The Research And Design Of Control System For The Automatic Welding Quality Inspection Equipment For Rails Welding Base

The jointless tracks is one of the main signs of railway modernization,the quality of jointless tracks especially the welding quality has a direct impact on the transportation safety,controlling the quality of welded joints has been the most direct and effective measure of reducing rail breaking,?ensuring the tracks smooth comfort.At present,because there is no suitable large fixed detection equipment,most of the domestic rail welding base are using portable testing equipment,there are problems of less equipment reliability because of frequent use?part of the detection results existing low accuracy with human errors etc.Therefore,Developing high performance of rail welding quality automatic detection equipment which can meet the practical requirements of the current production has very strong practical significance.According to the standard requirements of rail welding base of flash welding joints quality,the paper analyzed technical characteristics of finished joint ultrasonic testing and straightness measurement.Referring to the use of related equipment in rail welding base,the paper puts forward the overall design scheme of the rail welding quality automatic detection equipment controlling system.With the latest generation of OMRON NJ series PLC controller as control core,combining Frequency conversion control technology and human-machine interface technology,the paper developed the equipment controlling system.For a larger number of probe and process for ultrasonic flaw detection,starting from the angle of automation equipment,the paper puts forward a kind of meet the technical requirements of the rail weld inspection section scanning probe walking trajectory control method,by calculating the position of the probe,scanning range and set the zero position,using an array of variables in the programming.According to the method of probe inspection process requirements in order to fall / back,with the man-machine interface design formula,can adjust the probe operation parameters,to meet the needs of different types of different rail flaw detection technology.Based on the above work,the paper finished controlling system hardware selection and building,the control system circuit diagram and hydraulic principle diagram design,PLC software programming,man-machine interface design,Finally I simulated and debugged the controlling system,the trolley and calibration rail mobile controlling system,hydraulic system,automatic detection module,straightness action module automatic action and other projects were carried out on-site commissioning test and improvement.The results show that the welding quality inspection can be completed including Straightness detection,camera appearance and welding seam detection of welding joints by rail welding quality automatic detection equipment controlling system,and achieved the desired design goals,provides a new technical proposal for the further development of rail welding quality automatic testing equipment and application in the future.