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With the development of China's high-speed railway technology, high-speed railway networks are increasingly dense. When everyone enjoys the "high on the rail" high-speed rail service, many people may not know why the rails under the wheels are so smooth. Originally, the seamless rail was welded by a short rail of 100 meters. After welding, a series of treatments were needed. Grinding was one of the important processes. It was the rail that was “flat†that made the high-speed train smooth. .
Lu Xinnai, the quality control officer of the section, told the author: “The rail grinding is a technical activity, and the precision requirements are comparable to those of embroidery. It used to require two operators to cooperate with each other. Everyone needs to use 4 kinds of grinding equipment to complete, lasting 40 minutes, labor The strength is high, the precision is not well controlled, and the dust is large at the scene. Now, the grinding robot 'Little Magic' can automatically measure the weld projection and the amount of misalignment of the rail, and automatically set the grinding program according to the actual condition of each joint. After re-grinding, it will be re-measured to ensure the quality of the weld appearance. This complicated process can be completed with the click of a button."
Since January 2014, in order to solve the problem that the quality of manual rough grinding after rail welding is difficult to control and the precision is not high, which affects the quality of subsequent flaw detection and low production efficiency, this section will start to develop a rough grinding system for robots, and strive to replace artificial grinding with machines. . The members of this group actively studied and explored a lot of work for the design of the grinding device, the optimization of the grinding process, the selection of the grinding wheel, etc., and completed the design of the 3rd generation grinding device, more than 50 types of grinding wheel selection, and more than 40 process tests. On-site commissioning for more than 2 months. They strive to do their best in every detail, and solve the problem of grinding blue, smashing, grinding and over-limit in the test process one by one. After two years of exploration and practice, in December 2016, the section finally completed the research and development of grinding robots, and the technical indicators such as polishing quality and efficiency met the design requirements.
“Every part of this smart grinding robot is carefully selected and we will continue to explore and summarize it in practice. You see these two small grinding heads. Because of it, we almost searched the domestic The manufacturer of the external grinding head has tested more than 50 kinds of types, models and materials, and finally selected these two small grinding heads to completely solve the problem of polishing shallow martensite. Engineer Yuan Taibei proudly said.
Originally, the shape of the rail weld is quite complicated, including the tread, squat, rail waist, low rail, etc. Due to the particularity of the material of the rail, the selection of the grinding wheel requires repeated trials and repeated data analysis to find the ideal grinding wheel. To achieve the purpose of ensuring the quality of polishing, durability and efficiency. Taking into account the high temperature, dust and high precision requirements of the grinding work environment, the grinding robot "Little Magic" also has corrosion resistance, high temperature resistance, dust resistance, high load, high speed, high flexibility, force induction, force feedback, etc. It can control the grinding intensity in real time and achieve a smoother grinding.
After continuous improvement, the current "Little Magic" can automatically polish and polish the welds of the rail joints, automatically detect the data after grinding, and smoothly control the grinding force, and the grinding precision is up to 0.01 mm. In the 2016 inspection of the entire welding track base, the research and development results were unanimously affirmed and appreciated by the inspection team experts.
The successful application of the high-speed rail welding and grinding robot has transformed the welding operation from human control to machine control, and the production quality has been greatly improved. The production efficiency has increased by 30%, the energy consumption has been reduced by 15%, and the number of operators has decreased by 50%. Therefore, this high-speed rail grinding robot has been favored by everyone since its launch, and everyone affectionately calls it "Little Devil."
It is reported that this section is the first unit in the 15 welding track bases that use grinding robots. The railway engineering industry has more repetitive labor and the degree of automation needs to be further improved. This technology fills the gap in the application of robots to high-speed rail rail welds, and the market prospect is very impressive.
Chinese rail grinding also has intelligent robots
Abstract The rail just arrived at the station, and the high-speed rail welding and grinding robot began to make a comprehensive measurement of the weld. It took only a few seconds to start the grinding operation... This is the author's overhaul in Guangzhou on the afternoon of December 24, 2016. .
The rail just arrived at the station, and the high-speed rail welding and grinding robot began to make a comprehensive measurement of the weld. It took only a few seconds to start the grinding operation... This is the author's red sea welding in the Guangzhou Public Works section on the afternoon of December 24, 2016. The scene seen by the rail workshop.