Rail Welding Automaton with Multi-Pass Cooling Control
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Solution Overview
Problem
Existing rail maintenance technologies, such as electric arc welding automata, are inadequate for efficiently repairing wear on rails and switches/crossings with complex three-dimensional surfaces, often leading to overheating and inadequate coverage of damaged areas.
Innovation Solution
An electric arc welding automaton capable of moving in three dimensions, depositing weld beads successively and allowing each bead to cool before the next is applied, with a temperature control system to prevent excessive heating, particularly suitable for manganese foundry steel rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the torch deposits weld beads continuously to cover the work surface quickly, then productivity is improved, but the rail metal overheats and loses mechanical properties
Solution Approach 1:
The welding process is segmented into multiple passes with cooling intervals. Instead of continuous welding, the torch deposits weld beads in sequences, allowing the rail metal to cool between passes. This segmentation prevents excessive heat accumulation while maintaining productivity through systematic multi-pass welding.
Solution Approach 2:
The welding process uses periodic action by alternating between welding phases and cooling phases. The torch deposits weld beads, then pauses to allow cooling, then resumes welding. This periodic cycle of welding and cooling ensures the rail metal temperature remains below 250°C while still achieving complete coverage of wear areas.
2Manufacturing precision
If the automaton treats the entire rail surface, then coverage is improved, but time and energy are wasted on areas that do not require repair
Solution Approach 1:
The welding process applies local quality by treating only the specific wear areas on the rail surface rather than the entire surface. The control unit identifies and targets only the zones requiring repair, concentrating welding energy where needed and avoiding unnecessary treatment of intact areas, thus saving time and energy.
3Adaptability or versatility
If the torch moves in three dimensions to accommodate complex surfaces, then adaptability is improved, but device complexity increases
Solution Approach 1:
The torch positioning system incorporates three-dimensional movement capabilities, adding vertical (Z-axis) movement to the existing horizontal (X-Y plane) positioning. This dimensional extension allows the torch to accommodate complex rail surfaces including crossings and switches with varying heights, while the control unit manages the increased complexity through coordinated multi-axis control.
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
This method effectively repairs complex rail surfaces without overheating, ensuring thorough coverage and preserving mechanical properties by allowing each bead to cool before deposition, while maintaining low temperatures.
Implementation Method 1
electric arc welding automaton for the maintenance of rails
Implementation Method 2
the sheath melts and mixes with the core
Data Source
Figure 1~2
Figure 3~5
AI summary
The present invention relates to an electric-arc welding automaton (10) for maintaining or repairing rails and turnouts, the automaton including a frame (11) and welding equipment (12) that includes a torch (13) for welding a rail area, wherein the frame is provided with at least two means (16, 17) for bearing on a rail or turnout. Said two means and the torch are substantially aligned, and the torch includes a means (51, 54, 56) for moving on at least two horizontal axes. The automaton is characterized in that it is provided with a means (14, 37) enabling the following steps to be carried out: within an at least two-dimensional frame of reference, storing spatial coordinates of points (P) forming at least two polygons defining at least two separate work surfaces (42, 43, 44) inside an area (40) to be welded; and implementing a welding program (37) including the movement of the torch relative to the frame so as to sequentially operate on all of said separate work surfaces. The invention also relates to a welding method for maintaining or repairing rails and turnouts.