Article(id=1156264264181605054, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1156264148657886112, articleNumber=null, orderNo=null, doi=10.12404/j.issn.1671-1815.2402476, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1712419200000, receivedDateStr=2024-04-07, revisedDate=1733932800000, revisedDateStr=2024-12-12, acceptedDate=null, acceptedDateStr=null, onlineDate=1753604482932, onlineDateStr=2025-07-27, pubDate=1740672000000, pubDateStr=2025-02-28, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1753604482932, onlineIssueDateStr=2025-07-27, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1753604482932, creator=13701087609, updateTime=1753604482932, updator=13701087609, issue=Issue{id=1156264148657886112, tenantId=1146029695717560320, journalId=1146123166801305609, year='2025', volume='25', issue='6', pageStart='2193', pageEnd='2636', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1753604455388, creator=13701087609, updateTime=1753771257443, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1156963767234945803, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1156264148657886112, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1156963767234945804, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1156264148657886112, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=2539, endPage=2547, ext={EN=ArticleExt(id=1156264265758663361, articleId=1156264264181605054, tenantId=1146029695717560320, journalId=1146123166801305609, language=EN, title=Research and Application of Automatic Lubrication Device for Railway Track Fasteners and Bolts, columnId=1156262728772735295, journalTitle=Science Technology and Engineering, columnName=Papers·Traffics and Transportations, runingTitle=null, highlight=null, articleAbstract=

The anti-corrosion maintenance workload of railway fasteners and bolts in China is large, and the cost of manual lubrication operation is high, the efficiency is low, and the labor intensity is high, and there are problems such as operation safety risks and ballast pollution. In order to solve this series of problems, an automatic lubrication device based on PLC(programmable logic controller)control that can automatically lubricate fasteners and bolts on railway tracks was developed to realize the efficiency, intelligence and automation of the construction process. Optimize the design of the equipment’s traveling mechanism, lubrication system, fastener bolt identification and sensing device, control system, etc. The adjustable spraying structure was innovatively designed to realize the oil coating operation of different types of tracks, and the sensor device that can adapt to the change of the height and position of the rail fastener bolts was innovatively designed, so as to realize the accurate identification of the track fastener bolts with different height distribution. According to the characteristics of anti-rust grease, the quantitative atomization technology of the device was analyzed and optimized. Delta’s DVP ES2-24MR PLC is connected to an external actuator, which processes data through the PLC to control the corresponding sensors in real time, and uses compensation algorithms to achieve accurate control of the equipment oil coating operation. The experiment shows that the automatic lubrication device shortens a large number of construction periods, solves the pollution phenomena such as inaccurate lubrication, oil dripping and wire pulling of the existing mechanical lubricating machine, and the device can effectively guarantee the quality and safety of the lubrication operation, effectively improve the construction efficiency and reduce the construction cost.

, correspAuthors=Yuan-hua ZHOU, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, authorCompany=null, fund=null, authors=null, authorsList=Yong YANG, Yuan-hua ZHOU, Hang-ming LIU, Zhi-hui SONG, Yan-qi ZHAO, Kang-kang DONG, Xian-ming JIANG), CN=ArticleExt(id=1156264360424104818, articleId=1156264264181605054, tenantId=1146029695717560320, journalId=1146123166801305609, language=CN, title=铁路轨道扣件螺栓自动涂油装置研究与应用, columnId=1156262730664366426, journalTitle=科学技术与工程, columnName=论文·交通运输, runingTitle=null, highlight=null, articleAbstract=

全国铁路扣件螺栓防腐养护工作量大,人工涂油作业成本高、效率低、劳动强度大,存在作业安全风险、道碴污染等问题。针对这一系列问题,研发了一种基于可编程逻辑控制器(programmable logic controller,PLC)控制的可在铁路轨道对扣件螺栓进行自动涂油作业的自动涂油装置,实现施工过程的高效化、智能化和自动化。对设备的行走机构、涂油系统、扣件螺栓识别感应装置、控制系统等进行优化设计。创新性地设计了可调节的喷涂结构,实现了对不同类型轨道的涂油作业,创新性地设计了可自适应轨道扣件螺栓高度位置变化的传感器装置,实现了对不同高度分布的轨道扣件螺栓的精准识别。针对防锈油脂特性,对装置的定量雾化技术进行分析与优化设计。台达DVP ES2-24MR PLC与外部执行器件连接,通过PLC进行数据处理实时控制相应的传感器,采用补偿算法实现设备涂油作业的精确控制。实验表明,自动涂油装置缩短了大量的工期,解决了现有机械式涂油机涂油不精准、滴油、拉线等污染现象,装置可有效保障涂油作业质量和安全,有效提高施工效率,降低施工成本。

, correspAuthors=周元华, authorNote=null, correspAuthorsNote=
* 周元华(1980—),男,汉族,湖北武汉人,博士,副教授。研究方向:智能检测与控制。E-mail:
, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=OOUxQqGOIiVNKjT8Fed3cw==, magXml=DtXs06xPfzuQxxNNzdW3Og==, pdfUrl=null, pdf=9BW8HOEyBQgDjPdnkXHUAg==, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=IhqHbSqhXWNLQ/dX1NEkjg==, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=4BGWrcM9D8YhxPKeeg4uVg==, mapNumber=null, authorCompany=null, fund=null, authors=

杨勇(2000—),男,汉族,陕西汉中人,硕士研究生。研究方向:机电一体化。E-mail:

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杨勇(2000—),男,汉族,陕西汉中人,硕士研究生。研究方向:机电一体化。E-mail:

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杨勇(2000—),男,汉族,陕西汉中人,硕士研究生。研究方向:机电一体化。E-mail:

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9为回转安装架

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Automatic lubrication device control system I/O port distribution

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输入点 名称 输出点 名称
X0 急停 Y10 电磁阀开启
X1 启动 Y11 刹车+报警
X2 停止 Y12 加热
X3 遥控前进 Y13 推行
X4 遥控后退 Y30 方向
X5 遥控加速 模拟量 油泵电机控制0~5 V
X6 遥控减速 模拟量 行走电机控制0~5 V
X7 液位检测开关
X10 感应开关
), ArticleFig(id=1233422566581391838, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1156264264181605054, language=CN, label=表1, caption=

自动涂油装置控制系统I/O口分配

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输入点 名称 输出点 名称
X0 急停 Y10 电磁阀开启
X1 启动 Y11 刹车+报警
X2 停止 Y12 加热
X3 遥控前进 Y13 推行
X4 遥控后退 Y30 方向
X5 遥控加速 模拟量 油泵电机控制0~5 V
X6 遥控减速 模拟量 行走电机控制0~5 V
X7 液位检测开关
X10 感应开关
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铁路轨道扣件螺栓自动涂油装置研究与应用
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杨勇 1 , 周元华 1, * , 刘航铭 2 , 宋智慧 3 , 赵彦淇 1 , 董康康 1 , 江先明 1
科学技术与工程 | 论文·交通运输 2025,25(6): 2539-2547
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科学技术与工程 | 论文·交通运输 2025, 25(6): 2539-2547
铁路轨道扣件螺栓自动涂油装置研究与应用
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杨勇1 , 周元华1, * , 刘航铭2, 宋智慧3, 赵彦淇1, 董康康1, 江先明1
作者信息
  • 1 长江大学机械工程学院, 荆州 434023
  • 2 湖北省地质局第七地质大队, 宜昌 443000
  • 3 湖北瑞立德科技有限公司, 武汉 430051
  • 杨勇(2000—),男,汉族,陕西汉中人,硕士研究生。研究方向:机电一体化。E-mail:

通讯作者:

* 周元华(1980—),男,汉族,湖北武汉人,博士,副教授。研究方向:智能检测与控制。E-mail:
Research and Application of Automatic Lubrication Device for Railway Track Fasteners and Bolts
Yong YANG1 , Yuan-hua ZHOU1, * , Hang-ming LIU2, Zhi-hui SONG3, Yan-qi ZHAO1, Kang-kang DONG1, Xian-ming JIANG1
Affiliations
  • 1 School of Mechanical Engineering, Yangtze University, Jingzhou 434023, China
  • 2 The Seventh Geological Brigade of Hubei Geological Bureau, Yichang 443000, China
  • 3 Hubei Rolleader Technology Co., Ltd., Wuhan 430051, China
出版时间: 2025-02-28 doi: 10.12404/j.issn.1671-1815.2402476
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全国铁路扣件螺栓防腐养护工作量大,人工涂油作业成本高、效率低、劳动强度大,存在作业安全风险、道碴污染等问题。针对这一系列问题,研发了一种基于可编程逻辑控制器(programmable logic controller,PLC)控制的可在铁路轨道对扣件螺栓进行自动涂油作业的自动涂油装置,实现施工过程的高效化、智能化和自动化。对设备的行走机构、涂油系统、扣件螺栓识别感应装置、控制系统等进行优化设计。创新性地设计了可调节的喷涂结构,实现了对不同类型轨道的涂油作业,创新性地设计了可自适应轨道扣件螺栓高度位置变化的传感器装置,实现了对不同高度分布的轨道扣件螺栓的精准识别。针对防锈油脂特性,对装置的定量雾化技术进行分析与优化设计。台达DVP ES2-24MR PLC与外部执行器件连接,通过PLC进行数据处理实时控制相应的传感器,采用补偿算法实现设备涂油作业的精确控制。实验表明,自动涂油装置缩短了大量的工期,解决了现有机械式涂油机涂油不精准、滴油、拉线等污染现象,装置可有效保障涂油作业质量和安全,有效提高施工效率,降低施工成本。

扣件螺栓  /  防腐  /  自动涂油装置  /  PLC

The anti-corrosion maintenance workload of railway fasteners and bolts in China is large, and the cost of manual lubrication operation is high, the efficiency is low, and the labor intensity is high, and there are problems such as operation safety risks and ballast pollution. In order to solve this series of problems, an automatic lubrication device based on PLC(programmable logic controller)control that can automatically lubricate fasteners and bolts on railway tracks was developed to realize the efficiency, intelligence and automation of the construction process. Optimize the design of the equipment’s traveling mechanism, lubrication system, fastener bolt identification and sensing device, control system, etc. The adjustable spraying structure was innovatively designed to realize the oil coating operation of different types of tracks, and the sensor device that can adapt to the change of the height and position of the rail fastener bolts was innovatively designed, so as to realize the accurate identification of the track fastener bolts with different height distribution. According to the characteristics of anti-rust grease, the quantitative atomization technology of the device was analyzed and optimized. Delta’s DVP ES2-24MR PLC is connected to an external actuator, which processes data through the PLC to control the corresponding sensors in real time, and uses compensation algorithms to achieve accurate control of the equipment oil coating operation. The experiment shows that the automatic lubrication device shortens a large number of construction periods, solves the pollution phenomena such as inaccurate lubrication, oil dripping and wire pulling of the existing mechanical lubricating machine, and the device can effectively guarantee the quality and safety of the lubrication operation, effectively improve the construction efficiency and reduce the construction cost.

fastener bolts  /  anti-corrosion  /  automatic lubrication device  /  PLC
杨勇, 周元华, 刘航铭, 宋智慧, 赵彦淇, 董康康, 江先明. 铁路轨道扣件螺栓自动涂油装置研究与应用. 科学技术与工程, 2025 , 25 (6) : 2539 -2547 . DOI: 10.12404/j.issn.1671-1815.2402476
Yong YANG, Yuan-hua ZHOU, Hang-ming LIU, Zhi-hui SONG, Yan-qi ZHAO, Kang-kang DONG, Xian-ming JIANG. Research and Application of Automatic Lubrication Device for Railway Track Fasteners and Bolts[J]. Science Technology and Engineering, 2025 , 25 (6) : 2539 -2547 . DOI: 10.12404/j.issn.1671-1815.2402476
扣件是铁路轨道结构系统中提供弹性的主要部件,铁路轨枕螺栓是铁路轨道扣件的重要组成部分之一[1]。随着线路的运营时间的增长,由于其长期暴露在大气中,经受风吹雨淋,霜冻雪埋等循环性气候变化,线路轨枕上的扣件螺栓出现不同程度的氧化锈蚀,有的螺栓出现细脖现象,几个方面的锈蚀叠加已影响到扣件的扭矩,长期不动的螺栓形成假扭矩或弹条离缝扣压不紧等现象,严重影响行车安全,因此每年都要对扣件系统进行周期性涂油和周期性点油作业。
目前常用的涂油方式有解体涂油和扣件点油两种:①解体涂油:人工卸掉螺母,上油后再紧固处理达到防腐效果,作业程序复杂,纯人工作业,效率低,作业时间长,每个工日解体涂油仅能达到50~100 m,无法满足涂油周期,只能满足重点地段扣件涂油需要;②扣件点油:作业人员手提油桶,在各个螺栓上涂油防腐,点油省工,方法简单,每工日可以达到单轨扣件点油2 km,但由于扣件数量庞大,无法达到周期性彻底涂油,且油润保持时间短,人为因素影响较大,油料浪费严重,道碴污染严重[2]
随着高速铁路的发展,对线路的要求也不断提高,因此在现代铁路的建设和维修中,需大量地使用自动化程度很高的机械设备,如铺轨机、捣固机、清筛机、钢轨打磨机和道床整形机等[3]。实现轨道螺栓涂油首先需对轨道螺栓扣件进行识别定位,随着中国高铁的发展,国内已经开始对轨道螺栓扣件自动化识别技术进行相关的研究。张谋[4]提出了一种智能轨道螺栓作业机器人,采用反向传播神经网络(back propagation neural network,BPNN)比例积分微分(proportional-integral-derivative,PID)控制算法实现了较高精度的扣件装配及螺栓紧固精细化作业,该设备实现了一定的对轨道扣件螺栓装配和紧固的自动化。刘建东[5]提出了一种对轨道扣件自动化施工的解决方案,设计了一款轨道螺栓施工设备,采用单一传感器的方式对轨道螺栓以及螺母进行定位检测。
中外学者对扣件定位做了大量工作,采用计算机视觉的方法对扣件进行检测定位[6-8],高嘉琳等[9]提出了基于改进YOLOv4算法的轨道扣件与检测,实现对有砟轨道与无砟轨道上扣件的状态检测,对轨道扣件的检测准确率有一定提升。此类检测根据对扣件的特征分析完成扣件的定位,多是用于扣件的缺失及状态检测。现有设备多采用接触式感应或单一传感器感应,将传感器安装于一固定位置,存在识别精度低以及无法实现扣件识别与涂油作业的紧密联动等问题。单一的接触式感应可实现对扣件螺栓的感应识别,但在遇到障碍物(道碴、木块等)时接触式感应无法判断是否为螺栓扣件,造成误识别情况;铁路轨道螺栓存在高度随机变化的情况,且铁轨在长距离情况下存在高低起伏现象,安装于固定位置的单一传感器就无法应对这种扣件螺栓高低变化的情况,造成漏检问题。
针对这些问题,现设计一种基于可编程逻辑控制器(programmable logic controller,PLC)控制的铁路轨道扣件螺栓自动涂油装置。设备通过PLC控制连接外部传感器对外部信号进行采集,设计电源、控制电路,将各个执行、传感器相连接,实现实际涂油作业的控制,以进一步提升作业效率,降低作业成本。
在分析铁路轨道类型、轨道扣件螺栓排列分布情况以及满足扣件螺栓涂油作业模式要求的基础上,结合现有的机械式涂油装置,对扣件螺栓涂油设备车架机构、涂油模块、控制模块、感应模块等进行了优化设计,创新性地设计了一套可自适应扣件螺栓高度差异的铁路扣件螺栓自动涂油装置。
铁路扣件螺栓自动涂油装置总体结构如图1所示。由图1可知,该涂油装置主要由行车车轮、连接轴、车架、中控台、油箱、电磁阀组、行走电机、油泵电机、油泵、可调节喷嘴安装座、雾化喷嘴、感应装置以及其他的辅助装置组成。
此装置车架、油箱、中控台等主体结构均采用不锈钢材质,对设备重量进行优化设计,大大降低了装置在铁路轨道上搬运安装难度,减少工作量。装置设计为多个模块,各模块之间可进行快速拆解和组装,便于实际操作及维修工作。可调节喷嘴安装座的设计,实现了该装置可在不同轨道型号(50、60、75型等)上进行扣件螺栓涂油作业。
铁路扣件螺栓自动涂油装置工作原理为:设备运行过程中,通过传感器识别扣件螺栓,传感器反馈信号给PLC控制系统,PLC发出信号控制电磁阀开启,进而通过雾化喷嘴对目标扣件螺栓进行涂油作业。设备在铁路轨道上的运行通过搭载于车架上的行走电机驱动,通过可调节高度的感应装置对扣件螺栓进行识别。由电磁阀组、油泵、油泵电机和雾化喷嘴组成的涂油模块完成油脂喷涂工作,可通过中控台界面设置油泵电机转速参数,调节喷嘴压力和流量,可通过调节油脂的喷出时间及持续喷涂时间实现多工况涂油作业。根据不同的作业需求及扣件螺栓高度对感应装置进行高度调节,以实现对扣件螺栓的精准识别。安装于油箱内部的加热器装置可在冬天寒冷天气下对内部油脂进行加热处理,确保涂油作业工作和质量。油箱内部的液位传感器可实时监控油脂使用情况,确保运行过程中油脂充足,并避免油脂缺少造成油泵空载损坏。
铁路扣件螺栓自动涂油装置设备运行和工作流程如图2所示。从图2中可以看出,装置的施工可分为设备安装调试、油脂喷涂施工、设备拆解清理3个阶段。其中调试安装阶段即施工准备阶段,完成装置在铁路轨道上的组装、传感器调节以及油脂注入等准备工作。设备调试完成之后,设备启动开始进行自动涂油作业,由感应模块中的传感器识别扣件螺栓位置,继而由PLC控制装置对目标扣件螺栓进行油脂喷涂,完成对整个目标扣件螺栓的雾化喷涂作业后,设备继续运行至下一组扣件螺栓,继续涂油作业直至完成施工。
装置运行速度0~3 km/h;行走电机为12 N·m步进电机,油泵电机功率为1 000 W;传感器识别检测距离为0~20 mm,传感器高度调节范围为-40~40 mm,传感器工作温度:-25~55 ℃;油泵额定流量为10 L/min,额定压力2.5 MPa;喷嘴安装座可调节高度范围为0~60 mm;油箱容量为35 L,电池容量为20 Ah。
本文设计的铁路扣件螺栓自动涂油装置可根据工作流程完成扣件螺栓的识别和雾化喷涂任务,实现铁路轨道扣件螺栓防腐涂油施工过程的高效化和自动化。为满足高效的自动化作业需求,对装置的涂油模块和感应装置进行了创新性设计和优化改进。针对不同类型轨道的涂油作业;创新性地设计了可调节的喷涂结构,针对不同高度分布的轨道扣件螺栓的精准识别,创新性地设计了可自适应轨道扣件螺栓高度位置变化的传感器装置。根据扣件螺栓实际涂油作业需求,对装置的定量雾化涂油技术进行了研究,实现装置涂油作业过程中的精准定量喷涂以及良好的雾化效果。
根据涂油装置作业需求和设计要求,以及涂油设备液压系统压力、流量匹配的特点,对涂油装置液压油路进行设计,实现铁路扣件螺栓自动涂油装置的正常雾化涂油工作。保证涂油作业正常工作的条件下,实现轻载化、简单化。
液压原理如图3所示,其工作原理为:由油泵电机驱动齿轮油泵从油箱内吸入扣件螺栓防腐油脂,在油泵与油箱间加装过滤器对油脂进行过滤。通过二位四通电池换向阀控制油路的切换,在电磁阀初始状态时,油脂通过油泵吸入油路,经电磁阀回油口返回油箱;电磁阀换向动作时,油脂经出油口流出,通过雾化喷嘴喷出,实现对扣件螺栓的雾化喷涂。
电磁阀换向的触发条件是感应装置识别到扣件螺栓后,PLC收到信号进而发出控制信号控制电磁阀换向。溢流阀用于调节油脂雾化喷涂时油路系统的压力,通过调节压力大小控制油脂的雾化喷出角度。扣件螺栓防腐油脂中含有少量颗粒物和沉淀物,在油脂喷涂过程中,为防止油脂长时间停留在管道中时杂物沉积堵塞管道、阀门和喷嘴等,在油路系统中设置油脂过滤器,油脂出油箱先经过过滤器过滤进而进入管路。
为了实现各种轨道类型及不同工况的作业要求,创新性地设计了一种可进行高度调节的喷嘴安装座结构,能够根据现场实际作业需求实现对喷油嘴高度的适应调节。可调节喷嘴安装座的结构如图4所示,主要由喷油架安装接头、接头安装板,固定底板、调节螺杆以及锁紧螺母组成。安装座结构通过调节螺杆和锁紧螺母固定于装置主体,雾化喷嘴通过快速接头安装于喷油架安装接头,通过调节螺杆在装置主体上的高度进而调节喷油嘴高度。
在实际轨道线路中,存在铁路轨枕上的紧固螺栓的埋入深度不同以及扣件螺栓安装时存在的安装误差等问题,致使铁路轨道扣件螺栓存在高低不同的状态,为应对这种随机变化扣件螺栓高度的识别检测,创新性地设计了一种具有仿形功能的铁路轨道扣件螺栓自适应感应模块,能够实时应对扣件螺栓的高度变化,完成对扣件螺栓的精准识别。感应模块的结构如图5所示,该感应模块主要由辅助轮安装轴、辅助轮、感应传感器、回复拉簧、调节导轨、蝶形调节螺栓、调节滑板、回转轴、回转安装架等组成。采用调节导轨、蝶形调节螺栓和调节滑板组合设计,可快速调节传感器高度,应对不同轨道的作业需求;回转安装架、回复拉簧、感应传感器、辅助轮、辅助轮安装轴等下部仿形结构可自适应螺栓高度,随着螺栓高度的变化,传感器高度进行自我调节[10],实现对扣件螺栓的准确识别。
当铁路扣件螺栓自动涂油装置工作过程中,对高度升高的扣件螺栓进行识别时,辅助轮接触到螺栓后,回转安装架产生绕回转轴偏转,内侧的感应传感器随动提升,进而实现对扣件螺栓的感应工作。当回转安装架产生偏转时,安装架带动回复拉簧伸长,在回复拉簧的拉力作用下,辅助轮始终保持与轨道扣件螺栓接触,保证内侧的感应传感器的检测准确性。
铁路扣件螺栓自动涂油装置在工作前进过程中,当感应模块运动至轨道螺栓上方时,辅助轮接触到螺栓上表面,夹装于两侧辅助轮内部的感应传感器检测到螺栓,PLC接收到传感器信号后控制电磁阀开启一定时间,雾化喷嘴对扣件螺栓进行雾化涂油作业。通过模糊PID补偿算法实现从传感器识别扣件螺栓到电磁阀开启所需时间—喷油延时时间、电磁阀开启持续时长—喷油时间的精确控制[11],精确控制每次喷涂作业时的出油量,实现涂油装置对目标扣件螺栓的全面定量喷涂。
专用于铁路扣件螺栓防腐养护的油脂为一种高黏度防锈油脂,内含部分颗粒杂质,如图6所示,本文研究中利用HTD-08型八速旋转黏度计对其在不同温度下的黏度变化进行实验测量[12]
由实验测得,铁路扣件螺栓专用防锈油脂在室温25 ℃下时黏度为348 mPa·s,其黏度随着温度升高逐渐降低,其黏度-温度数据变化情况如图7所示。
根据实验数据可知,该防锈油脂具有较差的流动性,采用该油脂进行扣件螺栓涂油作业时存在油脂喷出不均匀、雾化效果不良好等现象。针对油脂的这一特性,本文研究对防锈油脂雾化喷嘴进行了创新优化设计,结构如图8所示。雾化喷嘴结构中设计采用单向阀结构,涂油作业过程中,油路系统压力达到单向阀压力设定值时单向阀开启,油脂经喷嘴雾化喷出。单向阀的这一结构设计,既保证了油脂喷出时的压力要求,提高喷嘴对油脂的雾化效果,也解决了由于油脂高黏度特性引起的喷涂结束时喷嘴滴漏油问题。
为了确保铁路扣件螺栓涂油装置各传感器及控制元件的准确性,涂油装置执行动作时安全、操作与调试的自动控制,涂油装置控制系统采用PLC作为控制元件。通过对铁路扣件螺栓涂油装置控制系统进行分析,系统共包括输入口9个,输出口5个,2组模拟量输出模块接口[13]。控制系统I/O地址分配如表1所示。
根据涂油装置控制系统要求以及涂油装置配套传感器的技术要求,结合实际运用需求,控制系统采用台达DVP ES2-24MR PLC作为控制器。该控制器兼具触摸屏功能,控制功能强大,具有多路模拟量输入输出功能,在工业控制领域发挥了重要作用。
控制系统方案紧密结合扣件螺栓涂油装置结构特点和现场实际运用情况,综合考虑控制系统的可靠性、经济性和实用性[14],设计如图9所示的控制系统结构。
图9可以看出,控制部分以PLC作为控制器,通过数字量、模拟量来控制执行与数据采集。
PLC通过数字量输入模块采集感应开关传感器信号、液位开关传感器信号来判断设备的运行状况;数字量输出模块执行接触器开关动作来控制设备正常运行;模拟量输入模块采集油箱内部油脂温度状态的数据;模拟量输出控制电机驱动器的状态。
根据系统控制要求,控制系统流程如图10所示。涂油装置控制系统通电后PLC将检查电机及液位传感器工作状态,若系统未能正常工作或油箱内部油脂含量过低,设备指示灯亮起并报警。系统正常工作时,通过手动控制触摸屏或中控台操作面上的启动按钮对PLC发出指令,PLC控制电机运行,涂油装置开始雾化涂油作业。
装置在铁路轨道上持续行进过程中,扣件螺栓感应模块对扣件螺栓进行实时识别,在识别到扣件螺栓后PLC控制电磁阀开启一定时间,雾化喷嘴完成对目标扣件螺栓的涂油作业。完成当前目标喷涂作业后,装置在油量充足的情况下继续完成其他扣件螺栓的喷涂任务,程序设定从传感器识别扣件螺栓到电磁阀开启再到目标扣件螺栓涂油结束为1个循环。当装置油量不足时,程序控制装置报警并停止运行。
根据涂油装置控制系统的工作流程和控制要求,本系统分为手动控制部分和自动控制部分。PLC控制程序通过台达专用编程软件WPL Soft完成编写[15],通过以太网通讯电缆完成PLC程序的上传与下载。
根据涂油装置工作过程的要求,装置在铁路轨道上的运行过程中,扣件螺栓感应模块识别到扣件螺栓时,PLC控制电磁阀开启,控制程序中的喷油延时时间和喷油时间可根据装置在铁路轨道上的运行速度以及扣件螺栓所需的喷涂范围进行调节,实现对不同工作环境及作业要求的灵活作业任务。如图11所示,为涂油装置喷油状态的PLC控制程序示例。
触摸屏是监控涂油装置系统的重要控制装置,通过中达优控触摸屏编程软件YK Builder设计控制系统的参数化人机交互界面[16],如图12所示。触摸屏共分为三个界面,分别是主界面、参数设置界面和辅助控制界面,触摸屏通电后首先显示进入主界面窗口,再由主界面窗口进入操作界面或辅助控制界面。主界面主要控制装置的整体运行,包括装置的启动及停止控制等,并对油液温度、设备状态显示实现实时观测。操作界面可对喷油时间、喷油延时时间、设定温度、行走速度和油泵转速等工艺参数进行设定。辅助控制界面由6个控制按钮组成[17],包括加热、推行、倒车和停车4个辅助功能按钮以及参数设置界面和主界面2个界面切换按钮。
在实际应用需求和理论研究的基础上,将此铁路轨道扣件螺栓涂油装置在武汉铁路局某工段工务区进行了现场试验,装置如图13所示。
将涂油装置安装于待喷涂区域轨道上,完成安装及调试后,启动装置进行实验测试,并与其他设备施工效果进行对比试验。对比效果如图14所示,本文所设计的铁路轨道扣件螺栓涂油装置对扣件螺栓的识别感应及油脂涂覆效果良好,满足铁路轨道扣件螺栓实际养护要求。
相较于传统的人工涂油和点油作业方式,本文研究中设计的涂油装置大大降低了人力成本和时间成本,利用本装置进行扣件螺栓涂油养护作业时,仅需2或3人进行安装搬运即可,装置的使用简单方便。对比相同作业量,本文的涂油装置效率是人工的数十倍。可以看出,本文设计的铁路轨道扣件螺栓涂油装置的施工费用和时间,远远低于人工施工。
(1)根据实际施工环境,对感应模块和涂油模块进行了创新性设计。创新性地设计了可自适应轨道扣件螺栓高度位置变化的扣件螺栓感应装置,实现了对不同高度分布的扣件螺栓的精准识别,创新性地设计了可调节的喷涂结构,实现了对不同类型轨道的涂油作业。
(2)针对防锈油脂高黏度的特性,对定量雾化技术进行了创新优化设计,提高了装置油脂喷涂时的雾化效果,实现了装置对扣件螺栓的全面雾化喷涂作业。
(3)根据实际控制要求,将电气控制与机械原理相结合,针对性地设计了PLC控制程序以及触摸屏控制界面,通过PLC与触摸屏实现了工人对扣件螺栓雾化喷涂全过程的掌控,提高了扣件螺栓涂油养护效率与质量。
(4)研发的铁路轨道扣件螺栓自动涂油装置可在铁路轨道上实现高效快速、自动化以及低成本的扣件螺栓涂油施工。相对于采用人工涂油作业,自动涂油装置不仅提高了作业效率、质量和安全性,且大大降低了人力和时间成本,因此,本装置具有良好的应用价值和推广价值。
  • 国家科技重大专项(2016ZX05022006-004)
  • 国家科技重大专项(2017ZX05009-003)
  • NSFC-石油化工联合基金(U1762214)
  • NSFC-石油化工联合基金(U1262108)
  • 西南石油大学油气储层地质与开发国家重点实验室开放基金(PLN2022-17)
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2025年第25卷第6期
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doi: 10.12404/j.issn.1671-1815.2402476
  • 接收时间:2024-04-07
  • 首发时间:2025-07-27
  • 出版时间:2025-02-28
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  • 收稿日期:2024-04-07
  • 修回日期:2024-12-12
基金
国家科技重大专项(2016ZX05022006-004)
国家科技重大专项(2017ZX05009-003)
NSFC-石油化工联合基金(U1762214)
NSFC-石油化工联合基金(U1262108)
西南石油大学油气储层地质与开发国家重点实验室开放基金(PLN2022-17)
作者信息
    1 长江大学机械工程学院, 荆州 434023
    2 湖北省地质局第七地质大队, 宜昌 443000
    3 湖北瑞立德科技有限公司, 武汉 430051

通讯作者:

* 周元华(1980—),男,汉族,湖北武汉人,博士,副教授。研究方向:智能检测与控制。E-mail:
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https://castjournals.cast.org.cn/joweb/kxjsygc/CN/10.12404/j.issn.1671-1815.2402476
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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