as a "low variation zone"; conversely, if the excess height curve has a protrusion or drops beyond the threshold, that segment is determined as a "high variation zone." The purpose of this segmentation is to avoid maintaining a constant extrusion pressure throughout the process, which could lead to over-extrusion of local protruding areas or insufficient extrusion of low excess height areas.

[0072] After obtaining the zoning results, the control unit generates a pressing pressure adjustment command based on the excess height parameter and flatness index. Specifically, the pressing pressure setting follows the basic principle that "the greater the excess height, the higher the loading pressure," while dynamically adjusting the loading rate in conjunction with the flatness index. For example, when the excess height exceeds the preset upper limit, the control unit will gradually increase the target pressing pressure to a higher level, but when approaching the expected flatness improvement target, it will reduce the loading rate to avoid over-extrusion and the formation of rail surface depressions.

[0073] The adjustment command is transmitted via a signal channel to the drive component within the extrusion forming unit. The drive component is typically a hydraulic cylinder or an electric push rod, with its output connected to the pressure shoe. As the component in direct contact with the rail surface, the pressure shoe continuously presses down under the drive of the adjustment command, thereby gradually plastically deforming the weld reinforcement. Because the extrusion pressure is dynamically adjusted, the contact between the pressure shoe and the rail surface is not a one-time hard-on process, but a continuous, meticulous process of "flattening—inspection—re-flattening," allowing the extrusion pressure to adapt to the rail surface morphology and avoiding stress concentration or rail surface damage.

[0074] In this way, the extrusion pressure adjustment commands generated by the control unit are equivalent to establishing a "closed-loop control logic" for the extrusion process. This makes the extrusion forming unit no longer a single actuator, but a flexible processing unit that can dynamically respond to the weld condition. The final technical effect is that it can quickly reduce the height when the weld excess height is large, and smoothly finish when the excess height is close to the target value, making the extrusion process both efficient and stable, and providing a guide surface that is closer to the target shape for the subsequent grinding unit.

[0075] Step S30: Based on the excess height and initial flatness index, a grinding parameter adjustment command is generated in the control unit and sent to the grinding unit to drive the grinding head to grind the weld surface after extrusion forming.

[0076] Specifically, after the initial reduction of excess weld height during the extrusion process, the weld surface may still have minor ripples or uneven surface roughness. This stage involves secondary shaping via a grinding unit. The control unit calculates the key process parameters required for grinding based on the residual excess weld height and flatness indicators, including wheel speed, depth of cut, feed rate, and oscillation amplitude.

[0077] For example, when the residual grinding height is still greater than the preset median value, the control unit will set a higher grinding depth and feed rate to quickly remove excess metal; while when the residual grinding height is close to the reference value and the flatness index gradually improves, the grinding depth is reduced and the oscillation amplitude is increased, so that the grinding wheel covers a larger area, thereby obtaining a more uniform surface effect. The grinding head is usually an electric spindle structure, the grinding wheel is driven by a motor and has an adjustable speed, the feed mechanism pushes the grinding head forward along the track, and the oscillation mechanism realizes a small reciprocating motion in the lateral direction of the track.

[0078] After the command is issued, the grinding head performs finishing operations on the rail surface, gradually removing surface protrusions and reducing the amplitude of ripples. Compared with traditional single-speed grinding, this dynamic adjustment based on detection parameters can achieve real-time matching between processing intensity and rail surface condition, reducing unnecessary metal loss and avoiding localized over-grinding. The technical effect is a significant improvement in the surface quality and consistency of rail surface shaping, ensuring the final service performance of the weld.

[0079] Step S40: During the extrusion and grinding process, acquire the hardness proxy parameters output by the hardness detection unit in the extrusion and grinding device for rail weld shaping and the temperature information output by the temperature detection unit in the extrusion and grinding device for rail weld shaping, and correct the extrusion pressure adjustment command and grinding parameter adjustment command in the control unit.

[0080] Specifically, due to the welding repair process, there is a hardness difference between the central area and the heat-affected zone in the weld area. To avoid a "one-size-fits-all" processing method, the device is equipped with a hardness detection unit, which includes an eddy current probe and an acoustic emission sensor. The eddy current probe indirectly calculates the hardness by sensing changes in the metal's conductivity, while the acoustic emission sensor collects the stress wave signal generated by the metal during extrusion. The two are fused to generate a hardness proxy parameter. At the same time, the temperature detection unit monitors the temperature in the grinding zone and its rate of rise in real time.

[0081] Upon receiving this data, the control unit modifies the original extrusion pressure and grinding parameter commands. For example, when the hardness proxy parameter indicates high hardness in the weld center area, the system reduces the extrusion pressure and grinding depth to avoid cracking or excessive wear; conversely, when the hardness in the heat-affected zone is low, the extrusion pressure and grinding parameters are appropriately increased to ensure efficient plastic removal. Temperature information is introduced to prevent overheating in the grinding zone. When the temperature exceeds a threshold, not only is spray cooling triggered, but the grinding wheel contact pressure and speed are also automatically reduced to suppress thermal damage.

[0082] By comprehensively correcting the information from multiple dimensions, the extrusion and grinding processes can be tailored to individual needs, adjusting the processing intensity according to the physical state of different areas of the weld. The final technical effect is a significant improvement in the safety and reliability of weld shaping, avoiding secondary defects caused by differences in hardness or excessively rapid temperature rise.

[0083] Step S50: Based on the corrected extrusion pressure adjustment command and grinding parameter adjustment command, drive the extrusion forming unit and grinding unit to operate in coordination until the flatness index output by the detection unit reaches the preset criterion.

[0084] Specifically, in the final stage, the control unit, based on the corrected parameters, simultaneously drives the extrusion forming unit and the grinding unit to operate in coordination. Coordination means that the two are not completely separate, but rather operate continuously with a certain spatial interval: the front-end press shoe performs dynamic extrusion on the excess material, while the rear-end grinding head follows closely behind for finishing. The two achieve real-time linkage at the command level through the control unit.

[0085] During operation, the detection unit continuously collects the latest contour information and feeds back the flatness index to the control unit in real time. The control unit compares this index with preset criteria. When the flatness gradually approaches the target value, it automatically reduces the extrusion pressure and grinding depth to achieve a "finishing" process and avoid over-removal. If the detection result still does not meet the standard, the corrected instructions continue to be executed until the set termination condition is met.

[0086] This closed-loop control transforms extrusion and grinding from two separate processes into a continuous and complementary whole. The ultimate technical benefit is that the rail surface flatness consistently meets the set standards, and over-extrusion, over-grinding, or thermal damage is avoided during processing, thereby improving the consistency of weld shaping and long-term service performance.

[0087] Those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware. This program is stored in a storage medium and includes several instructions to cause a microcontroller, chip, or processor to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as a USB flash drive, a portable hard drive, a read-only memory (ROM), a random access memory (RAM), a magnetic disk, or an optical disk.

[0088] The optional embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the embodiments of the present invention are not limited to the specific details described above. Within the scope of the technical concept of the embodiments of the present invention, various simple modifications can be made to the technical solutions of the embodiments of the present invention, and these simple modifications all fall within the protection scope of the embodiments of the present invention. It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. To avoid unnecessary repetition, the embodiments of the present invention will not further describe the various possible combinations.

[0089] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the embodiments of the present invention, they should also be regarded as the content disclosed by the embodiments of the present invention.

Claims

1. A pressing and grinding device for shaping rail welds, characterized in that, The extrusion grinding device for shaping rail welds includes: Follower frame, used to move along the weld direction on the rail; An extrusion forming unit, mounted on the follower frame, includes a pressure shoe and a drive component, for continuously extruding the weld reinforcement. A grinding unit, mounted on the follower frame, includes a grinding head and a drive component, and is used to grind the weld surface after extrusion forming; The detection unit, installed on the follow-up frame, is used to acquire the contour information of the weld surface and output the flatness index. The control unit is connected to the extrusion forming unit, grinding unit and detection unit respectively. It is used to receive the contour information output by the detection unit and issue execution commands to the extrusion forming unit and grinding unit.

2. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The pressure shoe has a replaceable end face module structure; The end face module structure is installed at the front end of the extrusion forming unit by means of fasteners and positioning pins, and corresponds to the rail surface section template in the preset rail type library.

3. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The extrusion forming unit is equipped with a six-axis force sensor and a linear displacement sensor; The force sensor is fixed between the pressure shoe and the drive component to collect the extrusion force signal in real time. The displacement sensor is connected to the stroke section of the drive component to collect displacement information; The extrusion pressure signal and displacement information are combined to generate force and position monitoring data for the extrusion process.

4. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The grinding unit includes an electric spindle grinding head, a feed mechanism, and a oscillating mechanism; The electric spindle grinding head is equipped with a grinding wheel and is driven by a motor to generate an adjustable speed. The feeding mechanism is connected to the follower frame for feeding along the rail direction; The swing mechanism is connected to the grinding head to generate directional swing.

5. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The grinding unit is equipped with a spray cooling nozzle and a temperature detection unit; The nozzle is positioned upstream of the grinding contact area and is connected to the liquid supply module; The temperature detection unit is used to collect the temperature and temperature rise rate of the grinding zone. When the temperature exceeds the preset threshold, the control unit outputs a trigger signal to start spray cooling, and at the same time, it reduces the target pressure value of the contact pressure loading component.

6. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The extrusion grinding device for shaping rail welds also includes a hardness detection unit. The hardness detection unit includes an eddy current probe and an acoustic emission sensor; The eddy current probe is installed at the front end of the servo frame to maintain a preset gap with the rail surface and to collect the signal of change in the conductivity of the metal in the weld zone. The acoustic emission sensor is fixed on the support of the extrusion forming unit to collect the stress wave signal generated by the weld during the extrusion process; The output signal of the hardness detection unit is transmitted to the control unit and fused within the control unit to generate a hardness proxy parameter for distinguishing between the weld center area and the heat-affected zone, thereby realizing the partitioned configuration of the extrusion forming unit and the grinding unit in different hardness areas.

7. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The detection unit includes a dual-line laser profilometer arranged in front of the weld and an image acquisition device set on the servo frame. The dual-line laser profilometer is used to obtain the profile of the rail head section and calculate the weld reinforcement height and flatness index. The image acquisition device is used to acquire surface texture information of the weld seam; The control unit determines whether the weld shaping meets the standards based on the weld reinforcement height, flatness index, and weld surface texture information.

8. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The follower frame is provided with a pair of guide wheels at the top of the rail and a pair of limit wheels at the waist of the rail. The guide wheels and limit wheels are respectively attached to the surface of the top of the rail and the surface of the waist of the rail to ensure that the device maintains a stable posture and suppresses lateral sway during the feeding process along the weld seam.

9. The extrusion grinding device for shaping rail welds according to claim 1, characterized in that, The extrusion and grinding device for shaping rail welds also includes a pressure shoe compliance adjustment unit; The pressure shoe compliance adjustment unit is disposed between the rail and the pressure shoe, and includes an elastic layer and a variable damping component; The variable damping component adjusts the contact compliance between the pressure shoe and the weld surface by controlling the pressure of the magnetorheological fluid or airbag, so as to maintain a uniform distribution of extrusion pressure and suppress high-frequency vibration when the weld reinforcement change is greater than a preset change threshold.

10. A control method for an extrusion grinding device for shaping rail welds, characterized in that, The method is applied to the extrusion grinding apparatus for shaping rail welds as described in any one of claims 1-9, and the method includes: The weld surface contour information collected by the detection unit is acquired, and the reinforcement height and initial flatness index are calculated in the control unit. Based on the weld height and initial flatness index, the extrusion pressure adjustment command is generated in the control unit and sent to the extrusion forming unit to drive the press shoe to continuously extrude the weld height. Based on the excess height and initial flatness index, the grinding parameter adjustment command is generated in the control unit and sent to the grinding unit to drive the grinding head to grind the weld surface after extrusion forming. During the extrusion and grinding process, the hardness proxy parameters output by the hardness detection unit in the extrusion and grinding device for rail weld shaping and the temperature information output by the temperature detection unit in the extrusion and grinding device for rail weld shaping are obtained, and the extrusion pressure adjustment command and grinding parameter adjustment command are corrected in the control unit. Based on the revised extrusion pressure adjustment command and grinding parameter adjustment command, the extrusion forming unit and grinding unit are driven to operate in coordination until the flatness index output by the detection unit reaches the preset criterion.

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