A fully automatic rail deruster

Abstract

This utility model relates to the field of rail rust removal technology, specifically a fully automatic rail rust removal machine, including a frame on which two sets of limiting and guiding components are mounted. This fully automatic rail rust removal machine, through the coordinated operation of the drive components and the limiting and guiding components, can automatically travel along the rail to complete rust removal, completely eliminating reliance on manual labor, reducing labor intensity, and improving work efficiency. The equipment is equipped with four sets of grinding wheels, which are used to cover the top, bottom, front and rear side groove surfaces, side tops, and inner bottom walls of the rail, effectively solving the problem of incomplete rust removal of hidden areas such as the rail bottom triangular area and groove surface by traditional equipment, achieving comprehensive rust removal without dead angles. Regarding grinding force control, the linear module precisely adjusts the contact force between the grinding wheels and the rail through adjusting bolts and drive wheels, and the fine-tuning of the transmission device with adjusting screws effectively avoids excessive rail wear or inadequate rust removal caused by fluctuations in grinding force.

Description

Technical Field

[0001] This utility model relates to the field of rail rust removal technology, specifically a fully automatic rail rust removal machine. Background Technology

[0002] Before welding, the rails need to be cleaned and free of rust and foreign matter from their entire contour. Pre-welding rust removal can improve the accuracy of rail dimensions and appearance inspection, thereby improving the welding quality of the rails. It can also reduce the generation of rust and dust during the transportation process and improve the workshop environment.

[0003] Currently, rail rust removal operations mostly rely on manual grinding or semi-automatic equipment. Manual grinding depends on the operator's experience to control the grinding force and range, which is not only labor-intensive and inefficient, but also greatly affected by human factors, making it difficult to guarantee the uniformity and thoroughness of rust removal. Especially in hidden areas such as the triangular area at the bottom of the rail and the side of the rail head, the rust removal effect is often unsatisfactory. Although semi-automatic rust removal equipment reduces reliance on manual labor to some extent, it generally lacks a precise control mechanism for grinding force. When the grinding wheel contacts the rail, the grinding force is prone to drastic fluctuations due to factors such as uneven rust on the rail surface and slight deviations in shape and size. When the grinding force is too high, it can easily cause excessive wear on the rail surface, affecting the service life of the rail; when the grinding force is too low, the rust layer cannot be effectively removed, resulting in incomplete rust removal. Utility Model Content

[0004] To achieve the above objectives, this utility model provides the following technical solution: a fully automatic rail rust removal machine, comprising a frame, on which two sets of limiting and guiding components are mounted, and multiple pairs of driving components are distributed between the two sets of limiting and guiding components from front to back. From front to back, the driving ends of each set of driving components are respectively equipped with a first grinding wheel, a second grinding wheel, a third grinding wheel, and a fourth grinding wheel. Each grinding wheel is adapted to different parts of the rail. The rail includes a rail head, a rail web, and a rail base. The first grinding wheel corresponds to the top of the rail head. The first grinding wheel is located on the bottom surface of the rail base. The second grinding wheel corresponds to the rail waist, and its outer top is provided with an arc surface, which corresponds to the bottom surface of the rail head. The third grinding wheel is higher than the second grinding wheel and corresponds to the side of the rail head. The fourth grinding wheel corresponds to the top surface of the rail base. The limiting guide assembly consists of a vertical frame and a pair of side frames. A lifting group is installed on the vertical frame. The bottom of the lifting group is connected to a connecting block that can slide inside the vertical frame. An upper guide roller is rotatably connected between the connecting blocks. A lower guide roller is provided inside the vertical frame below the upper guide roller. A pair of rollers are installed inside the side frames.

[0005] Furthermore, the drive assembly includes a linear module, a movable plate is fixed at the movable end of the linear module, a rotating rod and a belt-driven transmission device for driving the rotating rod to rotate are mounted on the movable plate, and a first grinding wheel, a second grinding wheel, a third grinding wheel and a fourth grinding wheel are respectively assembled at the ends of the corresponding rotating rods.

[0006] Furthermore, the linear module includes a lead screw mechanism and a mounting plate. The mounting plate has multiple slotted holes and rectangular holes between the slotted holes. The mounting plate is locked to the lead screw mechanism by screws passing through the slotted holes. A central block is fixed on the lead screw mechanism and located in the rectangular hole. An adjusting bolt is threaded into the central block. A nut is threaded into the outer side of the adjusting bolt near the central block. An auxiliary wheel connected to the internal lead screw is installed on the lead screw mechanism. A drive wheel connected to the auxiliary wheel is installed on the mounting plate.

[0007] Furthermore, the movable plate is fixed with a pair of blocks and hinged with a hinge plate that can cover the pair of blocks. A rotating shaft is rotatably connected between the pair of blocks, and an adjusting screw is threaded onto the rotating shaft. The hinge plate has an elongated hole, through which the adjusting screw can pass and be locked in place by a screw cap. A belt drive device is mounted on the hinge plate.

[0008] Furthermore, a housing is fixed on the movable plate, which covers the belt drive device inside. An adjustment hole is provided on the housing corresponding to the end of the drive motor shaft of the belt drive device. The adjustment hole is T-shaped and has an inclined cross-section.

[0009] Furthermore, the lifting assembly includes a lifting screw that is rotatably mounted on the top of the upright frame, a lifting plate that is threaded to the outside of the lifting screw, a connecting rod that is fixed to the bottom of the lifting plate, the connecting rod that is connected to a corresponding connecting block, and a rotating handle that is fixed to the top of the lifting screw.

[0010] Furthermore, the bottom of the side frame is provided with a waist hole, and screws are used to lock and fix it to the frame platform through the waist hole. A side block is fixed on the frame platform, and the side block is opposite to the outward side of the side frame. The side block is rotatably connected with a displacement bolt, and the displacement bolt is threadedly connected to the side frame.

[0011] Compared with the prior art, the technical solution of this application has the following beneficial effects:

[0012] This fully automatic rail rust removal machine, through the coordinated operation of the drive component and the limit guide component, can automatically move along the rail to complete rust removal, completely eliminating reliance on manual labor, reducing labor intensity, and improving work efficiency. The equipment is equipped with four sets of grinding wheels, which are divided to cover the top, bottom, front and rear side groove surfaces, side tops, and inner bottom walls of the rail, effectively solving the problem of incomplete rust removal of hidden parts such as the rail bottom triangular area and groove surface by traditional equipment, achieving comprehensive rust removal without dead angles. In terms of grinding force control, the linear module precisely adjusts the contact force between the grinding wheel and the rail through adjusting bolts and drive wheels, and with the fine adjustment of the transmission device by adjusting screws, it can effectively avoid excessive wear of the rail or substandard rust removal caused by fluctuations in grinding force. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of this utility model;

[0014] Figure 2This is a three-dimensional structural diagram of the limiting and guiding component in this utility model;

[0015] Figure 3 This is a schematic diagram of the connection structure of the first grinding wheel in this utility model;

[0016] Figure 4 This is a schematic diagram of the connection structure of the second grinding wheel in this utility model;

[0017] Figure 5 This is a schematic diagram of the connection structure between the second and third grinding wheels in this utility model;

[0018] Figure 6 This is a schematic diagram of the connection structure of the fourth grinding wheel in this utility model;

[0019] Figure 7 This is a partial schematic diagram of the connection structure of the linear module in this utility model;

[0020] Figure 8 In this utility model Figure 3-6 A three-dimensional schematic diagram of the connection structure of the mobile board.

[0021] In the diagram: 1. Stand; 2. Limiting and guiding assembly; 21. Frame; 22. Lower guide roller; 23. Lifting screw; 24. Rotary handle; 25. Lifting plate; 26. Connecting rod; 27. Connecting block; 28. Side frame; 29. ​​Counterroller; 210. Side block; 211. Alternating bolt; 212. Upper guide roller; 3. Drive assembly; 32. Linear module; 321. Screw mechanism; 322. Mounting plate; 323. Middle block; 324. Adjusting bolt; 325. Nut; 326. Drive wheel; 327. Auxiliary wheel; 33. Moving plate; 34. Counterblock; 35. Rotating shaft; 36. Adjusting screw; 37. Hinge plate; 38. Belt drive device; 39. Housing; 310. Adjusting hole; 311. Rotating rod; 4. First grinding wheel; 5. Second grinding wheel; 6. Third grinding wheel; 7. Fourth grinding wheel. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] Please see Figure 1-8This embodiment of a fully automatic rail rust removal machine includes a frame 1. Three sets of limiting and guiding components 2, spaced apart along the rail's extension direction, are mounted on the frame 1 for guiding the equipment's movement and positioning the rail. Four sets of drive components 3 are installed on the frame 1, distributed between the three sets of limiting and guiding components 2. From front to back, the four sets of drive components 3 are designated as a first drive, a second drive, a third drive, and a fourth drive, respectively. The first drive is located on the back of the rail, and its two drive ends are respectively equipped with first grinding wheels 4 that can contact the top and bottom of the rail. The second, third, and fourth drives are all distributed on the front and rear sides of the rail. The two drive ends of the second drive are each equipped with a second grinding wheel 5. The outer top of the second grinding wheel 5 has a slope, allowing it to contact the rail groove and its inner top wall. The two drive ends of the third drive are fixed with a third grinding wheel 6, which is higher than the second grinding wheel 5. The third grinding wheel 6 can contact the top ends of the front and rear sides of the rail. The fourth drive is installed at an angle, and its drive end is fixed with a fourth grinding wheel 7, which can contact the inner bottom wall of the rail. The rail is conveyed from the inlet to the outlet. The limiting and guiding components guide the rail, and the drive components operate, driving the corresponding grinding wheels to approach the designated positions. This allows the rail to pass sequentially through the first to fourth grinding wheels, completing the grinding of the rail top, bottom, web, rail head side, and the triangular area of ​​the rail bottom.

[0024] like Figure 2 The limiting and guiding assembly 2 includes a vertical frame 21 fixed on the platform 1 and a pair of side frames 28. A lifting assembly is installed on the vertical frame 21. The lifting assembly includes a lifting screw 23 rotatably passing through the top of the vertical frame 21. The outer side of the lifting screw 23 is threadedly connected to a lifting plate 25. The bottom of the lifting plate 25 is connected to a connecting block 27 that can slide vertically inside the vertical frame 21 through two sets of connecting rods 26. An upper guide roller 212 is rotatably connected between the connecting blocks 27. A lower guide roller 22 is installed on the inner side of the vertical frame 21 below the upper guide roller 212. A handle 24 is provided at the top of the lifting screw 23 to adjust the height of the upper guide roller 212, so as to adapt to the rails of different heights and guide and limit them.

[0025] The side frame 28 has a pair of waist holes at its bottom, and screws pass through the waist holes to lock it onto the frame 1. Side blocks 210 are fixed on the frame 1 and are distributed opposite to the side frame 28. Opposing bolts 211 are rotatably connected to the side blocks 210 and are threadedly connected to the side frame 28. Rollers 29 are installed on the inner side of the side frame 28. By loosening the screws in the waist holes, the screws limit the side frame. The side frame can be moved by rotating the opposing bolts, and the spacing of the rollers 29 can be adjusted. After adjustment, the screws are tightened to fix it. The rollers guide and limit the two sides of the rail. The spacing can be adjusted to adapt to rails of different widths.

[0026] like Figure 3-6The first, second, third, and fourth drives each include a pair of linear modules 32 mounted on a frame 1. The moving end of each linear module 32 is fixed to a moving plate 33, on which a belt drive 38 and a rotating rod 311 are mounted. The belt drive 38 drives the rotating rod 311 to rotate, and a grinding wheel is mounted at the end of the rotating rod 311. The linear modules move the moving plate, bringing the first to fourth grinding wheels closer to the designated positions on the rail. To control the grinding force, the linear modules precisely adjust the contact force between the grinding wheels and the rail using adjusting bolts and drive wheels. Then, the belt drive drives the rotating rod to rotate, thereby rotating the corresponding first to fourth grinding wheels to complete the grinding operation.

[0027] like Figure 7 Taking the example and direction, the linear module 32 includes a lead screw mechanism 321 fixed on the frame 1, and a mounting plate 322 that is screwed through a waist hole and locked onto the lead screw mechanism 321. A middle block 323 is fixed to the front of the lead screw mechanism 321 by screws. An adjusting bolt 324 is threaded onto the top of the middle block. The outer side of the adjusting bolt 324 is locked near the middle block by a nut 325. An auxiliary wheel 327 connected to the lead screw drive is mounted on the inner side of the lead screw mechanism 321. A drive wheel 326 connected to the auxiliary wheel drive is mounted on the mounting plate 322, driving the moving end of the lead screw mechanism 321 to move. Micron-level precision adjustment is achieved through the adjusting bolt 324 and nut 325 on the middle block 323. Combined with displacement compensation through the waist hole of the mounting plate 322, the adjustment flexibility and precision are greatly improved, ensuring a tight transmission between the drive wheel and the auxiliary wheel, resulting in high transmission efficiency and preventing vibration loosening, thus guaranteeing long-term operational stability.

[0028] like Figure 8 Taking the example and orientation, a pair of blocks 34 are fixed on the surface of the movable plate 33, and a hinge plate 37 covering the pairs of blocks is hingedly installed. A rotating shaft 35 is rotatably connected between the pairs of blocks 34. An adjusting screw 36 is threaded to the outside of the rotating shaft 35. The adjusting screw 36 passes through the elongated hole of the hinge plate 37 and is locked by a screw cap. The angle of the hinge plate 37 can be adjusted to make the belt of the belt-driven device 38 taut. The belt-driven device 38 is mounted on the hinge plate 37. A housing 39 covering the belt-driven device 38 is fixed on the movable plate 33. The housing 39 has a T-shaped tilt adjustment hole 310 corresponding to the end of the drive motor shaft. The housing can protect the belt-driven device and improve protection. At the same time, the adjustment hole can accommodate the movement space of the drive motor shaft after the hinge plate drives the belt-driven device 38 to tilt.

[0029] The working principle of the above embodiments is as follows:

[0030] Before starting the grinding operation, the equipment needs to be adjusted according to the height and width parameters of the rail to be ground, using the limit guide assembly. This ensures accurate positioning and height adjustment during rail transport. Rotating the handle at the top of the stand rotates the lifting screw, causing the lifting plate, threaded to the screw, to move vertically along the stand. This pulls the connecting block and upper guide roller to rise and fall synchronously until the distance between the upper and lower guide rollers matches the rail height, thus guiding and limiting the rail's vertical movement. Loosening the fixing screws in the waist hole at the bottom of the side frame, and rotating the shift bolts on the side block, which are threaded to the side frame, drives the side frame to move laterally along the platform, synchronously adjusting the spacing of the inner rollers until it matches the rail width. Finally, re-tighten the waist hole screws to secure the side frame. The frame completes the lateral guidance and limiting of the rail. After debugging, the linear modules of the four drive components and the transmission adjustment structure precisely align each grinding wheel to the part of the rail to be ground, and calibrate the contact force and transmission stability. The linear modules in each drive component are activated, and the screw mechanism drives the moving end and moving plate to move laterally, so that the first to fourth grinding wheels are close to the corresponding positions on the rail. The first grinding wheel moves to the back of the rail and aligns with the top and bottom of the rail. The second grinding wheel aligns with the inside of the rail groove and the inner top wall. The third grinding wheel aligns with the top ends of the front and rear sides of the rail. The fourth grinding wheel, along with the tilted fourth drive, aligns with the inner bottom wall of the rail. Rotating the adjusting bolt on the middle block of the linear module and locking it with the nut achieves micron-level precision adjustment, combined with the waist hole of the mounting plate. The displacement compensation precisely controls the transmission tension of the drive wheel and auxiliary wheel, thereby adjusting the contact force between the grinding wheel and the rail to avoid over- or under-grinding. Rotating the adjusting screw on the moving plate and locking it with the nut drives the hinge plate to rotate around the hinge point, adjusting the angle of the belt drive to keep the belt taut. Simultaneously, the T-shaped tilt adjustment hole on the outer casing provides movement space for the drive motor shaft, ensuring transmission efficiency and operational stability. When the equipment enters working condition, the rail is conveyed from the feed inlet to the platform. Under the coordinated action of the limiting guide assembly and the drive assembly, it completes graded grinding. During the conveying process, the rail is always guided by the upper and lower guide rollers of the upright frame and the side frame rollers. Three sets of spaced limiting guide groups... The system continuously positions and corrects the rails to ensure they travel stably along a preset path. The rails first pass through the first drive assembly, where a belt-driven transmission rotates a rotating rod, which in turn rotates the first grinding wheel to perform initial grinding on the top and bottom of the rail. As the rails move forward, they enter the working area of ​​the second drive assembly. The second grinding wheel, with a slope on its outer top, rotates to grind the rail groove and related areas on the inner top wall and rail web. Next, the third grinding wheel of the third drive assembly starts, grinding the top and side edges of the rail heads on both the front and rear sides. Finally, the fourth grinding wheel of the fourth drive assembly rotates to grind the triangular area at the bottom of the rail's inner bottom wall. After being processed by four sets of grinding wheels in sequence, the rails are output from the discharge port, completing all grinding operations.

[0031] The entire workflow is now complete, and anything not described in detail in this specification is existing technology known to those skilled in the art.

[0032] It should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0033] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automatic rail rust removal machine, comprising a frame (1), characterized in that: Two sets of limiting guide components (2) are mounted on the platform (1), and multiple sets of paired drive components (3) are distributed between the two sets of limiting guide components (2) from front to back. The drive ends of each set of drive components (3) from front to back are respectively equipped with a first grinding wheel (4), a second grinding wheel (5), a third grinding wheel (6) and a fourth grinding wheel (7). Each grinding wheel is assigned to adapt to different parts of the rail. The rail includes the rail head, rail web and rail base. The first grinding wheel (4) corresponds to the top surface of the rail head and the bottom surface of the rail base. The second grinding wheel (5) corresponds to the rail web. Its outer top is provided with an arc surface, which corresponds to the bottom surface of the rail head. The third grinding wheel (6) is higher than the second grinding wheel (5). The third grinding wheel (6) corresponds to the side of the rail head. The fourth grinding wheel (7) corresponds to the top surface of the rail base. The limiting guide assembly (2) consists of a vertical frame (21) and a pair of side frames (28). A lifting assembly is installed on the vertical frame (21). A connecting block (27) that can slide inside the vertical frame (21) is connected to the bottom of the lifting assembly. An upper guide roller (212) is rotatably connected between the connecting blocks (27). A lower guide roller (22) is provided on the inner side of the vertical frame (21) below the upper guide roller (212). A pair of rollers (29) are installed on the inner side of the side frames (28).

2. The fully automatic rail rust removal machine according to claim 1, characterized in that: The drive assembly (3) includes a linear module (32), a movable plate (33) is fixed at the movable end of the linear module (32), a rotating rod (311) and a belt drive device (38) for driving the rotating rod (311) to rotate are installed on the movable plate (33), and a first grinding wheel (4), a second grinding wheel (5), a third grinding wheel (6) and a fourth grinding wheel (7) are respectively assembled at the ends of the corresponding rotating rods (311).

3. The fully automatic rail rust removal machine according to claim 2, characterized in that: The linear module (32) includes a lead screw mechanism (321) and a mounting plate (322). The mounting plate (322) has multiple waist holes and rectangular holes between the waist holes. The mounting plate (322) is locked to the lead screw mechanism (321) by screws through the waist holes. A middle block (323) is fixed on the lead screw mechanism (321) and located in the rectangular hole. An adjusting bolt (324) is threaded on the middle block (323). A nut (325) is threaded on the outside of the adjusting bolt (324) near the middle block (323). An auxiliary wheel (327) connected to the internal lead screw is installed on the lead screw mechanism (321). A drive wheel (326) connected to the auxiliary wheel (327) is installed on the mounting plate (322).

4. The fully automatic rail rust removal machine according to claim 2, characterized in that: The movable plate (33) is fixed with a pair of blocks (34) and is hinged with a hinge plate (37) that can cover the pair of blocks (34). A rotating shaft (35) is rotatably connected between the pair of blocks (34). An adjusting screw (36) is threadedly connected to the rotating shaft (35). The hinge plate (37) has an elongated hole. The adjusting screw (36) can pass through the elongated hole and be locked and fixed by a screw cap. A belt drive device (38) is mounted on the hinge plate (37).

5. The fully automatic rail rust removal machine according to claim 4, characterized in that: The movable plate (33) is fixed with a housing (39), which covers the belt drive device (38) inside. The housing (39) has an adjustment hole (310) at the end of the drive motor shaft of the belt drive device (38). The adjustment hole (310) is T-shaped and has an inclined cross-section.

6. The fully automatic rail rust removal machine according to claim 1, characterized in that: The lifting assembly includes a lifting screw (23) that is rotatably installed on the top of the upright (21). The lifting screw (23) is threadedly connected to the lifting plate (25). A connecting rod (26) is fixed at the bottom of the lifting plate (25). The connecting rod (26) is connected to the corresponding connecting block (27). A rotating handle (24) is fixed at the top of the lifting screw (23).

7. The fully automatic rail rust removal machine according to claim 1, characterized in that: The bottom of the side frame (28) is provided with a waist hole, which is locked and fixed to the frame platform (1) by screws through the waist hole. A side block (210) is fixed on the frame platform (1). The side block (210) is opposite to the outward side of the side frame (28), and a displacement bolt (211) is rotatably connected on the side block (210). The displacement bolt (211) is threadedly connected to the side frame (28).

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