Study On The Reformation Of Monitoring & Conterolling System And Process For Imported AMS60 Rail Flash Butt Welding Machine

The rail welding plays a significant role in the construction of continuous railways, for it directly determines the quality of rail welding joints and the security of railways transportation. Now, long rails can be welded in field or in factory, flashing butt welding is always used in factory, and gas pressure rail welding and mobile flash butt welding are usually used in field. AMS60 is one kind of mobile flash welding machines, imported from Schlatter Company in Switzerland. Compared with other welding machines, AMS60 has the virtue of side automatic centering and so on. However, it has many problems when used in China, such as: (1) The fault rate of the machine is high; (2) The Human-Computer operation interface is inconvenience. (3)There is no suitable software for managing and judging the welding quality. All of these embarrass the domestic application of AMS60. Therefore, the project was put forward to solve above problems.According to the shortages of the monitoring and controlling system, the following works has been done: (1) the new monitoring and controlling system was designed, which is composed of PLC to control the welding progress and computer to monitor and control the welding parameters. There are two ways used for data collection (welding voltage, welding electrical current, welding displacement, the oil pressure and so on )at the same time, which make the welding parameters collection better and more unabridged, the one way is through PLC and the other one is through the ADVANTECH data collecting card.(2) New Human-Computer interaction desktop application program was developed by Visual Basic to unify modification of welding parameter and running platform of supervisory control program. (3) According to TB/T1632-2005, the impacted quality test of the U71Mn rails was done and the study on the welding process was researched. (4) Through high-speed acquisition, the parameters related to the process test were collected, and the characteristics of grey-spots were acquired as the input of the RBF neural network. The welding quality RBF prediction model which is suit for AMS60 was established. Compared with the BP prediction model, the RBF prediction model has higher speed of constringency and higher nicety rate. The prediction model can satisfy the real time requirement of rail welding.The reconstructed welding machine has past the technological test of TB and has been used in Beijing subway construction. The application indicated that fault rate of the new monitoring and controlling system is low, welding efficiency is high. New Human-Computer operation interface can unify modification of welding parameter and running platform of supervisory control program, and it's operation is convenience.