锻压技术

铁路道岔钢轨锻造生产线自动化方案设计

英文标题：Design on automation scheme for rail forging production line of railway turnout

作者：王子舒

单位：中铁宝桥集团有限公司

分类号：TG315.9

出版年,卷(期):页码：2022,47(6):67-74

摘要：

为解决道岔钢轨锻造工艺装备落后、操作人员作业环境差、生产效率低等问题，通过分析道岔钢轨的锻造成形过程及要求，研究开发了专用的双工位感应加热系统、钢轨自动上下料系统、四工位整体模具、横向自动换模机构及控制系统，建立了钢轨热锻成形自动控制生产线。经过系统联机调试，采用该生产线实现了钢轨上料、加热、送料、锻造成形以及下料的自动化生产，极大地减轻了操作人员的劳动强度，提高了生产效率和产品质量，改善了工人的工作环境。最后，通过60AT1钢轨锻造成形试验发现，单根钢轨的锻造成形时间由原来的20 min减少至9 min，每班操作员工由原来的6人减少至3人，产品质量合格且状态稳定，验证了该方案可用于铁路道岔钢轨的锻造自动化生产。

To solve the problems of backward forging technology and equipment, poor working environment for operators and low production efficiency of turnout rails, a special double-station induction heating system, automatic loading and unloading system of rail, four-station integral die, transverse automatic mold changing mechanism and control system were researched and developed by analyzing the forging process and requirements of turnout rail, and the automatic control production line for hot forging for rail was established. After on-line debugging of system, the automatic production of loading, heating, feeding, forging and unloading for rail was realized by using this production line, which greatly reduced the labor intensity of operators, improved the production efficiency and product quality, and improved the working environment of workers. Finally, the forging test of 60AT1 rail show that the forging time of single rail is reduced from 20 min to 9 min, and the number of operators per shift is reduced from six to three, and the product quality is qualified and the state is stable, which verifies that the scheme can be used in the forging automatic production of railway turnout rail.

基金项目：

中国中铁工业智能制造项目 (JK91-50)

王子舒（1989-），男，学士，高级工程师 E-mail：503430009@qq.com

参考文献：

[1]卢祖文. 我国铁路道岔的现状与发展[J].中国铁路，2005，(4)：11-14.

Lu Z W. The current situation and development of railway turnouts in China[J]. China Railway，2005，(4)：11-14.

[2]魏振兴, 张秀玉,石润波,等.感应加热计算及节能[J].电气开关,1998, 4(2):3-5.

Wei Z X, Zhang X Y, Shi R B, et al. Induction heating calculation and energy saving[J]. Electrical Switch, 1998，4(2):3-5.

[3]任建旭. AT型尖轨跟端无切削锻造工艺的设计[J].哈尔滨铁道科技,2000, (4):15-16.

Ren J X. Design of noncutting forging process of ATshaped heel end[J]. Harbin Railway Technology,2000, (4):15-16.

[4]杨振恒. 锻造工艺学[M].陕西：西北工业大学出版社, 1986.

Yang Z H. Forging Technology[M]. Shanxi: Northwestern Polytechnical University Press, 1986.

[5]李传民. DEFORM5.03金属成形有限元分析实例指导教程 [M].北京：机械工业出版社，2012.

Li C M. DEFORM5.03 Metal Forming Finite Element Analysis Example Tutorial Course [M]. Beijing: Mechanical Industry Press,2012.

[6]唐启成, 周炳海. 基于快速换模技术的冲压设备利用率改善[J].精密制造与自动化,2019,(4):60-64.

Tang Q C, Zhou B H. Improvement of stamping equipment utilization rate based on rapid die change technology [J]. Precise Manufacturing & Automation,2019,(4):60-64.

[7]朱霖, 孙健, 闾浩丁, 等. 自动换模系统在冲压生产线中的应用[J].锻压装备与制造技术，2018,53(5):17-18.

Zhu L, Sun J, Lyu H D, et al. Application of automatic die changing system in stamping production line[J]. China Metalforming Equipment & Manufacturing Technology,2018, 53(5):17-18.

[8]李硕，徐春国，郭永强，等. 半轴套管多工位挤压自动化生产线中冲连皮缺陷产生机理及参数优化 [J]. 锻压技术，2020,45(4):87-92.

Li S，Xu C G，Guo Y Q，et al. Mechanism of punching slug adhesion and parameter optimization in automatic production line for half shaft bushing multistation extrusion [J]. Forging & Stamping Technology，2020,45(4): 87-92.

[9]朱帅, 奚建胜. 基于DEFORM的重型汽车前轴成形工艺及模具设计[J]. 锻压技术,2021,46(5):194-200.

Zhu S，Xi J S. Forming process and die design for heavy duty truck front axle based on DEFORM[J]. Forging & Stamping Technology，2021,46(5):194-200.

[10]郑江. 锻造操作机电液比例位置控制系统研究[D]. 武汉: 华中科技大学, 2003.

Zheng J. Research on Electrohydraulic Proportional Control of Forging Manipulator[D]. Wuhan：Huazhong University of Science and Technology, 2003.

[11]郝晓蓓. 基于三角形速度规划的双锻造操作机大车行走同步控制方法[D]. 秦皇岛: 燕山大学, 2018.

Hao X B. Synchronization Control on Walking Hydraulic System of Dual Forging Manipulators Based on Triangular Velocity Planning[D]. Qinhuangdao：Yanshan University, 2018.

[12]桑育鑫. 重载锻造操作机大车行走精度控制的研究[D]. 兰州:兰州交通大学, 2017.

Sang Y X. Research on the Precision of Cart Movement Control of Heavy Load Forging Manipulator[D]. Lanzhou: Lanzhou Jiaotong University, 2017.

服务与反馈：

【本网站尚未开通全文下载服务】【加入收藏】