| Rail flash butt weld technology is one of the key of construction of jointless-track, and complete flash welding equipment-flash rail welder is the necessary means to support it. In recent years, with the efforts of experts in domestic rail welding field for years, our self-developed mobile rail AC flash welder has been developed and put into applications, and has obtained the good effect, and has made great contributions to the rapid development of national railway, but also put forward problems, such as the controllability of the welding process to be mentioned, welding parameters relevance with strong, and need manual testing voltage, speed, parameters setting with the control signal value, which is difficulties when debugging parameters, and understanding the process parameters, and has a high requirement to the staff of the debugging process demanding.According to these shortages, the paper developed by PLC control system and improved PC monitoring system software, whose main work is as follows:(1) Designing the flash welding system which has eight control stages and speed control mode as The ratio of the current range of variable speed control adjustment, and speed up the process into two stages of independent controlling with a given number of times and gradual increase in speed; (2) designing the PLC program of automatic test of speed and voltage; (3) designing the PLC program of the parameters; (4) Completing the PLC ladder program with the ladder function of GX-Developer software and software debugging program; (5) Improving the monitor system in real-time PC display and parameters.Using domestic mobile flash butt welder for several tests track, it shows that:(1) PLC control system can compete the automatic test of voltage and speed, establish the corresponding relationship between the real value of voltage(speed) and the signal value of PLC output control (PLC), and store them to form a database; (2)The program of test is stable, high efficiency, with accurate data and convenient operation;(3) PLC control system Achieves intuitive set of parameters with PC; (4) New flash welding process increases the parameters which can be set to and enhances the controllability of the welding process and improves the process adjustable.The PLC control system has been used in more than 10 domestic and international project applications, such as Sierra Leone. The welder has the ability of high integration and automation. The control system has Environmental adaptability, the welding quality, welding specification adjustability, good debugging process and has been well received. |
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