A clamping tool for processing of railway heart rail sample
Patent Information
- Application Number
- CN202522590538.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-05
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-12-05
AI Technical Summary
[0009]本实用新型的目的在于提供一种用于铁路心轨试样加工的装夹工装,所述的一种用于铁路心轨试样加工的装夹工装要解决现有技术中操作效率低下、装夹稳定性差、定位精度不足、试样易受损、安装繁琐的技术问题
[0020]1.本实用新型通过自动化的多个夹紧机构与对中机构,采用液压与伺服协同驱动,实现装夹过程自动化,安装时间由传统工装的40分钟缩短至10分钟,大幅提高了效率。
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Figure CN224896571U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of machinery, and in particular to equipment for processing railway track components, specifically a clamping fixture for processing railway core rail samples. Background Technology
[0002] The railway frog is a key component of the turnout system, and its processing technology needs to be verified through sample processing. Therefore, high requirements are placed on the positioning accuracy, clamping stability, and operational efficiency of the clamping fixture. Currently, the industry commonly uses "mechanical manual clamping" fixtures, which mainly include a flat base, fixed support blocks, manual screw clamps, and manual adjusting push blocks. During installation, this fixture requires rough leveling using a spirit level. After the sample is placed, it relies on the manual push block for single-sided positioning, and then clamping is achieved by rotating the screw clamp. The clamping force depends on the operator's feel and experience, lacking quantitative control. Furthermore, the top surface of the support block is flat, resulting in poor matching with the curved bottom surface of the frog and easily creating gaps; the steel clamp directly contacts the sample surface, easily causing scratches or indentations; the base lacks a T-slot design for machine tool worktables, leading to lengthy installation and adjustment times. Although this type of fixture has a simple structure, it suffers from low clamping efficiency, insufficient positioning accuracy, large fluctuations in clamping force, and easy damage to the sample, making it difficult to meet the needs of high-precision processing and batch testing of frog samples.
[0003] In addition, the existing technology also has the following drawbacks:
[0004] 1. Low operating efficiency: Clamping and centering are achieved by pure manual operation. The clamping process of a single sample requires adjustment of the screw pressure block and manual push block, and the clamping time is too long (minutes), which cannot meet the needs of efficient testing and process verification before mass production.
[0005] 2. Poor clamping stability: The clamping force depends on the operator's feel and experience, and the fluctuation range is large. It is easy to clamp too loosely, causing the center rail to shift during the test, or clamp too tightly, causing the sample to be implicitly deformed. In addition, there is no gap elimination structure.
[0006] 3. Insufficient positioning accuracy: Single-sided positioning is achieved by manually adjusting the push block, resulting in a large deviation in the geometric center. This cannot meet the positioning requirements of high-precision mandrel machining tests and makes it difficult to accurately guide process optimization.
[0007] 4. Samples are easily damaged: The steel pressure block is in direct contact with the surface of the mandrel, and the surface is easily scratched or indented during the clamping process. This is especially true for test samples after precision machining, which directly affects product quality.
[0008] 5. Cumbersome installation: The flat plate base lacks a T-slot to fit the machine tool worktable, making the installation process time-consuming and lacking in versatility. Utility Model Content
[0009] The purpose of this utility model is to provide a clamping fixture for processing railway frog sample. The clamping fixture for processing railway frog sample aims to solve the technical problems of low operating efficiency, poor clamping stability, insufficient positioning accuracy, easy damage to the sample, and cumbersome installation in the prior art.
[0010] This utility model provides a clamping fixture for processing railway core rail samples, comprising a square box, with a fixture module for clamping the core rail sample fixedly arranged on each side of the square box; each fixture module includes three or more support mechanisms, three or more floating support mechanisms, three or more spinning mechanisms, three or more centering mechanisms, a stop block, and an end clamping mechanism; the support mechanisms, floating support mechanisms, spinning mechanisms, and centering mechanisms are arranged along the length of the square box; each support mechanism includes two vertically facing support seats, with the sample placed between the two support seats; each floating support mechanism includes two vertically facing telescopic supports... The cylinder, wherein the end of the telescopic rod of any of the telescopic cylinders abuts against the surface of the sample; any of the spinning mechanisms includes two first rotary clamping cylinders arranged vertically opposite each other, wherein a rotary clamping arm is eccentrically fixed on the rotating shaft of the first rotary clamping cylinder, and the inner side of the rotary clamping arm abuts against the edge of the long side of the sample; any of the centering mechanisms includes a centering clamp, wherein the two jaws of the clamp are respectively located on both sides of the sample in the vertical direction; the stop block abuts against one end of the sample; the end clamping mechanism includes a second rotary clamping cylinder, wherein an end clamping arm is eccentrically fixed at the end of the telescopic rod of the second rotary clamping cylinder, and the end clamping arm abuts against the other end of the sample.
[0011] Furthermore, the support mechanism, floating support mechanism, spinning mechanism, and centering mechanism are uniformly arranged along the length direction of the sample.
[0012] Furthermore, the telescopic cylinder, the first rotary clamping cylinder, and the second rotary clamping cylinder are respectively hydraulically driven, and the centering clamp is clamped by servo drive.
[0013] Furthermore, the square box is provided with valve groups corresponding to the total number of the telescopic cylinders, the first rotary pressing cylinder, and the second rotary pressing cylinder. Each of the telescopic cylinders, the first rotary pressing cylinder, and the second rotary pressing cylinder is connected to a valve group through a pipeline. Each valve group includes a reversing valve, a speed regulating valve, a pressure regulating valve, and a pressure gauge.
[0014] Furthermore, at least two mounting slots are provided on both sides of the square box. The cross-section of the mounting slot is T-shaped. The support mechanism, floating support mechanism, spinning mechanism, centering mechanism, stop block and end clamping mechanism are fixedly connected to the mounting slot by bolts.
[0015] Furthermore, the mounting groove is provided along the length direction of the sample.
[0016] Furthermore, the bottom of the square box is also provided with at least two mounting slots, and the square box is bolted to the external workbench through the mounting slots at its bottom.
[0017] Furthermore, a pad is provided at the contact end between the centering clamp and the sample.
[0018] Furthermore, the contact surface between the support and the sample is an arc-shaped surface.
[0019] Compared with existing technologies, the advantages of this invention are positive and obvious:
[0020] 1. This utility model uses multiple automated clamping and centering mechanisms, with hydraulic and servo drives, to automate the clamping process, reducing the installation time from 40 minutes for traditional tooling to 10 minutes, thus greatly improving efficiency.
[0021] 2. This utility model uses multiple sets of rotating pressure arms of the floating support mechanism to clamp the object together, which greatly reduces the gap and displacement, and the clamping force is controllable, thus improving the clamping stability.
[0022] 3. This utility model reduces geometric center deviation by using a centering clamp, improves the positioning accuracy of the mandrel, and ensures the accuracy of test data.
[0023] 4. This utility model uses replaceable pads to prevent the metal of the centering clamp from directly contacting the sample surface, effectively preventing scratches and indentations, and avoiding scratches or indentations on the surface of the mandrel during clamping.
[0024] 5. The square box base of this utility model is provided with a T-slot, which facilitates the installation of various clamping mechanisms. It can also be directly connected to an external workbench for quick installation and fixation, adapting to various machine tools and improving versatility. Attached Figure Description
[0025] Figure 1 A schematic diagram of the isometric structure of Embodiment 1 of this utility model.
[0026] Figure 2 A side view of the structure of Embodiment 1 of this utility model.
[0027] Figure 3 A top view of the structure of Embodiment 1 of this utility model.
[0028] Figure 4 The clamping flowchart of Embodiment 1 of this utility model.
[0029] Figure 5 A rear view structural diagram of Embodiment 2 of this utility model.
[0030] Figure 6 A schematic diagram of the valve assembly connection in Embodiment 2 of this utility model.
[0031] In the diagram: 1. Square box; 11. Mounting slot; 2. Floating support mechanism; 21. Telescopic cylinder; 22. Telescopic rod; 3. Spinning mechanism; 31. First rotary clamping cylinder; 32. Rotary clamping arm; 4. Centering mechanism; 41. Servo motor; 42. Centering clamp; 5. Stop block; 6. End clamping mechanism; 61. Second rotary clamping cylinder; 62. End clamping arm; 7. Support mechanism; 71. Support base; 8. Sample; 9. Valve group; 91. Reversing valve; 92. Speed regulating valve; 93. Pressure regulating valve; 94. Pressure gauge. Detailed Implementation
[0032] The following embodiments will further illustrate the present invention, but are not intended to limit the present invention.
[0033] Example 1
[0034] like Figures 1 to 4 As shown, this embodiment provides a clamping fixture for processing railway frog sample, including a square box 1 as the basic load-bearing structure. The square box 1 is made of QT450-10 cast iron to ensure overall stability and resistance to deformation. On both sides of the square box 1 along its length, an independent fixture module is fixedly installed by bolts, allowing the fixture to clamp two railway frog samples 8 simultaneously for processing, thus improving equipment utilization and testing efficiency.
[0035] Each tooling module includes multiple functional mechanisms, all integrated and mounted on a square box, for omnidirectional positioning and clamping of a single mandrel specimen 8. Specifically, each module is equipped with three sets of support mechanisms 7, three sets of floating support mechanisms 2, three sets of spinning mechanisms 3, three sets of centering mechanisms 4, a stop block 5, and an end clamping mechanism 6. These mechanisms are evenly arranged along the length of the specimen 8, thereby achieving uniform and stable support and clamping of the entire length of the long strip mandrel specimen 8, effectively improving clamping accuracy and suppressing processing vibration and deformation.
[0036] The support mechanism 7, made of 45# steel, is used to provide pre-support for the specimen 8. Each set of support mechanisms 7 includes two support seats 71 arranged facing each other in the vertical direction, located near the upper and lower surfaces of the specimen 8, respectively. The support surface of the support seat 71 that contacts the specimen 8 is an arc-shaped surface, which matches the standard arc contour of the bottom of the railway track specimen 8, improving the fit and stability of the initial positioning.
[0037] The floating support mechanism 2 is used to eliminate any possible gap between the specimen 8 and the support base 71 and to provide initial preload. Each set of floating support mechanisms 2 includes two vertically oriented telescopic cylinders 21 facing each other, which are hydraulically driven. The ends of the telescopic rods 22 of the telescopic cylinders 21 directly abut against the surface of the specimen 8. By controlling the synchronous micro-extension of the telescopic rods 22, a gentle and uniform vertical force can be applied to the specimen 8, ensuring a tight fit between it and the upper and lower support bases 71, and keeping the assembly gap within a very small range. In this embodiment, the gap should be ≤0.02mm after the floating support mechanism eliminates the gap.
[0038] The spinning mechanism 3 is the main dynamic clamping unit, used to provide continuous and adjustable lateral clamping force during processing. Each spinning mechanism 3 includes two vertically oriented, opposing first rotary clamping cylinders 31, which are hydraulically driven. A rotary clamping arm 32 is eccentrically mounted on the piston rod of the first rotary clamping cylinder 31. When the piston rod of the first rotary clamping cylinder 31 drives the rotating shaft to rotate, the eccentrically mounted rotary clamping arm 32 swings accordingly. After swinging to the vertical direction, the piston rod of the first rotary clamping cylinder 31 retracts, causing the inner side of the rotary clamping arm 32 to fit tightly against the edge of the long side of the sample, constraining the sample to move outward. Multi-point clamping with multiple rotary clamping arms ensures that the center rail displacement is ≤0.02mm during processing, thereby achieving high-precision positioning and clamping.
[0039] The centering mechanism 4 is used to ensure that the geometric center of the sample 8 in the horizontal plane is consistent with the center of the machining coordinate system. Each centering mechanism 4 includes a centering clamp 42, with two jaws located on the upper and lower sides of the sample 8, respectively. A servo motor 41 drives the two jaws to move synchronously towards or away from each other via a lead screw, precisely adjusting the vertical position of the sample 8 in the vertical direction to achieve high-precision centering and positioning, ensuring that the geometric center deviation does not exceed 0.1 mm. The centering clamp is a conventional device that uses a servo motor to drive a lead screw to rotate. The lead screw is threadedly connected to the jaws on both sides. The rotation of the lead screw causes the jaws on both sides to move linearly towards or away from each other, thereby achieving high-precision centering, clamping, and releasing.
[0040] The stop block 5 is fixedly installed at one end of the specimen 8 along its length, serving as a reference surface for axial positioning of the specimen 8. When the specimen 8 is clamped, one end of it must be close to the stop block 5 to determine its initial axial position on the fixture.
[0041] The end clamping mechanism 6 is used to apply axial clamping force from the other end of the sample 8 to prevent axial movement of the sample 8 during processing. This mechanism includes a second rotary clamping cylinder 61, with an end clamping arm 62 eccentrically fixed to the end of its telescopic rod 22. Through the combined action of the second rotary clamping cylinder 61, the end clamping arm 62 can be rotated to a predetermined position, and then the telescopic rod 22 can be driven to extend, causing the clamping arm to press against the end face of the sample 8 to achieve locking.
[0042] To enable flexible arrangement and secure installation of the aforementioned functional mechanisms on the tooling module, mounting structures are machined on both working surfaces and the bottom of the square box 1. Specifically, at least two continuous T-shaped mounting slots 11 are formed along the length of the specimen 8 on each side of the square box 1 used for mounting the tooling module. The bases of all support mechanisms 7, floating support mechanisms 2, spinning mechanisms 3, centering mechanisms 4, stop blocks 5, and end clamping mechanisms 6 are all designed with bolts that match the T-shaped mounting slots 11. Through the cooperation of the bolts and T-slots, each mechanism can easily slide within the length of the slot, and after adjusting to the most suitable position, the nuts can be tightened for fixation. This design improves the modularity and layout flexibility of the tooling, and can adapt to specimens 8 of different lengths and specifications.
[0043] Similarly, at least two T-shaped mounting slots 11 are also provided at the bottom of the square box 1, so that the entire tooling can be quickly and accurately installed onto the T-slots of the worktable of the machining center or milling machine by means of T-bolts, realizing the standardized and rapid connection between the tooling and the machine tool, saving installation and adjustment time.
[0044] The specific usage method of this embodiment is as follows:
[0045] I. Installation and Calibration
[0046] 1. Basic support module installation: Align the QT450-10 cast iron square box with the machine tool worktable through the bottom T-slot, and lock the square box on the worktable with 4 sets of M20 pressure plates + 20mm pads. Check the levelness of the top surface of the square box with a dial indicator, which should be ≤0.03mm / m. Fix the 45# steel quenched and tempered support base (arc surface R50mm) to the top surface of the square box with M16 hexagon socket screws. Calibrate the parallelism of the two support bases to ≤0.03mm / m, and ensure that the arc support surface is fully adapted to the bottom surface of the mandrel.
[0047] 2. Hydraulic drive module connection: Connect the rotary cylinder, floating support cylinder and hydraulic valve group with φ10mm piping according to the hydraulic schematic diagram. Turn on the hydraulic station, set the system pressure to 7MPa, and hold the pressure for 30 minutes to check for leakage. Debug the action sequence through the valve group: float cylinder rises (6MPa) → centering clamp clamps → rotary pressure arm clamps (clamping force 5kN). Cycle test 3 times to ensure smooth and continuous action.
[0048] 3. Positioning and clamping module calibration: The reference position of the servo centering clamp is calibrated by a laser positioning instrument to ensure that the positioning accuracy within a stroke range of 100mm is ≤0.05mm; the float cylinder stroke is adjusted to 40mm, and the gap between the bottom surface of the core rail and the arc surface of the support seat after it is lifted is ≤0.02mm.
[0049] II. Sample clamping
[0050] 1. Pre-placement and alignment: Hoist the core rail sample 8 onto the arc surface of the arc support 71, with the end facing the positioning end face of the stop block 5; start the servo motor 41 of the servo alignment clamp 42 to drive the alignment clamp 42 to move (stroke 5mm) and push the side of the core rail until its geometric center is aligned with the reference center of the square box 1 (deviation ≤0.1mm).
[0051] 2. Clearance and clamping: Activate the floating support cylinder to make the bottom surface of the sample 8 fit against the arc surface of the support seat 71 (feeler gauge detection gap ≤ 0.02mm); then activate the spinning mechanism 3 and the end clamping mechanism 6 to make the rotating pressure arm 32 clamp the side of the long side of the sample 8 and the end pressure arm 62 clamp the end of the sample 8.
[0052] 3. Protection and Inspection: The displacement of the side of the mandrel is measured with a dial indicator and is ≤0.02mm, which meets the clamping accuracy requirements.
[0053] III. Processing and Unloading
[0054] 1. Processing execution: Start the machine tool to process sample 8, and monitor the clamping force in real time during the processing.
[0055] 2. Unloading and maintenance: After processing, the hydraulic system reverses (each pressure arm is raised, the centering is released, and the floating support cylinder is lowered). Manually unload the mandrel sample 8 and check whether the processing dimensions and tolerances meet the standards. The thickness of the pad block also needs to be measured. If the pad block is worn too much, replace it with a new pad block. Prepare for the next clamping.
[0056] Example 2
[0057] like Figure 5 As shown, this embodiment is a preferred solution of Embodiment 1, which further defines the specific configuration of the drive control system.
[0058] In this embodiment, to achieve automation and precise force control during the clamping process, the telescopic cylinder 21 in the floating support mechanism 2, the first rotary clamping cylinder 31 in the spinning mechanism 3, and the second rotary clamping cylinder 61 in the end clamping mechanism 6 are all hydraulically driven. The hydraulic system provides a stable and powerful driving force, and facilitates multi-point synchronous control and precise pressure adjustment. Meanwhile, the centering clamp 42 in the centering mechanism 4 is driven by a servo motor 41. Servo drives are characterized by high control precision, fast response speed, and accurate position control, making them ideal for centering operations requiring precise positioning.
[0059] To enable independent and precise control of the aforementioned multiple hydraulic actuators, a valve assembly system 9 is integrated into the side or interior of the box 1. The number of valve assemblies 9 corresponds to the total number of hydraulic cylinders; that is, each hydraulic cylinder is connected to and controlled by a corresponding valve assembly 9 via hydraulic piping. The hydraulic piping uses φ10mm pipes with a pressure resistance of 7MPa. Each valve assembly 9 is integrated and mounted on a valve block, typically including a directional valve 91, a speed control valve 92, a pressure regulating valve 93, and a pressure gauge 94.
[0060] Among them, the solenoid directional valve 91 is used to control the movement direction of the hydraulic cylinder (such as extension or retraction, forward or reverse rotation). The speed regulating valve 92 is used to precisely adjust the movement speed of the hydraulic cylinder, ensuring smooth and synchronized operation of each mechanism and avoiding impact. The pressure regulating valve 93 is used to set and stabilize the working pressure of this circuit, thereby precisely controlling the clamping force of the hydraulic cylinder. This allows the clamping force to be quantitatively set and kept constant according to process requirements, eliminating the uncertainty of manual operation. The pressure gauge 94 displays the current circuit pressure visually, facilitating monitoring and debugging.
[0061] Detailed pipeline connection diagram as follows Figure 6 As shown. This integrated hydraulic control system, combined with a servo drive system, allows operators to sequentially control all clamping actions via a central control panel or PLC program. This achieves full automation of the entire process, from gap elimination and centering to multi-dimensional clamping, improving clamping efficiency and consistency.
[0062] Example 3
[0063] This embodiment is a preferred solution based on Embodiment 1 or Embodiment 2.
[0064] In this embodiment, since the jaws of the centering clamp 42 are typically made of metal, direct contact with the surface of the finished mandrel sample 8 may cause surface scratches or indentations when a large clamping force is applied. To solve this problem, a pad is detachably installed at the end of each jaw of the centering clamp 42 that contacts the sample 8.
[0065] The pad can be made of a material softer than that of sample 8, such as copper, engineering plastics, or non-metallic materials such as polyurethane inlaid on the surface. In this embodiment, POM material with a thickness of 5mm is used.
[0066] The contact surface of the pad can be machined into a curved surface that matches the local shape of the side of the mandrel sample 8, thereby increasing the contact area and reducing pressure. The pad can be replaced individually after wear, reducing maintenance costs and extending the service life of the clamp body.
[0067] In the description of this utility model, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the present 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 the present invention. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present utility model.
Claims
1. A clamping fixture for processing railway frog sample, characterized in that: Includes a square box (1), and a tooling module for clamping the core rail sample (8) is fixedly provided on both sides of the square box (1); Each tooling module includes three or more support mechanisms (7), three or more floating support mechanisms (2), three or more spinning mechanisms (3), three or more centering mechanisms (4), a stop block (5), and an end clamping mechanism (6); the support mechanisms (7), floating support mechanisms (2), spinning mechanisms (3), and centering mechanisms (4) are arranged along the length of the square box (1); Each of the support mechanisms (7) includes two support seats (71) arranged facing each other in the vertical direction, and the sample (8) is placed between the two support seats (71); Each of the floating support mechanisms (2) includes two telescopic cylinders (21) arranged facing each other in the vertical direction, and the end of the telescopic rod (22) of each of the telescopic cylinders (21) abuts against the surface of the sample (8); Any of the aforementioned spinning mechanisms (3) includes two first rotary pressing cylinders (31) arranged facing each other in the vertical direction. A rotary pressing arm (32) is eccentrically fixed on the rotating shaft of the first rotary pressing cylinder (31). The inner side of the rotary pressing arm (32) abuts against the edge of the long side of the sample (8). Each of the centering mechanisms (4) includes a centering clamp (42), the two jaws of which are located on both sides of the vertical direction of the sample (8); The stop block (5) abuts against one end of the sample (8); The end clamping mechanism (6) includes a second rotary clamping cylinder (61), and an end clamping arm (62) is eccentrically fixed to the end of the telescopic rod (22) of the second rotary clamping cylinder (61), and the end clamping arm (62) abuts against the other end of the sample (8).
2. The clamping fixture for processing railway track specimens according to claim 1, characterized in that: The support mechanism (7), floating support mechanism (2), spinning mechanism (3) and centering mechanism (4) are uniformly arranged along the length direction of the sample (8).
3. The clamping fixture for processing railway frog sample according to claim 1, characterized in that: The telescopic cylinder (21), the first rotary clamping cylinder (31), and the second rotary clamping cylinder (61) are respectively driven by hydraulics, and the centering clamp (42) is clamped by servo drive.
4. The clamping fixture for processing railway track specimens according to claim 3, characterized in that: The box (1) is provided with valve groups (9) corresponding to the total number of the telescopic cylinder (21), the first rotary pressing cylinder (31) and the second rotary pressing cylinder (61). Each of the telescopic cylinder (21), the first rotary pressing cylinder (31) and the second rotary pressing cylinder (61) is connected to a valve group (9) through a pipeline. Each valve group (9) includes a reversing valve (91), a speed regulating valve (92), a pressure regulating valve (93) and a pressure gauge (94).
5. A clamping fixture for processing railway track specimens according to claim 1, characterized in that: At least two mounting slots (11) are provided on both sides of the square box (1). The cross-section of the mounting slot (11) is T-shaped. The support mechanism (7), floating support mechanism (2), spinning mechanism (3), centering mechanism (4), stop block (5) and end clamping mechanism (6) are fixedly connected to the mounting slot (11) by bolts.
6. A clamping fixture for processing railway track specimens according to claim 5, characterized in that: The mounting groove (11) is provided along the length direction of the sample (8).
7. A clamping fixture for processing railway track specimens according to claim 5, characterized in that: The bottom of the square box (1) is also provided with at least two mounting slots (11), and the square box (1) is bolted to the external workbench through the mounting slots (11) at its bottom.
8. A clamping fixture for processing railway frog sample according to claim 1, characterized in that: A pad is provided at the contact end between the centering clamp (42) and the sample (8).
9. A clamping fixture for processing railway frog sample according to claim 1, characterized in that: The contact surface between the support base (71) and the sample (8) is an arc-shaped surface.