Steel rail welding rib grinding and polishing cutter and grinding and polishing process

Abstract

The invention discloses a steel rail welding rib grinding and polishing cutter set and a grinding and polishing technology. The steel rail welding rib grinding and polishing cutter set comprises a first grinding wheel, a second grinding wheel and a polishing wheel. The first grinding wheel is mainly made of diamond, and the value range of the outer diameter of the first grinding wheel is 130 mm to 170 mm. The second grinding wheel is mainly made of diamond, and the value range of the outer diameter of the second grinding wheel is 60-100 mm. The polishing wheel comprises a rotating body and a plurality of gauze pieces. The grinding and polishing technology comprises the following steps that S1, a first grinding wheel or a second grinding wheel is selected as a grinding tool; and S2, the first grinding wheel or the second grinding wheel is driven to rotate and grind the welding seam of the steel rail. And S3, the first grinding wheel or the second grinding wheel used in the step S2 continues to be used for grinding the ground position of the steel rail. And S4, a polishing wheel is driven to polish the polishing area in the step S3. The steel rail welding rib grinding and polishing cutter has the advantages of being high in grinding and polishing efficiency and resistant to high temperature.

Description

Technical Field

[0001] This application relates to the field of rail weld bar grinding and polishing, and in particular to a rail weld bar grinding and polishing tool and grinding and polishing process. Background Technology

[0002] In the field of railway construction and maintenance, the welding quality of rails plays a crucial role in the safety and smoothness of train operation. With the rapid development of high-speed railways, the requirements for smoothness and seamlessness of rail weld joints are becoming increasingly stringent. The grinding and polishing of rail weld beads, as a key step in ensuring the quality of weld joints, directly affects the overall performance of the rail due to its high level of technical expertise.

[0003] In existing rail weld bead grinding and polishing operations, resin grinding wheels are typically used for grinding, while louvered polishers are used for polishing. Resin grinding wheels are common abrasive tools made by mixing abrasives and a binder, and they have certain applications in general grinding operations. Louvered polishers, on the other hand, are secondary polishing tools composed of multiple layers of blade-shaped abrasives, which can polish the ground surface to a certain extent.

[0004] However, existing grinding and polishing tools have significant drawbacks. The resin binder has poor thermal conductivity, causing most of the heat generated by friction to accumulate in the contact area. Furthermore, the resin easily softens and spreads onto the rail surface, leading to rail blockage or burns. Simultaneously, due to the complex, irregular curved surfaces of the rail weld ribs, fixed-size grinding wheels cannot conform to different areas, failing to achieve true full-contour grinding. In addition, louvered polishers, as secondary polishing tools, require frequent replacements during use, increasing production costs and making the entire grinding and polishing process cumbersome and inefficient. How to solve these technical problems is a question that those skilled in the art need to consider. Summary of the Invention

[0005] In one embodiment, the rail weld bead grinding and polishing tool includes a first grinding wheel, a second grinding wheel, and a polishing wheel. The first grinding wheel is primarily made of diamond, and its outer diameter ranges from 130 mm to 170 mm. The first grinding wheel is driven to rotate via a driving mechanism to grind the non-jaw position of the rail weld bead. The second grinding wheel is also primarily made of diamond, and its outer diameter ranges from 60 mm to 100 mm, with the outer diameter being smaller than that of the first grinding wheel. The second grinding wheel is driven to rotate via a driving mechanism to grind the jaw position of the rail weld bead. The polishing wheel includes a rotating body and multiple cloth pads. The cloth pads are arranged around the rotating outer circumference of the rotating body. The rotating body is driven to rotate via a driving mechanism to polish the area of ​​the rail weld bead that has been ground.

[0006] Understandably, the rail weld bead grinding tools utilize a first and second grinding wheel primarily made of diamond. The high hardness and high thermal conductivity of diamond effectively solve the heat accumulation problem caused by the poor thermal conductivity of traditional resin grinding wheels. Diamond also avoids track clogging or workpiece burning caused by softening resin applied to the rail surface. The first grinding wheel, with a diameter ranging from 130 mm to 170 mm, adapts to the curved surface variations of the rail's non-jaw positions due to its larger size, while the second grinding wheel, with a smaller outer diameter, can grind the jaw positions. The combination of different sized first and second grinding wheels enables full-contour grinding of the complex, irregular curved surfaces of the rail weld bead. A polishing wheel uses multiple cloth pads to polish the ground areas to remove grinding marks. The combined use of the first, second, and polishing wheels effectively solves the problems of existing tools being unable to achieve rail contour grinding and having low grinding efficiency.

[0007] In one embodiment, the first grinding wheel further includes a first connecting portion and a first grinding portion, the first grinding portion being connected to the rotating outer peripheral surface of the first connecting portion and used for grinding the non-jaw position of the rail weld bead. The second grinding wheel further includes a second connecting portion and a second grinding portion, the second grinding portion being located on the rotating outer peripheral surface of the second connecting portion and used for grinding the jaw position of the rail weld bead.

[0008] Understandably, this design incorporates a grinding wheel with a connecting section and a grinding section. The first and second connecting sections provide a stable rotating support base for the entire grinding wheel. The first and second grinding sections concentrate the diamond abrasive for cutting operations. This structural division facilitates functional optimization of the internal connecting area and the outer working area of ​​the first and second grinding wheels.

[0009] In one embodiment, the first connecting portion has a plurality of first weight-reducing holes, which penetrate the first connecting portion and are arranged at intervals around the rotation axis of the first connecting portion.

[0010] Understandably, the multiple weight-reducing holes on the first connecting part effectively reduce the overall weight of the first grinding wheel, which helps to reduce the rotational inertia of the first grinding wheel during high-speed rotation. The multiple weight-reducing holes reduce the load on the drive mechanism during start-up and braking, and the spaced-around-rotational-axis arrangement of the first weight-reducing holes ensures the dynamic balance performance of the first grinding wheel during rotation. Through mutual cooperation, the multiple weight-reducing holes improve the stability of the first grinding wheel under high-speed operation.

[0011] In one embodiment, a plurality of first ventilation holes are continuously spaced apart on the sidewall of the first grinding part away from the first connecting part. The plurality of first ventilation holes are located on the first grinding part near the plurality of first weight-reducing holes, and are connected to the plurality of first weight-reducing holes. A plurality of second ventilation holes are continuously spaced apart on the sidewall of the second grinding part away from the second connecting part. The plurality of second ventilation holes are located on the sidewall of the second grinding part near the end face of the second grinding part, and are disposed through the second grinding part.

[0012] Understandably, the multiple first ventilation holes and multiple first weight-reducing holes are spatially connected. The high-speed rotation of the first grinding wheel drives airflow through the first weight-reducing holes and outward through the first ventilation holes. The connected structure forms an active air circulation cooling channel, and the flowing air directly carries away the grinding heat located near the first grinding section. The through-type second ventilation hole on the second grinding section also plays a role in guiding airflow for heat dissipation using centrifugal force. This aerodynamic structural design further reduces the temperature during the grinding process of the rail weld reinforcement.

[0013] In one embodiment, a first through hole is provided at the rotation axis of the first connecting portion. The first connecting portion also includes a plurality of first connecting ribs, which are protruding structures extending from the end face of the first connecting portion away from the first connecting portion. The plurality of first connecting ribs are respectively located between the first through hole and a plurality of first weight-reducing holes. One end of the first connecting rib is located on the first connecting portion near the first through hole, and the other end of the first connecting rib is located on the first connecting portion near the first weight-reducing hole. A second through hole is provided at the rotation axis of the second connecting portion. The second connecting portion also includes a plurality of second connecting ribs, which are protruding structures extending from the end face of the second connecting portion away from the second connecting portion. The plurality of second connecting ribs are respectively located between the second through hole and a plurality of second ventilation holes. One end of the second connecting rib is located on the second connecting portion near the second through hole, and the other end of the second connecting rib is located on the second connecting portion near the second ventilation hole.

[0014] Understandably, multiple first and second connecting ribs enhance the structural rigidity of the first and second grinding wheels, compensating for any potential loss in structural strength caused by the through holes and / or weight-reduction holes. The connecting ribs located between the holes stably transmit torque from the through hole at the center of the grinding wheel to the grinding section around its periphery, ensuring that the grinding wheel does not deform under high-intensity grinding forces of 130 N to 170 N. The connecting ribs also increase the airflow velocity through the ventilation holes. This facilitates the organic unity of lightweight design, high heat dissipation performance, and high mechanical strength in the grinding wheel.

[0015] In one embodiment, step S1 involves identifying the location of the weld seam on the rail and selecting a first grinding wheel or a second grinding wheel as the grinding tool. Step S2 involves driving the first or second grinding wheel to rotate with a grinding force between 130 N and 170 N, moving the first or second grinding wheel at a speed of 80 mm / s to 120 mm / s to grind the weld seam on the rail, with a grinding interval of 5 mm to 9 mm. Step S3 involves continuing to use the first or second grinding wheel used in step S2, and driving the first or second grinding wheel to rotate with a different torque than in step S2, with a grinding force between 30 N and 70 N, moving the first or second grinding wheel at a speed of 280 mm / s to 320 mm / s to grind the area on the rail that has been ground, with a grinding interval of 1 mm to 3 mm. Step S4: Replace the first or second grinding wheel with a polishing wheel, drive the polishing wheel to rotate at a speed of 50 to 90 Newtons, which is greater than the polishing force in step S3, and move the polishing wheel at a speed of 280 mm / s to 320 mm / s, which is the same as in step S3, to polish the grinding area in step S3. The polishing spacing is 3 mm to 7 mm, which is greater than the spacing in step S3.

[0016] Understandably, this process employs a step-by-step, variable-parameter grinding and polishing strategy to optimize rail treatment. Step S1 ensures that grinding wheels of different diameters accurately match the non-jaw and jaw positions of the rail. Step S2 utilizes high torque and low travel speed with the grinding wheel to quickly remove excess weld beads. Step S3 uses the same grinding wheel as in Step S2, achieving fine finishing by reducing grinding force and increasing travel speed. Continuing to use the same grinding wheel reduces auxiliary time spent on frequent tool changes. Step S4 uses a polishing wheel to eliminate surface textures remaining from the fine grinding stage. Specific parameter combinations improve the efficiency of grinding and polishing rails, preventing rail clogging or burning.

[0017] In one embodiment, step S1 includes the following steps: identifying the specific location of the weld on the rail. When the weld is located at the rail jaw position, a second grinding wheel is used for grinding. When the weld is not located at the rail jaw position, a first grinding wheel is used for grinding.

[0018] Understandably, automatically matching the first or second grinding wheel based on whether the weld is located at the rail jaw position avoids damage to the rail caused by the larger first grinding wheel grinding narrow rail jaws, while also preventing low grinding efficiency caused by the smaller second grinding wheel grinding non-rail jaw positions. Targeted selection of the first or second grinding wheel ensures that weld beads in all areas of the rail can be effectively removed. This achieves automation and precision in the full-contour grinding and polishing process of the rail.

[0019] In one embodiment, step S2 includes the following steps: S21, bringing the first grinding wheel or the second grinding wheel into contact with the rail near the weld, and identifying the relative distance between the first grinding wheel or the second grinding wheel and the rail near the weld. S22, driving the first grinding wheel or the second grinding wheel to rotate with a grinding force between 130 N and 170 N, moving the first grinding wheel or the second grinding wheel at a speed of 80 mm / s to 120 mm / s to cyclically grind the weld along the direction of the rail extension, with a grinding interval of 5 mm to 9 mm, and identifying the relative distance between the first grinding wheel or the second grinding wheel and the weld in real time during the grinding process. S23. When the relative distance between the first or second grinding wheel and the weld is less than the relative distance between the first or second grinding wheel and the rail near the weld, continue grinding the weld repeatedly until the relative distance between the first or second grinding wheel and the weld is equal to the relative distance between the first or second grinding wheel and the rail near the weld, then stop grinding the weld.

[0020] Understandably, S21 and S23 establish a closed-loop feedback control mechanism based on relative distance comparison. The cyclical grinding process continues until the weld height is consistent with the rail surface height, avoiding damage to the rail base material due to excessive grinding and ensuring that the smoothness of the weld after grinding meets the requirements of railway operation.

[0021] In one embodiment, step S4 includes the following steps: S41, recording the original radius value of the unpolished polishing wheel, and recording the initial position when the unpolished polishing wheel is driven at a polishing force between 50 N and 90 N, which is greater than the polishing force in step S3 when it contacts the track. S42, identifying whether the difference between the radius value of the spare polishing wheel and the original radius value is greater than 20 mm, and selecting a polishing wheel with a radius value difference less than 20 mm. S43, moving the initial position of the polishing wheel in contact with the track a distance equal to the radius value difference of the polishing wheel towards the track. S44, driving the polishing wheel to rotate at a polishing force between 50 N and 90 N, the same as in step S41, and moving the polishing wheel at a speed of 280 mm / s to 320 mm / s, the same as in step S3, to polish the grinding area of ​​step S3, with a polishing interval of 3 mm to 7 mm, which is greater than the interval in step S3. S45. Keep the polishing wheel rotating at a polishing force between 50 N and 90 N, the same as in step S44. When the polishing wheel wears out, drive it to move closer to the track again to maintain a constant polishing force. S46. When the sum of the distance the polishing wheel moves the first time and the distance it moves the second time is greater than 20 mm, stop polishing and replace the polishing wheel with a new one.

[0022] Understandably, the initial position compensation amount can be determined by comparing the radius of the spare polishing wheel with the original radius of the polishing wheel. The dynamic movement of the polishing wheel compensates for the reduction in the polishing wheel radius caused by the wear of the gauze sheet. This ensures that the polishing wheel maintains a constant contact pressure of 50 to 90 Newtons throughout its entire service life, and the 20 mm wear threshold prevents a failed polishing wheel from affecting the final surface quality.

[0023] In one embodiment, step S3 includes: continuing to use the first or second grinding wheel used in step S2, and driving the first or second grinding wheel to rotate with a grinding force between 30 N and 70 N with a torque different from that in step S2; moving the first or second grinding wheel at a speed of 280 mm / s to 320 mm / s to grind the position of the rail that has been ground, with a grinding interval of 1 mm to 3 mm; each position is ground only once, and it is not necessary to identify the relative distance between the first or second grinding wheel and the rail near the weld during the grinding process.

[0024] Understandably, this step improves grinding efficiency by limiting the grinding to a single pass and eliminating the need for distance detection. Step S2 has already removed the weld seams from the track surface using distance feedback, while step S3 primarily improves the surface roughness at the location where the weld seams were removed. A low grinding force of 30 to 70 Newtons combined with a high-speed movement of 280 to 320 millimeters per second is sufficient to quickly remove surface scratches. This simplified strategy based on step S2 achieves a balance between grinding and polishing efficiency. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of a rail processed using the rail weld bar grinding and polishing tool provided in the embodiments of this application.

[0026] Figure 2 This is a schematic diagram of the tool magazine for grinding and polishing steel rail weld bars provided in the embodiments of this application.

[0027] Figure 3 This is a schematic diagram of the structure of the first grinding wheel of the first type of rail weld bar grinding and polishing tool provided in the embodiments of this application.

[0028] Figure 4 This is a schematic diagram of the structure of the second type of first grinding wheel of the rail weld bar grinding and polishing tool provided in the embodiments of this application.

[0029] Figure 5 This is a schematic diagram of the structure of the second grinding wheel of the first type of rail weld bar grinding and polishing tool provided in the embodiments of this application.

[0030] Figure 6 This is a schematic diagram of the structure of the second type of second grinding wheel of the rail weld bar grinding and polishing tool provided in the embodiments of this application.

[0031] Figure 7 This is a schematic diagram of the polishing wheel of the rail weld bar grinding and polishing tool provided in the embodiments of this application.

[0032] Explanation of reference numerals in the attached figures: 1. First grinding wheel; 11. First connecting part; 111. First weight reduction hole; 112. First through hole; 113. First connecting rib; 12. First grinding part; 121. First ventilation hole; 2. Second grinding wheel; 21. Second connecting part; 211. Second through hole; 212. Second connecting rib; 22. Second grinding part; 221. Second ventilation hole; 3. Polishing wheel; 31. Rotating body; 32. Gauze sheet; 4. Rail; 41. Rail jaw position. Detailed Implementation

[0033] The following is in conjunction with the appendix Figure 1 To be continued Figure 7 This application will be described in further detail below.

[0034] Example 1: In one embodiment, the rail weld bead grinding and polishing tool includes a first grinding wheel 1, a second grinding wheel 2, and a polishing wheel 3. The first grinding wheel 1 is mainly made of diamond, and its outer diameter ranges from 130 mm to 170 mm. The first grinding wheel 1 is driven to rotate via a driving mechanism to grind the non-jaw position of the weld bead of the rail 4. The second grinding wheel 2 is also mainly made of diamond, and its outer diameter ranges from 60 mm to 100 mm, and its outer diameter is smaller than that of the first grinding wheel 1. The second grinding wheel 2 is driven to rotate via a driving mechanism to grind the jaw position 41 of the weld bead of the rail 4. The polishing wheel 3 includes a rotating body 31 and multiple gauze sheets 32. The multiple gauze sheets 32 are arranged around the rotating outer circumference of the rotating body 31. The rotating body 31 is used to drive the connection with a driving mechanism so that the polishing wheel 3 can be driven to rotate to polish the position where the weld bead of the steel rail 4 is ground.

[0035] Understandable, refer to Figure 1 , Figure 3 , Figure 5 and Figure 7The rail weld bead grinding tool uses a first grinding wheel 1 and a second grinding wheel 2, both made primarily of diamond. The outer diameter of the first grinding wheel 1 is 140 mm, and the outer diameter of the second grinding wheel 2 is 100 mm. The high hardness and high thermal conductivity of the diamond material in the first and second grinding wheels 1 and 2 effectively solve the problem of heat accumulation caused by the poor thermal conductivity of traditional resin grinding wheels. The diamond material avoids track blockage or workpiece burning caused by softened resin applied to the surface of the rail 4. The 140 mm first grinding wheel 1 adapts to the curved surface changes of the non-jaw position of the rail 4, while the 100 mm second grinding wheel 2 is used to grind the jaw position 41. The combination of the first grinding wheel 1 and the second grinding wheel 2, with their different sizes, achieves full-contour grinding of the complex and irregular curved surface of the weld bead of the rail 4. Multiple gauze pieces 32 are adhered to the rotating outer circumference of the rotating body 31 to form a polishing wheel 3. The multiple gauze pieces 32 can be used to polish the ground area to remove grinding marks. The combined use of the first grinding wheel 1, the second grinding wheel 2, and the polishing wheel 3 solves the problem that existing tools cannot achieve grinding of the track contour and have low grinding efficiency.

[0036] In one embodiment, the first grinding wheel 1 further includes a first connecting portion 11 and a first grinding portion 12. The first grinding portion 12 is connected to the rotating outer peripheral surface of the first connecting portion 11 and is used to grind the non-jaw position of the weld bead of the rail 4. The second grinding wheel 2 further includes a second connecting portion 21 and a second grinding portion 22. The second grinding portion 22 is located on the rotating outer peripheral surface of the second connecting portion 21 and is used to grind the jaw position 41 of the weld bead of the rail 4.

[0037] Understandable, refer to Figure 3 and Figure 5 The first connecting part 11 has a circular plate-like structure, and the first grinding part 12 has a circular ring-like structure. The first connecting part 11 and the second connecting part 21 provide a stable rotating support base for the entire grinding wheel, and the first grinding part 12 and the second grinding part 22 concentrate diamond abrasive to perform cutting operations. Designing the grinding wheel with a structure of connecting part and grinding part facilitates functional optimization of the internal connecting area and the outer working area of ​​the first grinding wheel 1 and the second grinding wheel 2.

[0038] In one embodiment, the first connecting portion 11 has a plurality of first weight-reducing holes 111, which penetrate the first connecting portion 11 and are arranged at intervals around the rotation axis of the first connecting portion 11.

[0039] Understandable, refer to Figure 3The first grinding wheel 1 has six first weight-reducing holes 111, each with an inner diameter of 12 mm. These holes are spaced apart along the axis of the first connecting portion 11. The multiple first weight-reducing holes 111 on the first connecting portion 11 effectively reduce the overall weight of the first grinding wheel 1, which helps reduce its rotational inertia during high-speed rotation. The multiple first weight-reducing holes 111 also reduce the load on the drive mechanism during start-up and braking. The spaced first weight-reducing holes 111 around the rotation axis ensure the dynamic balance performance of the first grinding wheel 1 during rotation. Through mutual cooperation, the multiple first weight-reducing holes 111 improve the stability of the first grinding wheel 1 during high-speed operation.

[0040] In one embodiment, a plurality of first ventilation holes 121 are continuously spaced apart on the sidewall of the first grinding part 12 away from the first connecting part 11. The plurality of first ventilation holes 121 are located on the first grinding part 12 near the plurality of first weight reduction holes 111, and the plurality of first ventilation holes 121 are connected to the plurality of first weight reduction holes 111. A plurality of second ventilation holes 221 are continuously spaced apart on the sidewall of the second grinding part 22 away from the second connecting part 21. The plurality of second ventilation holes 221 are located on the sidewall of the second grinding part 22 near the end face of the second grinding part 22, and the plurality of second ventilation holes 221 are disposed through the second grinding part 22.

[0041] Understandable, refer to Figure 3 and Figure 5 The first grinding wheel 1 has six first ventilation holes 121, each with an inner diameter of 5 mm. These six ventilation holes 121 are connected to six first weight-reducing holes 111. The high-speed rotation of the first grinding wheel 1 drives airflow through the first weight-reducing holes 111 and outwards through the first ventilation holes 121. This interconnected structure forms an active air circulation cooling channel, where the flowing air directly carries away the grinding heat located near the first grinding section 12. The through-hole second ventilation hole 221 on the second grinding section 22 also serves to guide airflow for heat dissipation using centrifugal force. This aerodynamic structural design further reduces the temperature during the grinding process of the welded reinforcement of the steel rail 4.

[0042] In one embodiment, a first through hole 112 is provided at the rotation axis of the first connecting portion 11. The first connecting portion 11 also includes a plurality of first connecting ribs 113. The plurality of first connecting ribs 113 are protruding structures extending from the end face of the first connecting portion 11 away from the first connecting portion 11. The plurality of first connecting ribs 113 are respectively located between the first through hole 112 and the plurality of first weight-reducing holes 111. One end of the first connecting rib 113 is located in the first connecting portion 11 near the first through hole 112, and the other end of the first connecting rib 113 is located in the first connecting portion 11 near the first weight-reducing hole 111. The second connecting part 21 has a second through hole 211 at its rotation axis. The second connecting part 21 also includes a plurality of second connecting ribs 212. The plurality of second connecting ribs 212 are protruding structures extending from the end face of the second connecting part 21 away from the second connecting part 21. The plurality of second connecting ribs 212 are respectively located between the second through hole 211 and the plurality of second ventilation holes 221. One end of the second connecting rib 212 is located in the second connecting part 21 near the second through hole 211, and the other end of the second connecting rib 212 is located in the second connecting part 21 near the second ventilation hole 221.

[0043] Understandable, refer to Figures 3 to 6 The height of the first connecting rib 113 along the axis of the first grinding wheel 1 can be 8 mm, and the height of the first connecting rib 113 along the axis of the first grinding wheel 1 can be 5 mm. Multiple first connecting ribs 113 and multiple second connecting ribs 212 enhance the structural rigidity of the first grinding wheel 1 and the second grinding wheel 2, and compensate for any structural strength loss that may result from the opening of through holes and / or weight-reduction holes. The connecting ribs located between the holes stably transmit torque from the through hole at the center of the grinding wheel to the grinding part around the periphery of the grinding wheel, ensuring that the grinding wheel will not deform when subjected to high-intensity grinding forces of 130 N to 170 N. The connecting ribs also enhance the airflow velocity through the ventilation holes. This facilitates the organic unity of lightweight design, high heat dissipation performance, and high mechanical strength of the grinding wheel.

[0044] The implementation principle of this embodiment is as follows: This set of rail weld bead grinding and polishing tools uses different combinations of grinding wheels and polishing wheels 3 to process different positions of the weld bead on the rail 4. The first grinding wheel 1 is used for grinding non-rail jaw positions, the second grinding wheel 2 is used for grinding rail jaw positions 41, and the polishing wheel 3 is used to polish the ground surface. The diamond grinding wheel improves grinding accuracy and efficiency, and the design of the weight reduction holes and ventilation holes optimizes the performance of the grinding wheel, enhancing its stability and durability. Through this combination, the problems of low accuracy, poor processing effect on complex-shaped weld beads, and inconsistent grinding quality of existing grinding methods can be effectively solved, thus improving the quality and efficiency of weld bead processing on the rail 4.

[0045] Example 2: In one embodiment, step S1: Identify the location of the weld seam on the rail 4, and select either the first grinding wheel 1 or the second grinding wheel 2 as the grinding tool. Step S2: Drive the first grinding wheel 1 or the second grinding wheel 2 to rotate with a grinding force between 130 N and 170 N, and move the first grinding wheel 1 or the second grinding wheel 2 at a speed of 80 mm / s to 120 mm / s to grind the weld seam of the rail 4, with a grinding interval of 5 mm to 9 mm. Step S3: Continue using the first grinding wheel 1 or the second grinding wheel 2 used in step S2, and drive the first grinding wheel 1 or the second grinding wheel 2 to rotate with a grinding force between 30 N and 70 N with a torque different from that in step S2, and move the first grinding wheel 1 or the second grinding wheel 2 at a speed of 280 mm / s to 320 mm / s to grind the position of the rail 4 that has been ground, with a grinding interval of 1 mm to 3 mm. Step S4: Replace the first grinding wheel 1 or the second grinding wheel 2 with the polishing wheel 3, drive the polishing wheel 3 to rotate at a speed between 50 N and 90 N, which is greater than the polishing force in step S3, and move the polishing wheel 3 at a speed of 280 mm / s to 320 mm / s, which is the same as in step S3, to polish the grinding area in step S3. The polishing spacing is 3 mm to 7 mm, which is greater than the spacing in step S3.

[0046] Understandable, refer to Figure 2 , Figure 3 , Figure 5 and Figure 7Step S1: Identify the location of the weld seam on the rail 4 using an image acquisition device. The image acquisition device is electrically connected to a robot or a three-axis robotic arm. The robot or the three-axis robotic arm selects either the first grinding wheel 1 or the second grinding wheel 2 from the tool magazine as the grinding tool. Step S2: Drive the first grinding wheel 1 or the second grinding wheel 2 to rotate with a grinding force of 150 N and move it at a speed of 100 mm / s to grind the weld seam on the rail 4. The grinding interval is 7 mm. Step S3: Continue to drive the first grinding wheel 1 or the second grinding wheel 2 used in step S2 using a different torque than in step S2, rotating it with a grinding force of 50 N and moving it at a speed of 300 mm / s to grind the area on the rail 4 that has been ground. The grinding interval is 2 mm. Step S4: Replace the first grinding wheel 1 or the second grinding wheel 2 with a polishing wheel 3. Drive the polishing wheel 3 to rotate with a polishing force of 70 Newtons and move the polishing wheel 3 at a speed of 300 mm / s to polish the grinding area of ​​step S3, with a polishing interval of 5 mm. This process adopts a step-by-step and variable parameter grinding and polishing strategy to optimize the processing effect of the rail 4. Step S1 ensures that grinding wheels of different diameters can accurately match the non-jaw position and the jaw position 41 of the rail 4. Step S2 uses high torque and low movement speed in conjunction with the grinding wheel to quickly remove excess weld beads. Step S3 uses the same grinding wheel used in step S2 to achieve fine finishing by reducing the grinding force and increasing the movement speed. Continuing to use the same grinding wheel reduces the auxiliary time of frequent tool changes. Step S4 uses the polishing wheel 3 to eliminate the surface texture remaining in the fine grinding stage. The specific parameter combination improves the efficiency of grinding and polishing the rail 4 and avoids clogging or burning of the rail 4.

[0047] In one embodiment, step S1 includes the following steps: identifying the specific location of the weld on the rail 4. When the weld is located at the rail jaw position 41 of the rail 4, the second grinding wheel 2 is used for grinding. When the weld is not located at the rail jaw position 41 of the rail 4, the first grinding wheel 1 is used for grinding.

[0048] Understandable, refer to Figure 3 and Figure 5The angle between the working edge area at the top of the track and the rail web area in the middle of the track is smaller than the angle between the rail web area in the middle of the track and the rail tread area at the bottom of the track. Therefore, a second grinding wheel 2 with an outer diameter of 100 mm is used to grind the rail jaw position 41, while a first grinding wheel 1 with an outer diameter of 140 mm is used to grind the non-rail jaw positions. The robot or three-axis robotic arm automatically matches the second grinding wheel 2 or the first grinding wheel 1 according to whether the weld is located at the rail jaw position 41. This avoids the larger first grinding wheel 1 grinding the narrow rail jaw and damaging the rail 4, while also avoiding the low grinding efficiency caused by the smaller second grinding wheel 2 grinding the non-rail jaw positions. The targeted selection of the first grinding wheel 1 ensures that the weld beads in all areas of the rail 4 can be effectively removed. This achieves automation and precision in the full contour grinding and polishing process of the rail 4.

[0049] In one embodiment, step S2 includes the following steps: S21, bringing the first grinding wheel 1 or the second grinding wheel 2 into contact with the rail 4 near the weld, and identifying the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld. S22, driving the first grinding wheel 1 or the second grinding wheel 2 to rotate with a grinding force between 130 N and 170 N, moving the first grinding wheel 1 or the second grinding wheel 2 at a speed of 80 mm / s to 120 mm / s to cyclically grind the weld along the direction of the rail extension, with a grinding interval of 5 mm to 9 mm, and identifying the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the weld in real time during the grinding process. S23. When the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the weld is less than the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld, continue to grind the weld repeatedly until the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the weld is equal to the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld, then stop grinding the weld.

[0050] Understandably, in step S21, the robot or three-axis robotic arm brings the first grinding wheel 1 or the second grinding wheel 2 into contact with the rail 4 near the weld. A laser displacement sensor identifies the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld. In step S22, the robot or three-axis robotic arm drives the first grinding wheel 1 or the second grinding wheel 2 to rotate with a grinding force of 150 Newtons and move the first grinding wheel 1 or the second grinding wheel 2 at a speed of 100 millimeters per second, cyclically grinding the weld along the direction of the rail extension. The grinding interval is 7 millimeters. During the grinding process, the laser displacement sensor identifies the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the weld in real time. S23. When the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the weld seam, as identified by the laser displacement sensor, is less than the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld seam, the grinding of the weld seam continues cyclically until the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the weld seam is equal to the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld seam, at which point the grinding of the weld seam stops. S21 and S23 establish a closed-loop feedback control mechanism based on relative distance comparison. The cyclical grinding process continues until the height of the weld seam is consistent with the surface height of the rail 4, avoiding damage to the base material of the rail 4 due to over-grinding and ensuring that the smoothness of the weld seam after grinding meets the requirements of railway operation.

[0051] In one embodiment, step S3 includes: continuing to use the first grinding wheel 1 or the second grinding wheel 2 used in step S2, and driving the first grinding wheel 1 or the second grinding wheel 2 to rotate with a grinding force between 30 N and 70 N with a torque different from that in step S2; moving the first grinding wheel 1 or the second grinding wheel 2 at a speed of 280 mm / s to 320 mm / s to grind the position of the rail 4 that has been ground, with a grinding interval of 1 mm to 3 mm; each position is ground only once, and it is not necessary to identify the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld during the grinding process.

[0052] Understandably, step S3 includes: the robot or three-axis robotic arm continues to use the first grinding wheel 1 or the second grinding wheel 2 used in step S2, rotating it with a grinding force of 50 Newtons; moving the first grinding wheel 1 or the second grinding wheel 2 at a speed of 300 mm / s to grind the position of the rail 4 that has been ground, with a grinding interval of 2 mm; each position is ground only once, and it is not necessary to identify the relative distance between the first grinding wheel 1 or the second grinding wheel 2 and the rail 4 near the weld during the grinding process. This step improves grinding efficiency by limiting the grinding to a single pass and eliminating the need for distance detection. Step S2 has already removed the weld seam from the rail surface through distance feedback, and step S3 mainly improves the surface roughness of the rail at the position where the weld seam has been removed. A low grinding force of 30 to 70 Newtons combined with a high-speed movement of 280 to 320 mm / s is sufficient to quickly remove surface scratches. This simplified strategy based on step S2 achieves a balance between grinding efficiency and polishing efficiency.

[0053] In one embodiment, step S4 includes the following steps: S41, recording the original radius value of the unpolished polishing wheel 3, and recording the initial position when the unpolished polishing wheel 3 is driven at a polishing force between 50 N and 90 N, which is greater than the polishing force in contact with the track in step S3. S42, identifying whether the difference between the radius value of the spare polishing wheel 3 and the original radius value is greater than 20 mm, and selecting a polishing wheel 3 with a radius value difference less than 20 mm. S43, moving the polishing wheel 3 from its initial position in contact with the track a distance equal to the radius value difference towards the track. S44, driving the polishing wheel 3 to rotate at a polishing force between 50 N and 90 N, the same as in step S41, and moving the polishing wheel 3 at a speed of 280 mm / s to 320 mm / s, the same as in step S3, to polish the grinding area of ​​step S3, with a polishing interval of 3 mm to 7 mm, which is greater than the interval in step S3. S45. Keep the polishing wheel 3 rotating at a polishing force between 50 N and 90 N, the same as in step S44. When the polishing wheel 3 wears down, drive it to move closer to the track again to maintain a constant polishing force. S46. When the sum of the distance the polishing wheel 3 moves the first time and the distance it moves the second time is greater than 20 mm, stop polishing and replace the polishing wheel 3 with a new one.

[0054] Understandable, refer to Figure 7Step S4 includes the following steps: S41. Record the original radius value of the unpolished polishing wheel 3 using a computer or microcontroller, and record the initial position when the unpolished polishing wheel 3 is driven to contact the track with a polishing force of 70 Newtons using a computer or microcontroller. S42. Identify whether the difference between the radius value of the spare polishing wheel 3 and the original radius value is greater than 20 mm using an image acquisition device, and select a polishing wheel 3 with a radius value difference of less than 20 mm using a robot or three-axis robotic arm. S43. Move the polishing wheel 3 a distance equal to the radius value difference towards the track from its initial position of contact with the track using a robot or three-axis robotic arm. S44. Drive the polishing wheel 3 to rotate with a polishing force of 70 Newtons using a robot or three-axis robotic arm, and move the polishing wheel 3 at a speed of 300 mm / s to polish the polishing area of ​​step S3, with a polishing interval of 5 mm. S45. The polishing wheel 3 is rotated at a constant polishing force of 70 Newtons by a robot or a three-axis robotic arm. When the polishing wheel 3 wears, the robot or three-axis robotic arm drives the polishing wheel 3 to move it back towards the track to maintain a constant polishing force. S46. The computer or microcontroller records that when the sum of the distances the polishing wheel 3 moves the first and second times exceeds 20 mm, polishing is stopped and a new polishing wheel 3 is replaced. By comparing the radius of the spare polishing wheel 3 with the original radius of the polishing wheel 3, the initial position compensation amount can be determined. The dynamic movement of the polishing wheel 3 compensates for the reduction in the radius of the polishing wheel 3 caused by the wear of the gauze sheet 32. This ensures that the polishing wheel 3 maintains a constant contact pressure of 50 to 90 Newtons throughout its entire service life. The 20 mm wear threshold prevents a failed polishing wheel 3 from affecting the final surface quality.

[0055] The implementation principle of this embodiment is as follows: This rail weld bead grinding and polishing process, through precise step and parameter control, combined with rail weld bead grinding and polishing tools, can achieve high-precision grinding and polishing of the rail weld bead 4. By identifying the weld position and selecting a suitable grinding wheel, grinding and polishing are performed in stages. In each step, parameters such as grinding force, moving speed, and grinding spacing are controlled. At the same time, the wear of the polishing wheel 3 is monitored and adjusted in real time, ensuring the quality and efficiency of grinding and polishing, and avoiding the problems of low precision, low efficiency, and inconsistent quality existing in the existing grinding process. The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made to the structure, shape, and principle of this application should be covered within the scope of protection of this application.

Claims

1. A set of grinding and polishing tools for rail weld bars, characterized in that, include: The first grinding wheel (1) is mainly made of diamond. The outer diameter of the first grinding wheel (1) ranges from 130 mm to 170 mm. The first grinding wheel (1) is used to drive and connect with a driving mechanism so that the first grinding wheel (1) can be driven to rotate to grind the non-rail jaw position of the weld bead of the rail (4). The second grinding wheel (2) is mainly made of diamond. The outer diameter of the second grinding wheel (2) ranges from 60 mm to 100 mm. The outer diameter of the second grinding wheel (2) is smaller than that of the first grinding wheel (1). The second grinding wheel (2) is used to drive and connect with a driving mechanism so that the second grinding wheel (2) can be driven to rotate to grind the rail jaw position (41) of the weld bead of the rail (4). The polishing wheel (3) includes a rotating body (31) and multiple gauze pieces (32). The multiple gauze pieces (32) are arranged around the rotating outer circumferential surface of the rotating body (31). The rotating body (31) is used to drive and connect with a driving mechanism so that the polishing wheel (3) can be driven to rotate to polish the position where the weld bead of the rail (4) is ground.

2. The rail weld bead grinding and polishing tool according to claim 1, characterized in that, The first grinding wheel (1) further includes a first connecting part (11) and a first grinding part (12). The first grinding part (12) is connected to the rotating outer peripheral surface of the first connecting part (11) and is used to grind the non-rail jaw position of the weld bead of the rail (4). The second grinding wheel (2) also includes a second connecting part (21) and a second grinding part (22). The second grinding part (22) is located on the rotating outer peripheral surface of the second connecting part (21) and is used to grind the rail jaw position (41) of the weld bead of the rail (4).

3. The rail weld bead grinding and polishing tool according to claim 2, characterized in that, The first connecting part (11) has a plurality of first weight-reducing holes (111), which pass through the first connecting part (11) and are arranged at intervals around the rotation axis of the first connecting part (11).

4. The rail weld bead grinding and polishing tool according to claim 3, characterized in that, The first grinding part (12) has a plurality of first ventilation holes (121) continuously spaced on the side wall away from the first connecting part (11). The plurality of first ventilation holes (121) are located on the first grinding part (12) near the plurality of first weight reduction holes (111), and the plurality of first ventilation holes (121) are connected to the plurality of first weight reduction holes (111). The second polishing part (22) has a plurality of second ventilation holes (221) continuously spaced on the side wall away from the second connecting part (21). The plurality of second ventilation holes (221) are located on the side wall of the second polishing part (22) near the end face of the second polishing part (22), and the plurality of second ventilation holes (221) are disposed through the second polishing part (22).

5. The rail weld bead grinding and polishing tool according to claim 4, characterized in that, A first through hole (112) is provided at the rotation axis of the first connecting part (11). The first connecting part (11) also includes a plurality of first connecting ribs (113). The plurality of first connecting ribs (113) are protruding structures extending from the end face of the first connecting part (11) away from the first connecting part (11). The plurality of first connecting ribs (113) are respectively located between the first through hole (112) and the plurality of first weight-reducing holes (111). One end of the first connecting rib (113) is located in the first connecting part (11) near the first through hole (112), and the other end of the first connecting rib (113) is located in the first connecting part (11) near the first weight-reducing hole (111). The second connecting part (21) has a second through hole (211) at its rotation axis. The second connecting part (21) also includes a plurality of second connecting ribs (212). The plurality of second connecting ribs (212) are protruding structures extending from the end face of the second connecting part (21) away from the second connecting part (21). The plurality of second connecting ribs (212) are respectively located between the second through hole (211) and the plurality of second ventilation holes (221). One end of the second connecting rib (212) is located in the second connecting part (21) near the second through hole (211), and the other end of the second connecting rib (212) is located in the second connecting part (21) near the second ventilation hole (221).

6. A grinding and polishing process for rail weld bars, characterized in that, The rail weld bead grinding and polishing process is used to control the rail weld bead grinding and polishing tool as described in any one of claims 1-5, and the rail weld bead grinding and polishing process includes the following steps: Step S1: Identify the location of the weld on the rail (4) and select the first grinding wheel (1) or the second grinding wheel (2) as the grinding tool; Step S2: Drive the first grinding wheel (1) or the second grinding wheel (2) to rotate with a grinding force between 130 N and 170 N, and move the first grinding wheel (1) or the second grinding wheel (2) at a speed of 80 mm / s to 120 mm / s to grind the weld of the rail (4), with a grinding interval of 5 mm to 9 mm. Step S3: Continue using the first grinding wheel (1) or the second grinding wheel (2) used in step S2, and drive the first grinding wheel (1) or the second grinding wheel (2) to rotate with a grinding force between 30 N and 70 N with a torque different from that in step S2, and move the first grinding wheel (1) or the second grinding wheel (2) at a speed of 280 mm / s to 320 mm / s to grind the position of the rail (4) that has been ground, with a grinding interval of 1 mm to 3 mm; Step S4: Replace the first grinding wheel (1) or the second grinding wheel (2) with the polishing wheel (3), drive the polishing wheel (3) to rotate at a polishing force between 50 N and 90 N, which is greater than that in step S3, and move the polishing wheel (3) at a speed of 280 mm / s to 320 mm / s, which is the same as that in step S3, to polish the grinding area of ​​step S3. The polishing spacing is 3 mm to 7 mm, which is greater than that in step S3.

7. The rail weld bead grinding and polishing process according to claim 6, characterized in that, Step S1 includes the following steps: identifying the specific location of the weld on the rail (4); when the weld is located at the rail jaw position (41) of the rail (4), the second grinding wheel (2) is used for grinding; when the weld is not located at the rail jaw position (41) of the rail (4), the first grinding wheel (1) is used for grinding.

8. The rail weld bead grinding and polishing process according to claim 6, characterized in that, Step S2 includes the following steps: S21. The first grinding wheel (1) or the second grinding wheel (2) is brought into contact with the rail (4) near the weld seam, and the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the rail (4) near the weld seam is identified. S22. Drive the first grinding wheel (1) or the second grinding wheel (2) to rotate with a grinding force between 130 N and 170 N, and move the first grinding wheel (1) or the second grinding wheel (2) at a speed of 80 mm / s to 120 mm / s to repeatedly grind the weld along the direction of the track extension, with a grinding interval of 5 mm to 9 mm. During the grinding process, the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the weld is identified in real time. S23. When the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the weld is less than the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the rail (4) near the weld, continue to grind the weld repeatedly until the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the weld is equal to the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the rail (4) near the weld, then stop grinding the weld.

9. The rail weld bead grinding and polishing process according to claim 6, characterized in that, Step S4 includes the following steps: S41. Record the original radius value of the unpolished polishing wheel (3), and record the initial position when the unpolished polishing wheel (3) is driven with a polishing force between 50 N and 90 N that is greater than the polishing force in contact with the track in step S3. S42. Identify whether the difference between the radius value of the spare polishing wheel (3) and the original radius value is greater than 20 mm, and select a polishing wheel (3) with a radius value difference of less than 20 mm. S43, move the initial position of the polishing wheel (3) in contact with the track by a distance equal to the difference in radius of the polishing wheel (3) toward the track; S44. Drive the polishing wheel (3) to rotate at a polishing force of 50 N to 90 N, the same as in step S41, and move the polishing wheel (3) at a speed of 280 mm / s to 320 mm / s, the same as in step S3, to polish the grinding area of ​​step S3. The polishing spacing is 3 mm to 7 mm, which is greater than the spacing in step S3. S45. The polishing wheel (3) is always rotated with a polishing force between 50 N and 90 N, the same as in step S44. When the polishing wheel (3) is worn, the polishing wheel (3) is driven to move again toward the position close to the track to maintain a constant polishing force. S46. When the total distance of the first and second movement of the polishing wheel (3) is greater than 20 mm, stop polishing and replace the polishing wheel (3) with a new one.

10. The rail weld bead grinding and polishing process according to claim 6, characterized in that, Step S3 includes: continuing to use the first grinding wheel (1) or the second grinding wheel (2) used in step S2, and driving the first grinding wheel (1) or the second grinding wheel (2) to rotate with a grinding force between 30 N and 70 N with a torque different from that in step S2; moving the first grinding wheel (1) or the second grinding wheel (2) at a speed of 280 mm / s to 320 mm / s to grind the position of the rail (4) that has been ground, with a grinding interval of 1 mm to 3 mm; each position is ground only once, and it is not necessary to identify the relative distance between the first grinding wheel (1) or the second grinding wheel (2) and the rail (4) near the weld during the grinding process.

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