Hot Rail Forging Press Layout Without Rail Reorientation
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Solution Overview
Problem
Current forging processes for converting asymmetric to symmetric rail are inefficient, requiring manipulators for precise reorientation and rotation, leading to time wastage and heat loss due to the need for multiple heating cycles and manual handling.
Innovation Solution
A hydraulic forging press system with a unique press configuration and process that includes a roller table for linear movement, induction heating, and two forging stations with horizontal and vertical hydraulic cylinders, eliminating the need for rail rotation and using a linearly translatable top die to forge the rail in a single direction, thereby reducing heat loss and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manipulators are used for reorienting and rotating the rail during forging operations, then the rail can be positioned for multiple forging operations, but time is wasted and heat loss increases
Solution Approach 1:
The forging process is divided into multiple stations (first forging station, second forging station, third forging station) arranged linearly. The rail passes through each station sequentially without rotation, with each station performing a specific forging operation on different portions of the rail. This segmentation eliminates the need for manipulators to reorient the rail while maintaining comprehensive forging coverage.
Solution Approach 2:
The invention transitions from a vertical stacking arrangement of dies (requiring rail rotation) to a horizontal linear arrangement of multiple forging stations. The top die is made laterally movable between different positions, allowing it to forge different portions of the rail foot horizontally rather than requiring vertical die changes and rail rotation.
2Manufacturing precision
If manipulators are used for precise reorientation and rotation of the rail, then accurate positioning for forging can be achieved, but the process becomes slower and less cost-effective
Solution Approach 1:
The top die is designed with lateral movability, allowing it to dynamically adjust its position between different working positions corresponding to different portions of the rail foot. This dynamic positioning capability replaces the need for static manipulator-based rail reorientation, maintaining precision while improving speed.
Solution Approach 2:
The invention replaces the complex mechanical manipulator system with a simpler linear transport mechanism and a laterally movable top die. The roller table provides continuous linear movement, and the top die's lateral movement mechanism substitutes for the manipulator's rotation and repositioning functions, achieving similar positioning accuracy with higher efficiency.
3Adaptability or versatility
If multiple heating cycles are performed for consecutive forging operations, then the rail can be forged at different stations, but heat loss increases and efficiency decreases
Solution Approach 1:
The rail undergoes continuous linear movement through the heating station and subsequent forging stations without interruption. The induction heater continuously heats the rail as it passes, and the forging operations occur sequentially during the rail's continuous transport, eliminating the need for repeated heating cycles and minimizing heat loss.
Solution Approach 2:
The induction heater performs preliminary heating of the rail before it reaches the forging stations. The rail is heated to the required temperature in advance during its linear movement, so that all subsequent forging operations can be performed on pre-heated material without requiring additional heating cycles at each station.
4Device complexity
If a vertical stack of three pairs of dies is used on a single hydraulic press, then all forging operations can be performed in one location, but the rail must be rotated and repositioned between operations
Solution Approach 1:
The single vertical press configuration with stacked dies is segmented into three separate horizontal forging stations arranged in sequence. Each station has its own horizontal and vertical hydraulic cylinders operating independently, eliminating the need to manipulate the rail between operations at a single location.
Solution Approach 2:
The invention changes from a vertical arrangement of forging operations (stacked dies requiring vertical rail manipulation) to a horizontal arrangement (linear sequence of stations requiring only forward movement). The top die's lateral movability provides the vertical dimension of die selection within the horizontal flow, eliminating the need for rail rotation.
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 enables faster, cost-effective, and more accurate conversion of asymmetric to symmetric rail without the need for manipulators, reducing rejection rates and heat loss by allowing continuous linear movement and precise control of the forging process.
Implementation Method 1
an induction heater (208) adapted to receive an end portion of a railroad rail, the induction heater being laterally movable between a working position in line with a railroad rail
Implementation Method 2
a first pair of opposing horizontal hydraulic cylinders (206a, 206b) having horizontal strokes and driving a first set of horizontal forging dies (219), and a first top hydraulic cylinder (211) having a vertical stroke
Data Source
AI summary
A forge and method of forging is provided. The forge converts an asymmetric railroad rail to a symmetric railroad rail through a combination of vertical and horizontal forging operations. The rail is linearly translated to heating and forging stations on a roller table. The asymmetric to symmetric conversion can be completed without the need for reorienting the rail except along a single translational axis.