Rail grinding method

Abstract

The present application relates to a rail grinding method, and relates to the technical field of rail grinding.The rail grinding method sets a running speed threshold to trigger the timing of the down operation of the grinding head, which can adapt to different running conditions such as the start and stop of the grinding device and uniform speed running, thereby avoiding the problems of dislocation of the grinding track, insufficient regional overlap or local grinding failure caused by dynamic changes in the running speed, ensuring that the operation coverage of each group of grinding heads can be matched, thereby eliminating the rail surface grinding defects and improving the continuity of the longitudinal rail grinding and the smoothness of the rail surface.

Description

Technical Field

[0001] This invention relates to the field of rail grinding technology, and more particularly to a rail grinding method. Background Technology

[0002] Rails are subjected to long-term train rolling, friction impact, and natural environmental erosion, making their surfaces prone to various defects. These defects directly affect the stability and safety of train operation, thus requiring regular grinding and repair. Multi-head grinding equipment, with its wide operating range and high grinding efficiency, is widely used in rail profile repair and rail surface defect treatment. Currently, conventional multi-head grinding equipment generally lacks timing-based contact control logic based on the equipment's real-time travel speed. During operation, multiple grinding components mostly adopt a synchronous pressing and synchronous contact with the rail surface, with the pressing action and the equipment's travel and feed states being independent of each other, lacking a linkage matching mechanism. Because the actual operation of the grinding equipment involves different travel states such as start-stop speed changes and constant speed travel, the fixed synchronous pressing mode cannot adapt to dynamic speed changes. This easily leads to misalignment deviations in the rail surface contact position and initial stroke of each grinding head, resulting in problems with rail grinding flatness and profile accuracy, as well as uneven rail surface stress, preventing continuous, stable, and uniform grinding. Summary of the Invention

[0003] This invention provides a rail grinding method to solve at least one of the above-mentioned technical problems.

[0004] This invention provides a method for grinding steel rails, comprising the following steps: The total grinding amount is determined based on the actual profile data of the rail; The amount of grinding per pass and the number of grinding passes are determined based on the total amount of grinding. Based on the amount of grinding per pass and the number of grinding passes, determine the operating parameters of the grinding motor in the grinding device, and determine the grinding pressure and grinding speed of the grinding components in the grinding device. The contact sequence between multiple grinding components and the rail surface is controlled according to the traveling speed of the grinding device. The grinding components grind the rail surface according to the determined single grinding amount, number of grinding passes, grinding pressure and grinding speed.

[0005] In one implementation, determining the single grinding amount based on the total grinding amount includes the following sub-steps: Establish a material removal rate model that relates the material removal rate Q to the linear velocity of the grinding head and the grinding pressure in the grinding component; The linear velocity of the grinding head, v = π × D × n × i, is obtained from the operating parameters of the grinding motor in the grinding component, where D is the diameter of the grinding head, n is the rated output speed of the grinding motor, and i is the transmission reduction ratio of the transmission structure matched with the grinding motor. The grinding depth is determined based on the material removal rate model, where the single grinding depth h = Q / (v×B), and B is the contact width between the grinding head and the rail surface. In one implementation, the material removal rate model Q satisfies: Q=k v α F β ; Based on the influence of the linear velocity and grinding pressure of the grinding head on the material removal rate in the grinding component, the correlation curves between linear velocity and material removal rate and between grinding pressure and material removal rate are obtained by fixing the grinding pressure and linear velocity respectively, and a material removal rate model is obtained, where k is the coupling coefficient, and α and β are the working condition fitting exponents respectively.

[0006] In one embodiment, the actual operating linear speed and grinding pressure of the grinding head are controlled by adjusting the output power of the grinding motor to change the ratio of the grinding motor's speed to its output torque. When the grinding motor outputs at high speed and low output torque, the grinding adjustment mechanism reduces the grinding pressure; when the grinding motor outputs at low speed and high output torque, the grinding adjustment mechanism increases the grinding pressure.

[0007] In one embodiment, controlling the sequence of contact between multiple sets of grinding components and the rail surface according to the traveling speed of the grinding device includes the following sub-steps: Using the direction of travel of the grinding device as a reference, the positions of the first grinding head A and the second grinding head B on the left and right sides are calibrated. A preset travel speed threshold Vset is used as the grinding head pressing trigger condition. The grinding head pressing operation is only initiated when the actual travel speed of the grinding device reaches Vset. When starting the grinding head pressing operation, first control the first grinding head A to press down to contact the rail and enter the grinding state, and at the same time start the delay timer. After the delay ends, control the second grinding head B to press down to contact the rail and enter the grinding state.

[0008] In one embodiment, after both the first grinding head A and the second grinding head B have finished pressing down, the detection unit of the grinding device verifies the working coverage area of ​​the two sets of grinding heads to determine whether the grinding areas of the first grinding head A and the second grinding head B completely overlap.

[0009] In one embodiment, when the grinding component grinds the rail surface according to the determined single grinding amount, number of grinding passes, grinding pressure and grinding speed, the two sets of grinding heads are kept in a downward state and grinding pressure to perform continuous rail grinding operation until the single grinding stroke is completed. After the single grinding operation is completed, the second grinding head B is first controlled to rise and reset, and then the first grinding head A is controlled to rise and reset to complete the single downward grinding operation.

[0010] In one embodiment, when the grinding head pressing operation is initiated, the grinding head is pushed downward by extending a hydraulic push rod or a pneumatic telescopic component, so that the grinding head fits against the rail surface.

[0011] In one embodiment, when the grinding head is pressed down, if the contact force between the grinding head and the rail surface reaches the first contact threshold and the actual pressing displacement of the grinding head is less than the preset minimum contact displacement, the pressing is paused and an alarm signal is issued.

[0012] In one embodiment, the contact force is acquired in real time by a force sensor installed between the grinding adjustment mechanism and the grinding head, and the actual downward displacement of the grinding head is acquired by a laser displacement sensor or an ultrasonic sensor installed on the side of the grinding head.

[0013] Compared with the prior art, the present invention has the following beneficial effects: By setting a travel speed threshold to trigger the sequential pressing operation of the grinding head, the present invention can adapt to different travel conditions such as the start and stop of the grinding device and uniform speed travel, thereby avoiding problems such as grinding trajectory misalignment, insufficient area overlap or local missed grinding caused by dynamic changes in travel speed. It ensures that the working coverage area of ​​each group of grinding heads can be matched, thereby eliminating defects such as joints, stripes and uneven grinding of rail surface, and improving the continuity and smoothness of longitudinal grinding of rails. In addition, the step-by-step sequential pressing method can disperse the instantaneous grinding impact force, reduce the vibration interference and mechanical load impact of multiple grinding heads operating simultaneously, thereby improving the stability of the grinding operation process. While ensuring grinding accuracy and work quality, it gives full play to the high efficiency advantage of multi-grinding head combined operation, adapting to various on-site traveling grinding conditions, and improving both operational adaptability and grinding reliability. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a flowchart of the rail grinding method in an embodiment of the present invention; Figure 2This is a three-dimensional structural schematic diagram of the rail grinding device used to implement the rail grinding method in an embodiment of the present invention; Figure 3 yes Figure 2 A schematic diagram of the structure of the traveling component shown; Figure 4 yes Figure 2 The diagram shows the structure of the transverse moving component; Figure 5 yes Figure 2 Enlarged view at point A; Figure 6 yes Figure 2 The diagram shows the structure of the deflection component. Figure 7 This is a principle block diagram of the pneumatic mechanism in an embodiment of the present invention, wherein the solid line represents the air path and the dashed line represents the signal transmission direction; In the diagram: 1. Lifting component; 2. Power supply module; 3. Traveling component; 4. Lateral movement component; 5. Grinding component; 6. Deflection component; 7. Electrical control module; 8. Pneumatic mechanism; 101. Lifting lug assembly; 102. Rotating connector; 103. Lifting frame; 104. Crossbeam; 105. Quick connector; 301. Chassis frame; 302. Running wheels; 303. Traction seat; 401. Transverse drive motor; 402. Lead screw; 403. First mounting base; 404. Drive shaft; 405. Guide rail; 406. Transverse reducer; 407. Coupling; 408. Transition connecting shaft; 409. First planetary reducer; 4021, First lead screw guard seat; 4022, Second lead screw guard seat; 4031. Screw connector; 4032. Support plate; 4033. Guide groove; 4034. Connecting plate; 4051, Guide rail cover seat; 4061. Mounting bracket for transverse reducer; 4091, Transition Flange; 501. Grinding head; 502. Grinding motor; 503. Hydraulic mechanism; 504. Grinding motor mounting base; 601. First slewing bearing; 602. Deflection drive motor; 603. Deflection frame; 604. Second slewing bearing; 605. Grinding feed limit device; 606. Rotary shaft; 607. Second planetary reducer; 1051. Mounting base; 1053. Movable hook; 1052. Fixed hook; 81. Microcomputer control unit; 82. Cylinder; 83. Pressure detection element; 84. Proportional valve; 85. Air compressor; 86. Filter; 821. First chamber; 822. Second chamber; 823. Guide rod; 8024. Guide rod pressure plate; 841. First proportional valve; 842. Second proportional valve. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0017] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0018] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0019] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationships commonly used when the product is in use. These are merely for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," etc., appearing in the description of this invention are only used for distinguishing descriptions and should not be construed as indicating or implying relative importance.

[0020] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this invention does not imply that the components are required to be absolutely horizontal or suspended, but rather that they may be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it may be slightly tilted.

[0021] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] like Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6 As shown, the present invention provides a grinding device, including a transverse moving component 4, a deflecting component 6 connected to the transverse moving component 4, and a grinding component 5 connected to the deflecting component 6. The transverse moving component 4 can drive the deflecting component 6 and the grinding component 5 along the width direction of the rail (e.g., ...). Figure 2 (As shown in the Y-axis direction) the deflection component 6 can drive the grinding component 5 to rotate about the length of the rail as the rotation axis.

[0023] The lateral movement component 4 and the deflection component 6 are configured to move and / or rotate the grinding component 5 to a preset position before grinding. This preset position covers the area where grinding begins. The grinding component 5 is used to grind the surface of the rail, and it is configured to have a feature along the height direction of the rail (e.g., ...). Figure 2 The degree of freedom of movement (in the Z-axis direction shown) allows the grinding pressure of the grinding component 5 to be adjusted during the grinding process.

[0024] In existing technologies, when grinding the surface of rails, the grinding component is moved to the starting tool setting point, allowing it to travel along a preset path to grind the rail. This preset path is based on the theoretically constructed rail alignment. However, due to the irregular morphology of rail surfaces—such as pits, bumps, wavy wear, and localized thick edges—developed over long-term operation, the actual rail surface often deviates from the theoretical alignment. Therefore, the grinding component's path is actually a theoretical rail surface path, not a perfect match to the actual surface of the rail. Consequently, when the grinding component follows the theoretical path, it can lead to over-grinding of raised areas and under-grinding of recessed areas, resulting in inconsistent grinding depth and poor grinding uniformity.

[0025] To address this problem in the prior art, this invention does not strictly move the grinding component to the starting tool setting point before grinding. That is, this application does not strictly define the position of the grinding component in the height direction of the rail. Instead, the grinding component 5 is moved to an area that covers the starting tool setting position before grinding, i.e., a preset position (this preset position is not a fixed point), using the lateral movement component 4 and the deflection component 6. Because the grinding component 5 has a degree of freedom along the height direction of the rail, it can adaptively adjust its position in real time along the rail's height direction during grinding. For example, when there are local protrusions on the rail surface, the grinding component 5 can adaptively rise along the rail's height direction to avoid excessive grinding due to the height difference between the theoretical trajectory and the actual rail surface. When there are depressions, wear, or pits on the rail surface, the grinding component 5 can adaptively descend along the rail's height direction to ensure that the grinding component 5 can still effectively contact and grind the depressed area, avoiding incomplete grinding or under-grinding.

[0026] Therefore, the grinding component 5 in this invention can achieve real-time, dynamic, and adaptive height following adjustment, so that the grinding component 5 always maintains a stable contact with the actual surface of the rail throughout the entire grinding stroke, making the amount of material removed (grinding amount) on the rail surface tend to be consistent. Thus, it can eliminate the problems of local over-grinding and local under-grinding caused by unevenness of the rail surface and mismatch between theoretical trajectory and actual line, and can significantly improve the uniformity of rail surface grinding, ensure the consistency of grinding amount, and thus improve grinding accuracy and grinding quality.

[0027] like Figure 6 As shown, the grinding component 5 includes a grinding motor 502, a grinding head 501, and a grinding adjustment mechanism. The grinding motor 502 is connected to the grinding head 501 and is used to drive the grinding head 501 to rotate in order to grind the surface of the rail. The grinding adjustment mechanism is connected to the grinding motor 502 and is used to drive the grinding motor 502 and the grinding head 501 to move along the height direction of the rail.

[0028] The grinding head 501 can be, for example, a grinding wheel, and there can be multiple of them, for example, four. Figure 2 As shown, the four grinding wheels are arranged in pairs, with two grinding wheels on one side of each rail, allowing for simultaneous grinding of both sides of the rail. Understandably, the number of grinding heads 501 could be even greater.

[0029] The grinding motor 502 is designed to provide feedback on its phase current or output current, and the grinding adjustment mechanism is designed to adjust the grinding pressure of the grinding head according to the phase current or output current. In some implementations, the grinding adjustment mechanism is configured to be hydraulically controlled.

[0030] Specifically, the grinding adjustment mechanism includes a hydraulic mechanism 503, which includes a pressure valve and a grinding hydraulic cylinder connected to the grinding head 501. The grinding hydraulic cylinder can drive the grinding head 501 to move along the height direction of the rail. The hydraulic mechanism 503 may also include a hydraulic pump, which is connected to the grinding hydraulic cylinder to supply hydraulic oil. The pressure valve is a proportional pressure valve, which can adjust the working pressure of the hydraulic mechanism 503.

[0031] The hydraulic mechanism 503 may also include a directional valve, which is disposed in the hydraulic circuit between the hydraulic pump and the grinding hydraulic cylinder, and is used to control the direction of movement of the grinding hydraulic cylinder. When the directional valve is energized, hydraulic oil enters the rodless chamber of the grinding hydraulic cylinder, driving the hydraulic cylinder to extend and pressing down the grinding head 501; when the directional valve is de-energized, hydraulic oil enters the rod chamber of the grinding hydraulic cylinder, driving the hydraulic cylinder to retract and raising the grinding head 501.

[0032] The hydraulic mechanism 503 may also include a back pressure valve or a throttle valve, which is installed on the return oil line between the grinding hydraulic cylinder and the oil tank to generate back pressure and play a role in buffering, vibration reduction and shock prevention.

[0033] The working pressure is the active oil supply pressure input by the hydraulic pump to the rodless chamber of the grinding hydraulic cylinder, which drives the grinding head 501 to move along the height direction of the rail and apply grinding force. In addition, the reverse resistance pressure formed on the return oil path of the rod chamber of the grinding hydraulic cylinder is the back pressure, which is used for buffering, vibration reduction, and stabilizing the grinding head 501. The actual grinding pressure exerted by the grinding head 501 on the rail surface is the grinding pressure, which is determined by the difference between the working pressure and the back pressure.

[0034] The pressure valve can receive the phase current or output current fed back from the grinding motor 502 to adjust the working pressure of the grinding hydraulic cylinder. When the working pressure of the grinding hydraulic cylinder decreases, the grinding pressure of the grinding head 501 decreases; when the working pressure of the grinding hydraulic cylinder increases, the grinding pressure of the grinding head 501 increases.

[0035] The magnitude of the current (phase current or output current) of the grinding motor 502 reflects the grinding load of the grinding head 501. A high load and high current indicate excessive grinding pressure; conversely, a low load and low current indicate insufficient grinding pressure. This is because the heavier the grinding head 501 presses on the rail, the greater the grinding resistance. Increased grinding resistance leads to a larger load on the grinding motor 502, which in turn increases the current. Therefore, by real-time monitoring of the grinding motor 502's current and feeding it back to the controller, closed-loop regulation of the hydraulic mechanism 503's working pressure can be achieved, thereby controlling the grinding pressure.

[0036] When the pressure valve receives the phase current or output current fed back from the grinding motor 502 to adjust the working pressure of the grinding hydraulic cylinder, if the phase current or output current fed back from the grinding motor 502 is continuously greater than the target current within the first time T1 until the second time T2, the working pressure of the grinding hydraulic cylinder will decrease; if the phase current or output current fed back from the grinding motor 502 is continuously less than the target current within the first time T1 until the third time T3, the working pressure of the grinding hydraulic cylinder will increase; wherein, T1>T3≥T2.

[0037] Specifically, the grinding pressure of the grinding head 501 is adjusted according to the current of the grinding motor 502 as follows.

[0038] The grinding motor 502 drives the grinding head 501 to rotate (its speed can be, for example, 3600 rpm).

[0039] When hydraulic mechanism 503 is activated, the hydraulic pump supplies oil to the grinding hydraulic cylinder, the reversing valve is energized, and the hydraulic oil enters the rodless chamber of the grinding hydraulic cylinder, driving the hydraulic cylinder to extend and causing the grinding head 501 to press down.

[0040] The grinding head 501 contacts the rail and begins grinding the surface of the rail.

[0041] The sensor of the grinding motor 502 collects the current (phase current) of the grinding motor 502 in real time and feeds it back to the controller.

[0042] The controller compares the phase current I of the grinding motor 502 with the target current I0 and determines: Within the first time interval T1, the difference between the phase current I and the target current I0 is |I If I0| is greater than the allowable current error ΔI, and this state continues until the second time T2; if so, the controller sends an instruction to the hydraulic mechanism 503 to adjust the working pressure, and adjusts the working pressure according to the direction of the current deviation.

[0043] Specifically, for branches with excessively high current: If the phase current I is greater than the sum of the target current I0 and the allowable current error ΔI (i.e., I > I0 + ΔI), and the duration exceeds the set upper limit time (i.e., the second time T2), the controller sends a signal to the hydraulic mechanism 503 to reduce the working pressure. The proportional pressure valve of the hydraulic mechanism 503 receives the signal from the controller and correspondingly reduces its set pressure value, thereby reducing the hydraulic working pressure output by the proportional pressure valve. The pressurized oil enters the rodless chamber of the grinding hydraulic cylinder through the reversing valve in the energized working position. As the hydraulic working pressure in the rodless chamber decreases, the downward hydraulic pressure on the piston of the grinding hydraulic cylinder decreases, and the clamping force of the grinding head 501 on the rail decreases accordingly, thus reducing the grinding pressure of the grinding head 501. Consequently, the grinding load of the grinding motor 502 decreases, and its current falls back to the target range.

[0044] For branches with low current: If the phase current I is greater than the difference between the target current I0 and the allowable current error ΔI (i.e., I < I0 - ΔI), and the duration exceeds the set lower limit time (i.e., the third time T3), the controller sends a signal to the hydraulic mechanism 503 to increase the working pressure. The proportional pressure valve of the hydraulic mechanism 503 receives the signal from the controller and correspondingly increases its set pressure value, thereby increasing the hydraulic working pressure output by the proportional pressure valve. The pressurized oil after the pressure increase flows through the reversing valve and enters the rodless chamber of the grinding hydraulic cylinder when the reversing valve is in the energized working position. As the hydraulic working pressure in the rodless chamber increases, the downward hydraulic pressure on the piston of the grinding hydraulic cylinder increases, pushing the grinding head 501 downward to apply greater grinding pressure, thereby increasing the clamping force between the grinding head 501 and the rail, i.e., increasing the grinding pressure of the grinding head 501. Consequently, the grinding load of the grinding motor 502 increases, and its current rises to the target range.

[0045] During this period, the hydraulic oil on the rod chamber side of the grinding hydraulic cylinder can be connected to a constant back pressure through the back pressure valve in the return oil line to ensure that the grinding head 501 moves smoothly and without impact, thus maintaining the stability of the entire adjustment process.

[0046] For branches with normal current, i.e., the difference between phase current I and target current I0 is within the allowable current error ΔI range, or the error has not reached the set upper or lower limit time, the current working pressure and grinding pressure remain unchanged.

[0047] The target current I0 is related to parameters such as the standard grinding amount of the rail, the specifications of the grinding head 501, and the grinding travel speed. In one embodiment, the target current may be, for example, 5A.

[0048] In one implementation, the first time T1 can be, for example, 1s-10s.

[0049] The second time T2 and the third time T3 are the durations for determining the difference in duration, and both can be, for example, 0.5s.

[0050] In other embodiments, the grinding and adjustment mechanism is pneumatically controlled.

[0051] like Figure 7 As shown, the grinding adjustment mechanism includes a pneumatic mechanism 8, which comprises a pressure control unit, a microcomputer control unit 81 connected to the pressure control unit, and cylinders 82 connected to the grinding motor. The cylinders 82 are connected to the grinding motor 502 and are used to provide thrust / pressure to the grinding motor 502. The number of cylinders 82 is the same as the number of grinding motors 502, allowing each grinding motor 502 to be individually pressure-adjusted.

[0052] The pressure control unit is connected to each cylinder 82 via an air circuit. Each air circuit is equipped with a pressure detection element 83, which can feed back the actual pressure value to the microcomputer control unit 81. Based on the deviation between the received actual pressure value and the preset target pressure value, the microcomputer control unit 81 dynamically corrects the control signal output to the pressure control unit, thereby compensating for the pressure deviation of the cylinder 82. The preset target pressure value corresponds to a preset grinding pressure.

[0053] Specifically, the grinding motor 502 is mounted on the cylinder 82, which includes a first chamber 821 (rodless chamber / thrust chamber) and a second chamber 822 (rod chamber / back pressure chamber). When air enters the first chamber 821, the cylinder 82 extends, causing the grinding motor 502 and the grinding head 501 to press against the rail, thus generating thrust. When air enters the second chamber 822, it generates a reverse force (i.e., back pressure), which makes the pressure gentler and more stable.

[0054] The pressure control unit includes multiple proportional valves 84, each corresponding to an independent grinding motor. For example, there can be eight proportional valves, with four proportional valves corresponding to the first chamber 821 of the four cylinders and the other four proportional valves corresponding to the second chamber 822 of the four cylinders.

[0055] The pneumatic mechanism also includes an air compressor 85 and a filter 86. The air compressor 85 is connected to the filter 86; the air compressor 85 generates compressed air, and the filter 86 removes water, oil, impurities, etc., from the compressed air to ensure clean and stable compressed air supply. A pressure control unit is connected to the filter 86 and is used to precisely regulate the air pressure to achieve thrust variations.

[0056] The following explanation will be based on one of the cylinders 82 and the first proportional valve 841 and the second proportional valve 842 connected to it.

[0057] The pressure control unit internally distributes the compressed air from filter 86 before supplying it. The inlet of the first proportional valve 841 receives compressed air, and its outlet is connected to a first air pipe, which in turn connects to the first chamber 821 of cylinder 82. The first proportional valve 841 extends cylinder 82, thereby generating thrust. The inlet of the second proportional valve 842 receives compressed air, and its outlet is connected to a second air pipe, which in turn connects to the second chamber 822 of cylinder 82. The second proportional valve 842 can provide reverse air pressure, resulting in a gentler, more stable, and controllable pressure.

[0058] Each proportional valve is connected to a microcomputer control unit 81. During the grinding process, the microcomputer control unit adjusts the pressure of each proportional valve to control the power of the grinding motor (i.e., control the magnitude of the positive pressure). Since the grinding effect is related to the grinding pressure and the rotation speed of the grinding head, i.e., the amount of material removed (grinding power) is the product of the grinding pressure and the rotation speed, the microcomputer control unit 81 continuously adjusts the current of each proportional valve during the grinding process to achieve closed-loop regulation.

[0059] Specifically, the microcomputer control unit 81 calculates the target thrust in advance or in real time according to the grinding process (material, grinding amount, position, etc.), and the target thrust corresponds to the target pressure required by the first chamber 821 and the second chamber 822 of each cylinder 82.

[0060] The microcomputer control unit 81 outputs corresponding electrical signals to each proportional valve 84. Each proportional valve 84 continuously and linearly adjusts its output air pressure according to the magnitude of the electrical signal. A larger signal results in a higher output air pressure, and a smaller signal results in a lower output air pressure. For example, if the output air pressure of the proportional valve (first proportional valve 841) controlling the first chamber 821 increases, the thrust of the cylinder 82 increases; conversely, if the back pressure of the proportional valve (second proportional valve 842) controlling the second chamber 822 increases, it will offset part of the thrust, resulting in a smaller thrust. In other words, the air pressure in the first chamber 821 generates a forward thrust, and the air pressure in the second chamber 822 generates a reverse back pressure. The combined effect of these two forces forms the actual grinding pressure acting on the workpiece.

[0061] During the grinding process, the microcomputer control unit 81 also acquires the actual pressure value through the pressure detection element 83. For example, the pressure detection element 83 can be a pressure sensor integrated into each proportional valve 84, acquiring the actual pressure value and feeding back the current output air pressure to the microcomputer control unit 81 in real time. Alternatively, the pressure detection element 83 can be a pressure sensor installed in the corresponding chamber or air passage of the cylinder 82, directly collecting the actual pressure of each chamber of the cylinder and feeding back the current output air pressure to the microcomputer control unit 81 in real time. Alternatively, the grinding pressure can be indirectly estimated through the load, grinding amount, and position feedback of the grinding motor 502, and the estimated value can be fed back to the microcomputer control unit 81.

[0062] The microcomputer control unit 81 compares the target pressure with the received actual pressure and adjusts the output according to the deviation between the two. When the actual pressure is less than the target pressure, i.e., the deviation is positive, the microcomputer control unit 81 increases the electrical signal of the proportional valve 84 to increase the air pressure, thereby increasing the grinding pressure; when the actual pressure is greater than the target pressure, i.e., the deviation is negative, the microcomputer control unit 81 decreases the electrical signal of the proportional valve 84 to decrease the air pressure, thereby decreasing the grinding pressure; when the actual pressure is equal to the target pressure, i.e., the deviation is 0, the microcomputer control unit 81 maintains the current output of the proportional valve 84 unchanged.

[0063] The above process cycles continuously at a high frequency (e.g., milliseconds), ensuring uninterrupted and continuous correction throughout the grinding process, achieving real-time closed-loop pressure control. Through real-time closed-loop adjustment, the following can be achieved: First, automatically maintaining a constant set thrust during grinding, unaffected by air source fluctuations, load changes, or surface undulations; second, dynamically adjusting the pressure in real time according to the grinding conditions, with higher pressure during rough grinding and lower pressure during fine grinding; third, achieving high-precision, fast-response, and shock-free continuous adjustment of grinding pressure; and fourth, ensuring uniform removal of grinding material, improving grinding quality and consistency.

[0064] The function of the lateral movement component 4 is to drive the deflection component 6 and the grinding component 5 to move in the Y direction, thereby adjusting the position of the grinding component 5 before grinding to ensure a sufficient grinding angle. Figure 4 As shown, the traverse component 4 includes a lead screw 402, a drive shaft 404, and a traverse drive motor 401. The lead screw 402 extends along the width direction (Y-axis direction) of the rail, and a first mounting base 403 is movably mounted on the lead screw 402. Therefore, when the lead screw 402 rotates, the first mounting base 403 can move on the lead screw 402. The deflection component 6 is connected to the first mounting base 403. Therefore, when the first mounting base 403 moves on the lead screw 402, it can drive the deflection component 6 to move on the lead screw 402, thereby adjusting the position of the deflection component 6 and the grinding component 5 in the Y-axis direction.

[0065] like Figure 4 As shown, the drive shaft 404 extends along the length of the rail (X-axis direction) and can synchronize the movements of the two lead screws 402. The drive shaft 404 and the lead screws 402 are perpendicular to each other, therefore they can be connected by a gear mechanism or a worm gear mechanism to achieve the transmission of power in a different direction. The transverse drive motor 401 is connected to the drive shaft 404 and is used to drive the drive shaft 404 to rotate. There can be multiple lead screws 402, and the number of lead screws 402 can be the same as the number of grinding heads 501, so that the position of each grinding head 501 can be controlled individually. For example, there can be four lead screws 402, with two lead screws 402 having collinear axes and the other two having collinear axes. The parallel lead screws 402 are respectively arranged near two adjacent rails. Correspondingly, there are two drive shafts 404, which are respectively connected to the ends of the two parallel lead screws 402 through a gear mechanism or a worm gear mechanism.

[0066] The lateral movement component 4 also includes a guide rail 405, which is arranged correspondingly to the lead screw 402. For example, it may be located below the lead screw 402 and connected to the first mounting base 403, thereby guiding the movement of the first mounting base 403.

[0067] Specifically, such as Figure 5 As shown, the first mounting base 403 includes a lead screw connector 4031, a support plate 4032, a guide groove 4033, and a connecting plate 4034.

[0068] The lead screw connector 4031 can be a plate-like structure perpendicular to the extension direction of the lead screw 402, and has an internal threaded hole. The lead screw connector 4031 passes through the internal threaded hole onto the lead screw 402 and is threadedly connected to the lead screw 402. Therefore, when the lead screw 402 is driven to rotate by the drive shaft 404, the lead screw connector 4031 can move on it.

[0069] The bottom of the lead screw connector 4031 is connected to the support plate 4032. The support plate 4032 is a plate-shaped structure parallel to the extension direction of the lead screw 402, and it serves to connect the lead screw connector 4031, the guide groove 4033, and the connecting plate 4034. Figure 5 As shown, a guide groove 4033 is provided below the support plate 4032, which cooperates with the guide rail 405 to constrain and limit the movement path of the lead screw connector 4031, so that it moves along the extension direction of the lead screw 402.

[0070] The guide groove 4033 can be provided with grooves and protrusions on its two opposite inner walls, so that it can cooperate with the corresponding bosses on the side wall of the guide rail 405 to ensure a stable fit between the guide groove 4033 and the guide rail 405 and prevent them from separating.

[0071] A connecting plate 4034 is provided on one side of the support plate 4032, such as... Figure 5 As shown, the lead screw connector 4031, the support plate 4032, and the connecting plate 4034 are orthogonal to each other. That is, the lead screw connector 4031 is a vertically extending plate-shaped member, the support plate 4032 is a horizontally extending plate-shaped member, and the connecting plate 4034 is a longitudinally extending plate-shaped member.

[0072] The connecting plate 4034 is configured to connect with the deflection component 6, so that when the lead screw connector 4031 moves, it can drive the connecting plate 4034, the deflection component 6, and the grinding component 5 on the deflection component 6 to move together. At the same time, the guide groove 4033 on the support plate 4032, through its cooperation with the guide rail 405, ensures that the grinding component 5 does not deviate from the extension direction of the lead screw 402.

[0073] The reason why the connecting plate 4034 is set as a longitudinally extending plate-shaped member is that, as the connecting member between the deflecting component 6 and the lead screw connector 4031, it needs to ensure that the deflecting component 6 moves together with the lead screw connector 4031 when it moves; at the same time, since the deflecting component 6 also needs to rotate, it is necessary to ensure that the rotational movement of the deflecting component 6 does not interfere with its movement. Therefore, the connecting plate 4034 is set as a longitudinally extending plate-shaped member, with its upper end connected to one end of the support plate 4032 and its lower end connected to the deflecting component 6.

[0074] The deflection component 6 is used to drive the grinding component 5 to rotate around the X-axis to provide freedom of angle direction. The deflection component 6 works in conjunction with the transverse component 4 to achieve different changes in the grinding angle.

[0075] like Figure 6 As shown, the deflection component 6 includes a slewing bearing, a deflection frame 603, a second mounting base, and a deflection drive motor 602. Both ends of the deflection frame 603 are rotatably connected to the slewing bearing. The second mounting base is fixed to the deflection frame 603, and the grinding component 5 is connected to the second mounting base.

[0076] The deflection drive motor 602 is connected to the deflection frame 603 and is used to drive the deflection frame 603 to rotate about the length of the rail as the rotation axis.

[0077] Specifically, please combine Figure 5 The slewing bearing includes a first slewing bearing 601 and a second slewing bearing 604. The first slewing bearing 601 and the second slewing bearing 604 can be, for example, bearing mechanisms. They are located at both ends of the deflection frame 603 and are connected to the first mounting seat 403 on the corresponding lead screw 402.

[0078] like Figure 5 As shown, the first slewing bearing 601 is connected to the lower end of the corresponding connecting plate 4034. Specifically, the outer ring of the first slewing bearing 601 is fixedly connected to the lower end of the corresponding connecting plate 4034, and the inner ring of the first slewing bearing 601 is connected to one end of the deflection frame 603. The inner ring of the first slewing bearing 601 can rotate relative to its outer ring. Similarly, the outer ring of the second slewing bearing 604 is fixedly connected to the lower end of the corresponding connecting plate 4034, and the inner ring of the second slewing bearing 604 is connected to the other end of the deflection frame 603. Therefore, the deflection drive motor 602 can drive the deflection frame 603 to rotate relative to the connecting plate 4034.

[0079] By providing a first slewing support 601 and a second slewing support 604 at both ends of the deflection frame 603, the deflection frame 603 can form a rotation axis structure, thereby enabling rotation relative to the transverse moving component 4 about the length direction of the rail as the rotation axis. Figure 4 As shown, the rail grinding method of the present invention also includes a traveling component 3, which is constructed as a grinding vehicle structure. The traveling component 3 includes a chassis frame 301, a plurality of traveling wheels 302 located at the bottom of the chassis frame 301, and a traction seat 303 and / or a lifting component 1 disposed on the chassis frame 301. The number of traveling wheels 302 can be multiple, for example, four or more. The traveling wheels 302 can be installed on four mounting seats on the chassis frame 301 according to the standard track gauge of 1435mm, or the installation dimensions can be redesigned according to track gauge requirements. The traveling wheels 302 provide support and guidance for the movement of the grinding vehicle.

[0080] Optionally, when the traction device is a non-powered traction device, it is connected to the traction seat 303. For example... Figure 2 As shown, the traction seat 303 can be installed at the front end of the chassis frame 301.

[0081] Optionally, when the traction device is a powered traction device, it is connected to the lifting component 1. As described above, the powered traction device includes an excavator that provides power and electricity to the grinding device.

[0082] Optionally, when the traction device is a powered traction device, it is mounted on the chassis frame 301, that is, the traction device is integrated into the grinding device. The traction device can be a hydraulic motor or a hub motor or other types of power mechanism, thereby enabling the grinding device to move on its own.

[0083] like Figure 2 As shown, the rail grinding method of the present invention also includes a power supply module 2 and an electronic control module 7, wherein the power supply module 2 and the electronic control module 7 are both mounted on the chassis frame 301, or the power supply module 2 and the electronic control module 7 are both integrated into the powered traction device.

[0084] The power supply module 2 includes a generator set module or a battery pack module. The power supply module 2 is electrically connected to the lateral movement component 4, the deflection component 6, and the grinding component 5 to supply power to them. The hydraulic power source of the generator set module can be derived from the excavator, and the generator set is driven by a hydraulic motor to generate electricity, completing the hydraulic-to-electricity conversion process.

[0085] The receiver of the electronic control module 7 transmits data to the powered traction device via wired or wireless means. The electronic control module 7 is electrically connected to the lateral movement component 4, the deflection component 6, and the grinding component 5 respectively. The electronic control module 7 receives the signals fed back by the lateral movement component 4, the deflection component 6, and the grinding component 5, and sends the corresponding operation signals to them.

[0086] An operation panel can be installed on the excavator, through which users can input commands to control the rail grinding method to complete the grinding operation.

[0087] The purpose of grinding is to eliminate rail defects, and a grinding strategy can be specified according to actual needs. For example... Figure 1 As shown, the rail grinding method of the present invention includes the step of formulating a grinding strategy, which includes the following steps.

[0088] Step 10: Determine the amount of polishing.

[0089] The actual profile data of the rail is collected in real time by a laser profile sensor. This data is then compared with the ideal profile data to determine the total grinding amount and grinding accuracy requirements. The power supply mode is determined based on the working scenario (without external power supply or with external power supply), laying the foundation for subsequent operations.

[0090] Step 20: Develop a strategy and set polishing parameters, including the following steps: Step 21: Determine the amount of material to be ground in a single pass.

[0091] Optionally, the power of the grinding motor 502 can be adjusted to determine the amount of material removed in a single pass, ensuring a smooth and uniform grinding process. For example, in a low-power mode (e.g., 3 kW - 5 kW), the amount of material removed in a single pass is controlled at 0.1 mm - 0.2 mm / pass, with a total amount of material removed at 0.3 mm - 0.5 mm, requiring 3-5 passes. In a medium-power mode (e.g., 6 kW - 8 kW), the amount of material removed in a single pass is controlled at 0.2 mm - 0.3 mm / pass, with a total amount of material removed at 0.6 mm - 1.0 mm, requiring 3-5 passes. Alternatively, in a high-power mode (e.g., 9 kW - 12 kW), the amount of material removed in a single pass is increased to 0.3 mm - 0.5 mm / pass, with a total amount of material removed at 1.1 mm - 2.0 mm, requiring 4-7 passes, to avoid excessive grinding in a single pass that could damage the rail substrate.

[0092] Optionally, a material removal rate model is established based on the coupling relationship between the linear speed of the grinding head 501, the grinding pressure and the material removal rate. By adjusting the output torque and speed ratio of the grinding motor, the material removal capacity per unit stroke is formed, and thus the grinding amount per stroke is determined.

[0093] Specifically, determining the amount of material to be ground in a single pass includes the following steps.

[0094] Step S221: Collect core data under different working conditions, determine the linear velocity v of the grinding head 501, the grinding pressure F of the grinding head 501, and the material removal rate model related to the material removal rate Q, where the material removal rate Q is the volume of rail material removed per second.

[0095] For example, Experiment 1: Keep F constant, change v, and record the Q corresponding to different v values ​​to obtain the vQ correlation curve; Experiment 2: Keep v constant, change F, and record the Q corresponding to different F values ​​to obtain the FQ correlation curve. Based on these two types of curves, a coupling relationship can be fitted to obtain: Q=k v α F β .

[0096] Where k is the coupling coefficient, which can be determined experimentally, for example.

[0097] α and β are the working condition fitting indices, respectively. α is the linear velocity sensitivity index, which characterizes the influence of the change in the linear velocity of the grinding head 501 on the material removal rate; β is the grinding pressure sensitivity index, which characterizes the influence of the change in grinding pressure on the material removal rate.

[0098] During the specific calibration, a fixed-variable grouped experiment was first conducted. Two independent control experiments were set up: a speed test group and a pressure test group. In the speed test group, the grinding pressure F was kept constant, and the linear speed v of the grinding head 501 was gradually adjusted. The material removal rate Q of each group was collected. In the pressure test group, the linear speed v of the grinding head 501 was kept constant, and the grinding pressure F was gradually adjusted. The material removal rate Q of each group was collected.

[0099] Secondly, the exponent is solved by log-linear fitting.

[0100] For Q=k v α F β When performing linearization fitting, taking the natural logarithm of both sides of the formula transforms the nonlinear power function model into a linear fitting model, facilitating the calculation of the fitting coefficients using experimental data. Taking the logarithm of both sides of the formula yields: lnQ = lnk + αlnv + βlnF, where lnQ, lnv, and lnF are known data variables that can be collected in the experiment, lnk is a constant term, and α and β are the linear regression coefficients to be determined. By obtaining massive amounts of working condition data through multiple sets of single-variable comparative experiments, and combining this with the least squares method to perform linear regression fitting, the fixed indices α and β suitable for the grinding conditions of the grinding device of this invention can be solved, making the material removal rate calculation results more consistent with actual grinding characteristics.

[0101] In addition, for different working conditions (such as fine grinding, conventional grinding, and heavy delamination), corresponding indices can be fitted to obtain α and β values ​​under different grinding modes, thereby improving the model adaptation accuracy.

[0102] Step S222: Determine the depth of grinding per pass based on the material removal rate model.

[0103] For example, by adjusting the output torque M and rotational speed n of the grinding motor 502, the linear speed v and grinding pressure F of the grinding head 501 can be indirectly controlled, thereby controlling the material removal rate Q and ultimately determining the single grinding depth, as detailed below: The relationship between the output torque M of the grinding motor 502 and the linear velocity v of the grinding head 501 is as follows: v =π×D×n×i; Where D is the diameter of the grinding head 501, n is the rotational speed of the grinding motor 502, and i is the reduction ratio.

[0104] The linear velocity v of the grinding head 501 can be controlled by adjusting the rotational speed n of the grinding motor 502.

[0105] The relationship between grinding pressure F and the output power of grinding motor 502: The output power of grinding motor 502 is P = M×n, while the magnitude of grinding pressure F is controlled by grinding adjustment mechanism. Through feedback adjustment, the grinding pressure F is matched with v and Q.

[0106] Therefore, the higher the rotational speed n of the grinding motor 502, the faster the grinding head 501 rotates, i.e., the greater the grinding linear speed v. The corresponding working condition is a high-speed working condition, which is suitable for rapid cutting and large-area light grinding. Conversely, the lower the rotational speed n of the grinding motor 502, the slower the grinding head 501 rotates, i.e., the smaller the grinding linear speed v. The corresponding working condition is a low-speed working condition, which is suitable for high torque output and the removal of fatigue layers and deep grinding.

[0107] The grinding adjustment mechanism, such as a hydraulic mechanism or a drive mechanism, can adjust the grinding pressure F. The larger F is, the greater the resistance of the rail to the grinding head 501, the greater the load on the grinding motor 502, and thus the greater the torque M required. Therefore, the output torque M of the grinding motor 502 can determine the maximum grinding pressure F that the grinding head 501 can stably withstand at the current speed n.

[0108] Therefore, this invention allows for the adjustment of the rotational speed n and output torque M of the grinding motor 502 by controlling its output power P. Adjusting the rotational speed n of the grinding motor 502 changes the grinding linear speed v of the grinding head 501, while adjusting the output torque M enhances the load-bearing capacity of the grinding head 501 to match the grinding pressure F required for different grinding conditions. Furthermore, the grinding adjustment mechanism adaptively matches the rotational speed n and output torque of the grinding motor 502. Specifically, when the grinding motor 502 operates at high speed and low output torque, the grinding adjustment mechanism reduces the grinding pressure F; when the grinding motor 502 operates at low speed and high output torque, the grinding adjustment mechanism increases the grinding pressure F, thus achieving dynamic adaptive coupling between the motor's power characteristics and the hydraulic grinding pressure.

[0109] Based on the coupling relationship in step S221, the single grinding depth h = Q / (v×B), where B is the contact width of the grinding head 501. Since the grinding head 501 is a circular grinding wheel pressed against the surface of the curved rail, not the entire diameter of the grinding wheel participates in the grinding; only the contact area that is in contact with the rail surface will have material removed. The effective coverage width of this contact area in the transverse direction of the rail is the contact width B.

[0110] The grinding pressure F can be adjusted according to the hydraulic and pneumatic methods described above.

[0111] The depth of grinding per pass is determined based on the required material removal rate Q, and the specific correspondence is as follows: With a low Q value and small v and F values, the model calculates a single grinding depth h1 = 0.05 mm - 0.1 mm, ensuring fine grinding and avoiding over-cutting.

[0112] With a moderate Q value and appropriately increased v and F, the model calculation yields a single grinding depth h2 = 0.1 mm - 0.2 mm, balancing efficiency and accuracy. A high Q value increases the ratio of v to F. The model calculates a single grinding depth h3 = 0.2 mm - 0.3 mm, which quickly removes the damaged layer. At the same time, the model adjusts the grinding depth through feedback to avoid over-grinding.

[0113] Step 23: Calculate the number of polishing passes.

[0114] Based on the total grinding amount and the single grinding amount, the required number of grinding passes is calculated according to the following formula, and the focus of each grinding pass is clarified.

[0115] Number of grinding passes = Total grinding depth ÷ Grinding depth per pass.

[0116] For example, if the total grinding amount is 0.3 mm-0.5 mm and the single grinding amount is 0.1-0.2 mm, it needs to be ground 3-5 times, with a focus on fine grinding to ensure a smooth rail surface.

[0117] The total grinding amount is 0.6 mm-1.0 mm, and the single grinding amount is 0.2 mm-0.3 mm. It requires 3-5 grinding passes to balance efficiency and precision and avoid unevenness on the rail surface.

[0118] The total grinding amount is 1.1 mm-2.0 mm, and the single grinding amount is 0.3 mm-0.5 mm. It requires 4-7 grinding passes. The initial focus is on removing the damaged layer, and the later focus is on fine grinding to ensure the smoothness of the rail surface.

[0119] Step 24: Configure associated execution parameters.

[0120] By combining different power and grinding amounts, the grinding pressure and other parameters of the grinding adjustment mechanism are set synchronously.

[0121] For example, slow speed and low pressure grinding are used to ensure grinding accuracy; increasing the lateral speed and grinding pressure, combined with high power mode, improves grinding efficiency, while controlling the grinding temperature to avoid metallographic changes in the rail due to overheating, ensuring that the ground rail surface meets industry standards.

[0122] Step 30: Perform the polishing operation.

[0123] Start the power supply module 2 (generator set or battery pack) to provide stable power to the electrical loads such as the controller, lateral movement component 4, deflection component 6 and grinding component 5, and ensure the normal operation of each electrical component.

[0124] The control transverse component 4 drives the grinding head 501 to move to the target grinding area, and the control deflection drive motor 602 adjusts the rotation angle of the grinding head 501 so that the grinding head 501 is perpendicular to the normal of the target grinding point on the rail, and the grinding operation is started to complete the grinding according to the preset number of passes.

[0125] During the operation, the grinding progress and the condition of the rail surface are monitored in real time, and the motor power and grinding speed are dynamically adjusted to ensure uniform grinding and avoid over-grinding or under-grinding.

[0126] Step 40: Quality inspection and equipment reset.

[0127] After grinding, the flatness and profile accuracy of the rail surface are checked to confirm that the defects have been completely removed and the preset quality standards have been met.

[0128] Turn off the grinding motor 502 and the power supply system, reset the grinding device, clean up debris in the work area, and perform equipment maintenance and data recording to facilitate subsequent review and start-up of the next operation.

[0129] For example, when the grinding motor power is set to 3.5kW, the grinding amount per pass is consistently 0.1mm, which is suitable for small grinding scenarios such as fine grinding. If the total grinding amount per operation for a certain section of rail is determined to be 0.6mm after testing, the grinding device needs to grind back and forth 6 times along the length of the rail to gradually and evenly remove the defective layer and avoid excessive grinding amount per operation, which could lead to overheating of the rail head, changes in metallographic structure, or rough grinding surface.

[0130] When the total grinding volume requirement is high and there are clear requirements for work efficiency, the grinding motor power can be increased to 7kW. At this time, the single grinding volume of the grinding head can be increased to 0.15mm / pass. Taking a total grinding volume of 0.5mm as an example, the number of grinding passes can be reduced from 5 to 4 by using the high power mode. While ensuring that the grinding and repair quality meets the standards, the number of reciprocating operations is significantly reduced, and the efficiency of rail grinding construction is improved. It is especially suitable for large-scale grinding construction scenarios with tight track maintenance windows and long work sections.

[0131] Optionally or additionally, the rail grinding method of the present invention includes a step of adjusting the pressing sequence of the grinding head, which includes the following steps.

[0132] Step 1: Set the direction of travel and mark the position of the grinding head.

[0133] The overall forward direction of the device is determined by the location of the electronic control module 7 (i.e., Figure 2 (As shown in the positive X-axis direction), the positions of the two sets of grinding heads 501 on the left and right sides of the Y-axis direction are respectively marked. The grinding head 501 closer to the electronic control module 7 is marked as the first grinding head A, and the other grinding head farther away from the electronic control module 7 and located on the same side of the first grinding head A in the X-axis direction is marked as the second grinding head B (e.g., ...). Figure 2 As shown, the grinding head on the left is the first grinding head A, and the grinding head on the right is the second grinding head B), establishing the correspondence between the position marker and the controlled object.

[0134] Step 2: Configure the walking speed threshold Vset.

[0135] The preset start-up speed threshold is Vset, which serves as the trigger condition for the grinding head 501 to perform a downward pressing action. The grinding head can only enter the downward pressing operation when the real-time running speed of the traveling component 3 reaches this threshold. The speed threshold Vset can be, for example, 3 km / h, and can also be manually modified by the operator to other speed values ​​according to the working conditions, so as to adapt the downward pressing trigger condition to different grinding conditions.

[0136] Step 3: Collect the real-time speed parameter Vreal of the traveling component 3.

[0137] A speed detection unit (e.g., a speed encoder) is installed at the shaft end of the traveling wheel 302. The speed detection unit detects the rotational displacement signal of the traveling wheel 302 in real time and outputs a corresponding pulse signal to the electronic control module 7 to form traveling speed feedback data, thereby providing a speed determination basis for the downward control.

[0138] The speed detection unit collects the running speed parameter Vreal of the traveling component 3 in real time and continuously transmits the collected speed parameter to the electronic control module 7 to complete the real-time feedback of the speed signal.

[0139] Step 3: Compare the real-time speed with the set threshold.

[0140] The electronic control module 7 receives the real-time speed parameter Vreal and compares it with the preset speed threshold parameter Vset to determine whether the traveling component 3 meets the speed condition for the grinding head 501 to press down.

[0141] When the travel speed parameter Vreal reaches the speed threshold parameter Vset, the electronic control module 7 outputs a downward control signal to drive the first grinding head A to perform a downward action, causing the first grinding head A to contact the rail surface and enter the grinding state. Simultaneously with the initiation of the downward action of the first grinding head A, the internal delay unit of the electronic control module 7 starts timing and sets the delay duration parameter Tdelay (this delay parameter is set to an extremely short time interval) to ensure that the downward timing of the two sets of grinding heads is compact and the areas overlap.

[0142] When the delay time reaches the preset delay duration parameter Tdelay, the electronic control module immediately outputs a downward control signal to drive the second grinding head B to perform a downward action, so that the second grinding head B contacts the surface of the rail and enters the grinding state simultaneously.

[0143] After both sets of grinding heads have finished pressing down, the position detection unit verifies the working coverage area of ​​the two sets of grinding heads to confirm that the grinding areas of the first grinding head A and the second grinding head B completely overlap, thus avoiding the phenomenon of alternating grinding and ungrinding areas on the rail.

[0144] In the dual-grinding head staggered pressing operation mode, there is a time difference between the first grinding head A and the second grinding head B pressing down sequentially. At the same time, the grinding device is in a continuous traveling and feeding state. If no area verification is performed, the grinding start position and end position of the front and rear grinding heads are prone to longitudinal offset, which will cause the front and rear grinding trajectories to be misaligned and discontinuous.

[0145] Therefore, after both sets of grinding heads are fully pressed down and enter a stable grinding state, the present invention uses a position detection unit to collect the lateral position coordinates and longitudinal working area of ​​the two sets of grinding heads in real time, and compares and verifies the grinding coverage area of ​​the first grinding head A with the grinding coverage area of ​​the second grinding head B to ensure that the two sets of grinding heads completely overlap in the longitudinal grinding path of the rail and that the grinding coverage area is completely consistent.

[0146] By using the regional overlap verification method, the grinding trajectory deviation caused by time-series pressure and equipment movement displacement is completely eliminated, and defects such as grinding stripes, joint steps, and alternating distribution of ground and unground areas on the rail surface are prevented. This ensures that the longitudinal grinding texture of the entire rail section is uniform and the grinding amount is consistent, greatly improving the continuity and smoothness of the overall rail profile repair.

[0147] It should be noted that the transverse movement component 4 of the present invention remains locked and fixed during the grinding operation of a single grinding stroke, without dynamic lateral position adjustment. This ensures a stable grinding trajectory and uniform grinding texture on the rail surface, avoiding secondary grinding defects caused by lateral movement vibration during operation. Therefore, before both sets of grinding heads are fully pressed into place and initially contact the rail surface, and before formally entering continuous grinding operation, the present invention includes an operation step of automatic verification and pre-correction of the working area.

[0148] Specifically, the position detection unit includes a laser position sensor and a travel displacement encoder. The laser position sensor is respectively mounted on the side of the first grinding head A and the second grinding head B, and is used to collect the lateral alignment position and actual grinding coverage width of the two grinding heads in real time. The travel displacement encoder is installed on the travel wheel axle of the traveling component, and is used to collect the travel displacement of the grinding device in real time, determine the working range of the two grinding heads, and thus obtain the actual grinding coverage area of ​​the two grinding heads.

[0149] The controller compares the working coverage areas of the two sets of grinding heads in real time to complete the overlap verification. If the verification result shows that the grinding areas of the two sets of grinding heads are completely overlapped, with no offset, no gaps, and no insufficient overlap, then it enters a stable continuous grinding operation state. If deviations such as area offset, insufficient overlap, or local grinding gaps are detected, the controller executes a timing delay correction and operation parameter adaptation correction strategy. That is, by fine-tuning the downward pressure delay time of the second grinding head B, it compensates for the longitudinal position deviation caused by the equipment movement to match the grinding trajectory of the first grinding head A. At the same time, combined with the current rail surface grinding requirements, it fine-tunes the grinding pressure and grinding speed of the two sets of grinding heads to expand the effective grinding coverage width of a single set of grinding heads, make up for the defects of insufficient area overlap, and make the actual grinding working areas of the two sets of grinding heads completely matched and unified.

[0150] After the timing and grinding parameters have been fine-tuned and the working areas of the two grinding heads have been re-verified to be completely overlapping, continuous grinding operations are carried out. This pre-closed-loop detection and parameter adaptive correction mechanism eliminates the trajectory offset and regional misalignment problems caused by the timing grinding method of the dual grinding heads 501 without changing the lateral position of the grinding process, thereby improving the accuracy of rail profile repair and grinding smoothness.

[0151] The downward pressing action of the grinding head is driven by the grinding adjustment mechanism. The grinding adjustment mechanism uses hydraulic or pneumatic drive to achieve vertical lifting and feeding.

[0152] During actual operation, the electronic control module 7 determines the operation triggering conditions according to the preset travel speed threshold. After the travel speed reaches the standard, it outputs a downward control command to the grinding adjustment mechanism. The hydraulic push rod or pneumatic telescopic component of the adjustment mechanism extends and directly pushes the grinding head 501 to move downward as a whole, so that the grinding head 501 smoothly fits the rail surface and establishes a stable grinding pressure.

[0153] The pressing process of grinding head 501 adopts a flexible feed control method to avoid damage to the rail surface caused by rigid impact. It sequentially completes the step-by-step pressing action of the two sets of grinding heads. After pressing into place, the stroke is locked by the position detection unit to ensure that the working height of the grinding head is constant, which provides a foundation for subsequent stable and uniform layer grinding operations.

[0154] The specific steps involved in controlling the grinding head 501 to press down and contact the rail and enter the grinding state are as follows: The driving grinding adjustment mechanism causes the grinding head 501 to feed towards the rail surface in the vertical direction (Z-axis direction); During the pressing process, the distance signal or contact force signal between the grinding head 501 and the rail is collected in real time; When the distance between the grinding head and the rail surface is detected to reach a preset proximity threshold, the downward pressing speed is reduced to the first speed; When the contact force between the grinding head and the rail surface is detected to reach the first contact threshold, the downward feed is stopped and the current vertical position is maintained. The current grinding pressure is gradually increased from the initial holding pressure to the target grinding pressure, while monitoring the rate of change of contact force. If the rate of change exceeds the preset slope upper limit, the pressure increase is paused until it stabilizes, so that the grinding head smoothly enters the steady-state grinding state.

[0155] Furthermore, the contact force signal is collected in real time by a force sensor installed between the grinding adjustment mechanism and the grinding head during the pressing process; a distance signal is obtained by a laser displacement sensor or ultrasonic sensor installed on the side of the grinding head; when there is a logical conflict between the distance signal and the contact force signal, the contact force signal is used to determine the contact state. That is, if the contact force has reached the first contact threshold during the pressing process but the actual pressing displacement of the grinding head is less than the preset minimum contact displacement, it is determined that there is a foreign object or local protrusion on the rail surface, the pressing is suspended and an alarm signal is issued; if the displacement continues to increase during the pressing process but the contact force never reaches the first contact threshold and the pressing distance exceeds the preset maximum safe displacement, it is determined that there is an abnormality in the grinding head or the rail, an emergency lifting is performed and a fault prompt is issued.

[0156] Step 4: Maintain the downward pressure and perform continuous polishing.

[0157] Maintaining the downward pressure and grinding pressure of the two sets of grinding heads, and coordinating with the continuous movement of the traveling component 3, continuous rail grinding operations are performed until the end of a single grinding cycle or a stop operation command is received.

[0158] Step 5: Stop grinding and raise the grinding head.

[0159] After a single grinding operation is completed, the electronic control module 7 outputs lifting signals in sequence, first controlling the second grinding head B to lift and reset, and then controlling the first grinding head A to lift and reset, thus completing a single downward grinding operation.

[0160] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for grinding steel rails, characterized in that, Includes the following steps: The total grinding amount is determined based on the actual profile data of the rail; The amount of grinding per pass and the number of grinding passes are determined based on the total amount of grinding. Based on the amount of grinding per pass and the number of grinding passes, determine the operating parameters of the grinding motor in the grinding device, and determine the grinding pressure and grinding speed of the grinding components in the grinding device. The contact sequence between multiple grinding components and the rail surface is controlled according to the traveling speed of the grinding device. The grinding components grind the rail surface according to the determined single grinding amount, number of grinding passes, grinding pressure and grinding speed.

2. The rail grinding method according to claim 1, characterized in that, Determining the single grinding amount based on the total grinding amount includes the following sub-steps: Establish a material removal rate model that relates the material removal rate Q to the linear velocity of the grinding head and the grinding pressure in the grinding component; The linear velocity of the grinding head, v = π × D × n × i, is obtained from the operating parameters of the grinding motor in the grinding component, where D is the diameter of the grinding head, n is the rated output speed of the grinding motor, and i is the transmission reduction ratio of the transmission structure matched with the grinding motor. The grinding depth is determined based on the material removal rate model, where the single grinding depth h = Q / (v×B), and B is the contact width between the grinding head and the rail surface.

3. The rail grinding method according to claim 2, characterized in that, The material removal rate model Q satisfies: Q=k v α F β ; Based on the influence of the linear velocity and grinding pressure of the grinding head on the material removal rate in the grinding component, the correlation curves between linear velocity and material removal rate and between grinding pressure and material removal rate are obtained by fixing the grinding pressure and linear velocity respectively, and a material removal rate model is obtained, where k is the coupling coefficient, and α and β are the working condition fitting exponents respectively.

4. The rail grinding method according to claim 3, characterized in that, By adjusting the output power of the grinding motor to change the ratio of the grinding motor's speed to its output torque, the actual running linear speed and grinding pressure of the grinding head can be controlled. Specifically, when the grinding motor uses high speed and low output torque, the grinding adjustment mechanism reduces the grinding pressure; when the grinding motor uses low speed and high output torque, the grinding adjustment mechanism increases the grinding pressure.

5. The rail grinding method according to any one of claims 1-4, characterized in that, The sequence of contact between multiple grinding components and the rail surface is controlled according to the traveling speed of the grinding device, including the following sub-steps: Using the direction of travel of the grinding device as a reference, the positions of the first grinding head A and the second grinding head B on the left and right sides are calibrated. A preset travel speed threshold Vset is used as the grinding head pressing trigger condition. The grinding head pressing operation is only initiated when the actual travel speed of the grinding device reaches Vset. When starting the grinding head pressing operation, first control the first grinding head A to press down to contact the rail and enter the grinding state, and at the same time start the delay timer. After the delay ends, control the second grinding head B to press down to contact the rail and enter the grinding state.

6. The rail grinding method according to claim 5, characterized in that, After both the first grinding head A and the second grinding head B have finished pressing down, the detection unit of the grinding device verifies the working coverage area of ​​the two sets of grinding heads to determine whether the grinding areas of the first grinding head A and the second grinding head B completely overlap.

7. The rail grinding method according to claim 6, characterized in that, When the grinding component grinds the rail surface according to the determined single grinding amount, number of grinding passes, grinding pressure and grinding speed, it maintains the downward pressing state and grinding pressure of the two sets of grinding heads to perform continuous rail grinding operations until the single grinding stroke is completed. After the single grinding operation is completed, the second grinding head B is first controlled to rise and reset, and then the first grinding head A is controlled to rise and reset to complete the single pressing grinding operation.

8. The rail grinding method according to claim 6, characterized in that, When the grinding head is pressed down, the grinding head is pushed downward by the extension of the hydraulic push rod or pneumatic telescopic component, so that the grinding head fits against the rail surface.

9. The rail grinding method according to claim 6, characterized in that, When the grinding head is pressed down, if the contact force between the grinding head and the rail surface reaches the first contact threshold and the actual pressing displacement of the grinding head is less than the preset minimum contact displacement, the pressing will be paused and an alarm signal will be issued.

10. The rail grinding method according to claim 6, characterized in that, The contact force is acquired in real time by a force sensor installed between the grinding adjustment mechanism and the grinding head, and the actual downward displacement of the grinding head is obtained by a laser displacement sensor or an ultrasonic sensor installed on the side of the grinding head.

Images