Split type steel rail induction heating device

Abstract

The utility model provides a split type steel rail induction heating device, and belongs to the technical field of railway steel rail welding. The split type steel rail induction heating device comprises a heating power supply used for converting a three-phase power frequency alternating current into a single-phase intermediate frequency alternating current; the induction heating machine head comprises a machine head frame and two heating modules arranged on the machine head frame, a heating space capable of containing a steel rail is formed between the two heating modules, each heating module comprises a resonant capacitor and a resonant inductor which are electrically connected, and the two resonant capacitors are electrically connected with a heating power source. According to the split type steel rail induction heating device provided by the utility model, by adopting the split type design, the light weight and portability of the device are realized, so that the field operation personnel can operate by one person, and the operation efficiency is obviously improved.

Description

Technical Field

[0001] This utility model relates to the field of railway rail welding technology, and in particular to a split-type rail induction heating device. Background Technology

[0002] Heat treatment of rail welds is a key technology for seamless railways, playing a crucial role in their development, especially under high-speed, heavy-load conditions where the quality requirements for seamless track joints are even higher. Currently, seamless track rail welding primarily employs contact welding. Because the weld fusion line has undergone melting and high-temperature heating, an overheated zone appears near the fusion line, causing coarsening of the metal microstructure, particularly austenite grains, and a significant decrease in toughness and ductility. Tests show that the impact toughness near the weld fusion line is only 30-40% of the base material, and the ductility is only 50-60%. The drop hammer test, reflecting the comprehensive performance of the weld joint, fails to meet current standards, seriously affecting the safe use of seamless tracks. Furthermore, for fully hardened rails, the original hardened layer disappears after contact welding, resulting in a wider low-hardness zone. This easily leads to joint depressions and induced wavy wear during use, shortening the service life of fully hardened rail seamless tracks. To address these issues, post-weld heat treatment is essential.

[0003] Electromagnetic induction heat treatment is currently the most widely used post-weld heat treatment method. However, existing mobile rail post-weld heat treatment equipment is bulky and lacks stability. The heat treatment system requires generators, power supplies, chillers, hydraulic pump stations, and other related equipment, and the front end of the heat treatment machine head needs a medium-frequency transformer, resulting in a cumbersome induction heating system that cannot be easily handheld. Furthermore, most currently used induction heating coils are designed with two separate halves, using mechanical clamping to ensure the passage of high-frequency current. This clamping method requires a flat contact surface and appropriate external loading, posing potential risks when applied in complex field environments. The heavy transformers in existing equipment prevent a reduction in the working weight and size of the machine head, limiting its applicability in various scenarios due to its reliance on mechanical fixing and movement.

[0004] In view of this, based on years of experience in production and design in this and related fields, the inventor has designed a split-type rail induction heating device through repeated experiments in order to solve the problems existing in the prior art. Utility Model Content

[0005] The purpose of this invention is to provide a split-type rail induction heating device, which reduces the weight of the equipment and facilitates operation by on-site workers.

[0006] To achieve the above-mentioned utility model objectives, this utility model proposes a split-type rail induction heating device, wherein the heating power supply is used to convert three-phase power frequency AC power into single-phase medium frequency AC power.

[0007] An induction heating head includes a head frame and two heating modules mounted on the head frame. A heating space capable of accommodating a steel rail is formed between the two heating modules. Each heating module includes an electrically connected resonant capacitor and a resonant inductor. The two resonant capacitors are respectively electrically connected to a heating power supply.

[0008] Compared with the prior art, the present invention has the following features and advantages:

[0009] This utility model proposes a split-type rail induction heating device. By adopting a split design, the device is lightweight and portable, enabling single-person operation by on-site personnel and significantly improving work efficiency.

[0010] This utility model proposes a split-type rail induction heating device. The entire process water-cooled heat dissipation system effectively solves the heat dissipation problem of the equipment under high current and high frequency operating conditions. In addition, the DC power supply with IGBT as the core provides a stable and adjustable power supply. This not only improves the heat treatment quality, reduces labor intensity and safety risks, but also enhances the applicability and flexibility of the equipment. It provides an efficient, convenient and safe new solution for the rail welding field in the railway industry. Attached Figure Description

[0011] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. Those skilled in the art, under the guidance of this invention, can select various possible shapes and proportions to implement this invention according to specific circumstances.

[0012] Figure 1 This is a schematic diagram of the portable split-type rail induction heating device of this utility model.

[0013] Figure 2 This is a schematic diagram of the DC power supply of this utility model;

[0014] Figure 3 This is a front view of the induction heating head structure of this utility model;

[0015] Figure 4 This is a top view of the induction heating head structure of this utility model;

[0016] Figure 5 This is a side view of the induction heating head structure of this utility model.

[0017] Explanation of the attached figure numbers:

[0018] 10. Resonant capacitor; 20. Resonant inductor; 30. Headstock frame;

[0019] 31. Bracket; 32. Mounting plate; 33. Hinge;

[0020] 40. Heating power supply; 50. Cooling system; 60. Generator or grid power. Detailed Implementation

[0021] The details of this utility model can be more clearly understood by referring to the accompanying drawings and the description of specific embodiments. However, the specific embodiments of this utility model described herein are for illustrative purposes only and should not be construed as limiting the utility model in any way. Under the teachings of this utility model, those skilled in the art can conceive of any possible modifications based on this utility model, and these should all be considered to fall within the scope of this utility model.

[0022] This utility model proposes a split-type rail induction heating device, wherein the heating power supply 40 is used to convert three-phase power frequency AC to single-phase medium frequency AC; the induction heating head includes a head frame 30 and two heating modules disposed on the head frame, forming a heating space between the two heating modules that can accommodate the rail; the heating module includes an electrically connected resonant capacitor 10 and a resonant inductor 20, and the two resonant capacitors 10 are electrically connected to the heating power supply 40 respectively.

[0023] The split-type induction heating device proposed in this utility model has the following overall structure: Figure 1 As shown, it includes a heating power supply and an induction heating head. The input of the heating power supply is three-phase AC power provided by an external generator or grid power supply, and the output is single-phase medium-frequency AC power. The induction heating head includes two independent resonant circuits composed of two sets of resonant inductors and resonant capacitors. The steel rail is placed in the middle of the resonant inductors, and induction heating is performed using the principle of electromagnetic induction.

[0024] In the split-type induction heating device proposed in this utility model, the specific structure of the machine head is as follows: Figures 3-5 As shown, two independent resonant circuits are placed on both sides of the rail. When the split-type induction heating device is in operation, although the two resonant circuits are in an overlapping state, they still remain two independent resonant circuits. The two resonant circuits act on both sides of the rail joint respectively, performing post-weld induction heating on the rail joint. After the heating process is completed, the induction heating head is removed. The overall weight of the induction heating head does not exceed 20kg, allowing for single-person operation by on-site personnel.

[0025] This utility model proposes a split-type rail induction heating device, which heats the rail joint through two resonant circuits designed separately, achieving lightweight and portable equipment, enabling single-person operation on site and significantly improving work efficiency.

[0026] In an optional embodiment of this utility model, the resonant inductor 20 is an induction heating coil. The bending arc of the induction heating coil is adapted to the profile of the rail. The two induction heating coils enclose a heating space, and the cross-sectional shape of the heating space is the same as the cross-sectional shape of the rail.

[0027] Specifically, the induction heating coils are designed with a specific bending arc, which precisely corresponds to the cross-sectional shape of the rail, ensuring that the coils fit snugly against the rail's side. Two induction heating coils are symmetrically arranged on both sides of the rail, forming a closed heating space whose cross-sectional shape matches that of the rail. This ensures that the rail joint is uniformly heated throughout the entire process. During operation, single-phase medium-frequency AC power from the heating power supply is transmitted to the induction heating coils. Based on the principle of electromagnetic induction, eddy currents are generated inside the rail, resulting in rapid and uniform heating of the rail joint.

[0028] The structural design of the split-type rail induction heating device proposed in this invention not only ensures the high efficiency of the heat treatment process, but also ensures the uniformity of the heating process through the precise fit between the induction heating coil and the rail profile, avoiding problems such as localized overheating or underheating. This improves the quality of the welded joint and extends its service life. Furthermore, the symmetrical arrangement of the induction heating coils and the enclosed heating space design reduce heat loss and improve energy utilization efficiency. Finally, this design simplifies the assembly and operation of the equipment, as the induction heating coils can be quickly and accurately placed around the rail without complex adjustments or fixings. This not only improves the convenience of operation but also reduces operational complexity, making the equipment more suitable for on-site working environments. In summary, the above structure not only improves the heat treatment effect but also enhances the flexibility and practicality of the equipment, providing a highly efficient, reliable, and easy-to-operate rail induction heating solution.

[0029] In one alternative embodiment of this implementation, when the heating space is enclosed, there is a gap between the induction heating coil and the rail. This gap not only avoids damage that might be caused by physical contact but also allows heat to be evenly distributed within the rail via induction. During operation, the alternating current inside the induction heating coil generates an alternating magnetic field. This magnetic field passes through the gap and interacts with the rail, generating eddy currents within the rail, thus achieving rapid heating. This gap design allows the magnetic field generated by the induction heating coil to penetrate the rail more effectively, resulting in a more uniform distribution of eddy currents within the rail, improving heating efficiency and the quality of the welded joint.

[0030] In one optional embodiment of the present invention, the head frame 30 includes a bracket 31 and two mounting plates 32. The two mounting plates 32 are symmetrically arranged on opposite sides of the bracket 31. One side of each mounting plate 32 is hinged to the bracket 31, and the other side of each mounting plate 32 can swing up and down. The heating module is correspondingly arranged on the lower surface of the mounting plate 32.

[0031] The split-type rail induction heating device of this invention features a head frame 30 design that ensures the balance and symmetry of the device. One side of each mounting plate 32 is connected to the support 31 via a hinge structure, allowing the mounting plate 32 to swing up and down within a certain range. This adapts to rails of different sizes and provides necessary flexibility during installation and disassembly. Furthermore, the ability of the mounting plate 32 to swing up and down allows the heating module to precisely align with the upper surface of the rail. The heating module is correspondingly positioned on the lower surface of the mounting plate 32. When the mounting plate 32 swings into position, the heating module forms a closed heating space with the rail, allowing the heating module to conform to the rail and achieve efficient induction heating.

[0032] The split-type rail induction heating device of this utility model has a head frame 30 design that allows the heating module to flexibly adapt to rails of different sizes. The hinged and swing design of its mounting plate 32 allows the heating module to be quickly and accurately positioned above the rail, which simplifies the installation and adjustment process of the equipment.

[0033] In an alternative embodiment, the mounting plate 32 is hinged to the bracket 31 via two or more hinges 33, allowing the mounting plate 32 to swing freely along the axis of the hinges 33, thereby achieving adaptive contact with the rail. The use of hinges 33 not only provides a stable connection point but also allows the mounting plate 32 to be adjusted within a certain angle range to accommodate rails of different sizes or for fine-tuning under different operating conditions. The hinges 33 enhance the structural stability and durability of the entire device, ensuring that the mounting plate 32 maintains a stable position even under heavy loads or prolonged use, reducing uneven heating problems caused by deformation or displacement of the mounting plate 32.

[0034] In one optional embodiment of this invention, the resonant capacitor 10 is fixedly connected to the mounting plate 32, and the resonant inductor 20 is fixedly connected to the resonant capacitor 10. In the split-type rail induction heating device of this invention, the fixed connection of the resonant capacitor 10 and the resonant inductor 20 (i.e., the induction heating coil) achieves efficient induction heating. The resonant capacitor 10 and the resonant inductor 20 together constitute a resonant circuit, where the resonant capacitor 10 stores electrical energy, and the resonant inductor 20 acts as an inductor, forming a resonant circuit together with the resonant capacitor 10. When the single-phase intermediate-frequency AC power output from the power supply is transmitted to the resonant inductor 20, the current and voltage in the resonant circuit reach a resonant state, generating a strong electromagnetic field, thereby achieving efficient induction heating of the rail. The design of this utility model of a split-type rail induction heating device simplifies the assembly and maintenance process by fixing all key components in one position, making it easier for operators to perform quick inspections and maintenance. The fixed connection also reduces the risk of component displacement or damage due to vibration or impact during operation. This layout can greatly improve the stability and reliability of the device.

[0035] In an alternative embodiment, a handle is provided on the mounting plate 32. The specific position of the handle is preferably designed to ensure an optimal grip point during handling and operation. The handle is fixed to the mounting plate 32 and coordinated with the positions of the resonant capacitor 10 and the resonant inductor 20 to ensure the balance and symmetry of the overall design. In practical use, the operator can easily lift or move the entire induction heating device using the handle without direct contact with the induction heating coil or other sensitive components. The material and structure of the handle also take into account durability and impact resistance to withstand various environmental conditions that may be encountered in field operations. The handle provides a safe grip point for the split-type rail induction heating device, reducing the risk of electric shock or burns to the operator during handling and improving operational safety.

[0036] In an optional embodiment, the mounting plate 32 is further provided with a flipping drive mechanism (not shown in the figure), enabling the mounting plate 32 to flip around the hinge point. The flipping drive mechanism can be manual or electric, including but not limited to gear systems, hydraulic cylinders, or pneumatic cylinders, to adapt to different operating requirements and environmental conditions. The flipping drive mechanism allows the mounting plate 32 to move from a vertical position to a position in contact with the rail, achieving precise alignment between the resonant inductor 20 and the rail. This improves the flexibility and adaptability of the split-type rail induction heating device, simplifies the installation and adjustment process, and allows operators to quickly position the induction heating device to the required location even in different working environments and with different rail specifications.

[0037] In an optional embodiment of this utility model, the heating power supply is connected to the resonant capacitor 10 via a water-cooled cable, which ensures efficient energy transfer between the heating power supply 40 and the heating module, while solving the heat dissipation problem under high current operating conditions.

[0038] In this invention's split-type rail induction heating device, the connection between the heating power supply 40 and the resonant capacitor 10 is achieved through a water-cooled cable. This ensures efficient energy transfer between the heating power supply 40 and the heating module, while simultaneously solving the heat dissipation problem under high-current operation. The water-cooled cable not only serves as the current transmission medium but also acts as a coolant channel, effectively transferring the heat generated by the current from the power supply to the cooling system 50, thereby maintaining the temperature of the heating power supply 40 and the induction heating head within a safe operating range. In practical applications, the water-cooled cable design allows for a certain distance between the induction heating head and the heating power supply 40, while ensuring a stable connection between the heating power supply 40 and the resonant capacitor 10, enabling continuous and efficient induction heating. The use of the water-cooled cable significantly improves the thermal management efficiency between the heating power supply 40 and the heating module, preventing overheating caused by prolonged high-current operation, thus enhancing the stability and reliability of the equipment.

[0039] In one optional embodiment of this utility model, the heating power supply 40 is a DC power supply, comprising: a rectifier circuit for converting three-phase power frequency AC to fixed DC; a voltage regulating circuit for converting the fixed DC to stable and adjustable DC; and an inverter circuit for converting the stable and adjustable DC to single-phase medium frequency AC. The schematic diagram of the DC power supply for the portable split-type induction heating device is shown below. Figure 2 As shown, a DC-DC voltage regulating circuit and an inverter circuit are employed. The rectifier circuit uses an uncontrolled rectification method to convert the three-phase AC power from the generator or grid into DC power, which is then input to the DC-DC voltage regulating circuit. The DC-DC voltage regulating circuit adopts a BUCK-BOOST principle circuit structure, which steps up and down the DC power from the rectifier circuit to convert it into a stable and adjustable DC power, which is then output to the inverter circuit. The inverter circuit uses IGBT power devices as its core, converting the stable and adjustable DC power from the DC-DC voltage regulating circuit into single-phase medium-frequency AC power. This AC power is then output to the resonant circuit of the induction heating head after passing through the medium-frequency transformer located in the power cabinet. Through the combination of the rectifier circuit, voltage regulating circuit, and inverter circuit, a highly controllable power supply is provided for the split-type rail induction heating device. It can maintain stable performance and precisely adjust the output according to different heating requirements and operating conditions. It can provide uniform and consistent heating regardless of grid voltage fluctuations or changes in rail dimensions.

[0040] The detailed explanations of the above embodiments are intended only to explain the present invention so as to facilitate a better understanding of the present invention. However, these descriptions should not be construed as limiting the present invention for any reason. In particular, the various features described in different embodiments can be arbitrarily combined with each other to form other embodiments. Unless there is an explicit description to the contrary, these features should be understood to be applicable to any embodiment, and not limited to the described embodiments.

Claims

1. A split-type rail induction heating device, characterized in that, The split-type rail induction heating device includes at least: Heating power supply, used to convert three-phase power frequency AC to single-phase medium frequency AC; An induction heating head includes a head frame and two heating modules mounted on the head frame. A heating space capable of accommodating a steel rail is formed between the two heating modules. Each heating module includes an electrically connected resonant capacitor and a resonant inductor. The two resonant capacitors are respectively electrically connected to the heating power supply.

2. The split-type rail induction heating device as described in claim 1, characterized in that, The resonant inductor is an induction heating coil, the bending arc of which is adapted to the profile of the rail, and the two induction heating coils enclose the heating space, the cross-sectional shape of which is the same as that of the rail.

3. The split-type rail induction heating device as described in claim 2, characterized in that, When the heating space is formed, there is a gap between the induction heating coil and the rail.

4. The split-type rail induction heating device as described in claim 1, characterized in that, The machine head frame includes a bracket and two mounting plates. The two mounting plates are symmetrically arranged on opposite sides of the bracket. One side of each mounting plate is hinged to the bracket, and the other side of each mounting plate can swing up and down. The heating module is correspondingly arranged on the lower surface of the mounting plate.

5. The split-type rail induction heating device as described in claim 4, characterized in that, The mounting plate is hinged to the bracket by two or more hinges.

6. The split-type rail induction heating device as described in claim 4, characterized in that, The resonant capacitor is fixedly connected to the mounting plate, and the resonant inductor is fixedly connected to the resonant capacitor.

7. The split-type rail induction heating device as described in claim 4, characterized in that, The mounting plate is equipped with a handle.

8. The split-type rail induction heating device as described in claim 4, characterized in that, The mounting plate is equipped with a flip drive mechanism.

9. The split-type rail induction heating device as described in claim 1, characterized in that, The heating power supply is connected to the resonant capacitor via a water-cooled cable.

10. The split-type rail induction heating device as described in claim 1, characterized in that, The heating power source includes: The rectifier circuit will convert three-phase power frequency AC power into fixed DC power in the future. The voltage regulating circuit converts the fixed DC power into a stable and adjustable DC power. The inverter circuit converts the stable and adjustable direct current into single-phase intermediate frequency alternating current.

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