Integrated method for off-line additive repair and on-line adaptive welding of track component

Abstract

The invention provides a method for integrating off-line additive repair and on-line adaptive welding of a track component, which belongs to the technical field of track component repair and comprises the following steps: acquiring geometric data of a damaged track component and constructing a digital three-dimensional model of a damaged part; formulating an additive repair strategy based on the digital three-dimensional model; repairing the rail component by utilizing an additive manufacturing process based on an additive repairing strategy; carrying out post-treatment on the rail component subjected to additive repair to obtain a reliable microscopic structure, and recovering the rail component subjected to post-treatment to the original geometrical shape; and welding the track component with the restored original geometrical shape to a designated position book of the track line. According to the method, the use range of additive repair of the track component is remarkably widened, offline additive repair and online adaptive welding are combined, the repair quality is guaranteed, and the line occupation time is shortened.

Description

Technical Field

[0001] This invention relates to the field of track component repair technology, and in particular to an integrated method for offline additive repair and online adaptive welding of track components. Background Technology

[0002] As railway transportation develops towards high speed and heavy load, track components (such as rails and turnouts) are facing increasingly serious problems such as wear, fatigue damage, and cracks. If these damages on track components are not repaired in time, they will directly affect the safety and stability of train operation and increase maintenance costs.

[0003] Currently, most track component repair solutions employ direct online additive repair methods, such as using mobile repair vehicles. An additive repair system, including a heating device, additive repair equipment (such as laser cladding or arc additive manufacturing), and a post-repair milling device, is installed on the vehicle floor. This enables online surface additive repair, achieving rapid, online repair.

[0004] The limitations of existing online additive repair methods are as follows: First, the online environment is complex, making it difficult to control factors such as temperature and vibration during the repair process, leading to unstable repair quality and defects such as porosity and incomplete fusion in the repair layer. Second, due to the limitations of narrow spaces on some tracks, large repair equipment cannot be used directly online. Third, online repair work usually needs to be completed within the track closure time, while the detailed repair of complex components is time-consuming, conflicting with the limited track maintenance windows and affecting normal track operation.

[0005] In view of this, based on years of experience in production and design in this and related fields, the inventor has designed an offline additive repair method and an online welding method for track components through repeated experiments, in order to solve the problems existing in the prior art. Summary of the Invention

[0006] The purpose of this invention is to provide an offline additive repair method and an online welding method for track components, which combines offline additive repair with online adaptive welding to ensure repair quality and reduce track occupancy time.

[0007] To achieve the above objectives, this invention proposes an integrated method for offline additive repair and online adaptive welding of track components, characterized in that the integrated method for offline additive repair and online adaptive welding of track components includes:

[0008] Obtain geometric data of the damaged track components and construct a digital 3D model of the damaged area;

[0009] An additive repair strategy is formulated based on the aforementioned digital 3D model;

[0010] The track components are repaired using additive manufacturing processes based on the aforementioned additive repair strategy.

[0011] The track component after additive repair is post-processed to obtain a reliable microstructure, and the post-processed track component restores its original geometry.

[0012] The track components, restored to their original geometry, are welded to the designated locations on the track line.

[0013] Compared with the prior art, the present invention has the following features and advantages:

[0014] The proposed method for offline additive repair and online adaptive welding of track components decomposes the repair process of track components into two collaborative stages: offline high-precision additive repair and online adaptive welding. Through a controlled repair process based on 3D scanning modeling, material compatibility analysis, precision additive forming, heat treatment and machining in an offline environment, the method ensures that the repair layer has a dense structure and its performance matches the base material. This significantly improves the geometric accuracy, microstructure uniformity and mechanical property matching of the repair layer, effectively suppresses martensitic embrittlement and residual stress concentration, and greatly extends the service life of the repaired components.

[0015] The proposed method for offline additive repair and online adaptive welding of track components completes complex and time-consuming repair procedures offline and performs mature adaptive welding operations on-site. This significantly reduces track occupancy time, improves track maintenance efficiency, and expands the types of repairable damage and components, while ensuring that the strength, smoothness, and reliability of the welded joints meet railway specifications. Overall, it achieves comprehensive optimization of repair quality, efficiency, cost, and environmental adaptability. Attached Figure Description

[0016] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. Those skilled in the art, guided by the teachings of this invention, can select various possible shapes and proportions to implement the invention according to specific circumstances.

[0017] Figure 1 This is a schematic diagram of the integrated offline additive repair and online adaptive welding method for track components according to the present invention.

[0018] Figure 2 This is a schematic diagram of the online adaptability welding method for track components according to the present invention. Detailed Implementation

[0019] The details of the present invention can be more clearly understood by referring to the accompanying drawings and the description of specific embodiments. However, the specific embodiments of the present invention described herein are for illustrative purposes only and should not be construed as limiting the invention in any way. Under the teachings of this invention, those skilled in the art can conceive of any possible modifications based on the invention, and these should all be considered to fall within the scope of the invention.

[0020] like Figure 1 As shown, this invention proposes an integrated method for offline additive repair and online adaptive welding of track components, wherein the integrated method for offline additive repair and online adaptive welding of track components includes:

[0021] Obtain geometric data of the damaged track components and construct a digital 3D model of the damaged area;

[0022] Develop additive repair strategies based on digital 3D models;

[0023] The additive repair strategy utilizes additive manufacturing processes to repair track components;

[0024] The recovered track components are post-processed to obtain reliable microstructure, and the post-processed track components restore their original geometry;

[0025] The track components, restored to their original geometry, are welded to the designated locations on the track line.

[0026] This invention proposes an integrated method for offline additive repair and online adaptive welding of track components. It acquires the geometric data of damaged track components and constructs a digital 3D model of the damaged area. Based on this model, an additive repair strategy is formulated, and the track component is repaired using additive manufacturing processes. Post-processing is then applied to the repaired component to obtain a reliable microstructure and restore its original geometry. This allows for high-quality repair of complex damage in a controlled offline environment, avoiding defects such as porosity and incomplete fusion in the repair layer caused by environmental interference in online repair. It ensures a good match between the repair layer and the base material in terms of microstructure and mechanical properties, reduces residual stress and undesirable microstructure in the heat-affected zone, and improves repair accuracy, surface quality, and component service life.

[0027] The proposed method for offline additive repair and online adaptive welding of track components involves cleaning and preheating the welding area of ​​the track components and track lines, adjusting welding parameters according to track conditions, and performing heat treatment and polishing on the weld and surrounding areas after welding. This ensures that the microstructure and properties of the welded joint are optimized and meet the requirements of track welding specifications, thereby effectively improving the welding success rate and reliability.

[0028] In an optional embodiment of the invention, welding the track component, restored to its original geometry, to a designated location on the track line includes:

[0029] Clean the welding areas of the track components and track lines, and preheat and adjust the welding parameters;

[0030] The track components and track lines are connected by welding operations, and the welding process is monitored and welding parameters are controlled in real time.

[0031] After welding is completed, the weld and surrounding area are heat-treated and polished.

[0032] In an optional embodiment of the present invention, obtaining geometric data of the damaged track component includes performing a three-dimensional scan of the track component.

[0033] Specifically, laser scanning or structured light scanning is used to perform non-contact measurements on the surface of the disassembled damaged track components, acquiring three-dimensional point cloud data of the damaged area to completely record the actual geometric morphology of the damaged site. This scanning process is completed offline, unaffected by on-site vibration, temperature fluctuations, or spatial limitations, and can stably and efficiently acquire high-precision geometric data, providing the basic input for subsequent construction of a digital three-dimensional model. Obtaining geometric data of track components through three-dimensional scanning can realistically and comprehensively reflect the depth, extent, and contour features of the damage, avoiding subjective errors and information gaps caused by traditional manual measurement or visual assessment. This provides high-fidelity original evidence for the formulation of repair strategies, thereby ensuring the accuracy and repeatability of the offline additive repair process.

[0034] In an optional embodiment of the present invention, the additive repair strategy includes at least repair material, repair path, layer thickness, and process parameters.

[0035] Specifically, when formulating an additive repair strategy, a repair strategy is automatically generated using specialized software based on a pre-constructed digital 3D model of the damaged area. This strategy clearly defines at least the planning of the repair path and the layer thickness of each deposited material. Repair material parameters are selected or set according to the material and service requirements of the track component. For example, specific metal powders or wires with compositions similar to the base material of the track component are specified to ensure that the repair layer matches the base material in terms of microstructure and properties. The repair path is planned according to the damage geometry to ensure that the material is deposited layer by layer to completely cover and fill the damaged area. Layer thickness parameters are set according to the selected additive manufacturing process and material properties to balance repair efficiency and interlayer bonding quality. Process parameters are executed according to the optimal process plan. By clearly defining an additive repair strategy that includes repair materials, repair path, layer thickness, and process parameters, precise planning and standardized control of the repair process are achieved. The targeted selection or setting of repair material parameters ensures the compatibility between the repair layer material and the base material of the track component from the source; the rational planning of the repair path ensures the accuracy and integrity of material deposition, effectively restoring the original geometry of the component; the optimized setting of layer thickness ensures the quality of each layer of repair material and the firmness of interlayer bonding; the optimization of process parameters is conducive to obtaining a repair layer with excellent tissue properties.

[0036] In an alternative embodiment of the invention, repair material is deposited layer by layer at the damaged location of the track component until the original geometry of the track component is restored.

[0037] Specifically, when performing additive repair at the damaged location of a track component, according to a pre-defined repair strategy, the additive repair equipment is controlled to deposit selected repair materials layer by layer along a planned repair path in the damaged area. Each layer of material is precisely fused or deposited on top of the previous layer. This process is repeated, with material added layer by layer until the overall outline and dimensions of the deposit match the original geometry of the track component, thus completely filling and covering the damaged area and achieving precise restoration of the component's external dimensions. By using a layer-by-layer deposition of repair material at the damaged location, precise filling and outline reconstruction of complex damage morphologies can be achieved. This process precisely controls the location and amount of material added incrementally, ultimately ensuring that the external dimensions of the repaired area perfectly match the original design geometry. This restores the structural integrity of the component while ensuring that the dimensional accuracy of the repaired component meets the requirements.

[0038] In one alternative embodiment of this implementation, the repair quality is monitored and process parameters are controlled in real time during the process of layer-by-layer deposition of repair materials.

[0039] Specifically, materials are deposited layer by layer until the original geometry of the component is restored. This process is equipped with a high-precision CNC system and online monitoring devices, such as infrared thermal imagers or visual sensors, enabling precise control of the repair process, including temperature, speed, and real-time quality assessment, such as defect detection. Repair materials can be selected as needed, using metal powders or wires with similar composition or properties to the base material of the track component to ensure structural and performance matching. By monitoring the repair quality in real time and dynamically controlling process parameters, deviations during the repair process can be promptly detected and corrected, ensuring the geometric accuracy and bonding strength of the repair layers, avoiding defects caused by parameter fluctuations, and improving the quality stability and consistency of offline additive repair of track components.

[0040] In one optional embodiment of the present invention, the post-processing includes at least heat treatment and machining.

[0041] Specifically, after repair, appropriate heat treatment, such as annealing and tempering, is performed to improve the microstructure and reduce residual stress. This is followed by machining, such as milling or grinding, to ensure dimensional accuracy and surface roughness meet requirements. Finally, the repaired parts are marked and recorded for easy tracking and management. By implementing post-processing including heat treatment and machining, the microstructure and properties of the repaired area can be effectively optimized, and the geometry can be precisely controlled. This eliminates stress concentrations and surface irregularities generated during additive manufacturing, ensuring that the repaired track components meet the mechanical properties and assembly accuracy requirements for service.

[0042] In an optional embodiment of the present invention, the offline additive repair method for track components further includes: performing non-destructive testing on the post-processed track components.

[0043] Specifically, non-destructive testing (NDT) employs ultrasonic testing, magnetic particle testing, or X-ray inspection to check for defects such as porosity, cracks, and lack of fusion within the repaired area, ensuring that the repair quality meets the usage standards for track components. This testing is performed offline, independent of on-site conditions, and can comprehensively and reliably assess the integrity of the repair layer. By performing NDT on track components after post-processing, hidden defects within the repaired area can be effectively identified, preventing unqualified components from being put into service.

[0044] In an optional embodiment of the present invention, the offline additive repair method for track components further includes marking and recording the repaired parts of the track components.

[0045] Specifically, after the additive repair and subsequent processing of the track components are completed, the repaired areas are marked and recorded. Marking involves using a marking device to engrave or attach specific markings near the repaired area. Recording involves entering repair-related information, such as repair process parameters, material batches, operators, and repair time, into the information management system for subsequent tracking and management. By marking and recording the repaired areas, a traceable unique identifier and complete data archive are established for the repaired components. This allows for the long-term preservation and convenient retrieval of the repaired components' origin, process history, and quality information, greatly facilitating later use and maintenance, service status tracking, and retrospective analysis of potential quality issues, thus achieving standardized and information-based management of the repair process.

[0046] In another optional embodiment of the invention, in the on-line adaptability welding method for track components, the welding preparation process includes: transporting the repaired component to a designated location on the line, cleaning the welding area (e.g., removing oxide scale and oil), and preheating (if necessary) to ensure welding quality. Simultaneously, welding parameters are adjusted according to line conditions, such as track type and ambient temperature.

[0047] In another optional embodiment of the present invention, in the online adaptability welding method for track components, the online welding process involves selecting a suitable welding method, such as flash welding, aluminothermic welding, gas pressure welding, or narrow gap arc welding, based on site conditions and welding requirements, to achieve a stable and reliable connection between the repaired track components and the track.

[0048] In another optional embodiment of the present invention, in the on-line adaptability welding method for track components, the post-weld processing procedure includes: after welding, the weld and surrounding area undergo necessary heat treatment, such as normalizing or tempering, to optimize the microstructure and properties, and then grinding and polishing are performed to ensure that the welded joint meets the requirements of track welding specifications (e.g., flatness, strength). Finally, visual inspection and necessary non-destructive testing are conducted to ensure that the welding quality meets the standards.

[0049] In one optional embodiment of the present invention, the welding operation includes, but is not limited to, flash welding, aluminothermic welding, gas pressure welding, and / or narrow-gap arc welding. The detailed explanations of the above embodiments are intended only to illustrate the present invention and facilitate a better understanding of it. However, these descriptions should not be construed as limiting the present invention in any way. In particular, the various features described in different embodiments can be arbitrarily combined to form other embodiments. Unless explicitly stated otherwise, these features should be understood to be applicable to any embodiment, and not limited to the described embodiments.

Claims

1. A method for integrating offline additive repair and online adaptive welding of track components, characterized in that, The integrated method for offline additive repair and online adaptive welding of track components includes: Obtain geometric data of the damaged track components and construct a digital 3D model of the damaged area; An additive repair strategy is formulated based on the aforementioned digital 3D model; The track components are repaired using additive manufacturing processes based on the aforementioned additive repair strategy. The track component after additive repair is post-processed to obtain a reliable microstructure, and the post-processed track component restores its original geometry. The track components, restored to their original geometry, are welded to the designated locations on the track line.

2. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, Obtaining geometric data of the damaged track component includes performing a three-dimensional scan of the track component.

3. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, The additive repair strategy includes at least the repair material, repair path, layer thickness, and process parameters.

4. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, The repair material is applied layer by layer at the damaged location of the track component until the original geometry of the track component is restored.

5. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 4, characterized in that, During the process of layering the repair material, the repair quality is monitored and the process parameters are controlled in real time.

6. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, The post-processing includes at least heat treatment and machining.

7. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, The offline additive repair method for track components further includes: performing non-destructive testing on the post-processed track components.

8. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, The offline additive repair method for track components further includes marking and recording the repaired parts of the track components.

9. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 1, characterized in that, Welding the track components, restored to their original geometry, to the designated locations on the track line includes: The welding areas of the track components and track lines are cleaned, preheated, and welding parameters are adjusted. The track components and track line are connected by welding operations, and the welding process is monitored and welding parameters are controlled in real time. After welding is completed, the weld and surrounding area are heat-treated and polished.

10. The integrated method for offline additive repair and online adaptive welding of track components as described in claim 9, characterized in that, The welding operation employs flash welding, aluminothermic welding, gas pressure welding, or narrow-gap arc welding.

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