Research On Key Technology And Intelligence Of Rail Profile Grinding

Railway is the main artery of the national economy and plays an important role in the development of the country.However,in China,where the traditional wheel set is the main wheel rail guidance system,the huge railway network means a huge amount of rail usage.Due to China’s complex terrain,railways cross mountains and rivers,most of which are mixed passenger and freight lines,with large traffic volume,many curves,high traffic density and complex working conditions.Fatigue cracks,rail stripping,wave wear,rail surface scratch,rail wear,rail head crushing and other diseases will gradually occur in the process of use,affecting the service life of rails.The cost of line maintenance and rail replacement remains high every year.Therefore,it is one of the main problems to be solved in the railway system to study how to improve the wheel rail contact relationship,prolong the service life of the rail,and reduce the amount and cost of rail replacement.Therefore,it is very necessary to deeply study the rail maintenance methods such as rail grinding.Based on this,this paper studies the rail profile grinding technology and its intelligent implementation.The main work is as follows:1.An innovative design method of personalized rail grinding target profile is proposed.Firstly,through the organic combination of the reverse solution construction method,the field example construction method and the theory construction method,a rail grinding target profile library that can be used for line grinding is constructed,and then the rail profiles in the profile library are calculated with all the measured wheel profiles of the line in batches,and the profiles are preliminarily compared and selected according to the qualified ratio of the given wheel rail contact index,Finally,the comparison results are compared with the rail profile measured on site,and the final rail grinding target profile is determined based on the principle of minimizing the grinding amount.Compared with the traditional profile design method,this method can be designed for various curve radii and straight rail grinding target profiles of each line,making the target profile more targeted.The designed rail grinding target profile not only has a good wheel rail contact relationship,but also minimizes the grinding amount in field application,and greatly improves the design efficiency and engineering practicability.The details are discussed in Chapter 3.2.The design method of rail grinding vehicle operation scheme is improved,and the intelligent design system is developed.Combined with the characteristics of grinding vehicles mainly used in China’s railway system,the influencing factors affecting the grinding amount of rail grinding head are analyzed,and the influence relationship between the key factors such as grinding speed,grinding power and grinding head angle and the grinding amount of grinding head is obtained.The intelligent design system of rail grinding scheme(including grinding mode and grinding times)is developed,which can design the appropriate grinding mode in real time according to the performance of different grinding vehicles.The detailed list of rail grinding scheme can be intelligently generated according to the general line information table of the railway system,and the specific grinding scheme of each straight and curve line can be determined.The key technical problem of how to transform the design profile into a grinding scheme that can be directly adopted by the grinding vehicle is solved.Before the application of the intelligent grinding scheme design system,the grinding scheme is mainly arranged on site by the grinding vehicle operator according to the deviation between the measured profiles and the target profiles,according to the principle of"grinding at which angle is higher"and based on experience.In the grinding operation,the rail profile deviation needs to be checked after each grinding to determine the grinding mode of the next grinding,and the grinding times cannot be determined in advance,which has a great impact on the grinding efficiency and can not guarantee the grinding quality.After applying the intelligent grinding system of grinding scheme,the grinding scheme of each curve and straight line in the grinding section can be designed in advance according to the profile deviation.There is no need to repeatedly measure and arrange the grinding mode on site,which can greatly improve the grinding operation efficiency and effectively ensure the grinding quality.The details are discussed in Chapter 4.3.An innovative acceptance standard of rail grinding results based on GQI is proposed,and an intelligent acceptance system is developed.In the acceptance standard,the profile deviation index G_Dand area index G_Aare set for the first time.At the same time,which solves the uncertainty problem when only the normal deviation or area deviation is considered,and realizes the quantitative evaluation of grinding results.The acceptance standards of single profile and section line are put forward.The acceptance requirements of high-speed railway and usual speed railway are distinguished.And the intelligent acceptance system of rail grinding results is developed,which can realize the batch acceptance analysis of single profile and multiple profiles,and solve the problem that the current rail grinding acceptance standards in China can not accurately quantify the quality of rail profile.The details are discussed in Chapter 5.4.Based on the tracking observation of a large number of field application examples,three detailed cases of the whole process design and 32 other overview cases are analyzed to verify the grinding effect and the field applicability of the design method proposed in this paper.The details are discussed in Chapter 6.Finally,the next work direction is briefly discussed.The personalized rail grinding target profile design method,grinding scheme intelligent design system and grinding result intelligent acceptance system in the research results of this paper have been fully applied to China’s railway rail profile grinding operation,which has effectively solved the engineering practical problem of how to reasonably carry out rail profile grinding in the railway public works system.And its rationality and effectiveness have been effectively tested.