Heavy haul railway frog welding device and welding method thereof

Abstract

The invention discloses a heavy haul railway frog welding device and a welding method thereof, and belongs to the field of frog welding, the heavy haul railway frog welding device comprises a supporting seat, a moving assembly is arranged in the upper end of the supporting seat, a gravity block is arranged at the rear end of the supporting seat, a supporting frame is arranged at the front end of the supporting seat, and a position adjusting assembly is arranged at the rear end of the supporting seat. Gas is continuously injected into the closed gas cylinder through the gas cylinder, the first one-way valve, the second one-way valve, the piston block and the like, and the internal gas pressure is kept constant through the adjustable exhaust valve. The piston block is driven by constant air pressure, and then constant-orientation downward force is applied to the welding head through the polygonal rod. When the surface of the workpiece is uneven or the welding head displaces, the piston block can slide in the air cylinder for compensation, and the contact pressure of the welding head on the frog is automatically kept constant. The problems that in traditional manual or simple automatic welding, due to pressure fluctuation, weld beads are not uniform, and the penetration depth is not consistent are fundamentally solved, and the uniformity and high reliability of weld joints are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of frog welding, and more specifically, to a heavy-haul railway frog welding device and welding method thereof. Background Technology

[0002] The frog on heavy-haul railways is a core load-bearing component of the turnout. Under the long-term impact and crushing of train wheelsets, its key parts, such as the frog rail and wing rail, are prone to wear, crushing, or cracking. Efficient and high-quality on-site welding repair of these damages is an indispensable key technical means to ensure railway operation safety and extend the service life of the frog.

[0003] Currently, the repair surfaces of turnouts are typically uneven and have a certain contour angle. Traditional welding equipment or manual welding makes it difficult to maintain a constant pressure of the welding torch on the workpiece during the welding process. Excessive pressure can easily lead to burn-through and overheating of the base material; insufficient pressure may result in poor fusion and incomplete penetration. Pressure fluctuations directly affect the stability of the weld pool, the weld penetration and formation quality, and are the main cause of uneven weld performance and defects.

[0004] Chinese patent No. [Number] discloses a welding device and method for heavy-duty railway frogs, and a forging table cleaning device. (Prior art)

[0005] To address this, a welding device and welding method for heavy-haul railway frogs are proposed. Summary of the Invention

[0006] To address the problems existing in the prior art, the purpose of this invention is to provide a welding device and welding method for heavy-haul railway frogs, which can keep the interaction force between the welding head and the frog constant.

[0007] To solve the above problems, the present invention adopts the following technical solution.

[0008] A welding device and welding method for a heavy-haul railway frog, comprising a support base, a movable component inside the upper end of the support base, a gravity block at the rear end of the support base, a support frame at the front end of the support base, a position adjustment component at the rear end of the support frame, and a constant force welding component inside the support frame.

[0009] The constant force welding assembly includes electric rods fixedly connected to both sides of the upper end of a support frame. A movable block is fixedly connected to the output end of each electric rod. A first motor is fixedly connected to the upper end of the support frame. A first rectangular rod is slidably connected to the output end of the first motor. An air cylinder is fixedly connected inside the movable block. The upper end of the air cylinder is fixedly connected to the lower end of the first rectangular rod. A first circular block is fixedly connected inside the air cylinder. A first one-way valve is fixedly connected inside the first circular block. A second circular block is slidably connected to the upper end of the air cylinder. A first... A dual one-way valve is described, comprising: Vertical rods fixedly connected to both sides of the upper end of the first circular block; the rod walls of the vertical rods slidingly connected to the interior of the second circular block; a first spring sleeved on the rod walls of the vertical rods; a wedge fixedly connected to the upper end of the second circular block; a rotating block fixedly connected to the lower end of the first rectangular rod; a contact block fixedly connected to the lower end of the rotating block; an exhaust pipe fixedly connected to the left side of the air cylinder; a piston block movably connected inside the air cylinder; a polygonal rod fixedly connected to the lower end of the piston block; a welding head fixedly connected to the lower end of the polygonal rod; and a sliding connection between the rod walls of the polygonal rod and a moving block.

[0010] Preferably, a rectangular block is fixedly connected inside the exhaust pipe, a lead screw is rotatably connected to the left side of the rectangular block, a rectangular groove is provided inside the rectangular block, a push block is threadedly connected to the wall of the lead screw, a second spring is fixedly connected to the right side of the push block, a push rod is fixedly connected to the right side of the second spring, a block is fixedly connected to the right side of the push rod, and the push rod slides inside the rectangular groove.

[0011] Preferably, air holes are provided at both the top and bottom of the air cylinder.

[0012] Preferably, a rotating rod is rotatably connected to the right side of the movable block, the upper end of the rotating rod is connected to the lower end of the first rectangular rod via a belt drive, a second rectangular rod is slidably connected to the lower end of the rotating rod, a support rod is slidably connected to the left side of the movable block, a third spring is fixedly connected to the upper end of the support rod, a circular block is fixedly connected to the lower end of the support rod, a horizontal plate is fixedly connected inside the circular block, an annular block is rotatably connected to the upper end of the horizontal plate, a toothed ring is fixedly connected to the upper end of the annular block, a first gear is fixedly connected to the lower end of the second rectangular rod, the outer side of the first gear meshes with the toothed ring, a first protrusion is slidably connected to the inside of the annular block, a sixth spring is fixedly connected to one end of the first protrusion, a second protrusion is fixedly connected to the inside of the horizontal plate, and a contact rod is provided at the lower end of the horizontal plate.

[0013] Preferably, a cylinder is fixedly connected to the lower end of the cross plate, the lower end of the cylinder is slidably connected to the wall of the contact rod, and a fourth spring is fixedly connected to the upper end of the contact rod.

[0014] Preferably, a rotating ring is rotatably connected to the outer side of the circular block, the inner wall of the rotating ring is fixedly connected to a toothed ring, and a cleaning brush is fixedly connected to the lower end of the rotating ring.

[0015] Preferably, the movable component includes a second gear rotatably connected inside the support base, a rack fixedly connected to both the front and rear positions of the second gear, a locking block rotatably connected to the lower end of the rack, a movable wheel rotatably connected inside the locking block, a fifth spring fixedly connected to one side of the rack, and one end of the fifth spring fixedly connected to the interior of the support base.

[0016] Preferably, the front and rear positions of the support base are respectively fixedly connected to the sliding rods on both sides of the support base, and the rod walls of the sliding rods are slidably connected to the inside of the toothed rod.

[0017] Preferably, the support base has a sliding groove inside, a slider is slidably connected inside the sliding groove, a connecting rod is rotatably connected inside the slider, the front end of the connecting rod is fixedly connected to the rear end of the support frame, a second motor is fixedly connected to the right side of the support base, a threaded rod is fixed to the output end of the second motor, the wall of the threaded rod is threadedly connected to the inside of the slider, the support base has a moving groove, a third gear is fixedly connected to the rear end of the connecting rod, a toothed block is fixedly connected to the bottom of the rear end of the sliding groove, and the toothed block meshes with the outer side of the third gear.

[0018] A welding method for a heavy-haul railway frog welding device includes the following steps:

[0019] S1. The welding device is moved and fixed on the track of the heavy-duty railway frog by the moving component, and balanced by the gravity block device.

[0020] S2. Based on the contour of the part of the fork to be welded, start the position adjustment component to adjust the longitudinal position and tilt angle of the support frame so that the welding head is aligned with and adapted to the surface to be welded.

[0021] S3. Start the first motor to drive the first rectangular rod and rotating block to rotate, so that the contact block periodically pushes the inclined block and the second circular block downward, compresses the first spring, and through the cooperation of the first one-way valve and the second one-way valve, continuously pressurizes the gas into the cavity above the piston block of the gas cylinder.

[0022] S4. The continuously increasing gas pressure inside the air cylinder pushes the piston block and polygonal rod, causing the welding head to contact the frog surface downwards. When the pressure inside the air cylinder exceeds the threshold set by the block in the exhaust pipe and the second spring, the air is automatically vented to maintain a constant internal air pressure, thereby applying a welding pressure of constant magnitude and downward direction to the frog by the welding head.

[0023] S5. During the welding process, the power of the first motor is transmitted through the belt, rotating rod and the second rectangular rod, driving the first gear to mesh with the gear ring, causing the ring block to rotate; the first protrusion on the ring block periodically strikes the second protrusion on the horizontal plate, generating vibration and transmitting it to the fork through the contact rod to optimize the molten pool; at the same time, the gear ring drives the rotating ring and cleaning brush to rotate, cleaning the surface of the welding area.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] (1) Driven by a motor, the air cylinder, first / second check valves, piston block, etc., continuously inject gas into the sealed air cylinder, and maintain a constant internal air pressure using an adjustable exhaust valve. The constant air pressure drives the piston block, which in turn applies a constant downward force to the welding head through the polygonal rod. When the workpiece surface is uneven or the welding head is displaced, the piston block can slide inside the air cylinder to compensate, automatically maintaining a constant contact pressure between the welding head and the fork. This fundamentally solves the problems of uneven weld bead and inconsistent penetration depth caused by pressure fluctuations in traditional manual or simple automatic welding, ensuring the uniformity and high reliability of the weld.

[0026] (2) Pressure setting is achieved through a lead screw, push block, second spring, and plug in an exhaust pipe. The operator can change the gas pressure required to push open the plug (i.e., the preset balance gas pressure of the air cylinder) by rotating the lead screw. This means that the constant pressure value of the welding head on the workpiece can be precisely set and adjusted according to the needs of different materials and different process stages, thus improving the applicability of the device.

[0027] (3) The first protrusion strikes the cross plate, and the vibration is transmitted to the fork through the contact rod. This vibration helps to break the molten pool, promote the escape of gas, and make the molten metal flow more uniformly, thereby effectively reducing defects such as porosity and slag inclusion in the weld and improving the density of the weld. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 This is a schematic diagram of the structure of the present invention;

[0030] Figure 3 For the present invention Figure 2 Enlarged structural diagram at point A in the middle;

[0031] Figure 4 For the present invention Figure 2 Enlarged structural diagram at point B;

[0032] Figure 5 This is a schematic diagram of the movable block structure of the present invention;

[0033] Figure 6For the present invention Figure 5 Enlarged structural diagram at point C;

[0034] Figure 7 For the present invention Figure 5 Enlarged structural diagram at point D;

[0035] Figure 8 This is a schematic cross-sectional view of the air cylinder structure of the present invention;

[0036] Figure 9 This is a schematic diagram of the cross-sectional structure of the transverse plate of the present invention;

[0037] Figure 10 This is a schematic diagram of the rear view structure of the present invention.

[0038] Explanation of the labels in the diagram:

[0039] 1. Support base; 2. Gravity block; 3. Gear rack; 4. Locking block; 5. Second motor; 6. Moving wheel; 7. Support frame; 8. First motor; 9. Electric rod; 10. Moving block; 11. Connecting rod; 12. Threaded rod; 13. Third gear; 14. Gear block; 15. Slider; 16. Slide groove; 17. Moving groove; 18. Slide rod; 19. Second gear; 20. Air pump; 21. Second rectangular rod; 22. Circular block; 23. Support rod; 24. Third spring; 25. Welding head; 26. First rectangular rod; 27. Cleaning brush; 28. Exhaust pipe; 29. ​​Lead screw; 30. Push block; 31. Blocking block; 32. Second spring; 33. Push rod; 34. Gear ring; 35. First gear; 36. Rotating ring; 37. First protrusion; 38. Sixth spring; 39. Ring block; 40. Horizontal plate; 41. Cylinder; 42. Rectangular block; 43. Second protrusion; 44. Rotating rod; 45. Contact rod; 46. First round block; 47. First one-way valve; 48. First spring; 49. Vertical rod; 50. Air hole; 51. Rotating block; 52. Second round block; 53. Second one-way valve; 54. Inclined block; 55. Contact block; 56. Polygonal rod; 57. Piston block; 58. Fifth spring; 59. Belt; 60. Fourth spring. Detailed Implementation

[0040] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] Please see Figures 1 to 10A welding device and welding method for a heavy-duty railway frog, comprising a support base 1, a movable component inside the upper end of the support base 1 for enabling the entire device to move, a gravity block 2 at the rear end of the support base 1 for ensuring the front and rear positions of the entire device are in a balanced state, thereby making the device relatively stable, a support frame 7 at the front end of the support base 1, a position adjustment component at the rear end of the support frame 7, and a constant force welding component inside the support frame 7.

[0042] The constant force welding assembly includes electric rods 9 fixedly connected to both sides of the upper end of the support frame 7. The electric rods 9 are driving devices; in existing technology, their output ends can move up and down. A movable block 10 is fixedly connected to the output end of the electric rods 9, allowing the electric rods 9 to drive the movable block 10 to move up and down. A first motor 8 is fixedly connected to the upper end of the support frame 7. The first motor 8 drives rotation, and its output end can rotate. A first rectangular rod 26 is slidably connected to the output end of the first motor 8. Rotation of the output end of the first motor 8 drives the first rectangular rod 26 to rotate. The first rectangular rod 26 can move up and down relative to the output end of the first motor 8. The interior of the movable block 10... An air cylinder 20 is fixedly connected. A movable block 10 moves synchronously with the air cylinder 20. The upper end of the air cylinder 20 is fixedly connected to the lower end of the first rectangular rod 26. The up-and-down movement of the air cylinder 20 causes the first rectangular rod 26 to rotate. A first circular block 46 is fixedly connected inside the air cylinder 20. A first one-way valve 47 is fixedly connected inside the first circular block 46. The first one-way valve 47 allows gas to pass through in one direction only. In the prior art, a second circular block 52 is slidably connected to the upper end of the air cylinder 20. The second circular block 52 can move up and down inside the air cylinder 20. A second one-way valve 53 is fixedly connected inside the second circular block 52. The second one-way valve 53 is connected to the first one-way valve 46. The unidirectional nature of valve 47 is reversed by a reversed configuration. Vertical rods 49 are fixedly connected to both sides of the upper end of the first circular block 46. The first circular block 46 can move up and down relative to the vertical rods 49, which allow the first circular block 46 to move stably up and down. The rod wall of the vertical rod 49 is slidably connected to the interior of the second circular block 52. A first spring 48 is sleeved on the rod wall of the vertical rod 49, providing upward support to the second circular block 52. A wedge block 54 is fixedly connected to the upper end of the second circular block 52. A rotating block 51 is fixedly connected to the lower end of the first rectangular rod 26, allowing the first rectangular rod 26 to drive the rotating block 51 to rotate. A contact block 55 is fixedly connected to the lower end of the rotating block 51. 1. Rotation drives the contact block 55 to rotate. An exhaust pipe 28 is fixedly connected to the left side of the air cylinder 20. The exhaust pipe 28 is used for exhaust. A piston block 57 is movably connected inside the air cylinder 20. The piston block 57 can move up and down inside the air cylinder 20. A polygonal rod 56 is fixedly connected to the lower end of the piston block 57. The movement of the piston block 57 drives the polygonal rod 56 to move, which in turn drives the welding head 25 to move. The lower end of the polygonal rod 56 is fixedly connected to the welding head 25. The rod wall of the polygonal rod 56 is slidably connected to the moving block 10. Air holes 50 are opened at both the upper and lower positions of the air cylinder 20. The air holes 50 are used to keep the air pressure inside the air cylinder 20 constant at the upper and lower positions.

[0043] During operation, the movable components move the entire device to the upper end of the fork. When it reaches the welding position, the electric lever 9 activates, causing the moving block 10 to move downwards. The moving block 10 then moves the air cylinder 20, and the first motor 8 activates. The output of the first motor 8 drives the first rectangular rod 26 to rotate, which in turn drives the rotating block 51 to rotate. The rotating block 51 then moves the contact block 55, which contacts the inclined block 54, causing the inclined block 54 to move downwards. The movement of the inclined block 54 causes the first circular block 46 to move downwards, compressing the first spring 48. When the first circular block 46 moves downwards, the first one-way valve 47 is closed, and the second one-way valve 53 is open. As the second circular block 52 moves downwards, it forces gas into the lower part of the first circular block 46. When the contact block 55 and the inclined block 54 are misaligned, the first circular block 46 moves upwards under the action of the first spring 48. At this time, the first one-way valve 47 is open, and the second one-way valve 53 is closed. This allows gas to enter the space between the first circular block 46 and the second circular block 52, causing the second circular block 52 to move up and down continuously, thus continuously pushing gas into the air cylinder 20. The air cylinder 20 has a certain internal pressure, giving the piston block 57 a downward force. The piston block 57, through the polygonal rod 56, drives the welding head 25 downward, bringing it into contact with the frog. At this time, gas is continuously injected into the air cylinder 20. When there is too much gas inside, it is discharged through the exhaust pipe 28, thus maintaining a constant air pressure inside the air cylinder 20. This ensures a constant pressure thrust on the piston block 57, maintaining a constant contact force between the welding head 25 and the frog. When the pressure is too high, the piston block 57 moves upward relative to the air cylinder 20; when the pressure is too low, it moves downward relative to the air cylinder 20. Through the self-adjustment of the piston block 57, the pressure of the welding head 25 on the frog is kept constant, thereby improving the welding effect.

[0044] like Figure 5 and Figure 6 As shown, a rectangular block 42 is fixedly connected inside the exhaust pipe 28. A lead screw 29 is rotatably connected to the left side of the rectangular block 42. A rectangular groove is provided inside the rectangular block 42. A push block 30 is threadedly connected to the rod wall of the lead screw 29. By rotating the lead screw 29, the push block 30 moves inside the rectangular groove. A second spring 32 is fixedly connected to the right side of the push block 30. When the push block 30 moves, it changes the deformation of the second spring 32, thereby changing the elastic force of the second spring 32. A push rod 33 is fixedly connected to the right side of the second spring 32. The change in the elastic force of the second spring 32 changes the pushing force on the push rod 33. A block block 31 is fixedly connected to the right side of the push rod 33. The push rod 33 slides inside the rectangular groove.

[0045] When the internal air pressure of the air cylinder 20 reaches a certain value, the gas pushes the block 31 to move, thereby releasing the gas. According to the work requirements, by rotating the screw 29, the push block 30 moves inside the rectangular groove, thereby changing the deformation of the second spring 32. This change in the pushing force of the second spring 32 on the push rod 33 determines the required gas pressure for venting, thus changing the internal air pressure of the air cylinder 20 to better meet the work requirements. It also changes the contact between the welding head 25 and the fork, further improving the applicability of the device.

[0046] like Figure 5 , Figure 7 and Figure 9 As shown, a rotating rod 44 is rotatably connected to the right side of the movable block 10. The rotating rod 44 can rotate relative to the rotating rod 26. The upper end of the rotating rod 44 is connected to the lower end of the first rectangular rod 26 via a belt 59. The rotation of the first rectangular rod 26 causes the rotating rod 44 to rotate via the belt 59. A second rectangular rod 21 is slidably connected to the lower end of the rotating rod 44. The rotation of the rotating rod 44 drives the second rectangular rod 21 to rotate, and the second rectangular rod 21 can move up and down relative to the rotating rod 44. A support rod 23 is slidably connected to the left side of the movable block 10. A third spring 24 is fixedly connected to the upper end of the support rod 23. The third spring 24 exerts a downward thrust on the support rod 23. A circular block 22 is fixedly connected to the lower end of the support rod 23. The support rod 23 drives the circular block 22 synchronously. The circular block 22 is fixedly connected to a horizontal plate 40. The upper end of the horizontal plate 40 is rotatably connected to an annular block 39. The upper end of the annular block 39 is fixedly connected to a toothed ring 34. The lower end of the second rectangular rod 21 is fixedly connected to a first gear 35. The rotation of the second rectangular rod 21 drives the first gear 35 to rotate. The outer side of the first gear 35 meshes with the toothed ring 34. The rotation of the first gear 35 causes the toothed ring 34 to rotate. The rotation of the toothed ring 34 drives the annular block 39 to rotate. The annular block 39 is slidably connected to a first protrusion 37. The movement of the annular block 39 drives the first protrusion 37 to move. One end of the first protrusion 37 is fixedly connected to a sixth spring 38. The horizontal plate 40 is fixedly connected to a second protrusion 43. The lower end of the horizontal plate 40 is provided with a contact rod 45.

[0047] When the moving block 10 moves downward, it drives the support rod 23 to move downward, which in turn causes the circular block 22 to move downward. The downward movement of the circular block 22 causes the contact rod 45 to contact the upper end of the frog. The third spring 24 exerts a pushing force on the contact rod 45. This means that the support rod 23 has a certain amount of room to move and will not affect the contact between the welding head 25 and the frog. The rotation of the first rectangular rod 26 causes the rotating rod 44 to rotate via the belt 59. The rotation of the rotating rod 44 drives the second rectangular rod 21 to rotate. The rotation of the second rectangular rod 21 drives the first gear 35 to rotate. The first gear 35 causes the gear ring 34 to rotate. 4. The rotation drives the annular block 39 to rotate, and the rotation of the annular block 39 drives the first protrusion 37 to move. The first protrusion 37 moves and contacts the second protrusion 43, causing the first protrusion 37 to move and compress the sixth spring 38. When the first protrusion 37 and the second protrusion 43 are misaligned, the first protrusion 37 is reset under the action of the sixth spring 38 and strikes the horizontal plate 40, causing the horizontal plate 40 to vibrate. The vibration of the horizontal plate 40 causes the contact rod 45 to vibrate, which in turn causes the fork to vibrate. This makes the molten pool more uniform during welding, helps the molten pool to expel gas, and makes the welding effect better.

[0048] like Figure 9 As shown, a cylinder 41 is fixedly connected to the lower end of the horizontal plate 40. The lower end of the cylinder 41 is slidably connected to the wall of the contact rod 45. A fourth spring 60 is fixedly connected to the upper end of the contact rod 45. The fourth spring 60 enables multiple contact rods 45 to avoid contact with the frog respectively, making the contact effect between the contact rod 45 and the frog better and ensuring perfect vibration transmission.

[0049] like Figure 5 As shown, a rotating ring 36 is rotatably connected to the outer side of the circular block 22. The inner wall of the rotating ring 36 is fixedly connected to the toothed ring 34. A cleaning brush 27 is fixedly connected to the lower end of the rotating ring 36. The rotation of the toothed ring 34 drives the rotating ring 36 to rotate. The rotation of the rotating ring 36 can drive the cleaning brush 27 to rotate, thereby cleaning the surface of the fork and improving the welding effect.

[0050] like Figure 4 and Figure 10As shown, the moving component includes a second gear 19 rotatably connected inside the support base 1. A rack 3 is fixedly connected to both the front and rear positions of the second gear 19. A locking block 4 is rotatably connected to the lower end of the rack 3. A moving wheel 6 is rotatably connected inside the locking block 4. A fifth spring 58 is fixedly connected to one side of the rack 3. The fifth spring 58 exerts a certain pushing force on the rack 3, causing the rack 3 to be in a contracted state when no force is applied. One end of the fifth spring 58 is fixedly connected to the interior of the support base 1. Slide rods 18 are fixedly connected to both the front and rear positions of the support base 1, respectively, on both sides of the support base 1. The walls of the slide rods 18 are slidably connected to the interior of the rack 3. The two racks 3 can move synchronously under the action of the second gear 19, locking the locking block 4 onto both sides of the track. Then, the entire device moves via the moving wheel 6.

[0051] like Figure 2 and Figure 3 As shown, the support base 1 has a groove 16 inside, and a slider 15 is slidably connected inside the groove 16. The slider 15 can move inside the groove 16. A connecting rod 11 is rotatably connected inside the slider 15. The movement of the slider 15 drives the connecting rod 11 to move, and the connecting rod 11 can rotate relative to the slider 15. The front end of the connecting rod 11 is fixedly connected to the rear end of the support frame 7. The connecting rod 11 drives the support frame 7 to move. A second motor 5 is fixedly connected to the right side of the support base 1. A threaded rod 12 is fixed to the output end of the second motor 5. The output end of the second motor 5 can drive the threaded rod 12. 2. Rotation: The wall of the threaded rod 12 is connected to the internal thread of the slider 15. The rotation of the threaded rod 12 causes the slider 15 to move. The support base 1 has a moving groove 17, which allows the connecting rod 11 to move. The rear end of the connecting rod 11 is fixedly connected to the third gear 13. The movement of the slider 15 causes the connecting rod 11 to move, which in turn causes the third gear 13 to rotate. The third gear 13 rotates under the action of the tooth block 14, which in turn causes the connecting rod 11 to rotate. The rear end bottom of the slide groove 16 is fixedly connected to the tooth block 14, which meshes with the outer side of the third gear 13.

[0052] According to the welding position requirements, the second motor 5 drives the threaded rod 12 to rotate. The rotation of the threaded rod 12 causes the slider 15 to move inside the slide groove 16. When the slider 15 moves, it can drive the connecting rod 11 to move. The connecting rod 11 drives the support frame 7 to move, and at the same time drives the third gear 13 to move. Under the action of the tooth block 14, the third gear 13 rotates. The rotation of the third gear 13 drives the connecting rod 11 to rotate, thereby changing the tilt angle of the support frame 7, causing the welding head 25 to tilt. Because the front end of the frog has a certain tilt angle, this allows the welding head 25 to better contact the frog, thereby improving the welding effect.

[0053] Usage: During operation, the moving components move the entire device to the upper end of the fork. When it reaches the welding position, the electric lever 9 activates, causing the moving block 10 to move downwards. The moving block 10 moves the air cylinder 20, and the first motor 8 activates. The output of the first motor 8 drives the first rectangular rod 26 to rotate, which in turn drives the rotating block 51 to rotate. The rotating block 51 moves the contact block 55, which then contacts the inclined block 54, causing the inclined block 54 to move downwards. The movement of the inclined block 54 moves the first circular block 46 downwards, compressing the first spring 48. When the first circular block 46 moves downwards, the first one-way valve 47 is closed, and the second one-way valve 53 is open. As the second circular block 52 moves downwards, it presses gas into the lower part of the first circular block 46. When the contact block 55 and the inclined block 54 are misaligned, the first circular block 46 moves upwards under the action of the first spring 48. At this time, the first one-way valve 47 is open, and the second one-way valve 53 is closed. In the closed state, gas can enter the space between the first circular block 46 and the second circular block 52. This causes the second circular block 52 to move up and down continuously, thus continuously forcing gas into the air cylinder 20. The air cylinder 20 has a certain internal pressure, giving the piston block 57 a downward force. The piston block 57, through the polygonal rod 56, drives the welding head 25 downward, bringing it into contact with the frog. At this time, gas is continuously injected into the air cylinder 20. When there is too much gas inside, it is discharged through the exhaust pipe 28, thus maintaining a constant air pressure inside the air cylinder 20. This ensures that the pressure thrust on the piston block 57 remains constant, maintaining a constant contact force between the welding head 25 and the frog. When the pressure is too high, the piston block 57 moves upward relative to the air cylinder 20; when the pressure is too low, the piston block 57 moves downward relative to the air cylinder 20. Through the self-adjustment of the piston block 57, the pressure of the welding head 25 on the frog is kept constant, thereby improving the welding effect.

[0054] Furthermore, when the internal air pressure of the air cylinder 20 reaches a certain value, the gas pushes the block 31 to move, thereby releasing the gas. According to the work requirements, by rotating the screw 29, the push block 30 moves inside the rectangular groove, thereby changing the deformation of the second spring 32. This change in the pushing force of the second spring 32 on the push rod 33 determines the required gas pressure to release the gas, thus changing the internal air pressure of the air cylinder 20 to better meet the work requirements. This also changes the contact between the welding head 25 and the fork, further improving the applicability of the device.

[0055] Furthermore, when the moving block 10 moves downward, it drives the support rod 23 to move downward, which in turn causes the circular block 22 to move downward. The downward movement of the circular block 22 causes the contact rod 45 to contact the upper end of the frog. The third spring 24 exerts a pushing force on the contact rod 45. This means that the support rod 23 has a certain amount of room to move and will not affect the contact between the welding head 25 and the frog. The rotation of the first rectangular rod 26 causes the rotating rod 44 to rotate via the belt 59. The rotation of the rotating rod 44 drives the second rectangular rod 21 to rotate. The rotation of the second rectangular rod 21 drives the first gear 35 to rotate. The first gear 35 causes the gear ring 34 to rotate. The rotation of the toothed ring 34 drives the annular block 39 to rotate, and the rotation of the annular block 39 drives the first protrusion 37 to move. The first protrusion 37 moves and contacts the second protrusion 43, causing the first protrusion 37 to move and compress the sixth spring 38. When the first protrusion 37 and the second protrusion 43 are misaligned, the first protrusion 37 is reset under the action of the sixth spring 38, and strikes the cross plate 40, causing the cross plate 40 to vibrate. The vibration of the cross plate 40 causes the contact rod 45 to vibrate, which in turn causes the fork to vibrate. This makes the molten pool more uniform during welding, helps the molten pool to expel gas, and makes the welding effect better.

[0056] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concepts, should be covered within the scope of protection of the present invention.

Claims

1. A welding device for heavy-duty railway frogs, comprising a support base (1), characterized in that: The upper end of the support base (1) is provided with a moving component, the rear end of the support base (1) is provided with a gravity block (2), the front end of the support base (1) is provided with a support frame (7), the rear end of the support frame (7) is provided with a position adjustment component, and the inside of the support frame (7) is provided with a constant force welding component. The constant force welding assembly includes electric rods (9) fixedly connected to both sides of the upper end of the support frame (7). The output end of the electric rod (9) is fixedly connected to a moving block (10). The upper end of the support frame (7) is fixedly connected to a first motor (8). The output end of the first motor (8) is slidably connected to a first rectangular rod (26). An air cylinder (20) is fixedly connected inside the moving block (10). The upper end of the air cylinder (20) is fixedly connected to the lower end of the first rectangular rod (26). The air cylinder (20) is fixedly connected to a first circular block (46). The first circular block (46) is fixedly connected to a first one-way valve (47). The upper end of the air cylinder (20) is slidably connected to a second circular block (52). The second circular block (52) is fixedly connected to a second one-way valve (53). A vertical rod (49) is fixedly connected to both sides of the upper end of a circular block (46). The rod wall of the vertical rod (49) is slidably connected to the interior of the second circular block (52). A first spring (48) is sleeved on the rod wall of the vertical rod (49). An inclined block (54) is fixedly connected to the upper end of the second circular block (52). A rotating block (51) is fixedly connected to the lower end of the first rectangular rod (26). A contact block (55) is fixedly connected to the lower end of the rotating block (51). An exhaust pipe (28) is fixedly connected to the left side of the air cylinder (20). A piston block (57) is movably connected inside the air cylinder (20). A polygonal rod (56) is fixedly connected to the lower end of the piston block (57). A welding head (25) is fixedly connected to the lower end of the polygonal rod (56). The rod wall of the polygonal rod (56) is slidably connected to the moving block (10).

2. The heavy-haul railway frog welding device according to claim 1, characterized in that: A rectangular block (42) is fixedly connected inside the exhaust pipe (28). A lead screw (29) is rotatably connected to the left side of the rectangular block (42). A rectangular groove is provided inside the rectangular block (42). A push block (30) is threadedly connected to the rod wall of the lead screw (29). A second spring (32) is fixedly connected to the right side of the push block (30). A push rod (33) is fixedly connected to the right side of the second spring (32). A block (31) is fixedly connected to the right side of the push rod (33). The push rod (33) slides inside the rectangular groove.

3. The heavy-haul railway frog welding device according to claim 1, characterized in that: The air cylinder (20) has air holes (50) at both the top and bottom positions.

4. The heavy-haul railway frog welding device according to claim 1, characterized in that: A rotating rod (44) is rotatably connected to the right side of the movable block (10). The upper end of the rotating rod (44) is connected to the lower end of the first rectangular rod (26) via a belt (59). A second rectangular rod (21) is slidably connected to the lower end of the rotating rod (44). A support rod (23) is slidably connected to the left side of the movable block (10). A third spring (24) is fixedly connected to the upper end of the support rod (23). A circular block (22) is fixedly connected to the lower end of the support rod (23). A horizontal plate (40) is fixedly connected inside the circular block (22). The upper end of the second rectangular rod (21) is rotatably connected to an annular block (39), the upper end of the annular block (39) is fixedly connected to a toothed ring (34), the lower end of the second rectangular rod (21) is fixedly connected to a first gear (35), the outer side of the first gear (35) meshes with the toothed ring (34), the inside of the annular block (39) is slidably connected to a first protrusion (37), one end of the first protrusion (37) is fixedly connected to a sixth spring (38), the inside of the horizontal plate (40) is fixedly connected to a second protrusion (43), and the lower end of the horizontal plate (40) is provided with a contact rod (45).

5. The heavy-haul railway frog welding device according to claim 4, characterized in that: The lower end of the horizontal plate (40) is fixedly connected to a cylinder (41), the lower end of the cylinder (41) is slidably connected to the wall of the contact rod (45), and the upper end of the contact rod (45) is fixedly connected to a fourth spring (60).

6. The heavy-haul railway frog welding device according to claim 4, characterized in that: A rotating ring (36) is rotatably connected to the outer side of the circular block (22). The inner wall of the rotating ring (36) is fixedly connected to the toothed ring (34). A cleaning brush (27) is fixedly connected to the lower end of the rotating ring (36).

7. The heavy-haul railway frog welding device according to claim 1, characterized in that: The movable component includes a second gear (19) rotatably connected inside the support base (1). A rack (3) is fixedly connected to both the front and rear positions of the second gear (19). A locking block (4) is rotatably connected to the lower end of the rack (3). A moving wheel (6) is rotatably connected inside the locking block (4). A fifth spring (58) is fixedly connected to one side of the rack (3). One end of the fifth spring (58) is fixedly connected to the inside of the support base (1).

8. The heavy-haul railway frog welding device according to claim 1, characterized in that: The front and rear positions of the support base (1) are respectively located on both sides of the support base (1) and slide rods (18) are fixedly connected. The rod wall of the slide rod (18) is slidably connected to the inside of the toothed rod (3).

9. A heavy-haul railway frog welding device according to claim 1, characterized in that: The position adjustment assembly includes a slide groove (16) inside the support base (1), a slider (15) is slidably connected inside the slide groove (16), a connecting rod (11) is rotatably connected inside the slider (15), the front end of the connecting rod (11) is fixedly connected to the rear end of the support frame (7), a second motor (5) is fixedly connected to the right side of the support base (1), a threaded rod (12) is fixed at the output end of the second motor (5), the rod wall of the threaded rod (12) is threadedly connected to the inside of the slider (15), a moving groove (17) is opened in the support base (1), a third gear (13) is fixedly connected to the rear end of the connecting rod (11), a toothed block (14) is fixedly connected to the bottom of the rear end of the slide groove (16), and the toothed block (14) meshes with the outer side of the third gear (13).

10. A welding method applicable to the heavy-haul railway frog welding device according to any one of claims 1-9, characterized in that, Includes the following steps: S1. Move and fix the welding device on the track of the heavy-duty railway frog by means of the moving component, and balance it by means of the gravity block (2); S2. Based on the outline of the part of the fork to be welded, start the position adjustment component and adjust the longitudinal position and tilt angle of the support frame (7) so that the welding head (25) is aligned with and adapted to the surface to be welded. S3. Start the first motor (8) to drive the first rectangular rod (26) and the rotating block (51) to rotate, so that the contact block (55) periodically pushes the inclined block (54) and the second circular block (52) downward, compressing the first spring (48) and through the cooperation of the first one-way valve (47) and the second one-way valve (53), continuously pressurizing the gas into the cavity above the piston block (57) of the gas cylinder (20); S4. The continuously increasing gas pressure inside the air cylinder (20) pushes the piston block (57) and the polygonal rod (56) to make the welding head (25) contact the frog surface downwards. When the pressure inside the air cylinder (20) exceeds the threshold set by the block (31) in the exhaust pipe (28) and the second spring (32), the air is automatically vented to maintain a constant internal air pressure, thereby allowing the welding head (25) to apply a welding pressure of constant magnitude and downward direction to the frog. S5. During the welding process, the power of the first motor (8) is transmitted through the belt (59), the rotating rod (44) and the second rectangular rod (21) to drive the first gear (35) to mesh with the gear ring (34) and make the ring block (39) rotate. The first protrusion (37) on the ring block (39) periodically impacts the second protrusion (43) on the cross plate (40), generating vibration and transmitting it to the fork through the contact rod (45) to optimize the molten pool. At the same time, the gear ring (34) drives the rotating ring (36) and the cleaning brush (27) to rotate and clean the surface of the welding area.

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