|Rail grinding also has robots|
|Release time: 2017-1-12|
| The high-speed rail welding and polishing robot "Little Devil" recently successfully developed by Guangzhou Public Works Overhaul Section has been officially put into use and is widely favored by rail grinding workers. |
With the development of China's high-speed railway technology, the high-speed railway network has become increasingly dense. When you enjoy the "high and high" high-speed rail service, many people may not know why the rails under the wheels are so smooth. Originally, seamless rails were welded from short 100-meter rails. After welding, a series of treatments are required. Grinding is one of the important processes. It is the “flat” rails that make the high-speed trains run smoothly. .
Lu Xinnai, the quality controller in this section, told the author: "Steel rail grinding is a technical task with high precision comparable to embroidery. In the past, two operators were required to cooperate with each other sincerely. Each person needed 4 types of grinding equipment to complete. It took 40 minutes and labor The strength is strong, the accuracy is not easy to control, and the dust on the site is large. Today, the grinding robot 'Little Devil' can automatically measure the amount of weld protrusion and rail misalignment, and automatically set the grinding program according to the actual situation of each joint "After grinding, it will be re-measured to ensure that the appearance of the weld is acceptable. Such a complicated process can be completed with the push of a button."
Since January 2014, in order to solve the problems of difficult to control the quality of manual rough grinding after welding of the rails, the low accuracy affects the quality of subsequent flaw detection, and the production efficiency is not high, this section has begun to develop a robot rough grinding system, dedicated to using machines to replace manual grinding . The members of the research team in this section actively researched and explored, and did a lot of work for the design of the grinding device, the optimization of the grinding process, and the selection of the grinding wheel. 2. On-site commissioning for more than 2 months. They strive to do their best in every detail, and successively solve the problems of buffing, blanching, and over-limiting during the test. After 2 years of exploration and practice, in December 2016, this section finally completed the research and development of the grinding robot. The technical indicators such as the quality and efficiency of the grinding meet the design requirements.
"Every part of this intelligent grinding robot is carefully selected and determined after continuous exploration in practice. You see these two small grinding heads. Because of it, we almost searched the country. Manufacturers of external grinding heads have tested more than 50 types, types, models, and materials, and finally selected these two small grinding heads, which completely solved the problem of shallow martensite during grinding. " Engineer Yuan Taibei said proudly.
It turns out that the shape of the rail welds is quite complex, including treads, jaws, rail waists, and low rails. Due to the special nature of the rail material, the selection of the grinding wheel requires repeated experimental research and repeated data analysis to find the ideal grinding wheel. To achieve the purpose of ensuring the quality of grinding, durable and improve efficiency. Considering the high working temperature of the grinding site, dust, and high accuracy requirements, the grinding robot "little magic" also has the characteristics of corrosion resistance, high temperature resistance, dust resistance, high load, high speed, high flexibility, and force sensing and force feedback. , Can achieve real-time control of grinding intensity, to achieve more than smooth grinding.
After continuous improvement, the current "Little Devil" can automatically polish and grind the rail joint welds and automatically detect various data after grinding. The grinding intensity is smoothly controlled and the grinding accuracy is as high as 0.01 mm. In 2016, the whole rail welding base inspection and evaluation, this research and development results have been unanimously affirmed and appreciated by the inspection team experts.
The successful application of high-speed rail welding and grinding robots has transformed welding operations from human control to machine control, greatly improving production quality, increasing production efficiency by 30%, reducing energy consumption by 15%, and reducing the number of operators by 50%. Therefore, this high-speed rail grinding robot has been favored by everyone since its introduction. Everyone affectionately calls it a "little magic".
It is reported that this section is the first unit in the 15 welding rail bases using grinding robots. There is more repetitive labor in the railway engineering industry, and the degree of automation needs to be further improved. This technology fills the gap of robots used in the grinding of welds on high-speed rails, and the market prospect is very promising.