An integrated online rail milling, grinding, and full profile reshaping equipment

Abstract

This application relates to the field of rail milling machine technology, specifically disclosing an integrated online rail milling and grinding full-profile reshaping equipment. This application first provides a stable moving reference through a feed mechanism, then uses a hardness detection mechanism to proactively identify the hardness distribution on the rail surface, and immediately uses a heating mechanism for targeted pretreatment, creating favorable conditions for subsequent milling. After milling, a collection mechanism promptly cleans up debris, a lubrication mechanism provides a suitable interface environment for the next grinding step, and finally, a belt abrasive grinding mechanism completes the finishing process with the assistance of an ultrasonic oscillation mechanism. This sequentially connected and functionally complementary integrated design fundamentally solves the problems of low operating efficiency caused by the single function and separate processes of traditional equipment, as well as poor repair quality caused by the inability to adapt to the heterogeneity of rail materials, achieving efficient and high-precision full-profile reshaping of rails.

Description

Technical Field

[0001] This application relates to the field of rail milling machine technology, and in particular to an integrated online rail milling and grinding full profile reshaping equipment. Background Technology

[0002] In railway transportation systems, rails, as key components directly bearing train loads, are subjected to the constant pressure, friction, and impact of wheels, inevitably resulting in various damages such as corrugation, cracks, crushing, and side wear. This causes their profile to deviate from design standards, severely affecting the stability and safety of train operation. To restore the ideal profile of rails and extend their service life, rail milling technology is widely used as an efficient and precise repair method. This technology uses a cutter head mounted on a specialized milling machine to cut the rail surface, removing various surface defects in a single operation and precisely reshaping its geometric contour.

[0003] Currently, existing online rail milling vehicles typically integrate a power system, a traveling system, a milling system, and a corresponding control system. During operation, they travel along the track via the traveling system, while simultaneously driving a high-speed rotating milling cutter head to perform contour milling on the top and sides of the rail.

[0004] However, existing online rail milling technology has relatively limited functionality. The surface quality of the milled rail is directly linked to the milling quality of the milling system. In actual online milling, the rail surface is not clean; it may contain dust, grit, and other contaminants. Furthermore, due to factors such as material fatigue, work hardening, and wheel slip friction, different areas of the rail may exhibit uneven hardening and fatigue softening zones, resulting in varying degrees of damage. Whether the rail surface is unclean or the rail itself is in a different state of damage, it will affect the online milling quality of the milling mechanism. In addition, tool marks remain on the surface after milling, which will also severely impact the final grinding result. Summary of the Invention

[0005] In order to overcome the limitations of the above-mentioned online rail milling technology, such as the unstable milling quality caused by the difference in the cleanliness of the rail surface and the uneven distribution of material hardness, as well as the need for secondary treatment of tool marks left after milling, and to achieve efficient, high-precision, and integrated rail repair operations, this application provides an integrated online rail milling and grinding full profile reshaping equipment.

[0006] This application provides an integrated online rail milling, grinding, and full-profile reshaping equipment, which adopts the following technical solution:

[0007] An integrated online rail milling and full profile reshaping equipment includes a trailer and a main vehicle located behind the trailer. The main vehicle is provided with a feeding mechanism for stable movement of the main vehicle on the rail, a milling mechanism for milling the rail, and a fast travel mechanism for driving the main vehicle to move quickly in an unmilled state, arranged from front to back.

[0008] The feeding mechanism is integrated with a profile mechanism for profile-shaping the rail surface. Between the feeding mechanism and the milling mechanism, there is a hardness detection mechanism for detecting the hardness of the rail surface and a heating mechanism for heating rail surfaces of different hardnesses to different degrees according to the detection of the hardness detection mechanism.

[0009] Between the milling mechanism and the fast travel mechanism, there is a collection mechanism for collecting the milled debris and a lubrication mechanism for spraying different doses of lubricant according to the different hardness of the rail.

[0010] The fast-moving mechanism is provided with a belt grinding mechanism on the side away from the lubrication mechanism, and the belt grinding mechanism is provided with an ultrasonic oscillation mechanism for generating different oscillation magnitudes according to the different hardness of the rail.

[0011] The main vehicle is also equipped with a control system, which is electrically connected to the feeding mechanism, milling mechanism, rapid travel mechanism, profile mechanism, hardness detection mechanism, heating mechanism, collection mechanism, lubrication mechanism, belt sanding mechanism and ultrasonic oscillation mechanism.

[0012] Optionally, the hardness testing mechanism includes a telescopic cylinder, a rotating connecting rod, and a laser-induced breakdown spectrometer. The telescopic cylinder is mounted on the main vehicle. One end of the rotating connecting rod is rotatably mounted on the main vehicle, and the other end is rotatably connected to the telescopic end of the telescopic cylinder. The laser-induced breakdown spectrometer is coaxially fixed to the end of the rotating connecting rod away from the telescopic cylinder. The laser-induced breakdown spectrometer can be positioned directly facing the upper surface of the rail under the action of the telescopic cylinder.

[0013] Optionally, the heating mechanism includes a fiber laser and a laser beam expander. The fiber laser is fixedly installed on the main vehicle, and the laser beam expander is detachably installed on the laser head of the fiber laser and is positioned facing the upper surface of the rail.

[0014] Optionally, the collection mechanism includes a collection roller, an electromagnet, a collection plate, and a collection bin. The collection roller is rotatably mounted on the main vehicle and located on the side of the milling mechanism away from the trailer. The electromagnetic coil of the electromagnet is circumferentially mounted on the peripheral wall of the collection roller. The collection plate slides against the electromagnetic coil on the surface of the collection roller, and the collection plate communicates with the inner cavity of the collection bin.

[0015] Optionally, the collection mechanism further includes a dust removal chamber disposed at the bottom of the collection bin. A dust removal section is disposed on the side of the dust removal chamber away from the collection roller. The dust removal surface of the dust removal section is inclined downward, and two dust removal surfaces near the edge are provided with guide sections for guiding foreign objects. The inclination slopes of the two guide sections and the dust removal surface of the dust removal section are different, and multiple dust removal holes are opened on the two guide sections. A dust removal cavity for dust removal is disposed inside the dust removal bin. Each dust removal hole communicates with the inner cavity of the dust removal cavity. An air supply pipe communicating with the inner cavity of the dust removal bin is disposed on the outer wall of the dust removal bin, and the air supply pipe is connected to an external air source.

[0016] Optionally, the lubrication mechanism includes a liquid storage tank, a liquid filter, a micro pump, and a water mist nozzle. The liquid storage tank is filled with a lubricant for lubricating the milled rail. The micro pump is connected to the water mist nozzle. The liquid filter is located between the liquid storage tank and the micro pump to filter the lubricant flowing out of the liquid storage tank.

[0017] Optionally, the belt sanding mechanism includes a sanding frame, a power unit, sanding wheels, and a sanding belt. The sanding frame is fixed on the main vehicle. Multiple sanding wheels are rotatably mounted on the sanding frame. The power unit is mounted on the sanding frame and its output end is coaxially fixed with one of the sanding wheels. The sanding belt is wound between the sanding wheels and slides against the upper surface of the rail.

[0018] Optionally, the ultrasonic oscillation mechanism includes a host computer disposed on the main vehicle and an ultrasonic vibrating rod communicating with the host computer, wherein the ultrasonic vibrating rod is fixedly installed on the grinding frame.

[0019] In summary, this application includes at least one of the following beneficial technical effects:

[0020] 1. This application adopts a highly integrated and intelligent online repair system, which integrates modules with different functions such as detection, pretreatment, roughing, and finishing according to process logic, and endows them with adaptive capabilities based on working condition perception, thereby realizing the transformation of rail repair from extensive operation to precision operation. Its primary improvement lies in setting the hardness detection mechanism, heating mechanism, milling mechanism, collection mechanism, lubrication mechanism, belt grinding mechanism, and ultrasonic vibration mechanism sequentially on the travel path of the main vehicle, and coordinating them uniformly by the control system. This allows the equipment to complete the entire process from hardness identification, local heat treatment, profile milling, debris recovery to final flexible fine grinding in a single journey, completely solving the inherent defects of low efficiency and poor process connection in the traditional multi-equipment, multi-process operation mode.

[0021] 2. This application uses a laser-induced breakdown spectrometer for hardness testing and links a fiber laser and a laser beam expander to selectively thermally soften the hard areas. The equipment can actively reduce the processing difficulty of the material, creating favorable conditions for subsequent milling and grinding. At the same time, by adjusting the spraying of lubricant according to the working conditions and using an ultrasonic vibrating rod to apply different degrees of high-frequency mechanical oscillation to the belt grinding process, the physical environment of the grinding interface is dynamically optimized, effectively solving the problems of unstable grinding quality and easy tool wear caused by uneven steel rail material, ensuring a consistent and excellent final surface across the entire profile.

[0022] 3. This application adds a dust removal chamber at the bottom of the collection chamber and sets up a downward-sloping dust removal section on the dust removal chamber, which can mechanically scrape the upper surface of the rail about to enter the milling area, removing large particles of foreign matter in advance. The two guide sections near the edge have a unique design with a different slope than the dust removal surface, which can effectively guide the scraped foreign matter to the roadbed area on both sides of the rail, avoiding its accumulation on the rail surface and affecting subsequent operations. Multiple dust removal holes opened on the guide section are connected to the inner cavity of the dust removal chamber and connected to the air source through the air supply pipe, which can spray directional airflow onto the rail surface to remove residual dust and fine sand. This overcomes the reality of the rail surface being unclean due to dust and sand, and by actively cleaning the rail surface with a combination of mechanical and airflow before the milling process, it effectively eliminates the abnormal wear of the milling tool, interference with the milling path, and the risk of contamination of the subsequent lubrication and grinding interface caused by foreign matter. It provides a clean and stable operating foundation for the subsequent milling mechanism and belt grinding mechanism, which is a key pre-process to ensure the final surface quality of the full profile reshaping. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the overall structure of the online rail milling and grinding full profile reshaping integrated equipment in the embodiments of this application;

[0025] Figure 2 yes Figure 1 A partial structural schematic diagram of an integrated milling, grinding, and reshaping equipment for centerline rails;

[0026] Figure 3 yes Figure 2 Schematic diagram of the structure at the milling mechanism;

[0027] Figure 4 yes Figure 3 Schematic diagram of the structure of the medium hardness testing mechanism and the heating mechanism;

[0028] Figure 5 yes Figure 3 A schematic diagram of the collection mechanism;

[0029] Figure 6 yes Figure 5 A schematic diagram of the central collection mechanism from a frontal view;

[0030] Figure 7 yes Figure 3 Schematic diagram of the lubrication mechanism;

[0031] Figure 8 yes Figure 3 Schematic diagram of the medium sand belt grinding mechanism and the ultrasonic oscillation mechanism.

[0032] Figure label:

[0033] 1. Trailer;

[0034] 2. Main carriage; 21. Feed mechanism; 22. Milling mechanism; 23. Rapid travel mechanism;

[0035] 3. Hardness testing mechanism; 31. Telescopic cylinder; 32. Rotating connecting rod; 33. Laser-induced breakdown spectrometer;

[0036] 4. Heating mechanism; 41. Fiber laser; 42. Laser beam expander;

[0037] 5. Collection mechanism; 51. Collection roller; 52. Electromagnet; 53. Collection plate; 54. Collection bin; 55. Dust removal bin; 551. Dust removal section; 552. Guide section; 553. Dust removal hole; 56. Air supply pipe;

[0038] 6. Lubrication mechanism; 61. Liquid storage tank; 62. Liquid filter; 63. Micro pump; 64. Water mist nozzle;

[0039] 7. Belt sanding mechanism; 71. Sanding frame; 72. Power unit; 73. Sanding wheel; 74. Sanding belt;

[0040] 8. Ultrasonic oscillation mechanism; 81. Main unit; 82. Ultrasonic vibrator. Detailed Implementation

[0041] The following is in conjunction with the appendix Figure 1-8 This application will be described in further detail below.

[0042] This application discloses an integrated online rail milling and grinding full profile reshaping equipment.

[0043] Reference Figure 1 and Figure 2An integrated online rail milling and reshaping device includes a trailer 1 and a main vehicle 2 located behind the trailer 1. This embodiment only shows a portion of the structure of the trailer 1 and the main vehicle 2; other structures and the vehicle shell are not shown in the figures. The trailer 1 consists of a range extender, battery, inverter, fuel tank, PDU, etc., wherein the range extender can provide a power output of 75kW, and the battery capacity is 8kWh. The main vehicle 2 is equipped with, from front to back, a feed mechanism 21 for stable movement of the main vehicle 2 on the rail, a milling mechanism 22 for milling the rail, and a rapid travel mechanism 23 for rapidly moving the main vehicle 2 in an unmilled state.

[0044] The feed mechanism 21 includes a drive unit, an execution unit, a stabilization and pressure supply unit, and a support and guide unit. The drive unit includes a servo motor and a reducer. The servo motor serves as the core power source, providing precise speed and torque control, thereby achieving stepless speed regulation and stable feed speed. The reducer matches the high speed of the servo motor and the high torque required by the drive wheel.

[0045] The actuator includes four sets of polyurethane drive wheels, which press directly against the rail head. The polyurethane drive wheels provide high friction while avoiding damage to the rail surface.

[0046] The stabilization and pressure supply unit includes a hydraulic pump station, a control valve group, and a hydraulic cylinder. The hydraulic cylinder is connected to the drive wheel assembly to provide downforce, ensuring sufficient adhesion between the drive wheel and the rail to prevent slippage.

[0047] The support and guide unit includes a rigid support frame that supports the entire feed mechanism 21 and multiple sets of lateral guide wheels to ensure that the entire equipment travels in a straight line along the track and prevents deviation.

[0048] The milling mechanism 22 includes a high-power DD direct drive motor, a rotary milling cutter, and a precision positioning component. The rotor of the high-power DD direct drive motor is directly connected to the milling cutter disc, eliminating traditional transmission components such as belts and gears. Its advantages are compact structure, high transmission efficiency, low noise, low maintenance, and the ability to provide extremely high torque.

[0049] Rotary end mills can be customized according to the profile of the target rail. Multiple sets of indexable carbide inserts are installed on their circumference, and the arrangement of the insert profiles determines the final shape of the milled rail.

[0050] The precision positioning system includes an X-axis servo drive module and a Z-axis servo drive module. The X-axis servo drive module controls the entire power head to move horizontally, accurately aligning it with the centerline of the rail, and can make fine adjustments according to commands to correct asymmetrical side wear. The Z-axis servo drive module controls the entire power head to move vertically, precisely controlling the milling depth.

[0051] The rapid travel mechanism 23 includes an asynchronous motor, steel drive wheels, gearbox, etc., and is used for rapid movement of the equipment in non-operational states, such as entering and exiting a garage or transferring between different work areas.

[0052] Reference Figure 1 and Figure 2 The feed mechanism 21 is integrated with a profile mechanism for profile-shaping the rail surface. Between the feed mechanism 21 and the milling mechanism 22, there is a hardness detection mechanism 3 for detecting the hardness of the rail surface and a heating mechanism 4 for heating the rail surface of different hardness to different degrees according to the detection of the hardness detection mechanism 3.

[0053] Reference Figure 1 Between the milling mechanism 22 and the rapid travel mechanism 23, there is a collection mechanism 5 for collecting milled debris and a lubrication mechanism 6 for spraying different doses of lubricant according to the different hardness of the rail.

[0054] Reference Figure 1 and Figure 2 A belt grinding mechanism 7 is provided on the side of the rapid travel mechanism 23 away from the lubrication mechanism 6. The belt grinding mechanism 7 is equipped with an ultrasonic oscillation mechanism 8 for generating different oscillation magnitudes according to the different hardness of the rails. In this embodiment, a set of belt grinding mechanisms 7 is also provided on the main carriage 2 behind the rapid travel mechanism 2, corresponding to the two rails. This set of belt grinding mechanisms 7 is also equipped with an ultrasonic oscillation mechanism 8. This set of belt grinding mechanisms 7 and ultrasonic oscillation mechanism 8 can perform secondary grinding on the rail surface, thereby making the rail surface smoother.

[0055] The main vehicle 2 is also equipped with a control system, which is electrically connected to the feeding mechanism 21, milling mechanism 22, rapid travel mechanism 23, profile mechanism, hardness detection mechanism 3, heating mechanism 4, collection mechanism 5, lubrication mechanism 6, belt sanding mechanism 7 and ultrasonic oscillation mechanism 8.

[0056] The trailer 1, main car 2, feeding mechanism 21, milling mechanism 22, fast travel mechanism 23, profile mechanism, hardness detection mechanism 3, heating mechanism 4, collection mechanism 5, lubrication mechanism 6, belt sanding mechanism 7, ultrasonic oscillation mechanism 8, and control system are integrated into one integrated device. Through the unified scheduling of the control system, continuous and coordinated processing of rails can be achieved within a single operation stroke.

[0057] The equipment in this application can first provide a stable moving reference through the feed mechanism 21, then use the hardness detection mechanism 3 to proactively identify the hardness distribution on the rail surface, and immediately use the heating mechanism 4 to perform targeted pretreatment to create favorable conditions for subsequent milling; after milling, the collection mechanism 5 cleans up the debris in time, the lubrication mechanism 6 provides a suitable interface environment for the next grinding step, and finally the belt grinding mechanism 7 completes the finishing with the assistance of the ultrasonic oscillation mechanism 8.

[0058] This integrated design, which combines sequential connections and complementary functions, fundamentally solves the problems of low operational efficiency caused by the single function and separate processes of traditional equipment, as well as poor repair quality caused by the inability to adapt to the heterogeneity of rail materials, thus achieving efficient and high-precision full-profile reshaping of rails.

[0059] Each of the above structures can dynamically adjust the heating temperature, milling force, lubrication metering, and ultrasonic vibration intensity according to the different hardness of the rail, comprehensively optimizing the dynamic reshaping of the rail and greatly improving the quality of reshaping.

[0060] Reference Figure 3 and Figure 4 The hardness testing mechanism 3 includes a telescopic cylinder 31, a rotating connecting rod 32, and a laser-induced breakdown spectrometer 33. The telescopic cylinder 31 is mounted on the main vehicle 2. One end of the rotating connecting rod 32 is rotatably mounted on the main vehicle 2, and the other end is rotatably connected to the telescopic end of the telescopic cylinder 31. The laser-induced breakdown spectrometer 33 is coaxially fixed with the end of the rotating connecting rod 32 away from the telescopic cylinder 31. The laser-induced breakdown spectrometer 33 can be set facing the upper surface of the rail under the drive of the telescopic cylinder 31.

[0061] The telescopic cylinder 31 drives the rotating connecting rod 32 to rotate, thereby driving the laser-induced breakdown spectrometer 33 to rotate and adjust its detection angle and position, ensuring that the laser-induced breakdown spectrometer 33 can accurately align with the area to be detected on the upper surface of the rail. The laser-induced breakdown spectrometer 33 uses laser pulses to induce plasma on the rail surface and obtains the elemental composition and hardness information of the rail surface in real time and non-destructively by analyzing its spectral signal. This mechanism provides key material property data for the entire system, enabling the subsequent heating mechanism 4 to perform precise energy intervention based on this data, laying a solid data foundation for realizing differentiated processing strategies for areas with different hardness.

[0062] Reference Figure 3 and Figure 4 The heating mechanism 4 includes a fiber laser 41 and a laser beam expander 42. The fiber laser 41 is fixedly installed on the main vehicle 2, and the laser beam expander 42 is detachably installed on the laser head of the fiber laser 41 and is positioned facing the upper surface of the rail.

[0063] The fiber laser 41 generates a high-energy-density laser beam, providing a stable and controllable heat source for the localized thermal softening treatment of the rail surface. A laser beam expander 42, mounted on the laser head of the fiber laser 41, enlarges the diameter of the emitted laser beam, thereby forming a more uniform energy density distribution and a larger coverage area on the rail surface. This effectively avoids excessive melting or ablation of the rail surface due to excessive energy concentration, achieving uniform and controllable heating of the hardened area, moderately reducing its hardness, and thus significantly reducing cutting resistance and tool wear during subsequent milling operations.

[0064] The milling mechanism 22 includes a milling wheel 221 and a power assembly for providing power to the milling wheel 221. The milling wheel 221 can perform milling operations on the surface of the rail. Under the action of the power assembly, the milling wheel 221 can also be separated from the surface of the rail. Since the functions achieved by the power assembly are all conventional technologies known to those skilled in the art, this structure will not be described in detail in this embodiment.

[0065] Reference Figure 3 and Figure 5 The collection mechanism 5 includes a collection roller 51, an electromagnet 52, a collection plate 53, a collection bin 54, and a drive component. The collection roller 51 is rotatably mounted on the main vehicle 2 and located on the side of the milling mechanism 22 away from the trailer 1. The drive component is a motor and its output end is coaxially fixed with the collection roller 51. The electromagnetic coil of the electromagnet 52 is circumferentially mounted on the peripheral wall of the collection roller 51. The collection plate 53 slides against the electromagnetic coil on the surface of the collection roller 51, and the collection plate 53 communicates with the inner cavity of the collection bin 54.

[0066] After the milling mechanism 22 has finished its operation, the rotating collection roller 51 covers the width of the milling area. The electromagnet 52 mounted on its peripheral wall generates a strong magnetic field when energized, efficiently attracting most of the ferromagnetic chips generated during milling. As the collection roller 51 rotates, the collection plate 53, which slides against the surface of the roller 51, scrapes off the chips attracted to the electromagnet 52 and uses gravity or airflow to guide them into the collection chamber 54, which is connected to the collection plate 53, for centralized storage. This process achieves immediate and automatic recovery of milling chips, keeping the work area clean and effectively preventing contamination and interference from chips on the working interfaces of the subsequent lubrication mechanism 6 and belt sanding mechanism 7.

[0067] Furthermore, refer to Figure 5 and Figure 6The collection mechanism 5 also includes a dust removal chamber 55 located at the bottom of the collection chamber 54. A dust removal section 551 is provided on the side of the dust removal chamber 55 away from the collection roller 51. The dust removal surface of the dust removal section 551 is inclined downward, and two dust removal surfaces near the edge are provided with guide sections 552 for guiding foreign objects. The inclination slope of the two guide sections 552 is different from that of the dust removal surface of the dust removal section 551, and multiple dust removal holes 553 are provided on the two guide sections 552. A dust removal cavity for dust removal is provided inside the dust removal chamber 55. Each dust removal hole 553 is connected to the inner cavity of the dust removal cavity. An air supply pipe 56 is provided on the outer wall of the dust removal chamber 55 and is connected to an external air source.

[0068] To save external energy, in a feasible implementation, a turbofan is coaxially fixed on the milling wheel 221. A wind shroud is provided around the turbofan, with an air inlet at one end and an air outlet at the other end. The turbofan is located inside the wind shroud. During the rotation of the milling wheel 221, power can be transmitted to the turbofan, causing the turbofan to rotate and deliver air. External air enters the wind shroud from the air inlet and is delivered out from the air outlet. A connecting pipe is provided on the air outlet, which is connected to the air supply pipe. The air is finally sprayed out through each dust removal hole.

[0069] By adding a dust removal chamber 55 at the bottom of the collection chamber 54 and setting an inclined downward dust removal part 551 on the dust removal chamber 55, the upper surface of the rail that is about to enter the milling area can be mechanically scraped to remove large particles of foreign matter in advance.

[0070] The two guide sections 552 near the edge have a unique design with a different slope than the dust removal surface, which can effectively guide the scraped foreign objects to the roadbed area on both sides of the rail, preventing them from accumulating on the rail surface and affecting subsequent operations.

[0071] Multiple dust removal holes 553 are provided on the guide section 552, which are connected to the inner cavity of the dust removal chamber and connected to the air source through the air supply pipe 56. They can spray directional airflow onto the surface of the rail to remove residual dust and fine sand.

[0072] In a feasible implementation, the turbine fan is coaxially driven by the milling wheel 221 to generate wind power and deliver it to the air supply pipe, thereby realizing automatic air supply.

[0073] The above design can overcome the real-world working conditions where the rail surface is unclean, such as dust and gravel. By actively cleaning the rail surface with a combination of mechanical and airflow before the milling process, it effectively eliminates the abnormal wear of the milling tool caused by foreign objects, the interference with the milling path, and the risk of contamination of the subsequent lubrication and grinding interface. This provides a clean and stable working foundation for the subsequent milling mechanism 22 and belt grinding mechanism 7, and is a key preliminary step to ensure the final surface quality of the full profile reshaping.

[0074] Reference Figure 7The lubrication mechanism 6 includes a liquid storage tank 61, a liquid filter 62, a micro pump 63, and a water mist nozzle 64. The liquid storage tank 61 is filled with lubricant for lubricating the milled rail. The micro pump 63 is connected to the water mist nozzle 64. The liquid filter 62 is located between the liquid storage tank 61 and the micro pump 63 and is used to filter the lubricant flowing out of the liquid storage tank 61.

[0075] When lubrication is required, the micro pump 63 starts, pumping lubricant from the reservoir 61. The lubricant flows through the liquid filter 62 located between the reservoir 61 and the micro pump 63 to remove any impurities that may be present in the liquid, preventing clogging of subsequent components. The filtered clean lubricant is finally atomized and sprayed onto the milled rail surface through the water mist nozzle 64, forming an extremely thin lubricating film on the rail surface. This reduces the coefficient of friction between the abrasive belt 74 and the rail surface during subsequent belt grinding operations, effectively reducing grinding resistance and heat generation. This improves grinding efficiency while protecting the abrasive belt 74 and enhancing the surface quality after grinding.

[0076] Reference Figure 8 The belt sanding mechanism 7 includes a sanding frame 71, a power unit 72, sanding wheels 73, and a sanding belt 74. The sanding frame 71 is fixed on the main vehicle 2. The sanding wheels 73 are rotatably mounted on the sanding frame 71 and there are multiple of them. The power unit 72 is mounted on the sanding frame 71 and its output end is coaxially fixed with one of the sanding wheels 73. The sanding belt 74 is wound between each sanding wheel 73 and slides against the upper surface of the rail.

[0077] The grinding frame 71, fixed on the main vehicle 2, provides stable support for the entire belt grinding mechanism 7. The power unit 72 serves as the power source, driving a grinding wheel 73, which is coaxially fixed with its output end, to rotate. Since the sanding belt 74 is wound between multiple grinding wheels 73, the rotation of the active grinding wheel 73 drives the sanding belt 74 to move together through friction, so that the sanding belt 74 can slide and abut against the upper surface of the rail at a constant linear speed to perform grinding operations.

[0078] This multi-wheel supported abrasive belt 74 transmission method ensures stable tension and smooth operation of the abrasive belt 74 during the grinding process. Its flexible contact characteristics enable it to better adapt to the profile curve of the rail, achieving uniform material removal and surface finishing.

[0079] Reference Figure 8 The ultrasonic oscillation mechanism 8 includes a host 81 mounted on the main vehicle 2 and an ultrasonic vibrating rod 82 connected to the host 81. The ultrasonic vibrating rod 82 is fixedly mounted on the grinding frame 71.

[0080] The host 81 generates a high-frequency electrical signal and transmits it via cable to the ultrasonic vibrating rod 82, which is fixedly mounted on the grinding frame 71. The ultrasonic vibrating rod 82 converts the received high-frequency electrical signal into micro-mechanical vibration of the same frequency and directly transmits this vibration to the grinding frame 71. This vibration then acts on the abrasive belt 74 through the entire belt grinding mechanism 7, thereby adding high-frequency micro-impact and scratching motions to the abrasive grains on the basis of conventional grinding motion. This significantly enhances the cutting ability of the abrasive grains, especially when dealing with high-hardness areas. It can effectively reduce the cutting force and help prevent the abrasive belt 74 from clogging, ultimately improving grinding efficiency and surface quality.

[0081] The implementation principle of the online rail milling and full profile reshaping integrated equipment in this application embodiment is as follows: the main carriage 2 moves along the rail under the drive of the feeding mechanism 21 and the fast travel mechanism 23; first, the angle of the laser-induced breakdown spectrometer 33 is adjusted by the rotary motor so that it scans the surface of the rail in front and transmits the detected hardness data to the control system in real time.

[0082] The control system then instructs the fiber laser 41 and laser beam expander 42 in the heating mechanism 4 to perform precise, non-contact local heating and softening on the identified high-hardness areas; thereafter, the milling mechanism 22 performs profile milling on the pre-treated rail, and the collection mechanism 5 that follows efficiently recovers the milling debris by means of adsorption by the electromagnet 52.

[0083] The collection mechanism 5 collects the debris generated by the milling mechanism 22 during rail milling. On the other hand, before milling by the milling mechanism 22, it cleans the upper surface of the rail by a combination of physical and air cleaning methods. This ensures that the milling mechanism 22 can mill the clean rail surface, reducing the wear on the milling wheel 221 and the rail surface during milling, and reducing the wear on the sanding belt 74 and further damage to the rail surface during the subsequent fine grinding stage.

[0084] After the milled surface is sprayed with atomized lubricant by the lubrication mechanism 6, it enters the fine grinding stage. The sanding belt 74 runs at high speed under the drive of the power component 72. At the same time, the ultrasonic vibrating rod 82 transmits high-frequency oscillations to the grinding area. Through the vibration-assisted grinding mechanism, efficient and smooth final processing is achieved in various hardness areas. Thus, the entire integrated operation of rail inspection and reshaping is completed.

[0085] The above are all optional embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An integrated online rail milling, grinding, and full-profile reshaping equipment, characterized in that: It includes a trailer (1) and a main vehicle (2) located behind the trailer (1). The main vehicle (2) is provided with a feeding mechanism (21) for making the main vehicle (2) move stably on the rail, a milling mechanism (22) for milling the rail, and a fast travel mechanism (23) for driving the main vehicle (2) to move quickly in an unmilled state, from front to back. The feeding mechanism (21) is integrated with a profile mechanism for profile shaping the rail surface. Between the feeding mechanism (21) and the milling mechanism (22), there is a hardness detection mechanism (3) for detecting the hardness of the rail surface and a heating mechanism (4) for heating the rail surface with different hardness to different degrees according to the detection of the hardness detection mechanism (3). Between the milling mechanism (22) and the fast travel mechanism (23), there is a collection mechanism (5) for collecting the milled debris and a lubrication mechanism (6) for spraying different doses of lubricant according to the different hardness of the rail. The fast walking mechanism (23) is provided with a belt grinding mechanism (7) on the side away from the lubrication mechanism (6), and the belt grinding mechanism (7) is provided with an ultrasonic oscillation mechanism (8) for generating different oscillation magnitudes according to the different hardness of the rail. The main vehicle (2) is also equipped with a control system, which is electrically connected to the feeding mechanism (21), milling mechanism (22), fast travel mechanism (23), profile mechanism, hardness detection mechanism (3), heating mechanism (4), collection mechanism (5), lubrication mechanism (6), belt sanding mechanism (7) and ultrasonic oscillation mechanism (8).

2. The integrated online rail milling, grinding, and reshaping equipment according to claim 1, characterized in that: The hardness testing mechanism (3) includes a telescopic cylinder (31), a rotating connecting rod (32), and a laser-induced breakdown spectrometer (33). The telescopic cylinder (31) is mounted on the main vehicle (2). One end of the rotating connecting rod (32) is rotatably mounted on the main vehicle (2), and the other end is rotatably connected to the telescopic end of the telescopic cylinder (31). The laser-induced breakdown spectrometer (33) is coaxially fixed with the end of the rotating connecting rod (32) away from the telescopic cylinder (31). The laser-induced breakdown spectrometer (33) can be set facing the upper surface of the rail under the drive of the telescopic cylinder (31).

3. The integrated online rail milling, grinding, and reshaping equipment according to claim 1, characterized in that: The heating mechanism (4) includes a fiber laser (41) and a laser beam expander (42). The fiber laser (41) is fixedly installed on the main vehicle (2), and the laser beam expander (42) is detachably installed on the laser head of the fiber laser (41) and is positioned facing the upper surface of the rail.

4. The integrated online rail milling, grinding, and reshaping equipment according to claim 1, characterized in that: The collecting mechanism (5) includes a collecting roller (51), an electromagnet (52), a collecting plate (53), and a collecting bin (54). The collecting roller (51) is rotatably mounted on the main vehicle (2) and located on the side of the milling mechanism (22) away from the trailer (1). The electromagnetic coil of the electromagnet (52) is circumferentially mounted on the peripheral wall of the collecting roller (51). The collecting plate (53) slides against the electromagnetic coil on the surface of the collecting roller (51), and the collecting plate (53) communicates with the inner cavity of the collecting bin (54).

5. The online rail milling, grinding, and full-profile reshaping integrated equipment according to claim 4, characterized in that: The collection mechanism (5) further includes a dust removal chamber (55) located at the bottom of the collection chamber (54). A dust removal part (551) is provided on the side of the dust removal chamber (55) away from the collection roller (51). The dust removal surface of the dust removal part (551) is inclined downward, and two dust removal surfaces near the edge are provided with guide parts (552) for guiding foreign objects. The inclination slopes of the two guide parts (552) and the dust removal surface of the dust removal part (551) are different, and multiple dust removal holes (553) are provided on the two guide parts (552). A dust removal chamber for dust removal is provided inside the dust removal chamber (55). Each dust removal hole (553) is connected to the inner cavity of the dust removal chamber. An air supply pipe (56) is provided on the outer wall of the dust removal chamber (55) and is connected to the inner cavity of the dust removal chamber (55). The air supply pipe (56) is connected to an external air source.

6. The integrated online rail milling, grinding, and full-profile reshaping equipment according to claim 1, characterized in that: The lubrication mechanism (6) includes a liquid storage tank (61), a liquid filter (62), a micro pump (63), and a water mist nozzle (64). The liquid storage tank (61) is filled with a lubricant for lubricating the milled rail. The micro pump (63) is connected to the water mist nozzle (64). The liquid filter (62) is located between the liquid storage tank (61) and the micro pump (63) to filter the lubricant flowing out of the liquid storage tank (61).

7. The integrated online rail milling and grinding full profile reshaping equipment according to claim 1, characterized in that: The belt sanding mechanism (7) includes a sanding frame (71), a power unit (72), a sanding wheel (73), and a sanding belt (74). The sanding frame (71) is fixed on the main vehicle (2). Multiple sanding wheels (73) are rotatably mounted on the sanding frame (71). The power unit (72) is mounted on the sanding frame (71), and its output end is coaxially fixed with one of the sanding wheels (73). The sanding belt (74) is wound between each of the sanding wheels (73) and slides against the upper surface of the rail.

8. The online rail milling, grinding, and full-profile reshaping integrated equipment according to claim 7, characterized in that: The ultrasonic oscillation mechanism (8) includes a host (81) disposed on the main vehicle (2) and an ultrasonic vibrating rod (82) connected to the host (81), the ultrasonic vibrating rod (82) being fixedly installed on the grinding frame (71).

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