【作者】 谭洪涛；

【导师】 吕其兵；

【作者基本信息】 西南交通大学 ， 材料加工工程， 2007， 硕士

【摘要】 钢轨焊接是无缝线路建设的重要环节，它直接决定了钢轨接头的质量并影响到铁路安全性。铁路现行长钢轨的焊接包括工厂焊和工地焊两种，工厂焊采用闪光焊，工地焊采用气压焊或者移动式闪光焊。AMS60闪光焊机是我国从瑞士引进的移动式钢轨闪光焊机，与其它闪光焊机相比具有作用边自动对中等优点，但在国内进行实际生产时存在许多问题：(1)设备故障率较高；(2)人机操作界面差；(3)没有适合的质量管理及评判软件，阻碍了其应用，为此，立题对AMS60焊轨机的测控系统进行国产化改造。针对AMS60焊机测控系统的不足，论文进行了如下工作：(1)上位机采用工业控制计算机，下位机采用可编程控制器，研制了新的测控系统，数据采集同时通过PLC以及研华数据采集卡两种方式进行采集，更好、更完整的记录焊接过程参量(焊接电流、焊接电压、焊接位移、油压等)；(2)运用Visual Basic开发了新的人机交互界面，实现了焊接参数修改和监控程序运行平台的统一；(3)以TB/T1632-2005为试验标准，进行了U71Mn落锤试验，并进行了焊接工艺研究；(4)对工艺试验的有关参数进行高速采集，提取了灰斑特征量作为RBF径向基神经网络的输入量，建立了适合于AMS60焊机的基于MATLAB的钢轨焊接接头质量的RBF神经网络的预测模型，相对BP网络预测模型，采用RBF神经网络对灰斑面积进行预测收敛速度快，准确率高，基本能够满足钢轨焊接生产的实时性要求。改造后的焊机通过了铁标规定的型式检验，在北京地铁建设中的应用表明：新的测控系统故障率低，焊接生产效率高，实现了焊接参数修改和监控程序运行平台的统一，操作界面更加友好。更多还原

【Abstract】 The rail welding plays a significant role in the construction of continuous railways, for it directly determines the quality of rail welding joints and the security of railways transportation. Now, long rails can be welded in field or in factory, flashing butt welding is always used in factory, and gas pressure rail welding and mobile flash butt welding are usually used in field. AMS60 is one kind of mobile flash welding machines, imported from Schlatter Company in Switzerland. Compared with other welding machines, AMS60 has the virtue of side automatic centering and so on. However, it has many problems when used in China, such as: (1) The fault rate of the machine is high; (2) The Human-Computer operation interface is inconvenience. (3)There is no suitable software for managing and judging the welding quality. All of these embarrass the domestic application of AMS60. Therefore, the project was put forward to solve above problems.According to the shortages of the monitoring and controlling system, the following works has been done: (1) the new monitoring and controlling system was designed, which is composed of PLC to control the welding progress and computer to monitor and control the welding parameters. There are two ways used for data collection (welding voltage, welding electrical current, welding displacement, the oil pressure and so on )at the same time, which make the welding parameters collection better and more unabridged, the one way is through PLC and the other one is through the ADVANTECH data collecting card.(2) New Human-Computer interaction desktop application program was developed by Visual Basic to unify modification of welding parameter and running platform of supervisory control program. (3) According to TB/T1632-2005, the impacted quality test of the U71Mn rails was done and the study on the welding process was researched. (4) Through high-speed acquisition, the parameters related to the process test were collected, and the characteristics of grey-spots were acquired as the input of the RBF neural network. The welding quality RBF prediction model which is suit for AMS60 was established. Compared with the BP prediction model, the RBF prediction model has higher speed of constringency and higher nicety rate. The prediction model can satisfy the real time requirement of rail welding.The reconstructed welding machine has past the technological test of TB and has been used in Beijing subway construction. The application indicated that fault rate of the new monitoring and controlling system is low, welding efficiency is high. New Human-Computer operation interface can unify modification of welding parameter and running platform of supervisory control program, and it’s operation is convenience.更多还原