【作者】 廖东波；

【导师】 吕其兵；

【作者基本信息】 西南交通大学 ， 材料加工工程， 2004， 硕士

【摘要】 目前在中国铁路行业应用广泛的现场移动式钢轨气压焊机存在自动化水平低、人为影响因素多等问题，使得钢轨焊接质量波动大，影响到了行车安全。因此，进行钢轨气压焊的自动化研究具有深远的意义。 本论文根据现场移动式钢轨气压焊的工艺特点，针对原有的控制系统存在的问题，对气压焊自动控制系统的软、硬件进行了研究与设计，为实现现场移动式钢轨气压焊法的自动化迈出了坚实的一步。文章以PLC为控制核心，对控制系统的三段顺序加压系统、气体流量控制系统、加热器摆动控制系统等三个子系统进行了优化设计与改进，使这三个子系统能够更加可靠地工作；同时为了控制顶锻位移量而增加了顶锻位移量控制子系统；并采用单片机智能仪表与PLC通讯的方式，重新设计了焊接参数的设置、修改、实时调整等功能的软、硬件。从而成功地实现了对气压焊的焊接压力、气体流量、顶锻位移量等焊接过程参数的控制，并使控制系统具有较快的动态响应速度和较高的控制精度。 通过工艺试验证明，采用这套控制系统进行的钢轨气压焊焊接，可去除人为因素的影响，保证焊接参数的复现性，稳定和提高气压焊焊接质量，简化操作，降低工人劳动强度，使焊接过程稳定快捷，从而可提高气压焊生产效率。同时试验过程也证明，这套控制系统体积小，重量轻，可靠性高，搬运、维护、使用方便，且性能价格比比较高，适应于现场移动式钢轨焊接作业。更多还原

【Abstract】 There are some problems such as low automatic level, too much man-made influences in the wide application of mobile gas pressure welding of rails in China. Those problems result in unstable rail welding quality and insecure rail transport. So it is significant to research the automatic control system of gas pressure welding.According to the process of the gas pressure welding, some research and design aiming at the hardware and software of the control system is carried out based on the old one. PLC is the control core of the gas pressure welding system. The pressure system, gas flux control system and heating system are optimized, as a result, three systems can work steadier. In order to control upsetting length, a new system about upsetting length control is added. Furthermore, the software and hardware for the setting, modification and adjusting of welding parameter are redesigned by the communication mode between the SCM and PLC. So the control of the welding parameter such as welding pressure, gas flux, upsetting length is realized, and the system has a high dynamic response rapid and a high control precision.Many welding procedure tests shows, by using this control system, man-made influence can be eliminated, welding quality can get steadier, welding operation can be simplified, labor’s intensity can be reduced, welding speed can be increased, so the welding efficiency will be improved. What’s more, this equipment has a compact structure, a light in weight, and a good reliability, and it is easy to carry, repair and operate, so it is fit for outdoor rail welding work.更多还原