现场钢轨闪光焊动夹动态响应仿真分析

Simulation analysis on dynamic response of flash welding movable clamp in field rail

闪光焊作为无缝线路现场钢轨焊接最主要的方法,其加热主要通过短路液桥电阻热实现,因此液桥存在的时间影响着加热与端面状态,而液桥存在时间又受焊机动夹动态性能的影响。针对现场钢轨闪光焊的具体施工工况,以实际系统为基础,在MATLAB环境下运用Sim Hydraulics软件建立闪光焊机顶锻系统的液压仿真模型,并针对油路系统的不同结构参数以及负载变化等情况,仿真分析动夹动态响应。结果表明:通过适当减小油管直径和油管长度以及增大机头液压系统压力等方式能够有效提高动夹的动态响应速度,焊接环境变化时,可通过改变液压系统设置值和调整控制算法来保证环境变化后的焊机动夹动态响应,为现场焊接质量保证提供方向。

Flash welding is the most important welding method of jointless track in field rail. Because its heating is mainly achieved through the resistance heat of a short circuited liquid bridge. As a result,the liquid bridge existing time affects the heating and end surface＇s state. However,the existence time of the liquid bridge is affected by the dynamic performance of the movable clamp of the welding machine. Therefore,aiming at the specific field construction conditions of rail flash butt welding,based on the actual system,under the environment of MATLAB,using Sim Hydraulics software to establish the hydraulic simulation model of forging system of flash welding machine. And the dynamic response of the movable clamp is simulated and analyzed in the case of different structural parameters of the oil system and the change of the load. The results show that the dynamic response speed of the movable clamp can be effectively improved by reducing the diameter and length of the tubing and increasing the hydraulic system pressure of the handpiece. When the welding environment changes,the dynamic response of the movable clamp can be guaranteed by changing the setting value of the hydraulic system and adjusting the control algorithm,which provides the direction for the quality assurance of the welding field.