Rail Weld Zone Cooling Device for Residual Stress Reduction
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Solution Overview
Problem
Existing methods for cooling rail weld zones fail to effectively reduce residual stress, leading to fatigue cracks, particularly in the rail web portion, and are limited by high operational costs and inefficiencies in shot-peening treatments and previous cooling devices.
Innovation Solution
A device and method that individually control the cooling of the rail head and web portions using temperature-detecting sections and adjustable cooling fluid ejection, allowing for precise control of cooling rates and fluid types to optimize the cooling width and rate, reducing residual stress and improving fatigue strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If shot-peening treatment is used to improve fatigue strength, then fatigue resistance is enhanced, but operational cost increases and treatment efficiency is low
Solution Approach 1:
The patent replaces the mechanical shot-peening process with a thermal field-based cooling system. Temperature-detecting sections monitor the weld zone, and cooling fluid ejection sections deliver controlled cooling to induce compressive residual stress without the operational complexities of shot-peening equipment
Solution Approach 2:
The patent changes the physical state and parameters of cooling fluids (temperature, flow rate, fluid type) based on real-time temperature detection to optimize the cooling effect and residual stress distribution, replacing the fixed mechanical impact of shot-peening
2Temperature
If conventional cooling is applied to the rail weld zone, then cooling is provided, but residual stress is not effectively reduced and fatigue cracks still occur
Solution Approach 1:
The patent applies cooling to specific locations (head portion and web portion) with different cooling parameters rather than uniform cooling. Temperature-detecting sections positioned at specific locations enable localized temperature control to optimize residual stress reduction in critical areas
Solution Approach 2:
The patent implements a feedback control system where temperature-detecting sections continuously monitor the weld zone temperature and adjust cooling fluid ejection accordingly. This closed-loop control ensures optimal cooling rates to minimize tensile residual stress and prevent fatigue cracks
3Manufacturing precision
If individual control of cooling for head and web portions is implemented, then cooling control precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the cooling system into separate sections: temperature-detecting sections positioned at the head portion and web portion, and corresponding cooling fluid ejection sections. This segmentation enables independent control of cooling parameters for each critical area without requiring a completely complex system architecture
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 effectively reduces residual stress in the rail weld zone, enhancing fatigue strength by allowing for targeted and controlled cooling, thereby extending the life of rail welds and reducing maintenance costs.
Implementation Method 1
a first temperature detecting section (22) that detects the temperature of the head portion (12), and a second temperature detecting section (23) that detects the temperature of the rail web portion (13)
Implementation Method 2
a first ejection section (26) that ejects a first cooling fluid to the head portion (12), and a second ejection section (27) that ejects a second cooling fluid to the rail web portion (13)
Data Source
AI summary
A device for cooling a rail weld zone according to the invention includes a first cooler cooling a head portion of the rail weld zone, a second cooler cooling a rail web portion of the rail weld zone, and a control section controlling the first and second coolers. The first cooler includes a first temperature detecting section that detects the temperature of the head portion, and a first ejection section that ejects a first cooling fluid to the head portion. The second cooler includes a second temperature detecting section that detects the temperature of the rail web portion, and a second ejection section that ejects a second cooling fluid to the rail web portion. The control section individually changes the kinds, the flow rates, and the flow velocities of the first and second cooling fluids while cooling the head portion and the rail web portion.