Insulation assembly for welding after wagon assembly
By designing insulating components, the problem of current passing through bearing ablation during railway truck welding is solved, and the safety and reliability of the welding process is achieved. It is suitable for a variety of vehicle models, with low cost and easy to modify.
Patent Information
- Application Number
- CN202422265005.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-14
- Publication Date
- 2025-07-18
- Estimated Expiration
- 2034-09-14
AI Technical Summary
During the welding process of existing railway trucks, the welding machine grounding wire clamp accidentally touches the track or the ground causes current to pass through the bearing, which poses a risk of ablation. The existing insulation method has high operating requirements and cannot avoid external environmental impact.
An insulating component including a first insulating component, a second insulating component and a third insulating component is designed. The insulation resistance value of the insulating component itself is greater than 500MΩ, the first insulating component is a J-shaped structure with a grounding wire, and the second insulating component is a U-shaped component fixed in the contact area between the wheel and the rail. The third insulating component enhances insulation between the rails to ensure that current passes through the regular circuit.
Ensure that the overall insulation resistance of the welding table at the source meets the standards, avoiding current burning through the bearing, solving the disadvantages of traditional insulation methods, ensuring the safety and reliability of the welding process, suitable for a variety of models, low cost and easy to modify.
Smart Images
Figure CN223114437U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of railway freight car assembly, in particular to an insulating component for welding after railway freight car assembly. Background Art
[0002] At present, after the railway freight car body and bogie assembly are completed, some welding must be performed on some positions. The welding process is to park the railway freight car on the track at the welding station and use the welding machine next to the welding station for welding. The incoming line of the welding machine is its own power line. After the internal power conversion of the welding machine, a handle line and a ground line are connected. The ground line clamps the welding conductor, and the handle line contacts the welding point, so that a large current passes through the welding point to melt the metal and complete the welding. It is very necessary to carry out insulation treatment during the welding process. Through reasonable insulation measures, a safer, more efficient and reliable environment can be provided for welding operations, ensuring the safety of operators and the stability of welding quality.
[0003] There are two existing rail insulation methods: one is to achieve rail insulation by continuously increasing the insulation resistance of the welding machine output line and the welding clamp itself to be greater than 500MΩ. This method also requires workers to be careful and attentive during operation so as not to cause bearing burns due to the current not flowing in the preset direction after the grounding wire welding clamp is clamped in the wrong position. The second is to insulate the track from the ground, by laying insulating rubber at the bottom of the rail and using insulating embedded bolt assemblies, pressure plate insulating partitions, and insulating connecting plates and baffles at the rail connection. This method requires workers not to overlap the wire and the grounding wire with the rail. If the rail is accidentally overlapped, the current from the welding machine wire will pass through the rail → wheel → axle → bearing → car body → grounding wire to form a current closed loop. These two methods have high operating requirements for operators in actual use, and both cannot avoid the influence of the external environment on the insulation of the welding machine and the problem that the grounding wire clamp accidentally touches the track (or the ground) when the welding machine is working, and the welding current directly flows through the bearing. Utility Model Content
[0004] The utility model aims to provide an insulating component for welding after assembling a railway freight car, so as to solve the technical problems of poor insulation effect and unreliability of the existing method.
[0005] The basic scheme provided by the utility model is: an insulating component for welding after assembling a railway freight car, which is used in conjunction with a welding machine at a welding station, the welding machine output line includes a grounding line, and the welding station is provided with a rail for parking the railway freight car, the insulating component includes a first insulating component, a second insulating component and a third insulating component, and its own insulation resistance is greater than the standard insulation resistance;
[0006] The first insulating component has a J-shaped structure, including a horizontal bottom, a first opening part and a second opening part perpendicular to the horizontal bottom, for sleeving the grounding wire and leaving a part of the grounding wire outside the top end of the second opening part; wherein, the height of the first opening part close to the welding machine is less than the height of the second opening part close to the railway wagon, and the height of the second opening part is greater than the length of the reserved part of the grounding wire;
[0007] The second insulating component is arranged in the contact area between the railway wagon wheel and the rail, including a set of U-shaped parts. Using its U-shaped structure, the U-shaped parts are fixed on the rail, and the U-shaped structure is consistent with the shape of the rail; the U-shaped part has a first length, and the first length is greater than the maximum distance between the two wheels on the corresponding rail of the U-shaped part;
[0008] The third insulating component includes an insulating rail end and an insulating connection block; along the track extension direction, the insulating rail end is installed at the connection of the tracks at adjacent welding positions; along the track extension direction, the insulating connection block is installed on the side of the track and connects the tracks at adjacent two welding positions, and has a second length.
[0009] The working principle and advantages of the present utility model are as follows:
[0010] After a comprehensive inspection and in-depth analysis of the welding positions, it is found that currently, the insulation resistance value between each joint of the secondary lead-out wire of the electric welding machine and the steel rail on the welding position does not meet the requirement of the relevant specified resistance value ≥ the standard insulation resistance value (500 MΩ). Therefore, when the grounding wire clamp of the welding machine accidentally touches the rail (or the ground), causing overcurrent in the bearing, there is a potential safety hazard for train operation.
[0011] The normal working state should be as Figure 1 shown. The current forms a loop through the connecting wire, the welded part, and the grounding wire, and the current does not pass through the bearing, so there will be no risk of overcurrent. However, there are negligence situations during the operation of workers. The grounding wire is placed on the ground. As Figure 2 shown, after one end of the connecting wire is connected to the vehicle body, if the resistance value between the grounding wire and the steel rail does not reach the specified value, the current forms a loop through the connecting wire, the welded part, the bearing, the wheel, the rail, the ground, and the grounding wire, thus generating overcurrent at the bearing part and posing a risk of burning. There is also a situation where the grounding wire is placed on the ground. As Figure 3 shown, when the grounding wire is directly connected to the rail, the current forms a loop directly through the connecting wire, the welded part, the bearing, the wheel, the rail, and the grounding wire, causing a risk of bearing ablation. Therefore, for the current insulation method, the grounding wire of the welding machine in the entire loop is a relatively large influencing factor.
[0012] Upon further in - depth comparison, it is found that the welding machine is placed on the ground without insulation isolation. Only relying on the insulation of the connecting cable itself to ensure the insulation between the secondary lead - out wire of the welding machine and the rail. The insulation value of the welding machine itself is relatively low. The grounding wire is also connected to the grounding wire of the workshop power supply system. The grounding wire joint contacts the ground through the wheels at the bottom of the welding machine and then is connected to the rail, resulting in the non - compliance of the insulation resistance value. The lack of insulation treatment between the rail and the ground may cause the insulation value to be non - compliant due to the relatively low local resistance value of the connecting cable, which is connected to the rail of this station after contacting the ground and adjacent rails. There is no insulation isolation between the wheel and the rail, and if there is current, it can be directly conducted. The insulation rubber of the connecting cable itself will have a decreased resistance value due to long - term dragging, aging, climate and other factors after a certain time limit, which will further affect the insulation value between the connecting cable and the rail.
[0013] Therefore, after comparing and analyzing the technical principles and the differences of the existing insulation methods in this solution, an insulation component is designed to form a brand - new insulation method. Compared with the existing insulation methods, it has the following advantages:
[0014] 1) The grounding wire is sleeved in the first insulation component (insulating hard pipe) with an insulation resistance greater than the standard insulation resistance (500 MΩ), blocking the problem of weak current flowing through the bearing due to the non - compliance of the insulation value caused by the aging of the grounding wire.
[0015] 2) The structure of the first insulation component (insulating hard pipe) is designed, and thus the current direction in the grounding wire is designed, avoiding the risk of over - current in the bogie bearing caused by accidental contact with some parts of the car body due to the random dragging of workers during use.
[0016] 3) The length of the grounding wire exposed at the vertical second opening is controlled within an appropriate range (400 mm - 500 mm), ensuring that the grounding wire can only be clamped at the specified position of the car body to ensure that it does not contact other positions of the car body.
[0017] 4) The second insulation component is processed from a material with an insulation resistance greater than the standard insulation resistance (500 MΩ) into a U - shaped part consistent with the shape of the rail, preventing the connecting cable of the welding machine from falling to the ground or the problem of current forming a closed loop due to the non - compliance of the resistance value of the power supply wire of the connecting cable itself, i.e., current flowing along the ground → rail → wheel → axle → bearing → car body → grounding wire; at the same time, the insulation part is processed into a shape consistent with the rail to avoid affecting the passage of the vehicle on the track.
[0018] 5) The addition of the third insulation component strengthens the insulation between the rails, further insulating the wheels completely from the rails and the ground, and improving the overall insulation performance.
[0019] The practical application of this solution can ensure that the overall insulation resistance of the welding station meets the standard (≥500 MΩ) at the source, ensuring that the current can only form a loop through the connecting wire, the welding part, and the grounding wire, and will not pass through the bearing and cause burnout. It solves the drawbacks of traditional insulation methods, completely solves the problem of current flowing back to the grounding wire through the ground, ensures that no abnormal overcurrent will occur during the welding process of the welding station, meets the requirements of all vehicle models, has strong versatility, low cost of the insulation component, is easy to technically transform, and is suitable for popularization and use. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Figure 1 is a schematic diagram of the normal working state of the existing welding process;
[0021] Figure 2 is a schematic diagram of the working state of the grounding wire of the existing welding process connected to the ground;
[0022] Figure 3 is a schematic diagram of the working state of the grounding wire of the existing welding process connected to the track;
[0023] Figure 4 is a schematic diagram of the structure of an insulation component for welding after the assembly of a railway freight car provided by an embodiment of the present invention;
[0024] Figure 5 is a schematic diagram of the structure of the second insulation component provided by an embodiment of the present invention;
[0025] Figure 6 is the installation schematic of the second insulation component provided by an embodiment of the present invention Figure 1 ;
[0026] Figure 7 is a schematic diagram of the structure of the steel rail provided by an embodiment of the present invention;
[0027] Figure 8 is Figure 7 the sectional view taken along line A-A in
[0028] Figure 9 is the installation schematic of the second insulation component provided by an embodiment of the present invention Figure 2 ;
[0029] Figure 10 is a schematic diagram of the installation of the third insulation component provided by an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS
[0030] The following is a more detailed description through specific embodiments:
[0031] The reference signs in the attached drawings of the description include: welding machine 1, grounding wire 11, handle wire 12, railway freight car 2, wheels 21, intermediate connection part 22, axle 23, bearing 24, side frame 25, welding position 26, first insulation component 3, second insulation component 4, third insulation part 5, insulated rail end 51, insulated connection block 52, and rail 6.
[0032] The embodiment is basically as shown in the attached Figure 4 drawings: An insulation component for welding after the assembly of a railway freight car 2, which is used in cooperation with a welding machine 1 at a welding station. The outgoing line of the welding machine 1 includes a grounding wire 11, and a rail 6 for parking the railway freight car 2 is provided at the welding station; as Figure 6 shown, the railway freight car 2 includes wheels 21, intermediate connection part 22, axle 23, bearing 24, and side frame 25, and also a welding position 26.
[0033] The insulation component includes a first insulation component 3, a second insulation component 4, and a third insulation component 5, and their own insulation resistance values are all greater than the standard insulation resistance value. In this embodiment, the standard insulation resistance value is 500 MΩ.
[0034] The first insulation component 3 has a J-shaped structure, including a horizontal bottom, a first opening part and a second opening part perpendicular to the horizontal bottom, which are used to sleeved the grounding wire 11 and leave a part of the grounding wire outside the top of the second opening part. The height h1 of the first opening part close to the welding machine 1 is less than the height h2 of the second opening part close to the railway freight car 2, and the length of the grounding wire of the welding machine 1 reserved outside the second opening part is less than the height h2 of the second opening part. The first insulation component 3 is fixed at a preset position at the welding station. In this embodiment, the horizontal bottom is buried underground, and the first opening part and the second opening part are located on the ground.
[0035] The grounding wire 11 is led out from the grounding wire terminal interface on the welding machine 1, passes through the horizontal bottom from the first opening part of the first insulation component 3, and then passes out from the second opening part. The overall grounding wire 11 is kept properly tightened. After determining that the length of the part of the grounding wire reserved outside the second opening part is 400 - 500 mm, the reserved part of the grounding wire is close to the top of the second opening part and is clamped and fixed at a preset position at the top of the second opening part by a welding clamp, ensuring that the part of the grounding wire from the grounding wire terminal interface to the first opening part and the part of the grounding wire reserved outside the second opening part will not contact the ground or the track, and the length of the part of the grounding wire reserved outside the second opening part can only be moved near the specified welding part.
[0036] In this embodiment, the first insulation component is an insulating hard pipe with an insulation resistance value greater than 500 MΩ, and the cross-sectional diameter of the insulating hard pipe is 16 - 50 mm 2 , preferably 32 mm 2, ensure that the grounding wire 11 passes through smoothly and balance the cost; the height h1 of the first opening is 150 - 250 mm, preferably 200 mm, which is adapted to the height of the grounding wire terminal interface of the welding machine 1 from the ground; the height h2 of the second opening is 700 - 900 mm, preferably 800 mm, to keep the length of the grounding wire 11 reasonable and match the height of the welding position 26 of the railway wagon 2 and the length of the reserved part of the grounding wire, which is convenient for operation and does not interfere with other non-welding parts of the wagon; the length of the horizontal bottom is 500 - 600 mm, preferably 550 mm, and the length is less than the distance between the welding machine 1 and the welding table position, with a reasonable length to ensure that the grounding wire 11 is sleeved in the insulating hard pipe as long as possible, minimizing the frictional contact between the grounding wire 11 and the ground. The height h3 of the horizontal bottom buried underground is 50 - 100 mm, preferably 80 mm, with a reasonable height for construction and ensuring stable and reliable fixation. The straight-line distance L2 between the first opening and the grounding wire terminal interface on the welding machine 1 is 100 - 150 mm, preferably 120 mm, which is convenient for the grounding wire 11 to penetrate into the first opening with a suitable length as short as possible, avoiding excessive contact with the ground and reducing insulation; the straight-line distance L3 between the second opening and the adjacent track is 300 - 400 mm, preferably 350 mm, to ensure a reasonable distance between the second opening and the welding table position, facilitating the connection and disconnection operations of the grounding wire 11 and the welding part.
[0037] As Figure 5 in the front view (a) and the left view (b), Figure 6 , Figure 7 , Figure 8 , Figure 9 shown, the second insulating component is arranged in the contact area between the wheels 21 of the railway wagon 2 and the rail 6, including a set of two U-shaped parts. Using its U-shaped structure, one U-shaped part is fixed on one rail 6 of the track, and the U-shaped structure is consistent with the outer shape of the rail 6, specifically consistent with the outer shape of the middle section of the rail 6; the U-shaped part has a first length, and the first length is greater than the maximum distance between the two wheels 21 on the corresponding rail 6 of the U-shaped part; in this embodiment, the second insulating component is made of nylon 66 material with an insulation resistance greater than 500 MΩ. The first length L4 is 900 - 1200 mm, preferably 1000 mm, and the U-shaped height h4 is preferably 102 mm, which is adapted to the conventional welding table position guide rail and all models of railway wagons 2, with good fixing effect, material saving, and effective cost control.
[0038] As Figure 10As shown in the figure, the third insulation component includes an insulating rail end 51 and an insulating connection block 52. Along the track extension direction, the insulating rail end 51 is installed at the connection of adjacent welding station tracks, that is, an insulating rail end 51 is inserted between two steel rails 6. Along the track extension direction, the insulating connection block 52 is installed on the side of the track and connects adjacent welding station tracks, and has a second length, the second length is 700 - 800 mm, preferably 750 mm. With a suitable length, a nylon connecting plate with a standard insulation resistance value can be used to ensure insulation compliance.
[0039] During specific use:
[0040] After the first insulation component 3, the second insulation component 4, and the third insulation component 5 are installed as required above, the railway freight car 2 is parked on the track, and all four wheels 21 are in contact with the steel rails of the track through the second insulation component. Connect the grounding wire 11 reserved at the second opening to the grounding required point of the welding position 26 of the railway freight car 2, and weld the corresponding position of the welded part through the connecting wire 12. After welding, since the height of the second opening is greater than the length of the reserved part of the grounding wire, the situation where the grounding wire 11 touches the ground or the track can be completely avoided.
[0041] An insulation component for welding after the assembly of a railway freight car provided in this embodiment is a brand-new insulation method designed after fully analyzing the insulation problems of existing welding stations. The grounding wire is fixed to the preset position of the welding station by passing through an insulating tube. At the same time, insulation components are installed between the contact area of the railway freight car wheels and the track and between adjacent welding station tracks, which can completely insulate the wheels from the steel rails and the ground, ensuring that the overall insulation resistance value (≥500 MΩ) of the welding station meets the standard at the source, ensuring that the current can only form a loop through the connecting wire, the welded part, and the grounding wire, and will not pass through the bearing and cause burnout, solving the drawbacks of traditional insulation methods, completely solving the problem of current flowing back to the grounding wire through the ground, ensuring that no abnormal overcurrent will occur during the welding process of the welding station, meeting the requirements of all vehicle types, having strong versatility, low cost of the insulation component, being easy to technically transform, and being suitable for popularization and use.
[0042] The above are only embodiments of the present utility model. Specific structures and common knowledge such as characteristics that are well-known in the art are not described in detail herein. Those of ordinary skill in the art know all the common general technical knowledge in the technical field to which the utility model belongs before the filing date or the priority date, can know all the prior art in this field, and have the ability to apply conventional experimental means before this date. Those of ordinary skill in the art can, under the inspiration given in this application, improve and implement this solution in combination with their own abilities. Some typical well-known structures or well-known methods should not become obstacles for those of ordinary skill in the art to implement this application. It should be noted that for those skilled in the art, without departing from the structure of the present utility model, several deformations and improvements can be made, and these should also be regarded as the protection scope of the present utility model, and these will not affect the implementation effect of the present utility model and the practicality of the patent.
Claims
1. An insulating component for welding after the assembly of a railway freight car, which is used in cooperation with a welding machine at a welding station. The outgoing wire of the welding machine includes a grounding wire, and there are rails for parking railway freight cars at the welding station. It is characterized in that, The insulating assembly includes a first insulating assembly, a second insulating assembly and a third insulating assembly, and their respective insulation resistances are greater than the standard insulation resistance; The first insulating assembly is in a J-shaped structure, including a horizontal bottom, a first opening part and a second opening part perpendicular to the horizontal bottom, for sleeving a grounding wire and leaving a part of the grounding wire outside the top end of the second opening part; wherein, the height of the first opening part close to the welding machine is less than the height of the second opening part close to the railway wagon, and the height of the second opening part is greater than the length of the reserved part of the grounding wire; The second insulating assembly is arranged in the contact area between the railway wagon wheel and the rail, and includes a set of U-shaped parts. Using its U-shaped structure, the U-shaped parts are fixed on the rail, and the U-shaped structure is consistent with the shape of the rail; the U-shaped part has a first length, and the first length is greater than the maximum distance between the two wheels on the corresponding rail of the U-shaped part; The third insulating assembly includes an insulating rail end and an insulating connection block; along the track extension direction, the insulating rail end is installed at the connection of adjacent welding station tracks; along the track extension direction, the insulating connection block is installed on the side of the track and connects the tracks of adjacent two welding stations, and has a second length.
2. The insulating component for welding after assembly of a railway freight car according to claim 1, characterized in that The length of the reserved part of the grounding wire is 400-500 mm.
3. An insulating component for welding after the assembly of a railway freight car according to claim 1, characterized in that, The second insulating assembly is processed from nylon 66 material.
4. An insulating component for welding after the assembly of a railway freight car according to claim 1, characterized in that, One end of the reserved part of the grounding wire close to the top end of the second opening part is fixed at a preset position at the top end of the second opening part.
5. An insulating component for welding after the assembly of a railway freight car according to claim 4, characterized in that, The fixing is by clamping with a welding tong.
6. An insulating component for welding after the assembly of a railway freight car according to claim 1, characterized in that, The first insulating assembly is fixed at a preset position at the welding station.
7. An insulating component for welding after the assembly of a railway freight car according to claim 6, characterized in that, The horizontal distance L2 between the first opening part and the grounding wire terminal interface on the welding machine is 100-150 mm; the linear distance L3 between the second opening part and the adjacent track is 300-400 mm.
8. An insulating component for welding after assembly of a railway freight car according to claim 6, characterized in that, The horizontal bottom is buried underground, and the top ends of the first opening part and the second opening part are on the ground.
9. An insulating component for welding after the assembly of a railway freight car according to claim 8, characterized in that, The height h3 of the horizontal bottom buried underground is 50-100 mm.
10. An insulating component for welding after the assembly of a railway freight car according to claim 1, characterized in that, The height h1 of the first opening part is 150-250 mm, the height h2 of the second opening part is 700-900 mm; the length of the horizontal bottom is 500-600 mm; the second length is 700-800 mm.