An automatic rail loading device

Abstract

This utility model relates to the technical field of rail production equipment, specifically an automatic rail loading device. It includes an automatic rail loading device for transferring rails to be transferred, and a sensor system to assist in positioning the automatic rail loading device. The rails to be transferred are placed on rail support platforms, which are spaced out. A travel track is placed between the gaps in the rail support platforms. The automatic rail loading device is placed on the travel track, which passes through a roller conveyor and the rail support platforms. The loading device moves between the roller conveyor and the rail support platforms. This utility model achieves precise closed-loop control through mechatronics design, resulting in a comprehensive improvement in accuracy, reliability, and environmental adaptability, especially in terms of tolerance for errors in the initial position of the rails.

Description

Technical Field

[0001] This utility model relates to the field of rail production equipment technology, specifically an automatic rail loading device. Background Technology

[0002] Seamless track technology is an important direction for global railway development. However, due to limitations in existing manufacturing processes, transportation conditions, and construction techniques, the current common practice for laying seamless tracks is to use a segmented welding method. The specific implementation process includes: first, standard 100-meter rails are welded into 500-meter long rail units at the rail welding base, then transported to the construction site by rail or road, and finally, seamless welding across sections is completed on the construction site.

[0003] Currently, rail welding bases still rely on overhead cranes to transport 100-meter standard-length rails to the roller conveyor line. However, overhead cranes mainly pose safety issues such as falling objects from heights, rail collisions, and personnel falls; waste of human resources; and material deformation and damage caused by multi-point hoisting.

[0004] Existing patent CN216271558U mentions a translational rail-mounting device for rail transport. Both its traveling and lifting mechanisms are driven by sprockets, which leads to wear on the sprockets and chains, requiring regular chain lubrication and adjustment of the chain tensioning mechanism. Furthermore, the patent mentions a rail-lifting block that matches the width of a single rail, but lacks a stop block for the rail. If the traveling mechanism's accuracy is abnormal, it could cause partial contact during the lifting mechanism's lifting of the rail, leading to rail tipping. Finally, the rails to be transported may not be straight when placed on the support platform by the gantry crane, and the patent does not address how to control the traveling accuracy, resulting in the rails not being properly placed on the roller conveyor. Summary of the Invention

[0005] In view of the problems existing in the prior art, this utility model proposes an automatic rail loading device to solve a series of problems caused by traditional hoisting methods, realize automated operation and one-click rail loading function, and improve work efficiency.

[0006] To achieve the above objectives, the technical solution of this application is as follows: An automatic rail loading device includes an automatic rail loading device for transferring rails to be transferred and a sensor system to assist the automatic rail loading device in positioning. The rails to be transferred are placed on rail support platforms, which are distributed at intervals. A travel track is placed between the gaps in the rail support platforms. The automatic rail loading device is placed on the travel track, which passes through a roller conveyor and the rail support platforms. The rail loading device moves between the roller conveyor and the rail support platforms.

[0007] Furthermore, the automatic rail mounting device includes a walking device and a lifting device. The walking device includes a rail mounting frame, on which the lifting device and a sensor system are mounted. A walking gear transmission mechanism is mounted at the bottom of the rail mounting frame. A roller shaft is sleeved on the walking gear transmission mechanism. Both ends of the roller shaft are connected to walking rollers through walking roller bearings. The walking gear transmission mechanism is connected to a walking servo motor.

[0008] Furthermore, the bottom of the walking gear transmission mechanism is equipped with a gear transmission mechanism oil receiving sheet metal.

[0009] Furthermore, a rain shield sheet metal is installed on the upper part of the walking servo motor.

[0010] Furthermore, the lifting device includes a transition pad for the rail to be transferred, a worm gear jack, a lifting guide rod, a lifting servo motor, and a limit block. The lifting servo motor is mounted on the upper rail device mounting frame. The output side of the lifting servo motor is connected to the worm gear jack. The worm gear jack is connected to the bottom of the transition pad for the rail to be transferred. A limit block is installed above the transition pad for the rail to be transferred. The lower part of the transition pad for the rail to be transferred is connected to the lifting guide rod. Furthermore, a rain shield sheet metal is installed on the outside of the lifting servo motor.

[0011] Furthermore, the sensor system includes a contact sensor, an inductive sensor, a through-beam grating for the track storage area, and a through-beam grating for the roller conveyor line; The contact sensor and the inductive sensor are installed on the front and rear sides of the transition pad of the rail to be transferred, which is parallel to the cross section of the rail.

[0012] The through-beam gratings in the rail storage area are installed at both ends of the rail support platform to be transferred.

[0013] The through-beam gratings of the roller conveyor are installed on the left and right sides of the roller conveyor.

[0014] The sensor system is connected to the PLC.

[0015] Furthermore, the walking servo motor is an absolute servo motor.

[0016] The automatic rail loading process is as follows: the sensor system detects the condition of the rails and feeds back the information to the PLC. The PLC then precisely controls the corresponding walking servo motor and lifting servo motor to complete the fully automated operation and one-button rail loading function. The sensor system detects the condition of the rails, including whether there are rails in the rail storage area, whether the automatic rail loading device has successfully positioned the rails, whether the transition plate of the rail to be transferred is in contact with the rails, and whether there are rails on the roller conveyor line.

[0017] The beneficial effects of this utility model are: 1. This utility model provides an automatic rail loading device, which includes a traveling device for transporting rails to be transported and a lifting mechanism for lifting the rails. This loading device can complete the automatic rail loading process through a corresponding method, eliminating the need for manual operation. It effectively improves the efficiency of rail transportation, enhances the safety of the loading operation, and reduces the waste of human resources.

[0018] 2. This utility model achieves precise closed-loop control through mechatronics design (sensor + servo), which comprehensively improves accuracy, reliability and environmental adaptability, especially in terms of fault tolerance of the initial position of the rails (the rails are not placed on the same straight line). Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the on-site layout of the automatic rail-mounting device.

[0020] Figure 2 This is a schematic diagram of the automatic rail-mounting device.

[0021] Figure 3 This is a schematic diagram of the automatic rail-mounting device.

[0022] Figure 4 This is a flowchart of the automatic rail-mounting device.

[0023] In the attached image: 1-Automatic rail mounting device; 2-Steel rail support platform for transfer; 3-Roller conveyor; 4-Steel rail for transfer; 5-Traveling track; 6-Roller conveyor through-beam grating; 7-Steel storage area through-beam grating; 101-Traveling cable chain; 102-Inductive sensor; 103-Transition pad for steel rail for transfer; 104-Rail mounting device mounting frame; 105-Mounting frame rainproof sheet metal; 106-Lifting motor rainproof sheet metal; 107-Worm gear lift; 108-Traveling motor rainproof sheet metal; 109-Contact sensor; 110-Limit block; 111-Traveling gear transmission mechanism; 112-Traveling roller; 113-Roller shaft; 114-Traveling roller bearing; 115-Gear transmission mechanism oil receiving sheet metal; 116-Lifting guide rod; 117-Traveling servo motor; 118-Lifting servo motor. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the invention clearer, the technical solutions of the embodiments of the invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the invention, not all embodiments. The components of the embodiments of the invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0025] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0026] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0027] In the description of this invention, it should be noted that the terms "upper," "vertical," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use, or the orientation or positional relationship commonly understood by those skilled in the art. They are only used for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0028] Example 1 An automatic rail loading device includes an automatic rail loading device 1 for transferring rails 4 to be transferred and a sensor system for positioning the automatic rail loading device 1. The rails 4 to be transferred are placed on rail carrier platforms 2 by a gantry crane. The rail carrier platforms 2 are distributed at certain intervals. A travel track 5 is placed between the gaps of the rail carrier platforms 2. The automatic rail loading device 1 is placed on the travel track 5. The travel track 5 passes through the roller conveyor 3 and the rail carrier platforms 2 to ensure that the automatic rail loading device 1 can move between the roller conveyor 3 and the rail carrier platforms 2.

[0029] The automatic rail-mounting device 1 includes a traveling device and a lifting device. The traveling device includes a rail-mounting device mounting frame 104, on which the lifting device and a sensor system are mounted. A traveling gear transmission mechanism 111 is mounted at the bottom of the rail-mounting device mounting frame 104. A roller shaft 113 is sleeved on the traveling gear transmission mechanism 111. The two ends of the roller shaft 113 are connected to traveling rollers 112 through traveling roller bearings 114. The traveling gear transmission mechanism 111 is connected to a traveling servo motor 117. The entire traveling device can move along the traveling rail. The traveling device is controlled by a traveling servo motor 117, which is connected to the traveling gear transmission mechanism 111. The right traveling roller 112 is connected to the traveling gear transmission mechanism 111 via a roller shaft 113 as the driving roller, and the left traveling roller 112 is connected to the roller shaft 113 as the driven roller. The traveling roller bearing 114 is mounted below the upper rail mounting bracket 104 and connected to the roller shaft 113. The traveling roller 112 is positioned above the traveling rail and can rotate well relative to it. The gear transmission mechanism oil receiving sheet metal 115 is mounted below the gear transmission mechanism to house the gear transmission mechanism's lubricating oil tank.

[0030] The traveling cable chain 101 is placed below the automatic upper rail device 1 and between the traveling rails 5 to protect the cable.

[0031] The bottom of the walking gear transmission mechanism 111 is equipped with a gear transmission mechanism oil receiving sheet metal 115.

[0032] A rain shield sheet metal 108 is mounted on the upper part of the walking servo motor 117. The walking servo motor 117 is mounted on the upper rail device mounting bracket 104, and the rain shield is mounted on the outside of the walking servo motor 117 for outdoor rain protection and aesthetic purposes of the walking trolley.

[0033] The lifting device includes a rail transition pad 103 to be transferred, a worm gear jack 107, a lifting guide rod 116, a lifting servo motor 118, and a limit block 110. The lifting servo motor 118 is mounted on the upper rail device mounting frame 104. The output side of the lifting servo motor 118 is connected to the worm gear jack 107. The worm gear jack 107 is connected to the bottom of the rail transition pad 103 to be transferred. The limit block 110 is installed above the rail transition pad 103 to be transferred. The lower part of the rail transition pad 103 to be transferred is connected to the lifting guide rod 116. The lifting servo motor 118 is equipped with a rain shield sheet metal 106 on the outside, which is used for outdoor rain protection of the lifting motor and for aesthetic purposes.

[0034] The sensor system includes a contact sensor 109, an inductive sensor 102, a through-beam grating 7 for the track storage area, and a through-beam grating 6 for the roller conveyor. Contact sensor 109 and inductive sensor 102 are installed on the front and rear sides of the rail transition pad 103, which is parallel to the rail cross section, to detect whether the rail transition pad 103 contacts the rail 4 during the rising process and whether there is a rail above the rail transition pad 4, for automatic positioning function.

[0035] The through-beam grating 7 in the rail storage area is installed at both ends of the rail carrier platform 2 to detect whether there is a rail in the rail storage area.

[0036] The through-beam grating 6 of the roller conveyor is installed on the left and right sides of the roller conveyor 3 to detect whether there is a rail on the roller conveyor 3.

[0037] The sensor system is connected to the PLC.

[0038] The 117 walking servo motor is an absolute servo motor.

[0039] When the through-beam grating 7 in the rail storage area detects that there is a rail stored in the rail storage area, the through-beam grating 7 in the rail storage area will send a signal to the PLC. After receiving the signal from the through-beam grating 7 in the rail storage area, the PLC will send a pulse signal to the walking servo motor 117 to control the walking servo motor 117 to perform jog motion. Since an inductive sensor 102 has been added to the automatic rail loading device 1, regardless of whether the rail is in a straight line at this time, after the inductive sensor 102 detects the presence of a rail, it sends a signal to the PLC. The PLC immediately controls the walking servo motor 117 to stop moving. At this time, each automatic rail loading device 1 stops directly below the rail (the automatic rail loading device 1 is also not in a straight line).

[0040] When placing the rails, the travel servo motor 117 is an absolute servo motor, which can accurately record its zero position and perform precise positioning based on the number of pulses issued by the PLC. When entering the waiting area, the position of the waiting area is fixed, and the number of pulses issued by the PLC is the absolute position of the waiting area. Regardless of whether the traveling trolleys are in a straight line at this time, when one of the traveling trolleys reaches the waiting area position first, the travel servo motor 117 stops moving and waits for the other trolleys to reach the position. At this time, the rails will be in the same horizontal position. Furthermore, when placing the rails laterally, multiple trolleys move synchronously at the same time, which can accurately place the rails on the roller conveyor 3.

[0041] The automatic rail loading process is as follows: the sensor system detects the condition of the rails and feeds back the information to the PLC. The PLC then precisely controls the corresponding walking servo motor 117 and lifting servo motor 118 to complete the fully automated operation and one-button rail loading function. The sensor system detects the condition of the rails, including whether there are rails in the rail storage area, whether the automatic rail loading device 1 has successfully positioned the rails, whether the transition plate of the rail to be transferred 4 is in contact with the rails, and whether there are rails on the roller conveyor 3.

[0042] Example 2 like Figure 1As shown, the automatic rail loading device 1 mentioned in this embodiment is placed on a traveling track 5 parallel to the end face of the rail 4 to be transferred. The traveling track 5 spans the gap between the rail and the rail carrier 2 to be transferred. The traveling track 5 passes through the roller conveyor 3 and the rail carrier 2 to be transferred, so as to ensure that the automatic rail loading device 1 can move between the roller conveyor 3 and the rail carrier 2 to be transferred.

[0043] like Figure 2 , Figure 3 As shown, this utility model provides an automatic rail loading device 1 for automatically transporting rails from the rail storage area to the roller conveyor 3, including a traveling device, a lifting device, and a sensor system. Further, the traveling device consists of a traveling drag chain 101, a rail loading device mounting frame 104, a mounting frame rain shield sheet metal 105, a traveling motor rain shield sheet metal 108, a traveling gear transmission mechanism 111, traveling rollers 112, roller shafts 113, traveling roller bearings 114, a gear transmission mechanism oil receiving sheet metal 115, and a traveling servo motor 117; the lifting device consists of a rail transition pad 103, a lifting motor rain shield sheet metal 106, a worm gear lift 107, a lifting guide rod 116, and a lifting servo motor 118; the sensor system consists of a contact sensor 109, an inductive sensor 102, a rail storage area through-beam grating 7, and a roller conveyor through-beam grating 6.

[0044] In this specific embodiment, when the through-beam grating on the rail storage platform 2 detects the rail 4 to be transferred, the through-beam grating 7 in the rail storage area transmits a signal to the PLC. The PLC controls the walking servo motor 117 to reverse, and the walking servo motor 117 drives the walking gear transmission mechanism 111 to rotate clockwise. Specifically, when the walking gear transmission mechanism 111 rotates clockwise, the left and right walking rollers 112 are connected to the walking gear transmission mechanism 111 through the roller shaft 113 and rotate clockwise simultaneously. The walking rollers 112 are located on the walking track 5. When the walking rollers 112 rotate clockwise, the walking trolley moves towards the rail storage area.

[0045] Furthermore, when the inductive sensor 102 approaches the rail 4 to be transferred on the rail support platform 2, the inductive sensor 102 transmits a signal to the PLC. The PLC controls the walking servo motor 117 to stop reversing or rotating forward, so that the right side of the rail transition pad 103 (the area to the right of the limit block 110) is directly below the rail 4 to be transferred in the rail storage area. Further, when all inductive proximity sensors detect the rail 4 to be transferred (here, a total of 9 identical upper rail devices move in unison), the PLC controls the lifting servo motor 118 to rotate forward. Specifically, the lifting servo motor 118 is connected to the worm gear lift 107, controlling the internal mechanism of the worm gear lift 107 to rise, thereby controlling the rail transition pad 103 to rise until the contact sensor 109 contacts the rail 4 to be transferred and then stops. Furthermore, when the transition pad 103 of the rail to be transferred contacts the rail 4 to be transferred, the contact sensor 109 transmits a switch signal to the PLC, and the PLC controls the lifting servo motor 118 to stop rotating forward. Even further, when all nine contact sensors 109 of the rail-mounting device emit signals, the PLC starts controlling the lifting servo motor 118 to start rotating forward (the lifting height is determined by the number of pulses emitted by the PLC, and the lifting height is predetermined based on the number of pulses).

[0046] Furthermore, when the lifting servo motor 118 reaches a limited number of pulses, it stops rotating forward. The PLC controls the walking servo motor 117 to rotate forward. The walking servo motor 117 drives the walking gear transmission mechanism 111 to rotate counterclockwise. At the same time, the walking roller 112 rotates counterclockwise on the walking track 5. The walking trolley moves towards the roller line 3 to the waiting area (the movement distance is determined by the number of pulses issued by the PLC).

[0047] Specifically, when the roller conveyor 3 is inactive, the relay controlling the movement of the roller conveyor 3 sends a switching signal to the PLC. Furthermore, when the through-beam grating of the roller conveyor 3 detects that there is no rail on the roller conveyor 3, the through-beam grating sends a signal to the PLC. When the PLC receives both the switching signal indicating that the roller conveyor 3 is inactive and the signal indicating that there is no rail on the roller conveyor 3, the PLC controls the traveling servo motor 117 to rotate forward, driving the traveling roller 112 to rotate counterclockwise. The automatic rail-mounting device 1 then moves along the traveling track 5 to the roller conveyor 3 (the specific distance traveled is determined by the number of pulses sent by the PLC).

[0048] Furthermore, when the automatic rail mounting device 1 reaches the position of the roller conveyor 3, the PLC sends a pulse to control the lifting servo motor 118 to reverse, driving the internal mechanism of the worm gear lift 107 to descend, thereby driving the rail transfer pad 103 to descend until the rail 4 to be transferred is placed on the roller conveyor 3 to complete the automatic rail mounting operation.

[0049] In another embodiment, when either the walking servo motor 117 or the lifting servo motor 118 malfunctions, the malfunctioning servo motor will engage its brake, and the PLC will control all servo motors to stop operating. All the walking servo motors 117 and the lifting servo motor 118 will remain in their current positions, ensuring that the rail to be transferred 4 will not fall. The PLC will also record the current number of pulses from the servo motors (all servo motors are absolute value servo motors). After the malfunctioning servo motor is disengaged, the rail-raising device can continue its current rail-raising operation.

[0050] Based on the above solution, the cables of the inductive sensor 102, the contact sensor 109, the walking servo motor 117, and the lifting servo motor 118 are all located within the walking cable chain 101, ensuring that the cables of the automatic rail-mounting device 1 will not be broken during movement. Furthermore, since the equipment is used outdoors, it is equipped with the mounting bracket rainproof sheet metal 105, the lifting motor rainproof sheet metal 106, and the walking motor rainproof sheet metal 108, ensuring that the equipment can be used in rainy weather.

Claims

1. A rail automatic rail loader characterized by: The system includes an automatic rail loading device (1) for transferring the rail to be transferred (4) and a sensor system to assist the automatic rail loading device (1) in positioning. The rail to be transferred (4) is placed on the rail to be transferred carrier platform (2). The rail to be transferred carrier platform (2) is distributed at intervals. The travel track (5) is placed between the gaps of the rail to be transferred carrier platform (2). The automatic rail loading device (1) is placed on the travel track (5). The travel track (5) passes through the roller conveyor (3) and the rail to be transferred carrier platform (2). The rail loading device moves between the roller conveyor (3) and the rail to be transferred carrier platform (2).

2. The automatic rail loading device according to claim 1, characterized in that: The automatic rail mounting device (1) includes a walking device and a lifting device. The walking device includes a rail mounting frame (104). The lifting device and a sensor system are mounted on the rail mounting frame (104). A walking gear transmission mechanism (111) is mounted at the bottom of the rail mounting frame (104). A roller shaft (113) is sleeved on the walking gear transmission mechanism (111). The two ends of the roller shaft (113) are connected to walking rollers (112) through walking roller bearings (114). The walking gear transmission mechanism (111) is connected to a walking servo motor (117).

3. The automatic rail loading device of claim 2, wherein: The bottom of the walking gear transmission mechanism (111) is equipped with a gear transmission mechanism oil receiving sheet metal (115).

4. The automatic rail loading device according to claim 2, characterized in that: The walking servo motor (117) is equipped with a walking motor rain shield sheet metal (108) on its upper part.

5. The automatic rail loading device of claim 2, wherein: The lifting device includes a rail transition pad (103) to be transferred, a worm gear jack (107), a lifting guide rod (116), a lifting servo motor (118), and a limit block (110). The lifting servo motor (118) is mounted on the upper rail device mounting frame (104). The output side of the lifting servo motor (118) is connected to the worm gear jack (107). The worm gear jack (107) is connected to the bottom of the rail transition pad (103) to be transferred. The limit block (110) is installed above the rail transition pad (103) to be transferred. The lower part of the rail transition pad (103) to be transferred is connected to the lifting guide rod (116).

6. A rail automatic rail loading device according to claim 5, wherein: The lifting servo motor (118) is equipped with a rain shield sheet metal (106) on its outside.

7. The automatic rail loading device of claim 1, wherein: The sensor system includes a contact sensor (109), an inductive sensor (102), a through-beam grating (7) for the rail storage area, and a through-beam grating (6) for the roller conveyor. The contact sensor (109) and the inductive sensor (102) are installed on the front and rear sides of the rail transition pad (103) parallel to the rail cross-section. The through-beam grating (7) for the rail storage area is installed on the left and right ends of the rail carrier platform (2) for the rail to be transferred, and the through-beam grating (6) for the roller conveyor is installed on the left and right sides of the roller conveyor (3). The sensor system is connected to a PLC.

8. The automatic rail loading device of claim 2, wherein: The walking servo motor (117) is an absolute servo motor.

Images