The present invention relates to a weld cutting machine, especially suited for cutting rail welds, comprising a first cutting jaw part and a second cutting jaw part, a base frame having fixedly attached thereto said second cutting jaw part, a power unit and a transmission mechanism, wherein said power unit is connected to said transmission mechanism to move said first cutting jaw part, and wherein connecting members are arranged to enable said first cutting jaw part to move in a guided manner relative said second cutting jaw part.
At railway construction and even in repair, rail parts are welded together so that it becomes a coherent welded construction. When welding is made, a weld joint protrudes outside the rail surfaces. This excess part of the weld joint contains some slag and partly to remove slag but also to smooth the surface, the protruding part of the weld joint is cut with a special cutting machine. Other options are also available, such as grinding, but it is very time consuming and therefore weld cutting machines have gained more and more entry. From GB456326 there is known an old weld cutting machine having a design that presents many disadvantages, e.g. inability to deliver adequate forces.
Today's weld cutting machines are complex and heavy, e.g. as known from U.S. Pat. No. 4,175,897, GB 2316349 and EP0119820. One reason is that known machines mostly use hydraulics to drive the jaws that cut the excess portion of the weld string. Hydraulics have some disadvantages, among other things, hydraulic oil is an environmental problem, but it also makes the weld cutting machine heavy. Known weld cutting machines are generally therefore too heavy to be handled by a single person.
Further known weld cutting machines use cutting jaws that are relatively expensive and also relatively complex to exchange.
The object of the present invention is to provide a solution to the issues mentioned above by providing an improved welding cutting machine, as well as an improved method for cutting welds.
The object according to the invention is achieved by a welding cutting machine according to claim 1. The object is also achieved by a method as defined in claim 12. Preferred embodiments of the invention are defined in the dependent claims.
Thanks to the invention a weld cutting machine is provided that is substantially lighter than prior art machines, enabling a single person to carry the machine. Further, the invention in the basic principle may completely utilize mechanical drive of the cutting jaws, which provides an environmental advantage compared to prior art machines.
According to a further aspect of the present invention there is provided a solution regarding cutting jaws by providing an improved design, as well as an improved method, for such weld cutting jaws that may be provide a more cost-efficient solution compared to prior art.
The invention will be described in more detail in the following with reference to the accompanying drawings, which for the purpose of exemplification illustrate embodiments of the invention.
The invention relates to a_weld cutting machine 1 comprising cutting jaw parts 4, 5, which machine may be lighter than known machines. In
In a preferred weld cutting machine 1 according to the invention, a relatively small high-speed electric motor 2 operates a transmission mechanism 3 adapted for the purpose of providing a desired transmission. This transmission mechanism 3 comprises, two parts. On the one hand, a planetary gear 31 (preferably including an arrangement, shown in
At least one cutting jaw part 4, 5 is movably disposed by means of drive rods 6, e.g. having the first_cutting jaw part 4 movable in relation to the second fixed jaw part 5. The first cutting jaw part 4 includes a movable support body 40,41,42,43 having a transversal movable support plate 40 with a first set of fixed threaded bushings 48 attached on a backside in line with a through hole 49 in transversal support plate. Each threaded bushing 48 interacts with first threads 63 at a first end 62 of the drive rod 6. A plurality, preferably four, drive rods 6 are arranged in parallel.
The chain/wheel mechanism is a preferred dividing transmission device 32, for dividing the output torque from the, preferably centrally positioned, reduction gear 31 to synchronously drive at least two rod 6, wherein the at least two rods 6 extend parallelly along the centre line C and are positioned equidistant from the centre line C. It is evident for the skilled person that various transmissions, e.g. cog wheel train, belt transmission, etc, may be used to achieved basically the same functionality, but a chain/wheel mechanism may provide extra advantages.
The second jaw part 5 is fixed in relation to a base frame 500, including a fixed support body that preferably has the same design as the support body to the first jaw part 4, e.g. including a transversal fixed support plate 51. The drive rods 6 extend along the machine through holes 58 in the fixed transversal support plate 51 of the fixed jaw part 5, further through distances 50 and then with second end parts 60 into the transmission mechanism 3. A second set of fixed threaded bushings 52 are attached to the transversal support plate 51 of the second jaw part 5. The fixed threaded bushings 52 interact with second threads 64, positioned at a distance from the first threads 63, wherein the direction of the threads 63, 64 are opposite to each other. As a consequence, upon rotation of a drive rod 6, the drive rod 6 will move in the desired direction relative the fixed transversal support plate 51 of the second jaw part 5 and at the same time also force the first cutting jaw part 4 to move in the same direction, thereby either increasing or decreasing the gap, depending on the rotational direction.
The base frame 500 also includes a fixed housing 30, 35, 36, 37 of the transmission mechanism 3, i.e. the second support body and the fixed housing 30, 35, 36, 37 are fixedly attached to each other. Inside the housing of the chain/wheel mechanism 32 there are four drive members 61 that are in engagement with the second end parts 60 of each drive rod 6 arranged to transfer torque from the chain/wheel mechanism 32 to the drive rods 6, preferably by a form-locking shaped part 65, e.g. hexagonal interfit.
The output shaft 319 from the planetary gear 31 is positioned along a central plane (including the intended line of extension C of a rail) within the fixed housing 30, 35, 37 of the chain/wheel mechanism 32. The fixed housing 30, 35, 37 is arranged with a first transversal wall 30 providing support for bearings/parts of the transmission mechanism 3, e.g. a first supporting structure 301 for the motor 2 that is attached to an inner side of the first transversal wall 30. Further there is a plurality of second supporting structures 302 each providing support for a drive member 61 of a drive rod 6.
The drive members 61 preferably enable the rods 6 to slide forth and back within them, which preferably is achieved by the use of drive members 61 that include an outer part 61 B of a harder material (e.g. steel, which preferably also is weld able) and an inner part 61A of a softer material (e.g. brass), to thereby enable the form-locking shaped part 65 of the drive rods 6 to slide relative the drive members 61 with low friction and also enable high strength (e.g. steel) chain wheels 326 to be welded onto the outer periphery of drive member 61.
The output 342 of the planetary gear 31 drives a shaft 319 (see
In
At the outer end of the motor output shaft 312 there are dents forming a sun wheel 314 that mesh with dents 353 at the inner side of planet wheels 351 of the planet assembly 350. The planet assembly 350 includes three circular planet wheels 351 symmetrically attached to a planet carrier 352, having a central collar 354 providing support/bearing (not shown). Hence, the planet carrier 352 may rotate together with the planet wheels 351. The planet wheels 351 at their outer sides mesh with dents of a fixed ring wheel (not shown) and also with dents 341 of a rotatable ring wheel 340. The rotatable ring wheel 340 is non rotatably attached via dents 342 at its inner periphery to a shaft 319 (see
In the preferred embodiment the planetary gear is a harmonic gear, i.e. the rotatable ring wheel 340 and the fixed ring wheel have different amounts of dents, e.g. 51 and 48 respectively, which provides for a drastic reduction of the rotational speed from the motor shaft 312 to the rotate able ring wheel 340. In an exemplary embodiment the number of dents 314 of the motor shaft 312 is 6 and each planet (3 pcs) has 22 dents. In combination with a ring wheel (first outer ring) that is fixed having 48 dents and a rotatable ring wheel 340 (second outer ring) having 51 dents there will be achieved a gear ratio of 1:153, i.e. when the sun wheel 314 has made 9 turns, each planet has made one turn (360 degrees) and thereby have driven the rotate able outer ring 1/17 of a turn.
Thanks to the transmission mechanism 3 and its combination of the (preferably harmonic kind) planetary gear 31 and the chain/wheel mechanism 32, a reliable and compact torque transfer/rotational motion is provided to the drive rods 6.
The use of an electric motor 2 may further provide the advantage that an adaptive torque/speed is automatically created to the drive rods 6, in that the higher the resistance the lower the transmitted speed to the drive rods 6, i.e. when the resistance increases the rotational speed is reduced and the torque of the motor 2 increases and thus the force that effect the moving jaw 4. Preferably an out board electric motor 2 is used that may provide a larger torque than traditional motors.
Furthermore, there is shown that there is a kind of base frame 500 that fixates basics parts of the weld cutting machine 1; the fixed supporting structure including the transversal support plate 51, the electric motor 2, the fixed housing 30, 35, 37 of the chain/wheel gearing 32, the planetary gearing 31 and other parts that need to be fixated at least in one direction in relation to the second jaw part 5. Moreover, the base frame 500 also has handles 7 attached thereto for ease of carrying and lifting the weld cutting machine 1. At the outer side of the outer plate 37 of the chain/wheel gear housing there is an expandable protection devise 9, having a protecting plate 90 at the outer end and resilient, expendable rubber membrane 91 enclosing a space. This protective device 9 enables the drive rods 6 to move out from the fixed housing 30/35/37 and to be protected from dirt and dust, entering in to the space.
Moreover, as schematically shown in
In operation, the weld cutting machine 1 is transported to the weld between two rail parts, which is to be cut. The transportation may easily be performed by carrying the weld cutting machine 1 by hand, holding in to the handles 7. A protective plate 36 may be arranged at the bottom of the gear will housing 30, 35, 37 in order to enable weld cut machine to be put down but also uneven ground without risk of causing damages. The weld cutting machine 1 is then lifted on to the rail (not shown) having the weld that is to be cut. The handles 84, 85 are then in inactive mode and the guide members 86 are parallel with the rail 600. The weld cutting machine 1 is positioned such that the weld is positioned in the gap between the two jaw parts 4,5, and preferably such that the weld is close to the fixed jaw part 5. The rail will fit into the gaps 4A, 5B of the jaw parts 4,5 and also in the gap 38 in the housing 30, 35, 37, which has the form of an inverted U.
A batterie, (not shown), which may be carried separately, is positioned in a batterie holder 34, preferably positioned on top of the housing 30,35, 37. The batterie provides power to the electric motor 2 and also a control unit 33, e.g. attached to upper side of the housing 30, 35, 37. Further, the adjustment members 8 are activated by first turning the wheel members 87 to turn the guide members 86 and thereafter pivoting the handles 84, 85 into the active position, i.e. by pivoting downwards. Now the adjustable abutment member 82 is turned until the guide members 86 contact and grip under the rail head.
In a next stage the adjustable abutment member 82 is turned to obtain a desired play during cutting, e.g. about 1 mm, and then the adjustable rod 81 is pushed down to again obtain contact with the lower contact surface 820 on the pivotable body 83. Hence, now the guide members 86 have been positioned into a desired guiding position underneath the head of the rail 600. Hence, an appropriate clearance between the surfaces of the rail and the guide members 86, e.g. about one millimeter, is provided for by adjusting the adjustment member 86. Now the weld cutting machine 1 is ready to be operated. Once the machine is started the electric motor 2 starts spinning where by the rotation will be transmitted first to the planetary gearing 31 and then to the chain/wheel gear 32 to rotate the drive rods 6, whereby the movable jaw part 4 will start moving towards the weld that is to be cut. Preferably a harmonic planetary gear is used that provides a gear ratio of at least 1:100 and an electric motor 2 rotating with at least 3000 rpm, preferably about 4000-6000 rpm. The electric motor 2 the will quickly move the movable jaw part 4 in a first stage when there is no resistance and move it more slowly once resistant is encountered when the jaw front 46 meets the weld, thereafter the two jaw fronts 46, 56 will move towards each other to cut the weld, which is achieved when the two jaw fronts 46, 56 meet each other.
Thereafter the weld cutting machine is easily dismounted by pivoting the handles 84, 85, such that the guide members 86 get out of contact with the rail head. Then the wheel members 87 may be easily turned to position the guide members 86 parallel with the rail 600, where by the machine 1 is free to be lifted up from the rail.
The above exemplified solution of machine 1 means that the jaw parts 4, 5 may be moved relatively quickly along the rail surface towards the weld joint with relatively little force and that as soon as the movable jaw 4, with the firm jaw engaging from the other side engages the weld joint, the speed will be lowered, and the torque/force will be increased and adapted to the need. Maximum power produced by a well-functioning prototype is above 10 tonnes, preferably above 12 tonnes. Thanks to the construction, a machine 1 may be obtained having about half the weight, about 25 kg, compared with known hydraulic machines that weigh about 50 kg.
As is shown in
In
It is evident for the skilled person that the novel cutting jaws 4, 5, divided into wear sections 56, 46 and support sections 57, 47, respectively, may also be used together with weld cutting machines of other kind, i.e. in place of homogeneous jaws. Also, the adjustable fastening device 8 for fixing the machine 1 to a rail, including an easily handled pivot mechanism 83 enabling easy and safe locking and unloading of the machine 1, may of course also be used together with other weld cutting machines.
In
Further, as presented above the rods are arranged with driving threads 64, for transfer of movement of one of the cutting jaw parts 4, 5. In this embodiment it will be the second cutting jaw part 5 that will move along the rods 6. This movement is achieved by rotating the drive member 620 which are fixedly positioned within the second cutting jaw part 5 by means of bearings (not shown). The drive members 620 are preferably made in a material that is of a different kind than the material in the rods 6, e.g. brass, in order to provide for low friction but for the skilled person it is evident that different kind of materials may be used for the drive members 620, e.g. also of same material, to fulfil the desired basic function, by use of appropriate lubrication. By use of brass in the drive members 620 lubrication maybe eliminated, which is an advantage in respect of several aspects. The drive members 620 may be driven by various appropriate transmission mechanisms.
As already described above a preferred transmission mechanism could be chain gears 320, 321, 323, to transmit, torque and rotation from the central output wheel 320. As it's indicated in
The invention is not limited by the embodiments presented above but may be varied within a plurality of aspects without departing from the basic principles of the invention. For instance, it is evident that instead of using a separate shaft 319 it may be integrated with the planetary gear 31 and/or the drive wheels 320. Further, if using a cog wheel train instead of a chain transmission it may suffice with one single outgoing member 320. It is foreseen that some of the aspects described above may be the subject for their own protection by one or more divisional applications, e.g. the use of separate wear parts, which may not be limited to a weld cutting machine according to the invention but may also be used in other kind of weld cutting machines.
Number | Date | Country | Kind |
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1850973-7 | Aug 2018 | SE | national |
1851588-2 | Dec 2018 | SE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/SE2019/050523 | 6/5/2019 | WO | 00 |