铁路道岔钢轨锻造生产线自动化方案设计  

Design on automation scheme for rail forging production line of railway turnout

作　　者：王子舒[1] Wang Zishu(China Railway Baoji Bridge Group Co.,Ltd.,Baoji 721006,China)

机构地区：[1]中铁宝桥集团有限公司,陕西宝鸡721006

出　　处：《锻压技术》2022年第6期67-74,共8页Forging & Stamping Technology

基　　金：中国中铁工业智能制造项目(JK91-50)。

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 60 AT1 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.

关 键 词：道岔钢轨 热锻成形 自动控制 四工位整体模具 自动上下料 快速换模 电感应加热 

分 类 号：TG315.9[金属学及工艺—金属压力加工]