Railway wheel recycling welding method

Abstract

A railway wheel recycling welding method according to an embodiment of the present comprises: a surface information acquisition step of acquiring surface information of a railway wheel flange; a welding torch position setting step of setting the position of a welding torch for performing overlay welding on the railway wheel flange on the basis of the surface information; and a welding step of performing welding on the railway vehicle flange in accordance with the position of the welding torch in the welding torch position setting step.

Description

Railway wheel reconditioning welding method

[0001] The present invention relates to a railway wheel reconditioning welding method for effectively performing burr welding in the reconditioning work of railway wheels.

[0002] In the maintenance of railway wheels, conventionally, when the lower thickness of the flange is worn down to 23 mm or less, the wheel diameter is reduced to about 68 mm by cutting the flange to restore the initial flange thickness of 32 mm through a grinding repair (see Fig. 1).

[0003] Due to this excessive amount of grinding, only 2-3 grinding repairs were possible from the initial wheel diameter of 860 mm to the usable limit of 690 mm, and accordingly, the wheel lifespan was very short, at 4 years for passenger cars and 10 years for freight cars, with an average of 6.8 years.

[0004] Recently, a method has been used to solve these problems by reducing the amount of scraping by performing agglomeration welding, and this has the effect of increasing the life of the wheel by 2 to 3 times compared to the existing scraping repair.

[0005] However, in the case of railway wheels, there is a research result that the contact load per wheel reaches approximately 10 tons, or if the contact load is assumed to be 85 kN, the maximum contact pressure reaches 1198.1 Mpa.

[0006] Due to their inherent risk of major accidents, railway wheels require conservative stability. Therefore, to allow for welding repairs, high-carbon steels with a carbon content of 0.56-0.66 wt% must be used. However, these materials exhibit very poor weldability, necessitating technical measures to verify weld defects.

[0007] (Patent Document 1) Republic of Korea Patent Publication No. 10-2108359

[0008] The present invention is intended to solve the above-mentioned problem, and provides a welding method capable of minimizing the phenomenon of insufficient melting when performing a build-up welding for railway wheel regeneration.

[0009] The problems to be solved by the present invention are not limited to the problems described above, and problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention pertains from this specification and the attached drawings.

[0010] The railway wheel re-welding method of the present invention for solving the above problem includes a surface information acquisition step for acquiring surface information of a railway wheel flange, a welding torch position setting step for setting a position of a welding torch for performing a build-up welding on the railway wheel flange based on the surface information, and a welding step for performing welding on the railway vehicle flange according to the position of the welding torch in the welding torch position setting step.

[0011] The above welding step may further include a monitoring step for monitoring the status of welding performed by the welding torch.

[0012] The above monitoring step may include a welding sensor signal collection process for collecting a welding sensor signal during the welding process in which the welding torch performs welding, and a monitoring process for monitoring the welding status based on the welding sensor signal.

[0013] The above welding sensor signal collection process can collect at least one signal among current, voltage, feed speed, and sound during the welding process of the welding torch.

[0014] The above monitoring process can monitor the state of welding through machine learning based on at least one signal among current, voltage, feed speed, and sound collected in the above welding sensor signal collection process.

[0015] The above welding step may further include a position verification step for verifying whether the welding torch performing the welding corresponds to the position set in the position setting step.

[0016] In the above position setting step, the position coordinates and inclination of the welding torch are set, and in the above position verification step, it is possible to verify whether welding is being performed according to the set position coordinates and inclination of the welding torch.

[0017] A railway wheel regeneration welding method according to one embodiment of the present invention has the following effects.

[0018] First, the lifespan of railway wheels can be extended by performing railway wheel regeneration work through welding.

[0019] Second, when performing welding work, the position of the welding torch can be set by considering the condition of the worn wheel, which can significantly reduce the possibility of welding defects.

[0020] Third, more effective welding results can be obtained by analyzing data on welding sensor signals in real time during the welding process and identifying welding defects using AI.

[0021] Fourth, during the welding process, it is difficult to determine through welding signal analysis, and the phenomenon of lack of fusion caused by misalignment of the welding torch can be prevented in advance by monitoring the position coordinates and inclination of the welding torch.

[0022] The effects of the present invention are not limited to the effects described above, and effects not mentioned can be clearly understood by a person having ordinary skill in the art to which the present invention pertains from this specification and the attached drawings.

[0023] Figure 1 is a drawing showing a railway wheel to explain the wear and regeneration process of the railway wheel.

[0024] Figure 2 is a drawing showing the sequence of a railway wheel regeneration welding method according to one embodiment of the present invention.

[0025] Figure 3 is a drawing for explaining the monitoring step of the railway wheel regeneration welding method of one embodiment of the present invention.

[0026] Figure 4 is a drawing for explaining the position setting step and position verification step of the welding torch in the railway wheel regeneration welding method of one embodiment of the present invention.

[0027] Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings. However, the spirit of the present invention is not limited to the presented embodiments, and those skilled in the art who understand the spirit of the present invention will be able to easily propose other inventions that are retrograde or other embodiments included within the scope of the spirit of the present invention by adding, modifying, or deleting other components within the scope of the same spirit. However, this will also be considered to be included within the scope of the spirit of the present invention.

[0028] FIG. 2 is a drawing showing the sequence of a railway wheel regeneration welding method according to an embodiment of the present invention, FIG. 3 is a drawing for explaining a monitoring step of a railway wheel regeneration welding method according to an embodiment of the present invention, and FIG. 4 is a drawing for explaining a position setting step and a position verification step of a welding torch of a railway wheel regeneration welding method according to an embodiment of the present invention.

[0029] Referring to FIG. 2, the railway wheel regeneration welding method of the present embodiment includes a surface information acquisition step (S10), a welding torch position setting step (S20), a welding step (S30), a monitoring step (S40), and a position verification step (S50).

[0030] The surface information acquisition step (S10) acquires surface information of a railway wheel flange or tread surface. Specifically, information on the polished state and surface shape of the railway wheel flange to be reworked is acquired. Based on this information, the position coordinates and inclination of the welding torch (10) performing the welding step (S30) described below are determined.

[0031] Various known methods or equipment can be used to obtain surface information on the flange or tread of a railway wheel (A). Specifically, in the present embodiment, information on the surface of the railway wheel is obtained using a 2D laser surface roughness tester. Furthermore, as described below, the present invention can verify the actual position coordinates and inclination of the welding torch (10) during the welding process using the 2D laser surface roughness tester.

[0032] In the welding torch position setting step (S20), the position of the welding torch for the bulging welding of the railway wheel flange is set based on the surface information on the railway wheel acquired in the surface information acquisition step (S10).

[0033] Generally, after the breeding welding step described below is performed, the regeneration work is completed through processes such as post-heat treatment, rough grinding, and finishing. Therefore, in the welding torch position setting step (S20), the degree to which the welding layer should be formed is determined by considering the welding material, welding equipment, and the amount of cutting in the subsequent welding, and the position coordinates and inclination of the welding torch at which such a welding layer can be formed are determined.

[0034] In the welding step (S30), welding is performed on the railway wheel flange (A) according to the position coordinates and inclination of the welding torch set in the welding torch position setting step (S20). As shown in FIGS. 3 and 4, as welding is performed, a welding racer (B) is formed on the upper part of the worn railway wheel.

[0035] In the monitoring step (S40), the status of the welding performed by the welding torch (10) is monitored.

[0036] That is, in the monitoring step (S40), if it is determined that the welding state is not sufficient to perform the roughing and finishing processes to be performed for subsequent regeneration work, the surface information acquisition step (S10) and welding torch position setting step (S20) described above can be performed again to obtain the desired burr welding result.

[0037] In the monitoring step (S30), a method for measuring various factors that can confirm the welding status can be applied, and in the present invention, as shown in FIG. 3, verification can be performed through artificial intelligence machine learning based on at least one signal among current, voltage, feed speed, and sound during the welding process.

[0038] That is, the monitoring step (S40) in this embodiment may include a welding sensor signal collection process (S41) and a monitoring process (S42).

[0039] In the welding sensor signal collection process (S41), data on current, voltage, feed speed, and sound are acquired during the welding process of the welding torch (10). For example, although not shown, welding voltage and current can be collected using a control device performing the welding process, wire feed speed can be collected using a rotary encoder, and sound can be collected using a sound sensor.

[0040] As shown in Fig. 3, signals for each data can be continuously collected during the welding process.

[0041] In the monitoring process (S42), AI machine learning is performed based on each data collected in the welding sensor signal collection process (S41), thereby enabling verification of a more accurate welding status.

[0042] In other words, the collected data is converted into signals that are easy to apply AI machine learning to, allowing AI learning to take place, and more precise verification will be possible as data accumulates.

[0043] In the position verification step (S50), it is verified whether the welding torch (10) corresponds to the position set in the welding torch position setting step (S20).

[0044] If the welding torch (10) deviates from the set position, a lack of fusion phenomenon occurs, in which the amount of welding to be done at that position is insufficient. In addition, this lack of fusion phenomenon is not easily detected during the monitoring process for the welding sensor signal, etc. described above, so a separate confirmation procedure is necessary to ensure the desired welding quality.

[0045] That is, in the position verification step (S50) of the present invention, verification is performed on whether the welding torch (10) performs welding work according to the position coordinates and inclination set in the welding torch position setting step (S20).

[0046] In particular, in the present invention, a 2D laser illuminator used to obtain surface information of a railway wheel in the surface information acquisition step (S10) is used to verify the position coordinates and inclination of the welding torch (10).

[0047] That is, there is no need to configure separate additional equipment by utilizing equipment for performing existing processes, and there is an advantage in that more objective verification is possible by verifying information on the position and inclination of the welding torch (10) externally rather than in the control unit that drives the welding torch.

[0048]

[0049] Although the configuration and features of the present invention have been described above based on embodiments according to the present invention, the present invention is not limited thereto, and it is obvious to those skilled in the art that various changes or modifications can be made within the spirit and scope of the present invention, and therefore, it is made clear that such changes or modifications fall within the scope of the appended patent claims.

[0050] [Explanation of symbols]

[0051] 10: Welding torch

[0052] A: Railway wheel

[0053] B: Welding layer

Claims

1. Surface information acquisition step for acquiring surface information of a railway wheel flange or tread surface; A welding torch position setting step for setting the position of a welding torch for performing a welding on the railway wheel flange based on the surface information; and A welding step of performing welding on the railway vehicle flange according to the position of the welding torch in the above welding torch position setting step; A railway wheel regeneration welding method including:

2. In paragraph 1, A railway wheel re-welding method further comprising a monitoring step for monitoring the status of welding performed by the welding torch in the above welding step.

3. In paragraph 1, The above monitoring step is, A welding sensor signal collection process for collecting a welding sensor signal during the welding process of the above welding torch; and A monitoring process for monitoring the welding status based on the above welding sensor signal; A railway wheel regeneration welding method including:

4. In paragraph 3, The above welding sensor signal collection process is a railway wheel regeneration welding method that collects at least one signal among current, voltage, feed speed, and sound during the welding process of the welding torch.

5. In paragraph 4, The above monitoring process is a railway wheel regeneration welding method that monitors the welding status through machine learning based on at least one signal among current, voltage, feed speed, and sound collected in the above welding sensor signal collection process.

6. In paragraph 1, A railway wheel re-welding method further comprising a position verification step of verifying whether the welding torch performing welding in the above welding step corresponds to the position set in the above position setting step.

7. In paragraph 6, In the above position setting step, the position coordinates and inclination of the welding torch are set, The above position verification step is a railway wheel regeneration welding step that verifies whether welding is being performed according to the set position coordinates and inclination of the welding torch.

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