Slope ballast cleaning machine's ballast separating device and control method

Abstract

The application discloses a ballast separating device and control method of a side slope ballast cleaning machine, and comprises the following steps: obtaining flow data; performing noise reduction processing on the flow data to obtain flow data; calculating a ballast separating flow deviation according to the effective flow data; comparing the ballast separating flow deviation with a preset uniformity qualified threshold value, and adjusting the angle of a flow distribution plate according to the comparison result; when the ballast separating flow deviation is not greater than the uniformity qualified threshold value, locking the current angle of the flow distribution plate; when the ballast separating flow deviation is greater than the uniformity qualified threshold value, calculating a target deflection angle according to the ballast separating flow deviation, and setting an upper limit threshold value for the single adjustment angle to change the angle of the flow distribution plate in a gradual adjustment mode until the ballast separating flow deviation is not greater than the uniformity qualified threshold value; based on the above steps, the application realizes uniform ballast separation under adverse working conditions, thereby realizing stable and uniform ballast slope backfilling operation in a full window period, and is practical, and is suitable for being widely promoted and applied.

Description

Technical Field

[0001] This invention relates to the field of railway engineering machinery technology, and in particular, to a ballast separating device and control method for a slope cleaning and screening machine. Background Technology

[0002] The ballast track bed is a core infrastructure component of railways, supporting the rails, distributing the dynamic load of trains, and buffering the impact of vehicles. Under the long-term effects of train rolling, rain erosion, and dust accumulation, the ballast can develop defects such as compaction, pulverization, and blockage of drainage channels. These defects directly reduce the track's elasticity and can lead to safety hazards such as gauge widening, elevation discrepancies, and train swaying. Therefore, regular cleaning and maintenance of the turnouts are necessary to restore the permeability and load-bearing capacity of the ballast track bed.

[0003] The slope cleaning and screening machine is a core large-scale track maintenance machine for railway track maintenance during maintenance windows. It primarily undertakes the entire process of ballast excavation on track bed slopes, ballast vibrating screening, waste soil transportation and disposal, and clean ballast layered backfilling. Compared to manual screening, the slope cleaning and screening machine has extremely high operating efficiency, significantly improving the utilization rate of railway track maintenance during maintenance windows and meeting the requirements of efficient railway maintenance. During the screening process, the core construction indicator is the uniformity of track bed backfilling. The cleaned ballast needs to be evenly backfilled onto the track bed slopes to restore the standard cross-sectional shape and geometric dimensions of the track bed. If the backfilled ballast is unevenly distributed on the left and right sides, it will cause excessive differences in the ballast accumulation thickness on both sides of the track, resulting in inconsistent lateral bearing stiffness of the track bed. Under long-term operation, this will lead to uneven track settlement and exceeding geometric dimensional limits. Therefore, how to achieve uniform ballast distribution on both sides after screening is a key technical problem that needs to be solved in the design of the slope cleaning and screening machine.

[0004] Currently, existing slope ballast clearing machines typically use ballast distribution devices to distribute and backfill clean ballast. These devices mainly control the discharge ratio on the left and right sides via a diversion plate. However, existing ballast distribution devices have the following shortcomings in practical applications: First, they rely primarily on manual adjustment of the diversion plate to control the left and right discharge ratios, lacking precise adjustment and real-time monitoring capabilities for the amount of ballast distributed on both sides, making it difficult to dynamically adjust the distribution ratio based on actual track conditions. Second, slope ballast clearing machines operate under extremely harsh conditions. High concentrations of dust exist at the construction site, generating significant dust around the machine. Furthermore, the screening device generates high-frequency vibrations during operation, and ballast particles exert continuous, instantaneous impacts on the device during excavation and conveying. These factors severely affect the measurement accuracy and long-term reliability of sensors, making it difficult to apply conventional sensor feedback control schemes to the uniform ballast distribution of slope ballast clearing machines. Summary of the Invention

[0005] This invention provides a ballast separating device and control method for a slope cleaning and screening machine, in order to solve the technical problems of existing ballast separating devices relying on manual adjustment of the diverter plate, resulting in low ballast separating accuracy and inability to monitor the left and right ballast separating amounts in real time, as well as the difficulty of existing sensor feedback control schemes adapting to the harsh working conditions of slope cleaning and screening machines such as high dust, high frequency vibration, and instantaneous impact of ballast, and thus failing to achieve automatic and accurate adjustment of the ballast separating ratio.

[0006] According to one aspect of the present invention, a method for controlling ballast distribution in a slope cleaning and screening machine is provided. The slope cleaning and screening machine includes a ballast distribution device, which includes a first diversion channel, a second diversion channel, and a diversion plate disposed between the first diversion channel and the second diversion channel. The method includes the following steps: Obtain the first flow data in the first diversion channel and the second flow data in the second diversion channel; The first and second flow data are denoised to obtain the first and second effective flow data. Calculate the ballast flow deviation based on the first and second valid flow data; The deviation of the ballast flow rate is compared with the preset uniformity qualification threshold, and the angle of the flow divider is adjusted according to the comparison result. When the deviation of the ballast flow rate is not greater than the uniformity qualification threshold, lock the current angle of the flow divider plate; When the ballast flow deviation is greater than the uniformity qualification threshold, the target deflection angle is calculated based on the ballast flow deviation, and an upper limit threshold constraint is set for the single adjustment angle to change the angle of the splitter plate in a gradual adjustment manner until the ballast flow deviation is not greater than the uniformity qualification threshold.

[0007] Furthermore, the specific steps for obtaining traffic data are as follows: Material weight data in the first sampling channel and material weight data in the second sampling channel are collected in real time at a set frequency to calculate the first flow rate data in the first diversion channel and the second flow rate data in the second diversion channel. The calculation formula is as follows: ; In the formula, Q L Q is the first flow rate within the first branch channel. R The second flow rate within the second diversion channel, Δm L The change in material weight, Δm, is collected at intervals in the first diversion channel. R The material weight change is collected at intervals for the second diversion channel.

[0008] Furthermore, the noise reduction process employs a first-order exponential low-pass filter for smoothing, using the calculated filtered flow data as the effective flow data. The calculation formula is as follows: ; In the formula, Q(K) represents the flow data for the k-th period, Q filt (k) represents the filtered flow rate, α is the filtering smoothing coefficient, and Q... filt (k-1) represents the flow rate after filtering in the previous cycle.

[0009] Furthermore, the noise reduction process also employs a limit amplitude elimination algorithm, specifically: The current period's traffic data is compared with the set upper and lower traffic thresholds, and the traffic data is processed based on the comparison results. When the traffic data for the current period is within the set upper and lower limit thresholds, the traffic data for the current period is considered valid traffic data. If the current period's traffic data falls outside the set upper and lower traffic limit thresholds, the filtered traffic data from the previous period will be used as the valid traffic data for the current period.

[0010] Furthermore, the noise reduction process also employs multi-period average steady-state calculation, specifically: Filtered flow data is continuously collected for multiple periods according to a preset time window length, and a moving average is calculated, with the average value used as the valid flow data.

[0011] Furthermore, the formula for calculating the target adjustment angle is: θ = k⋅ΔQ; In the formula, θ is the target deflection angle, and k is the proportional adjustment coefficient. This refers to the deviation in ballast flow rate.

[0012] Furthermore, the specific steps of gradual adjustment are as follows: The actual adjustment angle is calculated based on the target deflection angle, using the following formula: ; In the formula, Δθ t The actual adjustment angle is θ, where θ is the target deflection angle. prev Δθ represents the actual deflection angle of the splitter plate at the previous moment. max The maximum allowable adjustment angle threshold for a single operation; sign is the sign function. The final deflection angle is calculated based on the actual adjustment angle, using the following formula: ; In the formula, θ out This is the final deflection angle.

[0013] Furthermore, the ballast distribution control method also includes the following steps: The first and second diversion channels are vibrated according to a set cycle, and flow data acquisition and angle adjustment are stopped during the vibrating operation. After the rapping operation ends within a set time, flow data is acquired and angle adjustments are made. When the flow data falls below the no-load threshold, zero-point smoothing correction is performed to update the no-load reference. The zero-point smoothing update formula is as follows: ; In the formula, β is the zero-point update smoothing coefficient. To update the no-load zero point, F i For the current measured load, F i,0(old) This is the original no-load zero point.

[0014] According to another aspect of the present invention, a ballast separating device for a slope cleaning and screening machine is also provided, comprising: The return hopper is used to be installed below the outlet of the slope cleaning vibrating screen; The first guiding mechanism forms a first diversion channel connected to the first outlet of the return hopper for conveying ballast; The second flow guiding mechanism forms a second diversion channel connected to the second outlet of the return hopper, used for conveying ballast; Diverter plate, installed in return hopper and located between first diverter channel and second diverter channel, is used to adjust ballast flow rate in first diverter channel and second diverter channel; The first weighing mechanism is installed in the first diversion channel and is used to collect the weight of the ballast in the first diversion channel. The second weighing mechanism is installed in the second diversion channel and is used to collect the weight of the ballast in the second diversion channel. The actuator, with its actuator end connected to the splitter plate, is used to adjust the angle of the splitter plate; The control system is electrically connected to the first weighing mechanism, the second weighing mechanism and the actuator respectively. The control system includes a fully automatic control mode. In the fully automatic control mode, the control system is configured to execute the ballast separation control method of the slope cleaning machine described above.

[0015] Furthermore, the control system also includes a semi-automatic control mode: when the control system is in semi-automatic control mode, the operator inputs control parameters through the human-machine interface, and the control system generates auxiliary control commands based on the control parameters to drive the actuator to adjust the splitter plate; and / or the control system also includes a manual control mode: when the control system detects a fault, it switches to manual control mode, the control system stops working, and the operator adjusts the angle of the splitter plate through the mechanical operating mechanism.

[0016] The present invention has the following beneficial effects: The ballast distribution control method for the slope clearing and screening machine of the present invention first acquires first flow data in the first diversion channel and second flow data in the second diversion channel. Noise reduction processing is then applied to the first and second flow data to obtain first and second effective flow data. This noise reduction processing adapts to the harsh working conditions of the slope clearing and screening machine, such as high-frequency vibration and instantaneous impact on the ballast, making automatic and precise adjustment based on sensor feedback control feasible in actual operation of the slope clearing and screening machine. Then, the ballast distribution flow deviation is calculated based on the first and second effective flow data, and compared with a preset uniformity qualification threshold. When the ballast distribution flow deviation is not greater than the uniformity qualification threshold, the current angle of the diversion plate is locked. When the ballast distribution flow deviation is greater than the uniformity qualification threshold, the target deflection angle is calculated based on the ballast distribution flow deviation, and an upper limit threshold constraint is set for the single adjustment angle to gradually change the angle of the diversion plate until the ballast distribution flow deviation is reached. The difference should not exceed the uniformity threshold. Through gradual adjustment, problems such as sudden large swings of the diverter plate, ballast material leakage on one side, and material blockage in the return hopper are avoided. This effectively reduces the difference in backfill thickness between the left and right sides of the ballast bed, preventing uneven lateral stress, rail side wear, and excessive settlement in the later stages of the line. It significantly reduces the workload of later maintenance and repair of the line, and significantly improves the long-term service stability of the ballasted ballast bed and the standardization level of cleaning and screening construction. Based on the above steps, this solution can stably and quantitatively collect the instantaneous flow of ballast on both sides under the combined harsh conditions of high dust, high-frequency vibration, and instantaneous impact of ballast. It completely eliminates the observation lag and subjective error of the rough judgment mode of manual visual inspection, and provides continuous and high-precision data support for intelligent closed-loop control. It realizes precise adjustment and real-time monitoring of the ballast distribution on both sides, and can dynamically adjust the ballast distribution ratio according to the actual situation of the line, thereby achieving uniform ballast distribution under harsh conditions. This enables stable and uniform ballast slope backfilling operations throughout the entire window cycle. It is highly practical and suitable for widespread promotion and application.

[0017] In addition to the objectives, features, and advantages described above, the present invention has other objectives, features, and advantages. The invention will now be described in further detail with reference to the figures. Attached Figure Description

[0018] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a flowchart illustrating the steps of the ballast separation control method of the slope cleaning and screening machine according to a preferred embodiment of the present invention; Figure 2 This is a schematic diagram of the ballast separating device of the slope cleaning and screening machine according to a preferred embodiment of the present invention; Figure 3This is a partial structural schematic diagram of the ballast separating device of the slope cleaning and screening machine according to a preferred embodiment of the present invention.

[0019] Legend: 10. Return hopper; 20. First flow guiding mechanism; 21. Wear-resistant flow guiding channel; 22. Vibration assembly; 23. Floating support frame; 24. High-damping vibration damping support; 25. Base; 30. Second flow guiding mechanism; 40. Diverter plate; 50. Rotary hinge seat; 61. Weighing sensor. Detailed Implementation

[0020] The following description provides specific application scenarios and requirements for this specification, intended to enable those skilled in the art to make and use the contents of this specification. Various partial modifications to the disclosed embodiments will be apparent to those skilled in the art, and the general principles defined herein can be applied to other embodiments and applications without departing from the spirit and scope of this specification.

[0021] like Figure 1 As shown in this embodiment, the ballast separation control method of the slope cleaning and screening machine includes a ballast separation device, which includes a first diversion channel, a second diversion channel, and a diversion plate 40 arranged between the first diversion channel and the second diversion channel. The method includes the following steps: S1: Obtain the first flow data in the first diversion channel and the second flow data in the second diversion channel; S2: Perform noise reduction processing on the first flow data and the second flow data to obtain the first effective flow data and the second effective flow data; S3: Calculate the ballast flow deviation based on the first and second effective flow data; S4: Compare the ballast flow deviation with the preset uniformity qualification threshold, and adjust the angle of the flow divider plate by 40 degrees according to the comparison result; S41: When the deviation of the ballast flow rate is not greater than the uniformity qualification threshold, the current angle of the splitter plate 40 is locked and remains unchanged. S42: When the ballast flow deviation is greater than the uniformity qualification threshold, the target deflection angle is calculated based on the ballast flow deviation, and an upper limit threshold constraint is set for the single adjustment angle to change the angle of the splitter plate 40 in a gradual adjustment manner until the ballast flow deviation is not greater than the uniformity qualification threshold.

[0022] like Figure 1As shown, specifically, the ballast distribution control method of the slope clearing and screening machine in this embodiment first acquires the first flow rate data in the first diversion channel and the second flow rate data in the second diversion channel. The first and second flow rate data are then subjected to noise reduction processing to obtain the first and second effective flow rate data. This noise reduction processing adapts to the harsh working conditions of the slope clearing and screening machine, such as high-frequency vibration and instantaneous impact on the ballast, making the automatic and precise adjustment based on sensor feedback control feasible in actual operation of the slope clearing and screening machine. Then, the ballast distribution flow deviation is calculated based on the first and second effective flow rate data, and compared with a preset uniformity qualification threshold. When the ballast distribution flow deviation is not greater than the uniformity qualification threshold, the current angle of the diversion plate 40 is locked. When the ballast distribution flow deviation is greater than the uniformity qualification threshold, the target deflection angle is calculated based on the ballast distribution flow deviation, and an upper limit threshold constraint is set for the single adjustment angle to gradually change the angle of the diversion plate 40 until... The deviation of the ballast flow rate is not greater than the uniformity qualification threshold. Gradual adjustment avoids problems such as sudden large-scale swaying of the diverter plate, ballast spillage on one side, and blockage of the return hopper. This effectively reduces the difference in backfill thickness between the left and right sides of the track bed, preventing uneven lateral stress, rail side wear, and excessive settlement in the later stages of the track. It significantly reduces the workload of later track maintenance and repair, and significantly improves the long-term service stability of ballasted track and the standardization of ballast cleaning construction. Based on the above steps, this solution is suitable for high dust, high-frequency vibration, and sudden ballast flow... Under the combined harsh working conditions of impact, the system can collect the instantaneous flow of ballast on both sides in a stable and quantitative manner for a long period of time, completely eliminating the observation lag and subjective errors of the manual visual judgment mode. This provides continuous and high-precision data support for intelligent closed-loop control, enabling precise adjustment and real-time monitoring of the ballast distribution on both sides. The ballast distribution ratio can be dynamically adjusted according to the actual situation of the line, thereby achieving uniform ballast distribution under harsh working conditions. This allows for stable and uniform ballast slope backfilling operations throughout the entire window cycle. It is highly practical and suitable for widespread promotion and application.

[0023] In this embodiment, the specific steps for obtaining traffic data are as follows: Material weight data in the first sampling channel and material weight data in the second sampling channel are collected in real time at a set frequency to calculate the first flow rate data in the first diversion channel and the second flow rate data in the second diversion channel. The calculation formula is as follows: ; In the formula, Q L Q is the first flow rate within the first branch channel. R The second flow rate within the second diversion channel, Δm L The change in material weight, Δm, is collected at intervals in the first diversion channel. R The material weight change is collected at intervals for the second diversion channel.

[0024] It should be understood that the set time interval depends on the set frequency.

[0025] Specifically, based on the above steps, a weighing-based flow rate acquisition method is implemented to avoid interference from ballast accumulation, achieve high measurement accuracy, and adapt to the strong vibration working environment of the slope cleaning machine.

[0026] It should be understood that the ballast separating device of the slope cleaning and screening machine operates under harsh conditions of high-frequency excitation and instantaneous impact of ballast. Affected by high-frequency excitation and instantaneous impact, the raw flow data collected contains a large amount of noise components. If the raw flow data is directly used for deviation calculation and control decision, it is very easy to cause misjudgment and incorrect adjustment. Therefore, it is necessary to perform noise reduction processing on the raw flow data.

[0027] In this embodiment, the noise reduction process employs a first-order exponential low-pass filter for smoothing, and the calculated filtered traffic data is used as the effective traffic data. The calculation formula is as follows: ; In the formula, Q(K) represents the flow data for the k-th period, Q filt (k) represents the filtered flow rate, α is the filtering smoothing coefficient, and Q... filt (k-1) represents the flow rate after filtering in the previous cycle.

[0028] Specifically, the high-frequency vibration and instantaneous impact of ballast generated during the cleaning and screening operation will cause instantaneous peak interference in the flow rate. Based on the above steps, the original flow rate data is filtered and smoothed to output a stable and effective flow rate.

[0029] In this embodiment, the noise reduction process also employs a limit amplitude elimination algorithm, specifically: The current period's traffic data is compared with the set upper and lower traffic thresholds, and the traffic data is processed based on the comparison results. When the traffic data for the current period is within the set upper and lower limit thresholds, the traffic data for the current period is considered valid traffic data. If the current period's traffic data falls outside the set upper and lower traffic limit thresholds, the filtered traffic data from the previous period will be used as the valid traffic data for the current period.

[0030] Specifically, based on the above steps, abnormal flow data is effectively eliminated, and distorted data caused by single ballast impact and screen resonance are prevented from participating in deviation calculation, thus avoiding misadjustment of the diverter plate 40 and ensuring the uniformity and stability of ballast distribution.

[0031] In this embodiment, the noise reduction process also employs multi-period average steady-state calculation, specifically: Filtered flow data is continuously collected for multiple periods according to a preset time window length, and a moving average is calculated, with the average value used as the valid flow data.

[0032] Specifically, based on the above steps, the flow fluctuations caused by high-frequency excitation and instantaneous impact of ballast are further weakened to ensure the long-term stability and feasibility of the input data for wall thickness control.

[0033] In this embodiment, the ballast flow rate deviation is: ; In the formula, The first effective traffic, This is the second effective flow.

[0034] Specifically, when ΔQ is not greater than the uniformity qualification threshold, the current ballast distribution uniformity is determined to be qualified, that is, the current distribution state is kept stable; when ΔQ is greater than the uniformity qualification threshold, it is determined that there is unilateral material deviation, and the subsequent 40-degree angle adjustment of the distribution plate is started.

[0035] In this embodiment, the formula for calculating the target adjustment angle is: θ = k⋅ΔQ; In the formula, θ is the target deflection angle, and k is the proportional adjustment coefficient. This refers to the deviation in ballast flow rate.

[0036] Specifically, the target deflection angle of the diverter plate 40 is dynamically calculated based on the real-time ballast flow deviation using the above formula, achieving precise quantitative adjustment; when Q is detected... Lfilt Q Rfilt When the flow rate on the first side is too high, the controller controls the diverter plate 40 to deflect towards the second side, increasing the feed distribution ratio on the second side and reducing the feed rate on the first side, thus balancing the feed rates on both sides; when Q is detected... Rfilt Q Lfilt When the flow rate on the second side is too high, the flow divider plate 40 is deflected toward the first side to increase the feed distribution ratio on the first side and reduce the feed amount on the second side, thereby balancing the feed amount on both sides. By changing the deflection angle of the flow divider plate 40, the proportion of material entering the left and right discharge hoppers is dynamically divided, thereby adjusting the feed flow distribution on both sides from the source.

[0037] It should be understood that the proportional adjustment coefficient can be dynamically corrected according to the dry and wet conditions of the track bed and the total amount of material fed.

[0038] It should be understood that the slope cleaning screener is in a harsh working environment with high-frequency vibration during screening, instantaneous impact of ballast, large fluctuations in material flow, and lots of mud and dust in the open. The weighing acquisition signal itself has periodic vibration noise and instantaneous spike interference. If the output splitter plate is adjusted by 40 degrees using unconstrained open-loop proportional calculation, the robustness of the control system will be extremely poor, which will lead to multiple engineering problems.

[0039] In this embodiment, the specific steps of the gradual adjustment are as follows: The actual adjustment angle is calculated based on the target deflection angle, using the following formula: ; In the formula, Δθ t The actual adjustment angle is θ, where θ is the target deflection angle. prev Δθ represents the actual deflection angle of the splitter plate at the previous moment. max The maximum allowable adjustment angle threshold for a single operation; sign is the sign function. The final deflection angle is calculated based on the actual adjustment angle, using the following formula: ; In the formula, θ out This is the final deflection angle.

[0040] Specifically, based on the above steps, a progressive amplitude limiting adjustment strategy is introduced to set an upper limit threshold constraint on the single adjustment angle, prohibit excessive abrupt adjustment, ensure that the correction process is stable and controllable, and achieve stable convergence.

[0041] In this embodiment, the ballast separation control method further includes the following steps: The first and second diversion channels are vibrated according to a set cycle, and flow data acquisition and angle adjustment are stopped during the vibrating operation. After the rapping operation ends within a set time, flow data is acquired and angle adjustments are made. When the flow data falls below the no-load threshold, zero-point smoothing correction is performed to update the no-load reference. The zero-point smoothing update formula is as follows: ; In the formula, β is the zero-point update smoothing coefficient. To update the no-load zero point, F i For the current measured load, F i,0(old) This is the original no-load zero point.

[0042] Specifically, during the ballast separation process, wet ballast and slurry adhering to the inner wall of the distribution channel will generate a fixed additional mass, causing long-term drift in the weighing acquisition signal. Based on the above steps, periodic rapping operations are performed to remove the wet ballast and slurry from the inner wall of the distribution channel, thereby improving weighing accuracy. During the rapping operation, weighing is not performed to avoid interference from rapping vibration. Weighing is performed after a set time has elapsed since the end of the rapping operation, allowing the rapping vibration to attenuate. After calculating the flow rate based on the weighing acquisition, it is determined whether the no-load reference needs to be updated based on the flow rate data to eliminate metering drift caused by residual material accumulation.

[0043] It should be understood that the no-load threshold refers to the no-load threshold of the weighing sensor 61.

[0044] like Figure 2 and Figure 3 As shown. The ballast distribution device of the slope cleaning screen machine in this embodiment includes: a return hopper 10, which is arranged below the outlet of the slope cleaning vibrating screen; a first flow guiding mechanism 20, which forms a first flow diversion channel communicating with the first outlet of the return hopper 10, for conveying ballast; a second flow guiding mechanism 30, which forms a second flow diversion channel communicating with the second outlet of the return hopper 10, for conveying ballast; and a flow diversion plate 40, which is arranged in the return hopper 10 and located between the first flow diversion channel and the second flow diversion channel, for adjusting the ballast flow rate of the first flow diversion channel and the second flow diversion channel; The first weighing mechanism is installed in the first diversion channel to collect the weight of the ballast in the first diversion channel; the second weighing mechanism is installed in the second diversion channel to collect the weight of the ballast in the second diversion channel; the actuator has its actuator end connected to the diversion plate 40 to control the angle of the diversion plate 40; the control system (not shown) is electrically connected to the first weighing mechanism, the second weighing mechanism and the actuator respectively. The control system includes a fully automatic control mode. In the fully automatic control mode, the control system is configured to execute the ballast control method of the slope cleaning machine described above.

[0045] Specifically, the finished ballast after screening is collected by the return hopper 10, and the finished ballast flows to the first diversion channel and the second diversion channel through the first outlet and the second outlet respectively. The weight of the ballast in the first diversion channel and the second diversion channel is collected by the first weighing mechanism and the second weighing mechanism at a set frequency, and transmitted to the control system. The control system controls the operation of the actuator according to the ballast distribution control method of the slope cleaning screener described above. By changing the area of ​​the left and right shielding feeding area of ​​the plate, the volume flow rate of the ballast flowing to the left and right discharge hoppers is accurately distributed to achieve uniform ballast distribution.

[0046] Alternatively, the control system may be a PLC controller, a microcontroller, or an industrial computer.

[0047] Optionally, the return hopper 10 is welded and fixed to the frame below the vibrating screen discharge of the slope cleaning machine, and is made of wear-resistant steel plate.

[0048] Optionally, the diverter plate 40 is made of high-strength wear-resistant steel plate and is installed at the center of the feed position of the return hopper 10 via a rotating hinge seat 50. The tail is connected to the actuator, which can achieve stepless angle deflection from -15° to +15°.

[0049] Optionally, a self-lubricating bushing is embedded in the rotary hinge seat 50 to reduce frictional losses caused by frequent oscillations.

[0050] Optionally, dustproof retaining rings are provided at both ends of the self-lubricating bushing to prevent dust from entering the hinge gap and causing jamming.

[0051] Optionally, the actuator is a servo electric actuator or a hydraulic actuator.

[0052] Optionally, the first guiding mechanism 20 includes a wear-resistant guiding channel 21, a vibrating assembly 22 arranged on the side wall of the wear-resistant guiding channel 21, a floating support frame 23, multiple high-damping vibration damping supports 24, and a base 25. The floating support frame 23 is installed on the base 25 through the multiple high-damping vibration damping supports 24. A first weighing mechanism is arranged between the floating support frame 23 and the wear-resistant guiding channel 21. The inlet of the wear-resistant guiding channel 21 and the first outlet of the return hopper 10 maintain a preset gap so as to prevent the vibration of the slope cleaning screener from being transmitted to the first weighing mechanism through the floating support. The vibrating assembly 22 is used for vibrating operation to prevent long-term material accumulation from forming a fixed additional mass and to eliminate zero-point drift of the weighing.

[0053] Optionally, the high-damping vibration-damping support 24 is made of rubber.

[0054] Optionally, the first weighing mechanism includes three weighing sensors 61 evenly distributed at three points between the wear-resistant guide channel 21 and the floating support frame 23. The impact load of the falling ballast is evenly distributed by the three-point support, avoiding the distortion of the weighing sensor 61 due to uneven load caused by single-point force.

[0055] Optionally, the load cell 61 has an integrally molded rubber sealing sleeve on the outside.

[0056] Optionally, the specific structure of the second guiding mechanism 30 is the same as or similar to the specific structure of the first guiding mechanism.

[0057] Optionally, the specific structure of the second weighing mechanism is the same as or similar to that of the first weighing mechanism.

[0058] Optionally, wear-resistant rubber curtains are suspended at the first and second outlets of the discharge hopper. These curtains prevent dust and slurry from directly entering the first and second diversion channels, while also buffering the impact of the vertically falling ballast and reducing instantaneous load spikes.

[0059] Alternatively, the vibration component is a miniature eccentric rapper.

[0060] Specifically, the ballast separating device of the slope cleaning and screening machine in this embodiment forms an anti-interference system through hardware and software collaboration to simultaneously block four types of interference sources: vibration, dust, mud, and sudden changes in incoming material. By using hardware suspension vibration isolation, sealing protection, and vibratory material cleaning, signal noise is reduced from the source. By using software noise reduction processing and progressive amplitude limiting to suppress control loop oscillation, small-amplitude weighing noise will not trigger invalid mechanical actions. The anti-interference capability of the entire control system fully meets the all-weather continuous operation specifications of large railway track maintenance machinery, greatly improving the stability of equipment operation, extending the overhaul cycle of vulnerable parts such as servo push rods and hinge seats, and reducing equipment operation and maintenance costs.

[0061] In this embodiment, the control system also includes a semi-automatic control mode: when the control system is in semi-automatic control mode, the operator inputs control parameters through the human-machine interface, and the control system generates auxiliary control commands based on the control parameters to drive the actuator to adjust the diverter plate 40.

[0062] Specifically, in special local screening scenarios, the control system is in semi-automatic control mode. The operator inputs control parameters to manually set the diversion plate to 40 degrees and lock it until there is a slight deviation of tail material on one side. The operator actively adjusts the distribution ratio of ballast on both sides to meet the differentiated and refined construction needs such as local track bed defects and unilateral thickening backfilling. The working conditions are widely covered.

[0063] In this embodiment, the control system also includes a manual control mode: when the control system detects a fault, it switches to manual control mode, the control system stops working, and the operator adjusts the diverter plate at a 40° angle through the mechanical operating mechanism.

[0064] Specifically, when situations such as a broken wire in the weighing sensor 61, signal exceeding the range, no change in flow data for a long time, or malfunction of the rapping component 22 occur, the detection system will determine that a fault has been detected and switch to manual control mode. The operator can then adjust the diverter plate to a 40° angle through the mechanical operating mechanism to continue the daily screen cleaning work without stopping the machine for maintenance. This ensures continuous operation during the maintenance window, improves the fault tolerance and reliability of the screen cleaning operation, and prevents delays in the construction period and shutdowns for line maintenance.

[0065] In summary, after reading the detailed disclosure of this specification, those skilled in the art will understand that the foregoing detailed disclosure is presented by way of example only and is not restrictive. Although not explicitly stated herein, those skilled in the art will understand that this specification requires various reasonable changes, improvements, and modifications to the embodiments. These changes, improvements, and modifications are intended to be made by this specification and are within the spirit and scope of the exemplary embodiments described herein.

Claims

1. A method for controlling ballast distribution in a slope cleaning and screening machine, the slope cleaning and screening machine including a ballast distribution device, the ballast distribution device including a first diversion channel, a second diversion channel, and a diversion plate (40) disposed between the first diversion channel and the second diversion channel, characterized in that, Includes the following steps: Obtain the first flow data in the first diversion channel and the second flow data in the second diversion channel; The first and second flow data are denoised to obtain the first and second effective flow data. Calculate the ballast flow deviation based on the first and second valid flow data; The deviation of the ballast flow rate is compared with the preset uniformity qualification threshold, and the angle of the flow divider (40) is adjusted according to the comparison result. When the deviation of the ballast flow rate is not greater than the uniformity qualification threshold, lock the current angle of the flow divider (40); When the ballast flow deviation is greater than the uniformity qualification threshold, the target deflection angle is calculated based on the ballast flow deviation, and an upper limit threshold constraint is set for the single adjustment angle to change the angle of the split plate (40) in a gradual adjustment manner until the ballast flow deviation is not greater than the uniformity qualification threshold.

2. The ballast separation control method for the slope cleaning and screening machine according to claim 1, characterized in that, The specific steps to obtain traffic data are as follows: Material weight data in the first sampling channel and material weight data in the second sampling channel are collected in real time at a set frequency to calculate the first flow rate data in the first diversion channel and the second flow rate data in the second diversion channel. The calculation formula is as follows: ； In the formula, Q L Q represents the first flow rate within the first branch channel. R The second flow rate within the second diversion channel, Δm L The change in material weight, Δm, is collected at intervals in the first diversion channel. R The material weight change is collected at intervals for the second diversion channel.

3. The ballast separation control method for the slope cleaning and screening machine according to claim 2, characterized in that, The noise reduction process employs a first-order exponential low-pass filter for smoothing, and the filtered traffic data is used as the effective traffic data. The calculation formula is as follows: ； In the formula, Q(K) represents the flow data for the k-th period, Q filt (k) represents the filtered flow rate, α is the filtering smoothing coefficient, and Q... filt (k-1) represents the flow rate after filtering in the previous cycle.

4. The ballast separation control method for the slope cleaning and screening machine according to claim 3, characterized in that, The noise reduction process also employs a limit amplitude elimination algorithm, specifically: The current period's traffic data is compared with the set upper and lower traffic thresholds, and the traffic data is processed based on the comparison results. When the traffic data for the current period is within the set upper and lower limit thresholds, the traffic data for the current period is considered valid traffic data. If the current period's traffic data falls outside the set upper and lower traffic limit thresholds, the filtered traffic data from the previous period will be used as the valid traffic data for the current period.

5. The ballast separation control method for the slope cleaning and screening machine according to claim 3, characterized in that, The noise reduction process also employs multi-period average steady-state calculation, specifically: Filtered flow data is continuously collected for multiple periods according to a preset time window length, and a moving average is calculated, with the average value used as the valid flow data.

6. The ballast separation control method for the slope cleaning and screening machine according to any one of claims 1-5, characterized in that, The formula for calculating the target adjustment angle is: θ = k⋅ΔQ; In the formula, θ is the target deflection angle, and k is the proportional adjustment coefficient. This refers to the deviation in ballast flow rate.

7. The ballast separation control method for the slope cleaning and screening machine according to claim 6, characterized in that, The specific steps for gradual adjustment are as follows: The actual adjustment angle is calculated based on the target deflection angle, using the following formula: ； In the formula, Δθ t The actual adjustment angle is θ, where θ is the target deflection angle. prev Δθ represents the actual deflection angle of the splitter plate (40) at the previous moment. max The maximum allowable adjustment angle threshold for a single operation; sign is the sign function. The final deflection angle is calculated based on the actual adjustment angle, using the following formula: ； In the formula, θ out This is the final deflection angle.

8. The ballast separation control method for the slope cleaning and screening machine according to any one of claims 1-5, characterized in that, The ballast distribution control method also includes the following steps: The first and second diversion channels are vibrated according to a set cycle, and flow data acquisition and angle adjustment are stopped during the vibrating operation. After the rapping operation ends within a set time, flow data is acquired and angle adjustments are made. When the flow data falls below the no-load threshold, zero-point smoothing correction is performed to update the no-load reference. The zero-point smoothing update formula is as follows: ； In the formula, β is the zero-point update smoothing coefficient. To update the no-load zero point, F i For the current measured load, F i,0(old) This is the original no-load zero point.

9. A ballast separating device for a slope cleaning and screening machine, characterized in that, include: The return hopper (10) is used to be installed below the outlet of the slope cleaning vibrating screen; The first guiding mechanism (20) forms a first diversion channel connected to the first outlet of the return hopper (10) for conveying ballast; The second guide mechanism (30) forms a second diversion channel connected to the second outlet of the return hopper (10) for conveying ballast; Diverter plate (40) is installed in return hopper (10) and located between the first diverter channel and the second diverter channel. It is used to adjust the ballast flow rate of the first diverter channel and the second diverter channel. The first weighing mechanism is installed in the first diversion channel and is used to collect the weight of the ballast in the first diversion channel. The second weighing mechanism is installed in the second diversion channel and is used to collect the weight of the ballast in the second diversion channel. The actuator, with its actuator end connected to the diverter plate (40), is used to adjust the angle of the diverter plate (40); The control system is electrically connected to the first weighing mechanism, the second weighing mechanism, and the actuator, respectively. The control system includes a fully automatic control mode. In the fully automatic control mode, the control system is configured to perform the ballast separation control method of the slope cleaning and screening machine according to any one of claims 1-8.

10. The ballast separating device of the slope cleaning and screening machine according to claim 9, characterized in that, The control system also includes a semi-automatic control mode: when the control system is in semi-automatic control mode, the operator inputs control parameters through the human-machine interface, and the control system generates auxiliary control commands based on the control parameters to drive the actuator to adjust the diverter plate (40); and / or The control system also includes a manual control mode: when the control system detects a fault, it switches to manual control mode, the control system stops working, and the operator adjusts the angle of the splitter plate (40) through the mechanical operating mechanism.

Images