Laser Processing Vehicle with Dual Driving Mechanism
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Solution Overview
Problem
Existing on-line laser processing devices for rail surfaces face challenges with mobility, precision, and efficiency due to limitations in power consumption, accuracy, and applicability, particularly in complex railway environments, where high-power CO2 lasers require complex setups and pre-coating processes, and separate components lead to reliability issues and restricted access.
Innovation Solution
An on-line laser processing vehicle with a dual driving and switching mechanism, utilizing a semiconductor laser and a movement actuator, allows precise control of speed and distance, integrates essential components like a generator set, control system, and laser processing head, and features a climbing-rail system for flexibility, enabling efficient and accurate processing on various rail types without the need for pre-coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-power CO2 laser is used for rail surface treatment, then laser processing capability is achieved, but energy consumption increases and photoelectric conversion efficiency decreases
Solution Approach 1:
The patent changes the fundamental parameter of laser wavelength from CO2 laser (10.6 microns) to semiconductor laser (near-infrared), fundamentally altering the energy efficiency characteristics while maintaining processing capability
2Power
If CO2 laser with wavelength of 10.6 microns is used, then laser processing is enabled, but metal substrate absorption is low and pre-coating procedures are required
Solution Approach 1:
The patent changes the laser wavelength parameter to near-infrared, which is naturally absorbed by metal substrates, thereby eliminating the need for light-absorbing coatings and simplifying the processing procedure
3Power
If flying light path or hard-light-path system is used for CO2 laser transmission, then laser beam transmission is achieved, but precision is affected by vehicle vibration and long-term stability is difficult to ensure
Solution Approach 1:
The patent replaces the mechanical/optical transmission system (flying light path or hard-light-path) with an electrical transmission system (fiber optic cable), which is immune to vibration and ensures stable laser beam delivery
4Manufacturing precision
If laser maintenance vehicle is stationary with maximum processing head movement of 1000 mm, then laser processing is performed, but long-distance processing is limited and relocation precision is poor
Solution Approach 1:
The patent transforms the stationary vehicle into a mobile vehicle that can move along the rail, enabling long-distance processing while maintaining precision through dynamic positioning capabilities
5Speed
If conventional driving system is used for laser processing vehicle, then vehicle movement is achieved, but speed and distance control precision is insufficient for accurate laser processing trajectories
Solution Approach 1:
The patent introduces a feedback control system with sensors that continuously monitor position and speed, enabling precise control of the vehicle's movement along the rail to achieve accurate laser processing trajectories
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances mobility and precision in laser processing, reduces energy consumption, and simplifies the processing procedure, allowing for effective wear resistance improvement on rails, especially for high-speed and heavy haul trains, while maintaining operational efficiency and flexibility across different rail configurations.
Implementation Method 1
a semiconductor laser as a light source capable of transmitting by fiber, the invention saves a complicated flying light path, and reduces loss of laser energy transmitted in an optical path; a laser used thereby emits a near-infrared laser with a wavelength of 1064 nmn, and absorption of the rail to the laser is high
Implementation Method 2
absorption of the rail to the laser is high, therefore, procedures of pre-spraying coating and cleaning coating following thereby are not required
Implementation Method 3
capable of transmitting by fiber, the invention saves a complicated flying light path, and reduces loss of laser energy transmitted in an optical path
Implementation Method 4
methods of laser surface strengthening have been applied to rail for surface treating
Implementation Method 5
The laser processing head moves along a preset trajectory to conduct laser processing on the rail surface
Data Source
AI summary
The invention discloses an on-line laser processing vehicle for a rail, including a chassis, a vehicle body, a steer-control chamber and a container; the steer-control chamber includes a console, a CCD monitoring system and a drive-switching operating system; a dual driving system and switching mechanism, which with a process-operation driving system, a conventional operation driving system and a switching mechanism, is disposed in the container; the process-operation driving system operates to provide driving power for the laser processing vehicle during laser processing, and precisely controls moving speed and distance of the laser processing vehicle; the switching mechanism operates to implement switching between the conventional operation driving system and the process-operation driving system. The invention ensures accurate processing trajectories of the laser processing vehicle during laser processing; facilitates on-line laser processing of a variety of rails, such as the rails of main line, curved rails, guard rails, switch rails and so on, so that wear resistance of the processed rail is greatly improved, and meets requirements of high-speed and heavy haul trains for wear resistance of the rail.