Study On Domestic Monitored Control System & Pulse Process For κ900 Rail Flash Butt Welding Machine

With the development of high speed and heavy transport, the freight and the density of train have increased mostly, and at the same time the new lines constructed and the old lines transformed develop to the countinuness railway, so the higher request of the steel rail material and the quality control of the weld has been brought forward to insure the safety and stability of the transport. Steel rail's welding is one of the key techniques of the seamless line construction . The alloy steel rail, which is used widely in the rail in our country, has poor weld ability although it has high intensity and excellent wearable capacity, and need to be welded by high quality welding machine. Therefore, it is an important task to do research in rail welding equipment and welding procedure to insure weld quality and the safety of the transport.The κ 900 imported last centuries, is rail alternating flash butt welding machine with a series of advantages, such as small physical volume, high welding efficiency and the stable welding quality, etc, but the machine currently used in our country has some shortages. Firstly the welding system runs under the Dos system and the interface is English, the man-machine interface isn't friendly. Secondly the pulse welding function hasn't been really applied because the control software wasn't perfect. Aiming at those problems the domestic control system has been designed. The new system integrates the function of collecting, showing, saving, searching, on-line modification the weld parameter and creating report forms of welding quality. On basis of the new control system the pulse welding process of κ 900 rail flash butt welding machine has been studied , the impacted quality test, static bending test and fatigue strength test had been done.The application indicated that the new monitored system with a good man-machine interface can easily monitor the weld process, manage the weldparameter and provide an assurance of quality control of welding joint. The optimized welding process parameter of U75V rail was got by experiment with orthogonal design, and the welding quality is up to TB1632-91 Standard.