Development On Monitor-Control System & Study On Process For New Portable Rail Flash Butt Welding Machine

UN5-150Z rail flash butt welding machine is developed by the welding institute of Southwest Jiaotong university which owns its independent intellectual property rights. It is a new type of portable rail flash butt welding machine which has a simple structure and is very convenient to maintain with a low expense. For all the advantages of the welding machine, it has been widely used in china. However, it also has some shortages in its monitor system as follows:1. Welding process is divided into a few stages so that the transformation from one stage to another is not stable, especially during the first low-voltage stage to the second low-voltage stage. Apparently, this shortage can't guarantee that the welding quality is always in a stable situation. To make things worse, it added the difficulty of the adjusting technique.2. The parameters which can be set by the user are limited and related mutually in each stage. For example, the feed speed and the backward speed of every stage will make the debugging technique tougher.3. During the process of welding technique, the device always identifies wrongly in every stage which makes the user deal with the data more inconvenient.4. The welding curves are shown unreasonable which added the difficulty in analyzing the curve line.To the defects of the monitor system of the UN5-150Z machine above, this paper gives such improvements:1. The process of the monitor system, including welding stage identification, data dealing, and curves showing is optimized by using the developing platform of Visual Basic 6.0. Consequently, the monitor system has a good function in human-computer interaction which offers an easy operation of this machine.2. The welding stages are increased to 8 stages which precisely divides thestages of the welding process and the transition between low-voltage stages becomes stable as well.3. The number of parameters set by the users is enlarged, added from 30 to 45. As a result, the problem of inter-impaction has been solved so that the parameters can be renewed independently and the adjustable range of the parameters is wider.5. The machine realizes the function of trimming with the pressure- keeping. Besides, both two modes of the pressure-keeping time can be set independently which makes unit -welding and lock-welding completed in locales.The updated welding machine has been applied well in the 9^th subway line in shanghai. The machine gives a stable welding process and excellent welding quality. What's more, it has passed the type-test according to the railway ministry's regulates(TB/T 1632.1-2005).