A rail grinding control system
The fully automated grinding technology of the rail grinding control system, which utilizes PLC control unit, hydraulic drive unit and robot control unit, combined with profile grinding wheel and six-axis robotic arm module, solves the problem of weld slag residue in manual grinding and achieves efficient and stable grinding of rail weld nodules.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- WUHAN LEADDO MEASURING & CONTROL CO LTD
- Filing Date
- 2025-07-24
- Publication Date
- 2026-07-21
Smart Images
Figure CN224526871U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of rail grinding technology, specifically to a rail grinding control system. Background Technology
[0002] Train tracks have been used in my country for many years, primarily to support trains and ensure their smooth operation. Train tracks are typically constructed by welding multiple rail sections together end-to-end. After welding, uneven weld beads (or bumps) often appear at the weld joint between adjacent rail sections. To improve the safety of train track use, grinding equipment is used to grind the joint between adjacent rail sections to eliminate these weld beads.
[0003] In existing technologies, the grinding of rail weld bead is generally done manually using a flap wheel polishing method. The disadvantage of this method is that after milling and polishing, weld slag will still remain in the lower jaw, triangular area and other parts of the rail, affecting the grinding quality. In addition, manual grinding is inefficient. Utility Model Content
[0004] The purpose of this utility model is to overcome the above-mentioned technical deficiencies and propose a rail grinding control system to solve the technical problems of the fact that the grinding of rail weld nodules is generally done manually using a flap wheel polishing method. The disadvantages of this method are that after milling and polishing, weld slag will still remain in the lower jaw, triangular area and other parts of the rail, affecting the grinding quality, and the manual grinding is inefficient.
[0005] To achieve the above-mentioned technical objectives, the present invention adopts the following technical solution: This utility model provides a rail grinding control system, including: Control panel; The PLC control unit is connected to the control panel; The hydraulic drive unit includes a drive source, a left rail clamp, and a right rail clamp. The drive source is connected to the PLC control unit and is connected to the left rail clamp. Under the control of the PLC control unit, the drive source can drive the left rail clamp to rotate to cooperate with the right rail clamp to clamp or release the rail. A signal detection unit, connected to the PLC control unit, is used to photograph the weld bead on the rail to determine its location; and The robot control unit includes a six-axis robotic arm module and a contour grinding wheel. The six-axis robotic arm module is connected to the PLC control unit and the contour grinding wheel, and is used to drive the contour grinding wheel to rotate to grind the weld burr on the rail.
[0006] In some embodiments, the robot control unit further includes a force control module, which is connected to the six-axis robotic arm module and the contour grinding wheel, and is used to sense the force exerted by the contour grinding wheel on the rail.
[0007] In some embodiments, the robot control unit further includes a tool magazine control module, which is connected to the PLC control unit and is capable of controlling the six-axis robotic arm module to change tools.
[0008] In some embodiments, the signal detection unit includes a visual detection module, the visual detection module includes a bracket and a visual camera and a fill light disposed on the bracket, the fill light being used to provide supplementary lighting for the visual camera.
[0009] In some embodiments, the signal detection unit further includes two spaced-apart linear laser modules, which emit two parallel laser lines, with a polishing area formed between the two laser lines, and the lens of the visual camera facing the polishing area.
[0010] In some embodiments, the signal detection unit further includes a clamping proximity sensor and a first detection plate. One side of the clamping proximity sensor is connected to the left rail clamp, and the other side is connected to the first detection plate. When the first detection plate clamps the rail, the clamping proximity sensor can output a first control signal to the PLC control unit.
[0011] In some embodiments, the signal detection unit further includes a release proximity sensor and a second detection plate. One side of the release proximity sensor is connected to the right rail clamp, and the other side is connected to the second detection plate. When the second detection plate releases the rail, the release proximity sensor can output a second control signal to the PLC control unit.
[0012] In some embodiments, the rail grinding control system further includes a housing and a positioning mechanism. The positioning mechanism includes a gantry and a drive component. The gantry is slidably disposed on the housing and forms a positioning space between the gantry and the housing. The drive component is disposed on the housing and connected to the gantry. The drive component can drive the gantry to slide back and forth to adjust the size of the positioning space.
[0013] In some embodiments, the hydraulic drive unit further includes a drive source, wherein the left rail clamp and the right rail clamp are rotatably mounted on the housing and their non-clamping ends are engaged with each other, and the drive source is connected to the left rail clamp and can drive the left rail clamp to rotate to clamp or release the rail.
[0014] In some embodiments, the rail grinding control system further includes a passive roller, which is rotatably mounted on the housing and located at the bottom of the gantry.
[0015] Compared with existing technologies, the rail grinding control system provided by this utility model has an operating console that can be operated by staff. The PLC control system controls the operation of various components, such as controlling the left and right rail clamps to hold or release the rail, controlling the signal detection unit to position the rail so that the area with weld beads is in the grinding position, and controlling the six-axis robotic arm module of the robot control unit to drive the contour grinding wheel to grind the weld beads on the rail, thus completing the fixing and grinding of the rail. The PLC control system mainly acts as a central hub, connecting various control units and detection units to work together to complete the fixing and grinding of the rail, achieving fully automatic grinding with high efficiency. Furthermore, this application uses a contour grinding wheel, combined with robot path planning and force control modules, to achieve constant force floating grinding, resulting in stable and reliable grinding quality and eliminating residual weld slag in the rail jaw and triangular area. Attached Figure Description
[0016] Figure 1 This is a control principle diagram of the rail grinding control system provided in this embodiment of the utility model; Figure 2 This is a flowchart of the rail grinding control system provided in this embodiment of the utility model; Figure 3 This is a schematic diagram of the rail grinding control system provided in this embodiment of the utility model; Figure 4 This is a schematic diagram of the integrated hydraulic drive unit and positioning mechanism provided in this embodiment of the utility model; Figure 5 This is a schematic diagram of the positioning mechanism provided in an embodiment of the present invention. Detailed Implementation
[0017] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.
[0018] To address the shortcomings of existing technologies that typically involve manual polishing using flap wheels to grind post-weld slag on rails, which leaves residual weld slag in areas like the rail jaw and triangular region after milling and polishing, affecting grinding quality, and which is also inefficient, this invention provides a rail grinding control system. This system enables fully automated and efficient grinding of post-weld slag on rails. By employing a contour grinding wheel and combining robot path planning and force control modules, it achieves constant-force floating grinding, ensuring stable and reliable grinding quality and eliminating residual weld slag in the rail jaw and triangular region.
[0019] It should be noted that the rail grinding control system described in this utility model is used for, but not limited to, rail grinding. For ease of explanation, this utility model only uses the application of the rail grinding control system to rail grinding as an example. The principle of the rail grinding control system applied to other types of equipment is essentially the same as that applied to rail grinding, and will not be described in detail here.
[0020] Please see Figure 1 , Figure 1 This is a schematic diagram of the rail grinding control system in one embodiment of the present invention. The rail grinding control system includes an operating table 1, a PLC control unit 2, a robot control unit 3, a signal detection unit 4, and a hydraulic drive unit 5. The PLC control unit 2 is connected to the operating table 1. The hydraulic drive unit 5 is connected to the PLC control unit 2 and includes a left rail clamp 51 and a right rail clamp 52, with a clamping space between the left rail clamp 51 and the right rail clamp 52 for clamping the rail. The signal detection unit 4 is connected to the PLC control unit 2 and is used to photograph the weld bead on the rail to determine its position. The robot control unit 3 includes a six-axis robotic arm module 31 and a contour grinding wheel 32. The six-axis robotic arm module 31 is connected to the PLC control unit 2 and the contour grinding wheel 32 and is used to drive the contour grinding wheel 32 to rotate to grind the weld bead on the rail.
[0021] The rail grinding control system 100 mainly consists of an operating console 1, a PLC control unit 2, a hydraulic drive unit 5, a signal detection unit 4, and a robot control unit 3. The PLC control unit 2 is connected to the operating console 1, enabling centralized control and issuing of operation commands for the entire system, thus achieving fully automatic control. The hydraulic drive unit 5, signal detection unit 4, and robot control unit 3 are all connected to the PLC control unit 2. Under the unified coordination of the PLC control unit 2, each unit works collaboratively to complete the fully automatic rail grinding operation, effectively improving work efficiency. Furthermore, this application uses a contour grinding wheel 32, combined with robot path planning and force control modules, to achieve constant force floating grinding, ensuring stable and reliable grinding quality and eliminating residual welding slag in the rail jaw and triangular area.
[0022] In one embodiment, please refer to Figure 3 and Figure 5The rail grinding control system 100 also includes a housing 6 and a positioning mechanism 7. The positioning mechanism 7 includes a gantry frame 71 and a drive component 72. The gantry frame 71 is slidably mounted on the housing 6 and forms a positioning space 73 between itself and the housing 6. The drive component 72 is mounted on the housing 6 and connected to the gantry frame 71. The drive component 72 can drive the gantry frame 71 to slide back and forth to adjust the size of the positioning space 73. In this embodiment, the gantry frame 71 is U-shaped and slidably mounted on the housing 6, forming a positioning space 73 between itself and the housing 6. The positioning space 73 is used to accommodate the rail to be ground, specifically, the rail passes through the positioning space 73. The drive component 72 is mounted on the housing 6 and connected to the gantry frame 71. When working, the drive component 72 can drive the gantry frame 71 to slide back and forth on the housing 6, thereby adjusting the size of the positioning space 73. For example, when the gantry frame 71 slides down, it can press down on the rail to restrict the rail from moving in the vertical direction.
[0023] The drive unit 72 includes a drive cylinder 721 and a force-applying frame 722 connected to each other. The force-applying frame 722 is slidably disposed on the housing 6 and connected to the gantry frame 71. When working, the drive cylinder 721 can drive the force-applying frame 722 to move up and down, so that the force-applying frame 722 drives the gantry frame 71 to slide down and press the rail, or the gantry frame 71 slides up to unlock the rail.
[0024] In one embodiment, please refer to Figure 4 The hydraulic drive unit 5 also includes a drive source 53. The left rail clamp 51 and the right rail clamp 52 are rotatably mounted on the housing 6, with their non-clamping ends meshing with each other. The drive source 53 is connected to the left rail clamp 51 and can drive the left rail clamp 51 to rotate to clamp or release the rail. In this embodiment, both the left rail clamp 51 and the right rail clamp 52 are arc-shaped clamping arms, with their non-clamping ends rotatably mounted on the housing 6 via a rotating shaft, and the two meshing with each other. In the initial state, the clamping ends of the left rail clamp 51 and the right rail clamp 52 are in an open state. The rail is first inserted into the positioning space 73, and the gantry 71 is controlled to slide down to press down the top of the rail 4. Then, the drive source 53 is controlled to drive the clamping ends of the left rail clamp 51 and the right rail clamp 52 to move closer together to clamp the rail from both sides, thereby completely fixing the rail.
[0025] In one embodiment, please refer to Figure 4 and Figure 5The rail grinding control system also includes a passive roller 8, which is rotatably mounted on the housing 6 and located at the bottom of the gantry 71. In this embodiment, when the rail is located within the positioning space 73, the rail is placed on top of the passive roller 8, and the rail is connected to a corresponding drive component (not shown in the figure). Under the action of the drive component, the rail can gradually move forward, moving on the passive roller 8 and driving the passive roller 8 to roll through friction. Therefore, the passive roller 8 in this embodiment mainly serves as a guide for the rail. Compared to sliding friction, this embodiment makes the movement of the rail more convenient through the passive roller 8.
[0026] In one embodiment, please refer to Figure 3 The robot control unit 3 also includes a force control module 33 and a tool magazine control module 34. The force control module 33 is connected to the six-axis robotic arm module 31 and the contour grinding wheel 32, and is used to sense the force exerted by the contour grinding wheel 32 on the rail. The force control module 33 controls the grinding force of the six-axis robotic arm module 31 on the rail, so as to improve the grinding quality of different parts of the rail and prevent the contour grinding wheel from stalling. The tool magazine control module 34 is connected to the PLC control unit, and can control its tool changing through the PLC control unit. The tool magazine control module 34 stores a variety of different types of grinding tools. The six-axis robotic arm module 31 can change to different types of grinding tools according to actual grinding needs to complete the grinding work smoothly. The process and method of the six-axis robotic arm module 31 changing tools are existing technologies, and the specific action details are not described in detail.
[0027] In one embodiment, please refer to Figure 1 and Figure 3 The signal detection unit 4 includes a vision detection module 41 and two spaced-apart linear laser modules 42. The vision detection module 41 includes a bracket 411, a vision camera 412 mounted on the bracket 411, and a supplementary light 413. The supplementary light 413 provides supplementary lighting for the vision camera 412. The two linear laser modules 42 emit two parallel laser lines, with a grinding area formed between them. The lens of the vision camera 412 faces the grinding area. In this embodiment, the supplementary light 413 provides sufficient supplementary lighting for the vision camera 412 in low-light environments, ensuring the clarity of the images captured after the rail weld. Two linear laser modules 42 are used to emit two parallel laser lines, with a grinding area formed between the two laser lines. The lens of the vision camera 412 is directly facing the grinding area. By capturing the weld bead on the rail, the position information of the weld bead is accurately determined and transmitted to the PLC control panel 2. The PLC control panel 2 transmits the position information of the weld bead to the six-axis robotic arm module 31. The six-axis robotic arm module 31 plans its motion path according to the position information of the weld bead so that the contour grinding wheel 32 can accurately grind the weld bead.
[0028] In one embodiment, the signal detection unit 4 further includes a proximity switch module 43. The proximity switch module 43 includes a clamping proximity sensor (not shown), a releasing proximity sensor (not shown), a first detection plate (not shown), and a second detection plate (not shown). One side of the clamping proximity sensor is connected to the left rail clamp 51, and the opposite side is connected to the first detection plate. When the first detection plate clamps the rail, the clamping proximity sensor can output a first control signal to the PLC control unit 2. The one side of the releasing proximity sensor is connected to the right rail clamp 52, and the opposite side is connected to the second detection plate. When the second detection plate releases the rail, the releasing proximity sensor can output a second control signal to the PLC control unit 2.
[0029] To further improve the accuracy of detection, clamping proximity sensors and releasing proximity sensors can be installed on both the left rail clamp 51 and the right rail clamp 52. When the left rail clamp 51 and the right rail clamp 52 clamp the rail, and the clamping proximity sensor detects that the reaction force applied by the first detection plate exceeds the preset pressure value, the clamping proximity sensor outputs a 24V high-level signal to the PLC control unit 2. The PLC control unit 2 then controls the drive source 53 to stop working to avoid the drive source 53 continuing to consume power to drive the clamps to apply force to the rail, thereby saving energy.
[0030] When the left rail clamp 51 and the right rail clamp 52 release the rail, the release proximity sensor detects that the reaction force applied by the second detection plate is lower than the preset pressure value, and outputs a 24V high-level signal to the PLC control unit 2 to indicate that the rail is unlocked and the PLC control unit 2 can control it.
[0031] The aforementioned clamping and releasing proximity sensors are used to automatically detect the status of the rail clamps. When the clamp is clamped or released, the proximity switch automatically outputs an electrical signal. The PLC control unit 2 determines the clamp status based on these signals, thereby enabling the drive components to automatically control the rail to continue moving forward and move the next weld bead to be ground to the grinding area.
[0032] To better understand this utility model, the following is combined with... Figures 1 to 5 Summary of the working process of the rail grinding system of this utility model: The operator inputs control commands on the control panel 1, which in turn controls the PLC control unit 2 to issue working commands to each working component. First, the designated robotic arm is used to grab the rail and place it on the platform on top of the housing 6, and the rail is then passed through the gantry 71. Then, the drive component that drives the rail is controlled to move the rail forward. When the weld bead on the rail is located between the two laser lines emitted by the linear laser module 42 (which can be identified and determined by the vision camera 412), the control drive component pauses its operation, stops the movement of the rail, and then controls the drive source 53 to work, causing the left rail clamp 51 and the right rail clamp 52 to clamp the rail; the vision detection module 41 captures the weld bead on the rail at the grinding station and transmits the position information of the weld bead to the six-axis robotic arm module 31, so that the six-axis robotic arm module 31 drives the contour grinding wheel 32 to grind the left weld bead, the bottom weld bead, and the right weld bead of the rail in sequence, and then changes the tool through the tool magazine control module 34 to grind the lower jaw weld of the rail, completing the overall grinding of the rail; the control of the left rail clamp 51 and the right rail clamp 52 unlocks the rail; the six-axis robotic arm module 31 changes the tool and returns to the initial position, waiting to grind the next weld.
[0033] The specific embodiments of this utility model described above do not constitute a limitation on the scope of protection of this utility model. Any other corresponding changes and modifications made based on the technical concept of this utility model should be included within the scope of protection of the claims of this utility model.
Claims
1. A rail grinding control system, characterized in that, include: Control panel; The PLC control unit is connected to the control panel; The hydraulic drive unit includes a drive source, a left rail clamp, and a right rail clamp. The drive source is connected to the PLC control unit and is connected to the left rail clamp. Under the control of the PLC control unit, the drive source can drive the left rail clamp to rotate to cooperate with the right rail clamp to clamp or release the rail. A signal detection unit, connected to the PLC control unit, is used to photograph the weld bead on the rail to determine its location; and The robot control unit includes a six-axis robotic arm module and a contour grinding wheel. The six-axis robotic arm module is connected to the PLC control unit and the contour grinding wheel, and is used to drive the contour grinding wheel to rotate to grind the weld burr on the rail.
2. The rail grinding control system according to claim 1, characterized in that, The robot control unit also includes a force control module, which is connected to the six-axis robotic arm module and the contour grinding wheel, and is used to sense the force exerted by the contour grinding wheel on the rail.
3. The rail grinding control system according to claim 1, characterized in that, The robot control unit also includes a tool magazine control module, which is connected to the PLC control unit and can control the six-axis robotic arm module to change tools.
4. The rail grinding control system according to claim 1, characterized in that, The signal detection unit includes a visual detection module, which includes a bracket and a visual camera and a fill light mounted on the bracket. The fill light is used to provide supplementary lighting for the visual camera.
5. The rail grinding control system according to claim 4, characterized in that, The signal detection unit also includes two spaced-apart linear laser modules, which emit two parallel laser lines. The space between the two laser lines forms a polishing area, and the lens of the visual camera is facing the polishing area.
6. The rail grinding control system according to claim 4, characterized in that, The signal detection unit further includes a clamping proximity sensor and a first detection plate. One side of the clamping proximity sensor is connected to the left rail clamp, and the other side is connected to the first detection plate. When the first detection plate clamps the rail, the clamping proximity sensor can output a first control signal to the PLC control unit.
7. The rail grinding control system according to claim 4, characterized in that, The signal detection unit also includes a release proximity sensor and a second detection plate. One side of the release proximity sensor is connected to the right rail clamp, and the other side is connected to the second detection plate. When the second detection plate releases the rail, the release proximity sensor can output a second control signal to the PLC control unit.
8. The rail grinding control system according to claim 1, characterized in that, The rail grinding control system also includes a housing and a positioning mechanism. The positioning mechanism includes a gantry and a drive component. The gantry is slidably mounted on the housing and forms a positioning space between it and the housing. The drive component is mounted on the housing and connected to the gantry. The drive component can drive the gantry to slide back and forth to adjust the size of the positioning space.
9. The rail grinding control system according to claim 8, characterized in that, The hydraulic drive unit also includes a drive source. The left rail clamp and the right rail clamp are both rotatably mounted on the housing and their non-clamping ends are engaged with each other. The drive source is connected to the left rail clamp and can drive the left rail clamp to rotate to clamp or release the rail.
10. The rail grinding control system according to claim 8, characterized in that, The rail grinding control system also includes a passive roller, which is rotatably mounted on the machine housing and located at the bottom of the gantry.