EP1652593B1 - Verfahren zum Richten von gewaltzten Metallprofilen - Google Patents

Verfahren zum Richten von gewaltzten Metallprofilen Download PDF

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Publication number
EP1652593B1
EP1652593B1 EP05292194A EP05292194A EP1652593B1 EP 1652593 B1 EP1652593 B1 EP 1652593B1 EP 05292194 A EP05292194 A EP 05292194A EP 05292194 A EP05292194 A EP 05292194A EP 1652593 B1 EP1652593 B1 EP 1652593B1
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EP
European Patent Office
Prior art keywords
profile
curve
straightening
straightness
pressing
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP05292194A
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English (en)
French (fr)
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EP1652593A1 (de
Inventor
Jacques Huart
Gilles Noel
Thierry Helle
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Societe des Anciens Etablissements Lucien Geismar SAS
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Societe des Anciens Etablissements Lucien Geismar SAS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D3/00—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts
    • B21D3/10—Straightening or restoring form of metal rods, metal tubes, metal profiles, or specific articles made therefrom, whether or not in combination with sheet metal parts between rams and anvils or abutments

Definitions

  • the invention relates to a process for straightening rolled metal sections, such as track rails, with the aid of a press comprising a device for measuring the straightness of a profile to be straightened and for establishing the deformation of the profile, and a pressing assembly comprising at least one device for deforming the rail by bending in a predetermined longitudinal plane of the profile, which comprises at least three members capable of coming into contact with the profile, at least one of which is a tool for pressing the profile or a support member on the profile and the others are support members or pressing.
  • Processes of this type and presses to be used for this purpose are particularly known for straightening rails of railroad tracks.
  • it is a press operator who executes the various consecutive operations of a straightening.
  • the operator controls for this purpose the actuator members of the press by means of push buttons, switches and manipulators, from a representation of the deformation of the rail to be straightened on a display screen. Therefore, the operator is the only judge of the levels of force to apply to the rail and must have good experience to reconcile quality and productivity.
  • the present invention aims to provide a method and a press that overcome these disadvantages. This object is achieved by the method according to claim 1 and the press according to claim 12.
  • the method according to the invention contains the characteristic that is brought to the press to acquire and automatically process in real time data concerning the relationship between the pressing forces exerted by the pressing tool on the profile and moving the tool for this purpose and applying the pressing force necessary to obtain the deformation determined from these data, to achieve the desired straightening of the profile, and the characteristic that is established the characteristic curve of the pressing forces of the tool on the profile as a function of the displacement of the tool in the fields of elastic and plastic deformation and validates the stopping condition of the straightening process for producing the desired residual deformation from this curve.
  • the stop condition of the straightening process is determined when the pressing force reaches a value such that the horizontal distance between the position on the abscissa which indicates the beginning of the zone plastic f and the actual position on the curve is equal to the plastic deformation to achieve.
  • the straightness of the section to be straightened is measured and, after processing of the measurement data, a straightness curve is established.
  • out-of-tolerance zones of the section to be straightened are determined to be located outside a tolerance corridor of a predetermined length and height that is moved along the curve. with the endpoints representative of the zero tolerance sliding on the curve.
  • the tolerance corridor is formed by a virtual rule.
  • an operation for detecting and eliminating defects in the straightness curve is carried out by filtering and smoothing the measurement data constituting this straightness curve.
  • ratios of the profile section measured are calculated by progressing step by step from one end to the other of this section.
  • a deformation ratio is established by sliding a straight line whose length corresponds to a real separation of the two external contact members, keeping the ends of this straight line on the straightness curve and Retain as ratio the difference of the algebraic areas and between the curve and the line above and below it, divided by the square of the spacing.
  • a deformation ratio value is established for each position of the aforementioned straight line for all the spacings between a maximum spacing value and a minimum spacing value.
  • an external contact member and the contact member located between the external members may constitute a variable to be taken into account during straightening.
  • the area to be straightened from the profile is chosen to be that having a maximum deformation ratio, with the point of application of the pressing force included in an out-of-tolerance zone.
  • the straightening press of rolled sections comprises, for the implementation of the method, an automatic device for the acquisition and processing in real time of data relating to the profile to straighten and calculation of the straightening operation according to a predetermined software.
  • the straightening press which is a hydraulic press, is intended in particular to straighten horizontally and vertically either the ends of the short rails or welded joints made between two short rails to obtain welded long rails. It is this latter application that will be described, without this being limiting.
  • This press which is designated in the figures by the general reference number 1, is mounted on a platform 2 capable of moving on rails 3 with the aid of axles 4.
  • the press 1 essentially comprises a set 6 of press a straightening rail indicated at 7, which is disposed in the central part of the press, a measuring device 8 of the rails to be treated and rail moving means 7 through the machine, in a horizontal plane. These means are not specifically represented.
  • the pressing assembly 6 comprises a device for straightening the rail in a vertical plane, which comprises an upper vertical jack 10 intended to actuate a hammer 11 constituting the pressing tool and which is vertically movable, a lower vertical jack 12 arranged vertically. Below the upper cylinder 10 and the hammer 11, and on either side of the cylinders, in the longitudinal direction of the rail, two articulated upper movable ablots 13 and 14 and two movable ablots lower 15, 16. The upper and lower ablots are respectively disposed above and below the rail 7 and intended to retain the rail during straightening.
  • the pressing assembly 6 further comprises a device for horizontal straightening of the rail 7, which comprises a member 18 for horizontal support of the rail, called the iron hand located at the vertical cylinders 10 and 12 and which is associated with a horizontal hydraulic jack actuator 19, and two iron hand members 20, 21 horizontally retaining the rail 7, each disposed at the level of the lower movable ablots 15 and 16.
  • a device for horizontal straightening of the rail 7, which comprises a member 18 for horizontal support of the rail, called the iron hand located at the vertical cylinders 10 and 12 and which is associated with a horizontal hydraulic jack actuator 19, and two iron hand members 20, 21 horizontally retaining the rail 7, each disposed at the level of the lower movable ablots 15 and 16.
  • the device 8 for measuring the straightness of the rails to be straightened 7 essentially comprises a measuring carriage 21 ( figure 5 ) provided with a vertical laser sensor 22, which is arranged in the vertical plane of symmetry of the rail 7 to measure the straightness of the rail in its vertical plane and, on either side of the rail head 23, in the same plane horizontal, two laser sensors 24, 25 for measuring the straightness of rail in its horizontal plane.
  • the measuring carriage 21 is movable along a horizontal guiding device 26, which is fixedly mounted on the structure of the press.
  • This method comprises a first phase of measuring the straightness of a section of the rail.
  • Straightness is measured by the measuring carriage 21 by continuously acquiring the signals via the laser sensors 22, 24 and 25.
  • the measurement values are acquired automatically during the carriage stroke on the rail section corresponding to the position of the press along its horizontal guiding device 26, under the control of appropriate computer equipment, acting according to a measuring software, according to the invention.
  • the measuring device establishes, by calculation of the algebraic average over a predetermined number of samples, the shape of the rail section considered. Then we proceed to a storage, for example every millimeter.
  • the absolute position of the carriage is given by an incremental encoder and a laser barrier fixed to the measuring beam.
  • the measuring device represents the shape of the section of rail considered on a display screen, in the form of a curve CR, as seen on the figure 6 .
  • This curve indicates the length of the section, the deviations of the rail, that is to say the deformation, of the reference axis R representative of the zero difference over the length of the section.
  • the rail section may have local straightness defects such as for example places where two short rails have been welded to each other for the realization of a long rail. These local defects are manifest in the form of sudden variations in the concavity of the straightness curve CR, as seen for example at the location S indicated by a dashed line, which could be a weld bead. More precisely, a local fault is considered as present when two successive and symmetrical variations are located in a zone of short length.
  • a second phase of the method according to the invention lies in the detection and the mathematical elimination of the defects found by a mathematical analysis from the data of the measure of straightness.
  • Each defect identified is eliminated by performing a replacement of the area concerned by a segment linear.
  • the qualitative data of each defect are kept for traceability of the rail.
  • the figure 6 illustrates the elimination of the defect S in the manner just indicated.
  • the measurement data of the straightness is extracted and filtered.
  • the raw measurement data are filtered to eliminate small irregularities in the curve.
  • smoothing is done.
  • the filtered measurement data are for this purpose extracted by sampling according to predetermined steps, for example every centimeter. Thus, on a measurement section with a length of 3000 millimeters, 300 steps are thus retained.
  • a tolerance corridor is characterized by its length and height, which are chosen according to the desired straightness qualities of the rail.
  • the determination of the out-of-tolerance zones is carried out by placing a virtual rule 28 of predetermined length and height which respectively represent the length and the height of the aforementioned tolerance corridor and by moving this rule along the whole of the CR curve in a step of constant value, the two ends 29, 30 of the rule still being on the curve of straightness, as seen on the figure 8 .
  • a virtual rule 28 of predetermined length and height which respectively represent the length and the height of the aforementioned tolerance corridor
  • this rule along the whole of the CR curve in a step of constant value, the two ends 29, 30 of the rule still being on the curve of straightness, as seen on the figure 8 .
  • the value of the ratio R is always positive and gives the indication of the deformation without precision of the direction of deformation which could be a hollow or a bump.
  • the line connecting the two points of support (as defined on the figure 10 ) on the straightness curve delimits with this one on the left a negative area A - and on the right a positive area A + since these two areas are respectively below and above the right.
  • the sixth phase that follows concerns the choice of the area to straighten, the measured rail section.
  • This zone is selected according to two criteria, namely the ratio R (p, e) maximum and the point of application of the effort to be made by the pressing tool, in an out of tolerance zone established during phase 4
  • the maximum ratio R (p, e) as well as the points of support and the position p of the pressing hammer, that is to say the point of application of the pressing force, which are associated with this maximum value R are deduced directly from Table I.
  • the distance of a tool ablot could be different from the distance of the tool of the other ablot and thus constitute a variable to be treated in a similar way away from the above.
  • the form factor is used to modulate the final state of straightness in order to obtain an optimal shape for the possible treatment after straightening.
  • the rail could be voluntarily "curved" to optimize the quality of a subsequent grinding operation.
  • the straightening process is a cycle consisting of a succession of a plurality of work steps, namely an exit step of the pressing tool, the approach of the rail to the vacuum, the contacting of the tool with the rail and a cycle part characterized by the repetition of a sequence of three successive work steps, that is the loading of the rail and / or a simultaneous control of the residual deformation while working in the zone of elastic deformation, loading at constant speed in plastic deformation zone of the rail, then unloading.
  • This figure 12 illustrates the relation between the hydraulic pressure P generating the pressing force indicated on the ordinate and the displacement X of the tool indicated on the abscissa, in different work situations.
  • the figure 12 firstly illustrates the first three steps of the straightening cycle, namely the steps of exit of the pressing tool and the no-load movement, both indicated by the reference a, and the step of contacting the the tool with the rail, indicated by the reference b. It is found that, during the first two steps, exit of the pressing tool then empty displacement, the pressure P can be assimilated to a constant.
  • the purpose of the output step is to overcome the disturbances of the pressure and position signals related to the use of certain components and to guarantee the stability of the control information. In the event that the stability of the signals is not validated, the straightening cycle is interrupted.
  • the contacting step b is characterized by a specific concavity of the pressure / displacement curve.
  • the figure 12 also illustrates the step of loading the rail by the tool in the elastic deformation zone c of the rail, which is characterized in that the curve is substantially rectilinear and follows the zone b.
  • the following plastic deformation zone denoted by f is characterized by the fact that the pressure / displacement curve has a convex shape, that is to say the curve deviates from the curve assimilable to a line defining the elastic zone c.
  • the estimate of the plastic deformation is defined and calculated from the horizontal difference between the position on the abscissa which indicates the start of the plastic zone f and the actual position on the curve. The loading step is completed to obtain the desired deformation established during the 7 th phase.
  • the elastic return zone g corresponding to the unloading step consists of a controlled return of the pressing tool ensuring that the tool is always in contact with the rail.
  • the figure 12 illustrates finally, the step of controlling the residual deformation by elastic reloading. This loading is done according to a curve comparable to a line h which presents the same slope as the initial elastic part c.
  • the horizontal distance of the two straight portions c and h represents the plastic deformation of the rail that the tool has made. Therefore, to obtain the desired deformation d, it was therefore necessary to go on the curve portion f up to the pressure P max .
  • the control of the residual deformation is performed only from a second loading sequence, after the first plastic deformation sequence. If it turns out that the desired deformation is not yet fully realized during the first loading step, the invention provides that the deformation control step continues in a new loading step.
  • TDP (x) the terms DP (x) constitute the delta-pressure measured at the position x
  • DP (x-1), DP (x-2) and DP (x-3) constitute the values measured at the three previous positions.
  • the establishment of the delta-pressure trend TDPn (x) makes it possible to note the engagement of the pressing tool with the rail since, at this instant of time, the threshold of n successive delta-pressure values exceeding a minimum difference is reached.
  • This position corresponds to the pressure rise zone b.
  • the beginning of the elastic zone c is observed when the pressure / displacement curve can be likened to a straight line, that is to say when the delta-pressure trend remains constant.
  • the pressure / displacement curve enters the plastic zone when this curve loses its linear characteristic and takes a convexity detected by the decay on n successive samples of the delta-pressure value.
  • the software calculates the ideal slope corresponding to the real elastic zone.
  • the difference between the line representative of the elastic zone and the curve in the plastic zone gives the residual plastic deformation.
  • the beginning of the plastic zone can be readjusted if the convexity of the pressure / displacement curve is lost.
  • Each of the readjustments of the plastic zone corresponds to a recalculation of the directing coefficient of the straight line of elastic characteristic, namely of the slope, and also of the residual plastic deformation to be achieved.
  • the partial residual plastic deformation is calculated before the readjustment of the plastic zone and then stored for cumulation.
  • the total residual plastic deformation corresponds to the set of partial residual plastic deformations detected during the complete straightening cycle.
  • Total residual plastic deformation is the sum of the partial residual plastic deformations detected during the cycle.
  • the invention is based on the acquisition and the real-time processing of the effort / displacement torque implemented by controlled elasto-plastic flexion.
  • the data processing allows the identification and use of the intrinsic behavior of the material, independently of the product being processed, in order to detect the transition between the elastic domain and the plastic domain, characterized by a slope break of the stress / strain curve. displacement and this in order to faithfully predict the effective plastic deformation after release.
  • the method makes it possible to perform measurement and analysis of the product deformations between each pressing phase and determines the optimal positioning of the support points.
  • the press and the method can be modified in many ways within the scope of the invention. Thus, it is not mandatory to use for a straightening in one plane a pressing tool and two ablots. We could also use two tools and an ablot or another configuration of tools and ablots support.
  • the invention is advantageously used for the manufacture of rails, but relates, in general, the straightening or reshaping of bars, tubes and metal profiles.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Straightening Metal Sheet-Like Bodies (AREA)
  • Control Of Heat Treatment Processes (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Crystals, And After-Treatments Of Crystals (AREA)
  • Machines For Laying And Maintaining Railways (AREA)
  • Laminated Bodies (AREA)

Claims (12)

  1. Verfahren zum Geraderichten von gewalzten Metallprofilen, wie etwa Eisenbahnschienen, mittels einer Presse, umfassend eine Vorrichtung zum Messen der Geradheit eines gerade zu richtenden Profils und zum Erstellen der Ablenkung des Profils, und eine Pressanordnung, umfassend mindestens eine Vorrichtung zum Verformen der Schiene durch Biegung in einer vorherbestimmten Längsebene des Profils, die mindestens drei Organe umfasst, die mit dem Profil in Berührung kommen können, wovon mindestens eines ein Werkzeug zum Pressen des Profils oder ein Organ zum Aufstützen auf dem Profil ist und wovon die anderen die Aufstütz- bzw. Pressorgane sind, dadurch gekennzeichnet, dass die Presse (1) dazu veranlasst wird, die Daten über die Beziehung zwischen den Presskräften, die vom Presswerkzeug auf das Profil (7) ausgeübt werden, und der Bewegung des Werkzeugs zu diesem Zweck, automatisch in Echtzeit zu erfassen und zu verarbeiten, und die Presskraft, die notwendig ist, um die von diesen Daten bestimmte Ablenkung zu erreichen, anzuwenden, um das erwünschte Geraderichten des Profils auszuführen, und dass die Kennlinie der Presskräfte des Werkzeugs auf das Profil in Abhängigkeit von der Bewegung des Werkzeugs in den elastischen und plastischen Verformungsbereichen erstellt wird und die Unterbrechungsbedingung des Verfahrens zum Geraderichten für die Ausführung der erwünschten restlichen Ablenkung von dieser Linie ausgehend bestätigt wird.
  2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Unterbrechungsbedingung des Verfahrens zum Geraderichten bestimmt wird, wenn die Presskraft einen Wert erreicht, so dass die waagerechte Abweichung zwischen der Position auf der X-Achse, die den Anfang der plastischen Zone (f) angibt, und der tatsächlichen Position auf der Linie gleich der auszuführenden (d) plastischen Verformung ist.
  3. Verfahren nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass die Geradheit des gerade zu richtenden Profils (7) gemessen wird und nach der Verarbeitung der Messdaten eine Geradheitskurve (CR) erstellt wird.
  4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass nicht maßhaltige Zonen des gerade zu richtenden Profils als sich außerhalb eines Toleranzstreifens vorherbestimmter Länge und Höhe befindlich bestimmt werden, wobei der Streifen an der Kurve entlang bewegt wird und die Endpunkte, welche die Nulltoleranz darstellen, auf der Kurve gleiten.
  5. Verfahren nach Anspruch 4, dadurch gekennzeichnet, dass der Toleranzstreifen durch ein virtuelles Lineal (28) gebildet wird.
  6. Verfahren nach einem der Ansprüche 4 oder 5, dadurch gekennzeichnet, dass vor dem Erstellen der nicht maßhaltigen Zonen ein Vorgang zur Erkennung und Beseitigung von Defekten der Geradheitskurve (CR) ausgeführt wird, indem die Messdaten, welche diese Geradheitskurve bilden, gefiltert und geglättet werden.
  7. Verfahren nach einem der Ansprüche 4 bis 6, dadurch gekennzeichnet, dass rechnerisch Verhältniszahlen R(p,e) des Profilquerschnitts erstellt werden, der gemessen wird, indem man Schritt für Schritt von einem Ende zum anderen dieses Querschnitts vorrückt.
  8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, dass ein Verformungsverhältnis R(p,e) erstellt wird, indem man eine Gerade verschiebt, deren Länge einem tatsächlichen Abstand (e) der beiden äußeren Kontaktorgane entspricht, indem die Enden dieser Geraden auf der Geradheitskurve (CR) gehalten werden, und indem man als Verhältnis den Unterschied der algebraischen Flächen (A+) und (A-) zwischen der Kurve und der Geraden oberhalb und unterhalb der Kurve, geteilt durch das Quadrat des Abstands e, zurückhält.
  9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass ein Verformungsverhältniswert erstellt wird für jede Position der genannten Geraden für alle Abstände (e) zwischen einem maximalen Abstandswert (emax) und einem minimalen Abstandswert (emin).
  10. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die Entfernung zwischen einem äußeren Kontaktorgan und dem Kontaktorgan, das sich zwischen den äußeren Organen befindet, eine Variable sein kann, die beim Geraderichten zu berücksichtigen ist.
  11. Verfahren nach einem der Ansprüche 9 oder 10, dadurch gekennzeichnet, dass die gerade zu richtende Zone des Profils derart gewählt wird, dass sie ein maximales Verformungsverhältnis aufweist, wobei der Anwendungspunkt der Druckkraft in der nicht maßhaltigen Zone enthalten ist.
  12. Presse zum Geraderichten eines Walzprofils von der Art umfassend eine Vorrichtung zum Messen der Geradheit des Profils und zum Erstellen der Ablenkung des Profils, wobei eine Pressanordnung mindestens eine Vorrichtung zum Verformen des Profils durch Biegung in einer vorherbestimmten Längsebene davon umfasst, dadurch gekennzeichnet, dass sie für die Durchführung des Verfahrens nach einem der Ansprüche 1 bis 11 eine Vorrichtung zum automatischen Erfassen und Verarbeiten in Echtzeit der Daten bezüglich des gerade zu richtenden Profils und zum Berechnen des Geraderichtvorgangs nach einer vorherbestimmten Software umfasst.
EP05292194A 2004-10-22 2005-10-19 Verfahren zum Richten von gewaltzten Metallprofilen Expired - Lifetime EP1652593B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR0411316A FR2876925B1 (fr) 2004-10-22 2004-10-22 Procede de redressage de profiles metalliques lamines

Publications (2)

Publication Number Publication Date
EP1652593A1 EP1652593A1 (de) 2006-05-03
EP1652593B1 true EP1652593B1 (de) 2008-10-08

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EP (1) EP1652593B1 (de)
AT (1) ATE410249T1 (de)
DE (1) DE602005010178D1 (de)
FR (1) FR2876925B1 (de)

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RU2438815C1 (ru) * 2010-04-27 2012-01-10 Закрытое акционерное общество "Псковэлектросвар" Установка для правки сварных стыков рельсов в холодном состоянии
CN105081016B (zh) * 2015-08-12 2017-01-04 张家港市张运机械制造有限公司 电梯导轨自动矫直输送线
CN112474897B (zh) * 2020-12-14 2024-06-14 核工业理化工程研究院 长管类组件矫直装置及矫直方法
CN113319152B (zh) * 2021-04-21 2022-10-28 邯郸钢铁集团有限责任公司 一种实现钢轨智能化压力矫直的方法
IT202200019458A1 (it) * 2022-09-22 2024-03-22 S I C E S R L Macchina raddrizzatrice
CN115647127B (zh) * 2022-11-01 2024-04-19 山东纬速铝业有限公司 一种铝型材生产用校直装置及其使用方法
CN119114690B (zh) * 2024-11-08 2025-02-18 广东赛福智能装备有限公司 一种压力矫直机控制系统、方法及可读存储介质
CN120571887B (zh) * 2025-08-05 2025-10-17 四川川润液压润滑设备有限公司 一种数据中心分集水器检测及矫形方法和系统

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US1796696A (en) * 1928-12-11 1931-03-17 Trimble Joseph Rail-reconditioning machine
US3295350A (en) * 1964-03-11 1967-01-03 Railway Automation Maintenance Continuous rail straightening press
US4077248A (en) * 1977-01-03 1978-03-07 Chemetron Corporation Rail straightening press
JPS57146422A (en) * 1981-03-06 1982-09-09 Toshiba Corp Automatic straightening device for shape steel
DE3927465A1 (de) * 1989-08-19 1991-02-21 Mae Maschinen U Apparatebau Go Biegerichtmaschine fuer langgestrecktes richtgut
DE3929397A1 (de) * 1989-09-05 1991-03-07 Mae Maschinen U Apparatebau Go Automatische biegerichtmaschine

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Publication number Publication date
FR2876925B1 (fr) 2008-05-30
FR2876925A1 (fr) 2006-04-28
DE602005010178D1 (de) 2008-11-20
ATE410249T1 (de) 2008-10-15
EP1652593A1 (de) 2006-05-03

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