【作者】 赵红光；

【导师】 吕其兵；

【作者基本信息】 西南交通大学 ， 材料加工工程， 2012， 硕士

【摘要】 根据铁路建设十二五规划,新修干线将会持续增加,投产新线总规模将会超过2万公里,因此在新线上建设中、既有线路维修中的钢轨闪光焊机越来越多,如何保证钢轨闪光焊机的质量可靠性与故障的快速检测将是一个非常严峻的问题。目前在国内大量应用的钢轨现场闪光焊机都是交流焊机,不管是国产焊机还是进口焊机都存在着对维修人员要求高、故障排查周期长等问题,且随着焊接接头数量增多,元器件的状态会发生改变,焊接质量很难保证,为此,本论文立题对成都艾格科技研发的UN-150ZB钢轨闪光焊机的计算机监控系统进行完善和优化。本论文进行了如下的工作：(1)建立位移智能标定模块,实现上位机对位移标定自动化；(2)建立焊机的输入信号检测模块和焊机启动故障的自诊断模块,便于一线设备维护人员对设备的检验和维修；(3)建立上位机监控系统的电压、速度标定在线显示模块和对电压、速度标定的PLC控制软件进行完善；(4)建立焊接过程中故障诊断模块,对焊接过程中控制系统中的过渡阶段信号、油压、位移信号进行检测与保存,并在数据记录图像界面上予以显示；建立压力、阻抗及顶锻量的检测模块进行焊机状态的监控并实时提出检修建议以保证焊接质量；建立数目的提示模块,对接头数目进行提示。经过现场实际运用表明：完善后的监控系统使焊机的整体性能得到提升、焊机的自动化水平得到提高；有良好的人机交互界面及良好的可操作性能,大大降低设备维护人员的难度,从而有力保证了施工进度。更多还原

【Abstract】 According to the12th Five-Year Plan of the railway construction, the newly built railway lines will continue to increase and the total size of the production of new lines will be more than20,000km. Therefore, there are more and more rail flash butt welding machines in the new line construction and old lines maintenance. How to ensure the quality reliability and the fault rapid detection of rail flash butt welding machine will be a very serious problem. In the domestic, the site flash butt welding machines Widely used belongs to the AC welder at present, Both of domestic welder and imported welder have many problems, such as high requirements for maintenance personnel, long cycle of troubleshooting And with the increase in the number of welded joints, the status of components will change, welding quality is difficult to be ensured. To this end, how to improve and optimize the computer monitoring system of UN-150ZB rail flash butt welding machine which developed by Chengdu Iger technology is the purpose of this thesis.The present paper had carried on following work:(1) the displacement of intelligent calibration module was established, which could achieve displacement calibration automation by host computer,(2) input signal detection module and welding machines boot failure diagnosis module were developed, which was easy for first-line maintenance personnel to inspect and maintain the equipment.(3) Voltage calibration and speed calibration line display module were developed on Computer Control System and the voltage, speed calibration of the PLC control software were improved:(4) pressure, impedance and the upset detection module was established to monitor the welder state and give Maintenance recommendations to personnel for the welding quality:joint number module was researched to Prompt number of joint.The practical application shows that the welding machine’s overall performance was enhanced and the level of automation welding machine was improved after the completion of the monitoring system, the good man-machine interface and good operation performance reduced maintenance personnel of difficulty greatly and insured the construction progress on the way.更多还原