Movable steel rail induction welding device

Abstract

The utility model relates to a movable steel rail induction welding device. A first rail clamping assembly, a second rail clamping assembly and a steel rail upsetting assembly are mounted on the frame machine body assembly; the device further comprises a weld beading pushing and protruding assembly and a welding heating assembly. The frame machine body assembly comprises a static frame piece and a movable frame piece. A plurality of frame guide shafts which are in sliding connection with the static frame part are mounted on the movable frame part; the steel rail upsetting assembly comprises an upsetting oil cylinder and an upsetting shaft; the welding heating assembly comprises a welding heating cylinder, a coil transverse moving seat plate and a switching electrode mechanism, a right coil mechanism and a left coil mechanism are arranged on the two sides of the switching electrode mechanism respectively, the welding heating assembly further comprises a coil driving mechanism, and the left coil mechanism and the right coil mechanism are in contact and electric connection with the switching electrode mechanism after being in butt joint and folded and are provided with a cavity matched with the section of a steel rail. The weld beading pushing and protruding assembly comprises a pushing and protruding oil cylinder, a pushing and protruding moving seat and a pushing and protruding cutter mechanism. According to the utility model, the functions of welding, upsetting, nodule removal and heat treatment can be completed by clamping the steel rail at one time, the relative position of the welding seam and the coil can be adjusted, the accurate positioning of the welding seam and the coil is realized, the integration level is high, the requirement on the site is reduced, and the labor intensity and the input cost of workers are reduced.

Description

Technical Field

[0001] This utility model belongs to the field of rail weld heating equipment, and particularly relates to a mobile rail induction welding device. Background Technology

[0002] Currently, flash welding is the primary method used for connecting railway rails. However, the high temperature at the weld joint causes excessive grain growth on both sides of the rail, severely impacting the mechanical properties of the weld joint. Normalizing treatment can effectively improve the grain size on both sides of the rail weld, thereby enhancing the rail's mechanical properties.

[0003] Currently, the normalizing system for rail welded joints mainly employs two heating methods: medium-frequency induction heating coil heating and flame heating. Induction welding utilizes the eddy current effect in the workpiece induced by an alternating magnetic field-electric field to heat the workpiece, causing it to melt and thus achieving welding; it belongs to pressure welding. Induction heating can be divided into high-frequency induction heating (100kHz~1000kHz), medium-frequency induction heating (1kHz~10kHz), and power frequency induction heating (50Hz) according to the frequency of the current used. Medium-frequency (1~10kHz) heating depth is 2-10mm, generally used for heating large-diameter shafts and large and medium-sized forged workpieces. Compared with flame heating, medium-frequency induction heating has advantages such as faster heating speed, measurable heating temperature, automatic control, and guaranteed normalizing quality.

[0004] Currently, rail welding and post-weld heat treatment at railway sites are carried out separately using different devices or equipment. This process suffers from low automation, high labor intensity, low organizational efficiency, and long construction cycles. Furthermore, the aforementioned separate devices are cumbersome and lack mobility. When welding and heat treatment is required at the rail joints, workers must manually operate the coil clamps to hold the rails and manually judge the coil alignment, resulting in high labor intensity and poor repeatability. Additionally, the welding devices lack weld bead removal capabilities, requiring manual removal, which is cumbersome. Moreover, after welding heating stops, the weld head cools rapidly from its high temperature; delays in removal significantly increase the difficulty. Therefore, there is an urgent need to design a mobile rail induction welding device to solve these problems. Utility Model Content

[0005] This invention provides a mobile rail induction welding device with a reasonable structural design to solve the technical problems existing in the prior art. This invention can complete welding, deburring, and heat treatment operations on a rail in a single clamping operation. It can also adjust the relative position of the weld and the coil to achieve precise positioning. It has a high degree of integration, reduces site requirements, lowers the labor intensity of workers, and reduces investment costs.

[0006] The technical solution adopted by this utility model to solve the technical problems existing in the prior art is as follows: A mobile rail induction welding device includes a frame body assembly, on which a first rail clamping assembly and a second rail clamping assembly are installed in parallel along the length of the rail for clamping the rail; a rail upsetting assembly is installed on the frame body assembly for driving the first rail clamping assembly and the second rail clamping assembly to move relative to each other along the length of the rail; it also includes a weld bead pushing assembly and a welding heating assembly installed on the frame body assembly, both of which can move along the length of the rail; it also includes a transformer installed on the welding heating assembly for providing electrical energy to the welding heating assembly; the frame body assembly includes a static frame member and a moving frame member arranged in parallel and respectively for installing the second rail clamping assembly and the first rail clamping assembly, and a rail groove for the rail to pass through is opened at the lower end of both the static frame member and the moving frame member; a component that is slidably connected to the static frame member and parallel to the rail is installed on the moving frame member. The system includes multiple frame guide shafts; a rail upsetting assembly including an upsetting cylinder mounted on a stationary frame member, an upsetting shaft mounted on the upsetting cylinder parallel to the frame guide shafts and fixedly connected to the moving frame member; a welding heating assembly including a welding heating cylinder mounted on a stationary frame member, a coil transverse shifting plate mounted at the extended end of the welding heating cylinder between the stationary and moving frame members, a transfer electrode mechanism electrically connected to a transformer mounted on the coil transverse shifting plate, a right coil mechanism and a left coil mechanism slidably connected to the coil transverse shifting plate on both sides of the transfer electrode mechanism, and a coil drive mechanism for driving the right and left coil mechanisms to dock / open, after which the right and left coil mechanisms are docked and electrically connected to the transfer electrode mechanism and have cavities adapted to the cross-section of the rail; and a weld bead pushing assembly including a pushing cylinder mounted on a moving frame member, a pushing moving seat mounted at the extended end of the pushing cylinder between the stationary and moving frame members, and a pushing knife mechanism mounted on the pushing moving seat.

[0007] The advantages and positive effects of this utility model are as follows: This utility model provides a mobile rail induction welding device. By setting up a welding heating component, it can realize induction welding and normalizing of rails. The coil drive mechanism in the welding heating component can drive the right coil mechanism and the left coil mechanism to close / open, thereby realizing the operation of wrapping the rail to be welded for induction welding, reducing the flash time during the welding process and reducing the amount of rail burning. The welding heating cylinder can drive the right coil mechanism and the left coil mechanism to move as a whole along the extension direction of the rail, thereby adjusting the relative position of the weld and the coil to achieve the desired welding effect. The precise positioning allows the right and left coil mechanisms to be moved to the weld position via a welding heating cylinder after welding to complete the heat treatment operation. This makes it suitable for various working environments and reduces site requirements. The rail upsetting assembly, in conjunction with the first and second rail clamping assemblies, applies upsetting pressure to the two mating rails, forging them and improving welding quality. The weld bead pushing assembly automatically removes the weld bead after welding, eliminating the need for manual removal and simplifying the process, further reducing labor intensity. This invention integrates induction welding and normalizing into a single welding heating assembly, using a single control and execution mechanism. This allows for multiple tasks—upsetting, induction welding, weld bead pushing, and normalizing—to be completed in a single rail clamping operation. The high degree of integration and automation, along with the compact and rational structure, improves work efficiency and reduces labor intensity and equipment costs.

[0008] Preferably, the first rail clamping assembly includes two clamping mounting shafts arranged in parallel, a support limiting block fixedly connected to the clamping mounting shaft is provided through the clamping mounting shaft, a clamping mechanism is provided on both sides of the support limiting block, a plate is installed at the jaw of each clamping mechanism and a positioning ball that rolls in contact with the rail is embedded in the plate; it also includes a clamping drive mechanism for driving the clamping mechanism; the structure of the second rail clamping assembly is the same as that of the first rail clamping assembly.

[0009] Preferably, the clamping mechanism includes two clamping main arms that are rotatably connected to and symmetrically arranged on two clamping mounting shafts. Each clamping main arm includes a pivot connecting part that is pivotally connected to the clamping mounting shaft. Engaging teeth are provided on the inner side of each pivot connecting part, and the engaging teeth on the two pivot connecting parts engage with each other. An upper driving part is integrally formed on the upper part of the pivot connecting part and is pivotally connected to the clamping driving mechanism. A lower clamping part is integrally formed on the lower part of the pivot connecting part. Rail clamping blocks can be detachably installed on the inner side of each lower clamping part.

[0010] Preferably, the clamping drive mechanism includes a cylinder limiting seat fixed to the support limiting block, a clamping cylinder slidably mounted on the cylinder limiting seat, the extended end of the clamping cylinder being pivotally connected to the support limiting block, and a clamping drive block mounted on the cylinder barrel of the clamping cylinder, with clamping joint plates pivotally connected between the clamping drive block and each clamping mechanism.

[0011] Preferably, the electrode transfer mechanism includes an electrode tapper mounted on a coil transverse support plate, a left short electrode mounted on one end of the electrode tapper via an insulating plate, a right short electrode mounted on the other end of the electrode tapper via an insulating plate, a left electrode plate mounted on the left short electrode, and a right electrode plate mounted on the right short electrode; both the left and right electrode plates are connected to the transformer.

[0012] Preferably, the left coil mechanism includes a left coil mounting frame slidably connected to the coil transverse sliding plate. A left first coil and a left second coil are mounted side by side on the left coil mounting frame. An insulating structure is provided between the left first coil and the left coil mounting frame, and between the left second coil and the left coil mounting frame. A left upper coil contact plate is installed on the upper part of both the left first coil and the left second coil, and a left lower coil contact plate is installed on the lower part of both the left first coil and the left second coil. Both the left first coil and the left second coil are made of hollow copper coils.

[0013] Preferably, the right coil mechanism includes a right coil mounting frame slidably connected to the coil transverse sliding plate. A right first coil and a right second coil are mounted side by side on the right coil mounting frame. An insulating structure is provided between the right first coil and the right coil mounting frame, and between the right second coil and the right coil mounting frame. A right upper coil contact plate is installed on the upper part of both the right first coil and the right second coil, and a right lower coil contact plate is installed on the lower part of both the right first coil and the right second coil. Both the right first coil and the right second coil are made of hollow copper coils.

[0014] Preferably, the coil drive mechanism includes two swing arm supports fixedly mounted on the coil transverse support plate. The two swing arm supports are arranged side by side and located on both sides of the transfer electrode mechanism. A coil swing arm rod is pivotally connected to each swing arm support. The two coil swing arm rods are symmetrically arranged. An opening and closing hydraulic cylinder is pivotally connected between the two coil swing arm rods. The mechanism also includes two coil slide rails installed on the right coil mechanism and the left coil mechanism, respectively. A coil drive slider is slidably connected in each coil slide rail. The two coil drive sliders are pivotally connected to the two coil swing arm rods, respectively.

[0015] Preferably, the push-out knife mechanism includes a left push-out knife seat mounted on a push-out moving seat, an upper push-out knife seat pivotally connected to the top of the left push-out knife seat, a right push-out knife seat pivotally connected to the end of the upper push-out knife seat, and a locking plate pivotally connected to the end of the left push-out knife seat for hooking with the right push-out knife seat. It also includes a locking member mounted on the right push-out knife seat for locking the locking plate to the right push-out knife seat. When the locking plate is hooked with the right push-out knife seat, the left push-out knife seat, the upper push-out knife seat, and the right push-out knife seat form a cavity adapted to the cross-section of the rail. At the edge of the cavity, there are bottom push-out knives and left push-out knives connected to the left push-out knife seat, top push-out knives connected to the upper push-out knife seat, and right push-out knives connected to the right push-out knife seat.

[0016] Preferably, several lifting rings are installed on both the static frame member and the dynamic frame member. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the main structure of this utility model;

[0018] Figure 2 This is a three-dimensional structural schematic diagram of the present invention;

[0019] Figure 3 This is a three-dimensional structural diagram of the frame body assembly and the rail upsetting assembly in this utility model;

[0020] Figure 4 This is a three-dimensional structural diagram of the first rail clamping assembly in this utility model;

[0021] Figure 5 This is a three-dimensional structural diagram of the welding heating assembly in this utility model;

[0022] Figure 6 This is a three-dimensional structural schematic diagram of the coil drive mechanism in this utility model;

[0023] Figure 7 yes Figure 6 Enlarged diagram of region A in the image;

[0024] Figure 8 This is a three-dimensional structural diagram of the left coil mechanism in this utility model;

[0025] Figure 9 This is a three-dimensional structural diagram of the right coil mechanism in this utility model;

[0026] Figure 10 This is a three-dimensional structural schematic diagram of the transfer electrode mechanism in this utility model;

[0027] Figure 11 yes Figure 10 Enlarged diagram of region B in the image;

[0028] Figure 12 This is a three-dimensional structural schematic diagram of the weld bead pushing and protruding component in this utility model;

[0029] Figure 13 This is a three-dimensional structural diagram of the push-convex knife mechanism in this utility model.

[0030] In the diagram: 1. Rail; 2. Valve assembly; 3. First rail clamping assembly; 3-1. Support limiting block; 3-2. Clamping positioning plate; 3-3. Clamping main arm; 3-3-1. Lower clamping part; 3-3-2. Pivoting connection part; 3-3-3. Upper drive part; 3-3-4. Meshing teeth; 3-4. Clamping joint plate; 3-5. Clamping drive block; 3-6. Clamping cylinder; 3-7. Cylinder limiting seat; 3-8. Clamping mounting shaft; 3-9. Positioning ball; 3-10. Rail clamping block; 4. Lifting ring; 5. Weld bead pushing assembly; 5-1. Pushing cylinder; 5-2. Pushing knife mechanism; 5-2-1. Locking plate; 5-2- 2. Bottom pusher; 5-2-3. Left pusher protrusion holder; 5-2-4. Upper pusher protrusion holder; 5-2-5. Right pusher protrusion holder; 5-2-6. Screw mounting block; 5-2-7. Pusher protrusion handle; 5-2-8. Left pusher; 5-2-9. Right pusher; 5-2-10. Top pusher; 5-3. Pusher protrusion moving seat; 6. Welding heating assembly; 6-1. Right coil mechanism; 6-1-1. Lower right coil contact plate; 6-1-2. Lower right insulation groove; 6-1-3. Lower right mounting block; 6-1-4. Right first coil; 6-1-5. Right second coil; 6-1-6. Upper right coil contact plate; 6-1-7. Upper right insulation groove; 6-1- 8. Upper right mounting block; 6-1-9. Right coil mounting frame; 6-2. Left coil mechanism; 6-2-1. Lower left coil contact plate; 6-2-2. Lower left insulation groove; 6-2-3. Lower left mounting block; 6-2-4. Left first coil; 6-2-5. Left second coil; 6-2-6. Upper left coil contact plate; 6-2-7. Upper left insulation groove; 6-2-8. Upper left mounting block; 6-2-9. Left coil mounting frame; 6-3. Coil drive mechanism; 6-3-1. Coil guide rail; 6-3-2. Coil swing arm; 6-3-3. Swing arm support; 6-3-4. Opening and closing hydraulic cylinder; 6-3-5. Coil sliding groove component; 6-3- 6. Coil drive slider; 6-4. Electrode transfer mechanism; 6-4-1. Insulating plate; 6-4-2. Electrode taper; 6-4-3. Left short electrode; 6-4-4. Left electrode plate; 6-4-5. Right electrode plate; 6-4-6. Right short electrode; 6-5. Coil transverse moving seat plate; 6-6. Welding heating cylinder; 6-7. Temperature probe seat; 6-8. Copper tube; 7. Transformer; 8. Second rail clamping assembly; 9. Frame body assembly; 9-1. Static frame component; 9-2. Frame guide shaft; 9-3. Moving frame component; 9-4. Rail groove; 10. Rail upsetting assembly; 10-1. Upsetting cylinder; 10-2. Upsetting shaft. Detailed Implementation

[0031] To further understand the invention content, features, and effects of this utility model, the following embodiments are provided in detail:

[0032] Please see Figure 1 and Figure 2 The mobile rail induction welding device of this utility model includes a frame body assembly 9. A first rail clamping assembly 3 and a second rail clamping assembly 8, arranged parallel to each other along the length of the rails 1, are mounted on the frame body assembly 9 to clamp the two rails 1 being joined. A rail upsetting assembly 10 is mounted on the frame body assembly 9 to drive the first rail clamping assembly 3 and the second rail clamping assembly 8 to move relative to each other along the length of the rails 1. It also includes a weld bead pushing assembly 5 and a welding heating assembly 6 mounted on the frame body assembly 9, both of which can move along the length of the rails 1. A transformer 7 is also mounted on the welding heating assembly 6 to provide electrical energy. This embodiment also includes a valve assembly 2 mounted on the moving frame component 9-3.

[0033] See further Figure 2 and Figure 3 The aforementioned frame body assembly 9 includes a static frame member 9-1 and a moving frame member 9-3 arranged side-by-side and respectively used for mounting the second rail clamping assembly 8 and the first rail clamping assembly 3. Both the static frame member 9-1 and the moving frame member 9-3 have rail grooves 9-4 at their lower ends for the rails 1 to pass through. Multiple frame guide shafts 9-2 are mounted on the moving frame member 9-3, slidably connected to the static frame member 9-1 and arranged parallel to the rails 1. In this embodiment, two frame guide shafts 9-2 are provided. Multiple through holes are provided on the static frame member 9-1 for the frame guide shafts 9-2 to pass through, and guide copper sleeves are installed in the through holes. Furthermore, for ease of lifting, several lifting rings 4 are installed on both the static frame member 9-1 and the moving frame member 9-3.

[0034] like Figure 3 As shown, the aforementioned rail upsetting assembly 10 includes an upsetting cylinder 10-1 mounted on a static frame member 9-1, and an upsetting shaft 10-2 mounted on the upsetting cylinder 10-1, which is parallel to the frame guide shaft 9-2 and fixedly connected to the moving frame member 9-3. In this embodiment, the maximum upsetting force of the aforementioned upsetting cylinder 10-1 is 1200kN.

[0035] like Figure 4As shown, in this embodiment, the first clamping rail assembly 3 includes two clamping mounting shafts 3-8 arranged side by side, which are mounted on corresponding frame members. Supporting and limiting blocks 3-1 are threaded through and fixedly connected to the clamping and mounting shafts 3-8. Clamping mechanisms are provided on both sides of the supporting and limiting blocks 3-1, and clamping positioning pieces 3-2 are provided on the outer sides of each clamping mechanism for positioning the clamping mechanisms.

[0036] Each clamping mechanism has a plate installed at its jaws, and a positioning ball 3-9 that rolls in contact with the rail 1 is embedded in the plate. The first rail clamping assembly 3 also includes a clamping drive mechanism for driving the clamping mechanism.

[0037] Furthermore, the aforementioned clamping mechanism includes two clamping main arms 3-3 symmetrically arranged and rotatably connected to two clamping mounting shafts 3-8. Each clamping main arm 3-3 includes a pivot connecting part 3-3-2 pivotally connected to the clamping mounting shaft 3-8. Engaging teeth 3-3-4 are provided on the inner side of each pivot connecting part 3-3-2, and the engaging teeth 3-3-4 on the two pivot connecting parts 3-3-2 engage with each other. An upper driving part 3-3-3 is integrally formed on the upper part of the pivot connecting part 3-3-2 and is pivotally connected to the clamping driving mechanism. A lower clamping part 3-3-1 is integrally formed on the lower part of the pivot connecting part 3-3-2. Rail clamping blocks 3-10 can be detachably installed on the inner side of each lower clamping part 3-3-1. In this embodiment, the lower part of the two clamping main arms 3-3 installed on the clamping mounting shaft 3-8 is equipped with the same rail clamping block 3-10. The plate with the positioning ball 3-9 is installed on the rail clamping block 3-10 by screws. The positioning ball 3-9 makes rolling contact with the top lower side of the rail 1. Several anti-slip ridges are provided on the inner side of the rail clamping block 3-10.

[0038] Furthermore, the aforementioned clamping drive mechanism includes a cylinder limiting seat 3-7 fixedly connected to the support limiting block 3-1, a clamping cylinder 3-6 slidably mounted on the cylinder limiting seat 3-7, and the extended end of the clamping cylinder 3-6 pivotally connected to the support limiting block 3-1 via a pin. The clamping drive mechanism also includes a clamping drive block 3-5 mounted on the cylinder of the clamping cylinder 3-6, and a clamping joint plate 3-4 pivotally connected between the clamping drive block 3-5 and each clamping mechanism, that is, a clamping joint plate 3-4 pivotally connected between the upper end of each upper drive part 3-3-3 and the clamping drive block 3-5.

[0039] In addition, to protect the safety of the clamping drive mechanism, a longitudinally adjustable contact sensor is installed on the cylinder limit seat 3-7. The contact sensor cooperates with the clamping drive block 3-5. In actual operation, a sensor mounting plate can be installed on the cylinder limit seat 3-7. The contact sensor is installed on the sensor mounting plate. A longitudinally extending strip hole is opened on the sensor mounting plate, and it is connected to the cylinder limit seat 3-7 by screws passing through the strip hole.

[0040] Furthermore, in this embodiment, the structure of the second rail clamping assembly 8 is consistent with the structure of the first rail clamping assembly 3.

[0041] See further Figure 5 The aforementioned welding heating assembly 6 includes a welding heating cylinder 6-6 mounted on the static frame member 9-1. There are two welding heating cylinders 6-6 arranged side by side. A coil transverse moving plate 6-5 located between the static frame member 9-1 and the moving frame member 9-3 is installed at the extended end of the welding heating cylinder 6-6. Multiple through holes are provided on the coil transverse moving plate 6-5 for the frame guide shaft 9-2 and the upsetting shaft 10-2 to pass through, and guide copper sleeves are installed in the through holes. A transfer electrode mechanism 6-4 electrically connected to the transformer 7 is installed on the coil transverse sliding seat plate 6-5. On both sides of the transfer electrode mechanism 6-4, a right coil mechanism 6-1 and a left coil mechanism 6-2 are respectively slidably connected to the coil transverse sliding seat plate 6-5. The welding heating assembly 6 also includes a coil drive mechanism 6-3, which is used to drive the right coil mechanism 6-1 and the left coil mechanism 6-2 to dock / open. In actual operation, after the right coil mechanism 6-1 and the left coil mechanism 6-2 dock and close, they are in contact with the transfer electrode mechanism 6-4 and have cavities adapted to the cross section of the rail 1.

[0042] See further Figure 6 and Figure 7The aforementioned coil drive mechanism 6-3 includes two swing arm supports 6-3-3 fixedly mounted on the coil transverse support plate 6-5. The two swing arm supports 6-3-3 are arranged side by side and located on both sides of the transfer electrode mechanism 6-4. A coil swing arm rod 6-3-2 is pivotally connected to each swing arm support 6-3-3. The two coil swing arm rods 6-3-2 are symmetrically arranged, and an opening and closing hydraulic cylinder 6-3-4 is pivotally connected between the two coil swing arm rods 6-3-2. It also includes two coil slides mounted on the right coil mechanism 6-1 and the left coil mechanism 6-2 respectively. Each of the slots 6-3-5 has a coil drive slider 6-3-6 slidably connected within it. The two coil drive sliders 6-3-6 are pivotally connected to the two coil swing arms 6-3-2 respectively. In addition, several transversely arranged coil guide rails 6-3-1 are fixedly attached to the coil transverse sliding seat plate 6-5. In this embodiment, four sets of coil guide rails 6-3-1 are provided, and the four sets of coil guide rails 6-3-1 are arranged in pairs. The right coil mechanism 6-1 and the left coil mechanism 6-2 are slidably connected to the coil guide rails 6-3-1 through sliders.

[0043] See further Figure 10 and Figure 11 In this embodiment, the aforementioned electrode transfer mechanism 6-4 includes an electrode taper 6-4-2 mounted on the coil transverse support plate 6-5. A left short electrode 6-4-3 is mounted on one end of the electrode taper 6-4-2 via an insulating plate 6-4-1, and a right short electrode 6-4-6 is mounted on the other end of the electrode taper 6-4-2 via an insulating plate 6-4-1. Additionally, a left electrode plate 6-4-4 is mounted on the left short electrode 6-4-3, and a right electrode plate 6-4-5 is mounted on the right short electrode 6-4-6. Both the left electrode plate 6-4-4 and the right electrode plate 6-4-5 are connected to the transformer 7. Furthermore, both the left short electrode 6-4-3 and the right short electrode 6-4-6 have passages connecting their top and side surfaces, and connectors are installed at both ends of these passages.

[0044] like Figure 9As shown, in this embodiment, the right coil mechanism 6-1 includes a right coil mounting frame 6-1-9. The right coil mounting frame 6-1-9 is slidably connected to the coil transverse sliding plate 6-5 via a coil guide rail 6-3-1 and a slider. A right first coil 6-1-4 and a right second coil 6-1-5 are mounted side by side on the right coil mounting frame 6-1-9. Insulation is provided between the right first coil 6-1-4 and the right coil mounting frame 6-1-9, and between the right second coil 6-1-5 and the right coil mounting frame 6-1-9. The structure consists of two parallel upper right mounting blocks 6-1-8 mounted on the upper end of the right coil mounting frame 6-1-9, and two parallel lower right mounting blocks 6-1-3 mounted on the lower end of the right coil mounting frame 6-1-9. Each upper right mounting block 6-1-8 has an upper right insulating groove 6-1-7 mounted on its inner surface, and each lower right mounting block 6-1-3 has a lower right insulating groove 6-1-2 mounted on its inner surface. The lower right insulating grooves 6-1-2 and upper right insulating grooves 6-1-7 form an insulation structure. Upper right coil contact plates 6-1-6 are mounted on the upper parts of both the first right coil 6-1-4 and the second right coil 6-1-5, and lower right coil contact plates 6-1-1 are mounted on the lower parts of both. Both the first right coil 6-1-4 and the second right coil 6-1-5 are composed of hollow copper coils. In addition, copper tubes 6-8 are connected to the hollow ports of the right first coil 6-1-4 and the right second coil 6-1-5.

[0045] like Figure 8As shown, the left coil mechanism 6-2 includes a left coil mounting frame 6-2-9 that is slidably connected to the coil transverse base plate 6-5. The left coil mounting frame 6-2-9 is slidably connected to the coil transverse base plate 6-5 via the coil guide rail 6-3-1 and the slider. A left first coil 6-2-4 and a left second coil 6-2-5 are mounted side by side on the left coil mounting frame 6-2-9. Insulation structures are provided between the left first coil 6-2-4 and the left coil mounting frame 6-2-9, and between the left second coil 6-2-5 and the left coil mounting frame 6-2-9. Specifically, two left upper mounting blocks 6-2-8 are mounted side by side at the upper end of the left coil mounting frame 6-2-9, and two left lower mounting blocks 6-2-3 are mounted side by side at the lower end of the left coil mounting frame 6-2-9. A left upper insulating groove 6-2-7 is installed on the inner side of each left upper mounting block 6-2-8, and a left lower insulating groove 6-2-2 is installed on the inner side of each left lower mounting block 6-2-3. The left lower insulating groove 6-2-2 and the left upper insulating groove 6-2-7 constitute an insulation structure. A left upper coil contact plate 6-2-6 is installed on the upper part of both the left first coil 6-2-4 and the left second coil 6-2-5, and a left lower coil contact plate 6-2-1 is installed on the lower part of both the left first coil 6-2-4 and the left second coil 6-2-5; both the left first coil 6-2-4 and the left second coil 6-2-5 are made of hollow copper coils. A copper tube 6-8 is connected to the hollow port of both the left first coil 6-2-4 and the left second coil 6-2-5.

[0046] In addition, such as Figure 10 As shown, two temperature probe seats 6-7 are installed on the coil transverse sliding seat plate 6-5, which are respectively distributed on the outside of the right coil mechanism 6-1 and the left coil mechanism 6-2. A temperature probe is installed on each temperature probe seat 6-7 (not shown in the figure).

[0047] In actual operation, when the left coil mechanism 6-2 and the right coil mechanism 6-1 are closed, the lower left coil contact plate 6-2-1 mounted on the left coil 6-2-4 contacts the lower right coil contact plate 6-1-1 mounted on the right coil 6-1-4, and the lower left coil contact plate 6-2-1 mounted on the left coil 6-2-5 contacts the lower right coil contact plate 6-1-1 mounted on the right coil 6-1-5; simultaneously, the lower left coil 6-2-5... The upper left coil contact plate 6-2-6 mounted on the top contacts the left short electrode 6-4-3. The upper left coil contact plate 6-2-6 mounted on the left first coil 6-2-4 contacts one end of the electrode taper 6-4-2. The upper right coil contact plate 6-1-6 mounted on the right first coil 6-1-4 contacts the right short electrode 6-4-6. The upper right coil contact plate 6-1-6 mounted on the right second coil 6-1-5 contacts the other end of the electrode taper 6-4-2. Finally, the electrode transfer mechanism 6-4, the left second coil 6-2-5, the left first coil 6-2-4, the right first coil 6-1-4, and the right second coil 6-1-5 form a double-turn circuit. The double-turn coil design significantly improves efficiency compared to a single-turn coil.

[0048] This embodiment also includes an IGBT power supply (not shown in the figure), which is electrically connected to the aforementioned transformer 7. The basic information of the IGBT power supply is as follows: operating mode—series resonance; DC voltage—550V; maximum power—120kW; alternating frequency—8000-20000Hz; cooling water requirement—0.3MPa.

[0049] See further Figure 12 The aforementioned weld bead pushing assembly 5 includes two sets of pushing cylinders 5-1 mounted on the moving frame member 9-3, arranged side by side. A pushing moving seat 5-3, located between the stationary frame member 9-1 and the moving frame member 9-3, is mounted at the extended end of the pushing cylinder 5-1. Multiple through holes are provided on the pushing moving seat 5-3 for the frame guide shaft 9-2 and the upsetting shaft 10-2 to pass through, and guide copper sleeves are installed within these through holes. Additionally, a pushing knife mechanism 5-2 is mounted on the pushing moving seat 5-3.

[0050] See further Figure 13 The aforementioned push-convex knife mechanism 5-2 includes a left push-convex knife seat 5-2-3 mounted on the push-convex moving seat 5-3, an upper push-convex knife seat 5-2-4 pivotally connected to the top of the left push-convex knife seat 5-2-3, a right push-convex knife seat 5-2-5 pivotally connected to the end of the upper push-convex knife seat 5-2-4, and a locking plate 5-2-1 pivotally connected to the end of the left push-convex knife seat 5-2-3 for hooking and connecting with the right push-convex knife seat 5-2-5. It also includes a locking member mounted on the right push-convex knife seat 5-2-5 for locking the locking plate 5-2-1 and the right push-convex knife seat 5-2-5.

[0051] The aforementioned locking component includes a push-pull handle 5-2-7 pivotally connected to the right push-pull cutter seat 5-2-5, and a screw mounting block 5-2-6 fixedly connected to the push-pull handle 5-2-7. When the locking plate 5-2-1 is hooked and connected to the right push-pull cutter seat 5-2-5, the screw mounting block 5-2-6 is connected to the locking plate 5-2-1 by bolts.

[0052] When the locking plate 5-2-1 is hooked and connected to the right push-face knife seat 5-2-5, the left push-face knife seat 5-2-3, the upper push-face knife seat 5-2-4, and the right push-face knife seat 5-2-5 form a cavity adapted to the cross-section of the rail 1. At the edge of the cavity, there are bottom push knife 5-2-2 and left push knife 5-2-8 connected to the left push-face knife seat 5-2-3, top push knife 5-2-10 connected to the upper push-face knife seat 5-2-4, and right push knife 5-2-9 connected to the right push-face knife seat 5-2-5. The bottom push knife 5-2-2, left push knife 5-2-8, top push knife 5-2-10, and right push knife 5-2-9 are made of high-quality high-temperature alloy material and can work normally at a high temperature of 1200℃.

[0053] This embodiment also includes a hydraulic station connected to the valve assembly 2. One end of the valve assembly 2 is connected to a hydraulic circuit, which is adapted to be connected to the inlet end of each of the above-mentioned oil cylinders. The other end of the valve assembly 2 is connected to the hydraulic station.

[0054] This embodiment also includes a cooling system. During welding and normalizing, the cooling system uses external water circulation, allowing water to pass through the hollow coils in the right coil mechanism 6-1 and the left coil mechanism 6-2 to prevent the coils from overheating. This embodiment also includes a control box, which includes a PLC controller and a touch screen connected to the PLC controller. The PLC controller is connected to the power circuit, and the control terminals of each hydraulic cylinder are connected to the control terminals of the PLC controller. Several sensors and probes are connected to the detection terminals of the PLC controller. The PLC controller receives the detection information from the sensors and probes, acquires and displays the detection information on the touch screen, and automatically controls the corresponding actions of each component after judgment, or sends instructions through the touch screen. After receiving the instructions, the PLC controller controls the corresponding actions of each component.

[0055] Working principle:

[0056] In use, first connect transformer 7 to IGBT power supply, then start the clamping cylinders in each rail clamping assembly. The clamping cylinders drive the clamping mechanism to rotate around the clamping mounting shaft 3-8, thereby causing the jaws at the bottom of the first rail clamping assembly 3 and the second rail clamping assembly 8 to clamp and center the two rails 1 to be welded. The upsetting cylinder 10-1 applies an initial upsetting force to make the end faces of the two rails 1 at the joint close together. The welding heating cylinder 6-6 pushes the right coil mechanism 6-1 and the left coil mechanism 6-2 to the joint of the rails 1 to be welded. The opening and closing cylinder 6-3-4 in the coil drive mechanism 6-3 causes the two coils in the right coil mechanism 6-1 and the two coils in the left coil mechanism 6-2 to move closer to the joint of the two rails 1, and realizes the closing of the right coil mechanism 6-1 and the left coil mechanism 6-2, thereby wrapping the joint of the rails 1.

[0057] The PLC controller starts the IGBT power supply, energizing the electrode transfer mechanism 6-4, which in turn heats the rail 1 via the right coil mechanism 6-1 and the left coil mechanism 6-2. Simultaneously, the cooling system is controlled to water-cool the coils in the right coil mechanism 6-1 and the left coil mechanism 6-2, and the hydraulic system is controlled to maintain the movement of the clamping cylinder and the upsetting cylinder 10-1. Once the welding heating assembly 6 has heated the joint of the rail 1 to the preset temperature (range 1200~1430℃), the PLC controller shuts off the IGBT power supply and... The opening and closing cylinder 6-3-4 controls the right coil mechanism 6-1 and the left coil mechanism 6-2 to open rapidly, while simultaneously commanding the upsetting cylinder 10-1 to apply the set upsetting force, so that the end faces of the two steel rails 1 are joined together; at the same time, the piston rod of the welding heating cylinder 6-6 drives the right coil mechanism 6-1 and the left coil mechanism 6-2 to return to their initial positions, and the push-out cylinder 5-1 in the weld bead pushing assembly 5 pushes the push-out knife mechanism 5-2 to cut the weld bead, completing the push-out action of the weld bead; after the push-out is completed, the push-out knife mechanism 5-2 returns to its initial position;

[0058] Then, the weld at the joint of the two rails 1 is heat-treated. The welding heating cylinder 6-6 pushes the right coil mechanism 6-1 and the left coil mechanism 6-2 back to the weld of the two rails 1. The opening and closing cylinder 6-3-4 pushes the right coil mechanism 6-1 and the left coil mechanism 6-2 towards the two rails 1 and encloses the weld. When the weld cools to below 500℃, the PLC controller restarts the IGBT power supply, and the right coil mechanism 6-1 and the left coil mechanism 6-2 are energized to heat the rails 1, raising the rail head temperature to the predetermined positive temperature. The heating temperature (usually in the range of 900 to 1100℃) completely austenitizes the microstructure at the rail weld. When the predetermined normalizing temperature is reached, the PLC controller shuts off the IGBT power supply, and the opening and closing cylinder 6-3-4 quickly pulls the right coil mechanism 6-1 and the left coil mechanism 6-2 apart. The welding heating cylinder 6-6 drives the right coil mechanism 6-1 and the left coil mechanism 6-2 back to their initial positions. Then, the clamping cylinder is started, driving the jaws in the first rail clamping assembly 3 and the second rail clamping assembly 8 to open, finally completing the induction welding and heat treatment of the rail.

Claims

1. A mobile induction welding device for steel rails, characterized in that: The system includes a frame body assembly (9), on which a first rail clamping assembly (3) and a second rail clamping assembly (8) are mounted side-by-side along the length of the rail (1) for clamping the rail (1); a rail upsetting assembly (10) is mounted on the frame body assembly (9) for driving the first rail clamping assembly (3) and the second rail clamping assembly (8) to move relative to each other along the length of the rail (1); it also includes a weld bead pushing assembly (5) and a welding heating assembly (6) mounted on the frame body assembly (9), both of which can be used to push the weld bead upwards along the rail. (1) Moves along the length direction; also includes a transformer (7) installed on the welding heating assembly (6) to provide power to the welding heating assembly (6); the frame body assembly (9) includes a static frame member (9-1) and a moving frame member (9-3) arranged side by side and used to install the second rail clamping assembly (8) and the first rail clamping assembly (3) respectively, and a rail groove (9-4) for the rail (1) to pass through is provided at the lower end of both the static frame member (9-1) and the moving frame member (9-3); a sliding connection with the static frame member (9-1) and arranged parallel to the rail (1) is installed on the moving frame member (9-3). The rail upsetting assembly (10) includes an upsetting cylinder (10-1) mounted on a stationary frame member (9-1), on which an upsetting shaft (10-2) is mounted, which is parallel to the frame guide shaft (9-2) and fixedly connected to the moving frame member (9-3); the welding heating assembly (6) includes a welding heating cylinder (6-6) mounted on a stationary frame member (9-1), on which a coil transverse shifting plate (6-5) is mounted at the extended end of the welding heating cylinder (6-6) between the stationary frame member (9-1) and the moving frame member (9-3), and the coil transverse shifting plate (6-5) is mounted at the extended end of the welding heating cylinder (6-6). A transfer electrode mechanism (6-4) electrically connected to the transformer (7) is installed on the seat plate (6-5). On both sides of the transfer electrode mechanism (6-4), a right coil mechanism (6-1) and a left coil mechanism (6-2) are respectively provided and slidably connected to the coil transverse seat plate (6-5). A coil drive mechanism (6-3) is also included to drive the right coil mechanism (6-1) and the left coil mechanism (6-2) to dock / open. After the right coil mechanism (6-1) and the left coil mechanism (6-2) are docked and closed, they are in contact with the transfer electrode mechanism (6-4) and have a cavity adapted to the cross section of the rail (1). The weld bead pushing assembly (5) includes a pushing cylinder (5-1) mounted on a moving frame member (9-3), a pushing moving seat (5-3) located between a stationary frame member (9-1) and a moving frame member (9-3) mounted on the extended end of the pushing cylinder (5-1), and a pushing knife mechanism (5-2) mounted on the pushing moving seat (5-3).

2. The mobile rail induction welding device as described in claim 1, characterized in that: The first rail clamping assembly (3) includes two clamping mounting shafts (3-8) arranged in parallel. A support limiting block (3-1) is fixedly connected to the clamping mounting shaft (3-8). A clamping mechanism is provided on both sides of the support limiting block (3-1). A plate is installed at the jaw of each clamping mechanism and a positioning ball (3-9) that rolls in contact with the rail (1) is embedded in the plate. The assembly also includes a clamping drive mechanism for driving the clamping mechanism. The structure of the second rail clamping assembly (8) is the same as that of the first rail clamping assembly (3).

3. The mobile rail induction welding device as described in claim 2, characterized in that: The clamping mechanism includes two clamping main arms (3-3) rotatably connected and symmetrically arranged on two clamping mounting shafts (3-8). Each clamping main arm (3-3) includes a pivot connecting part (3-3-2) pivotally connected to the clamping mounting shaft (3-8). Engaging teeth (3-3-4) are provided on the inner side of each pivot connecting part (3-3-2), and the engaging teeth (3-3-4) on the two pivot connecting parts (3-3-2) engage with each other. An upper driving part (3-3-3) is integrally formed on the upper part of the pivot connecting part (3-3-2), and the upper driving part (3-3-3) is pivotally connected to the clamping driving mechanism. A lower clamping part (3-3-1) is integrally formed on the lower part of the pivot connecting part (3-3-2). Rail clamping blocks (3-10) can be detachably installed on the inner side of each lower clamping part (3-3-1).

4. The mobile rail induction welding device as described in claim 2, characterized in that: The clamping drive mechanism includes a cylinder limiting seat (3-7) fixedly connected to the support limiting block (3-1), a clamping cylinder (3-6) slidably mounted on the cylinder limiting seat (3-7), the extended end of the clamping cylinder (3-6) being pivotally connected to the support limiting block (3-1), and a clamping drive block (3-5) mounted on the cylinder barrel of the clamping cylinder (3-6). A clamping joint plate (3-4) is pivotally connected between the clamping drive block (3-5) and each clamping mechanism.

5. The mobile rail induction welding device as described in claim 1, characterized in that: The electrode transfer mechanism (6-4) includes an electrode taper (6-4-2) mounted on a coil transverse support plate (6-5). A left short electrode (6-4-3) is mounted on one end of the electrode taper (6-4-2) via an insulating plate (6-4-1), and a right short electrode (6-4-6) is mounted on the other end of the electrode taper (6-4-2) via an insulating plate (6-4-1). A left electrode plate (6-4-4) is mounted on the left short electrode (6-4-3), and a right electrode plate (6-4-5) is mounted on the right short electrode (6-4-6). Both the left electrode plate (6-4-4) and the right electrode plate (6-4-5) are connected to the transformer (7).

6. The mobile rail induction welding device as described in claim 1, characterized in that: The left coil mechanism (6-2) includes a left coil mounting frame (6-2-9) slidably connected to the coil transverse sliding seat plate (6-5). A left first coil (6-2-4) and a left second coil (6-2-5) are mounted side by side on the left coil mounting frame (6-2-9). Insulation structures are provided between the left first coil (6-2-4) and the left coil mounting frame (6-2-9) and between the left second coil (6-2-5) and the left coil mounting frame (6-2-9). A left upper coil contact plate (6-2-6) is installed on the upper part of the left first coil (6-2-4) and the left second coil (6-2-5), and a left lower coil contact plate (6-2-1) is installed on the lower part of the left first coil (6-2-4) and the left second coil (6-2-5). The left first coil (6-2-4) and the left second coil (6-2-5) are both made of hollow copper coils.

7. The mobile rail induction welding device as described in claim 1, characterized in that: The right coil mechanism (6-1) includes a right coil mounting frame (6-1-9) slidably connected to the coil transverse sliding plate (6-5). A right first coil (6-1-4) and a right second coil (6-1-5) are mounted side by side on the right coil mounting frame (6-1-9). Insulation structures are provided between the right first coil (6-1-4) and the right coil mounting frame (6-1-9) and between the right second coil (6-1-5) and the right coil mounting frame (6-1-9). A right upper coil contact plate (6-1-6) is installed on the upper part of the right first coil (6-1-4) and the right second coil (6-1-5), and a right lower coil contact plate (6-1-1) is installed on the lower part of the right first coil (6-1-4) and the right second coil (6-1-5). Both the right first coil (6-1-4) and the right second coil (6-1-5) are made of hollow copper coils.

8. The mobile rail induction welding device as described in claim 1, characterized in that: The coil drive mechanism (6-3) includes two swing arm supports (6-3-3) fixedly mounted on the coil transverse support plate (6-5). The two swing arm supports (6-3-3) are arranged side by side and located on both sides of the transfer electrode mechanism (6-4). A coil swing arm rod (6-3-2) is pivotally connected to each swing arm support (6-3-3). The two coil swing arm rods (6-3-2) are symmetrically arranged. An opening and closing hydraulic cylinder (6-3-4) is pivotally connected between the two coil swing arm rods (6-3-2). The mechanism also includes two coil sliding grooves (6-3-5) installed on the right coil mechanism (6-1) and the left coil mechanism (6-2) respectively. A coil drive slider (6-3-6) is slidably connected in each coil sliding groove (6-3-5). The two coil drive sliders (6-3-6) are pivotally connected to the two coil swing arm rods (6-3-2) respectively.

9. The mobile rail induction welding device as described in claim 1, characterized in that: The push-convex knife mechanism (5-2) includes a left push-convex knife seat (5-2-3) mounted on a push-convex moving seat (5-3), an upper push-convex knife seat (5-2-4) pivotally connected to the top of the left push-convex knife seat (5-2-3), a right push-convex knife seat (5-2-5) pivotally connected to the end of the upper push-convex knife seat (5-2-4), and a locking plate (5-2-1) pivotally connected to the end of the left push-convex knife seat (5-2-3) for hooking and connecting with the right push-convex knife seat (5-2-5). It also includes a locking element mounted on the right push-convex knife seat (5-2-5) for connecting the locking plate (5-2-1) to the right push-convex knife seat. (5-2-5) Locking connection; When the locking plate (5-2-1) is hooked and connected to the right push-face knife seat (5-2-5), the left push-face knife seat (5-2-3), the upper push-face knife seat (5-2-4) and the right push-face knife seat (5-2-5) form a cavity adapted to the cross section of the rail (1). At the edge of the cavity, there are bottom push knife (5-2-2) and left push knife (5-2-8) connected to the left push-face knife seat (5-2-3), top push knife (5-2-10) connected to the upper push-face knife seat (5-2-4) and right push knife (5-2-9) connected to the right push-face knife seat (5-2-5).

10. The mobile rail induction welding device as described in claim 1, characterized in that: Several lifting rings (4) are installed on both the static frame member (9-1) and the dynamic frame member (9-3).

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