Abstract:
A system thermally treats rails. The system has a cooling device for spraying a cooling medium onto a rail to be treated. The cooling device defines a cooling path for receiving the rail to be treated. A conveyor moves the rail to be thermally treated through the cooling path. A vertically displacing device for displacing at least one of the cooling devices for adjusting a position of the one cooling device relative to the rail to be treated.

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The invention relates to a system for thermal treatments of rails. 
     Nowadays, the rapid rise in weight and speed of trains, has inevitably forced to enhance the rails wear rate, in terms of loss of material due to the rolling/sliding between wheel and rail, and therefore an increasing of hardness has been required in order to reduce wear. 
     Generally, the final characteristics of a steel rail in terms of geometrical profiles and mechanical properties are obtained through a sequence of a thermo-mechanical process: a hot rail rolling process followed by a thermal treatment and a straightening step. 
     The hot rolling process profiles the final product according to the designed geometrical shape and provides the pre-required metallurgical microstructure for the following treatment. In particular, this step allows the achievement of the fine microstructure which, through the following treatments, will guarantee the high level of requested mechanical properties. 
     Up to now the systems for thermal treatment of rails are of four different types:
         immersion into a water tank of the rail head by tilting the rail grabbed by its foot,   spraying of water only,   spraying of air only,   spraying air/water mist.       

     Document U.S. Pat. No. 6,432,230 discloses a device for hardening a rail. The solution presented in this document proposes to fix the rail to be cooled and to cool this rail with a cooling liquid. 
     In this document, an immersion system is presented that cannot allow flexibility of the cooling process. 
     Furthermore, this solution can be applied only when the rail can be clamped which is not always the best situation for thermal treatments. 
     Additionally, existing spraying devices locally cool the rail using water only or air only or a mixture of air and water. However, there is no solution to easily and quickly interchange a system spraying a given type of cooling medium with another system able to spray a different type of cooling medium. The existing spraying based system usually does not allow an easy and precise positioning of the spraying nozzles considering the variability of the possible rail profiles to be treated. 
     BRIEF SUMMARY OF THE INVENTION 
     A major objective of the present invention is to propose a system for thermal treatment of rails that can be adapted to different geometries of the rails to be treated and to different metallurgical characteristics/productivity to be achieved. 
     A companion objective of the present invention is to offer a solution able to restrain the rail both vertically—against rail bending- and also horizontally—against asymmetrical rail bending and rail fluctuation of a roll table-during the thermal process. 
     A supplemental objective of the present invention is to propose a solution wherein switches between different cooling media are easily and quickly feasible. 
     The present invention achieves these and other objectives and advantages by the features of a system for thermal treatment of rails comprising:
         cooling means intended to spray a cooling medium onto a rail to be treated, said cooling means defining a cooling path intended to receive the rail to be treated,   conveying means indented to move the rail to be thermally treated through said cooling path,
 
the system further comprises means for vertically displacing at least one of said cooling means to adjust the position of said cooling means relative to the rail to be treated.
       

     According to other features taken alone or in combination:
         the system further comprises a plurality of cooling supports overlooking, in operation, the conveying means, each cooling support carrying at least one of said cooling means;   the system comprises securing means for releasably securing each cooling support to said vertically displacing means;   the securing means are adapted and located in order to secure alternatively different cooling supports with different types of cooling means able to spray different kinds of cooling media to the vertically displacing means;   the system further comprises a first cooling block comprising a first set of cooling supports linked together, said first cooling block being connectable to said vertically displacing means to form said cooling path, said first cooling block being interchangeable with at least one second cooling block comprising a second set of cooling supports linked together by second pipes to supply a second type of cooling means, said second cooling block being also connectable to said same vertically displacing means to form said cooling path;   the means for vertically displacing at least one of said cooling means comprise:
           i. at least one deformable parallelogram comprising a plurality of sides and having one of said side fix,   ii. a plurality of supporting arms, each supporting arm being linked to said at least one articulated parallelogram,   iii. driving means secured to said at least one deformable parallelogram, actuation of said driving means provoking deformation of said at least one deformable parallelogram and vertical translation of at least one supporting arm.   
           the means for vertically displacing each cooling means comprise at least two deformable parallelograms secured together by means of at least one beam, said driving means being secured to said beam and being able to translate both deformable parallelograms;   each deformable parallelogram is secured to a linking shaft, said linking shaft being received in a flange of each supporting arm, said linking shaft connecting the supporting arms ones to the others;   the system comprises means for reversibly rotating at least one cooling support between a working position wherein said cooling support is located above the conveying means and a non-working position wherein each cooling support is located beside the conveying means;   the system comprises guiding means to guide the rail during its conveying, said guiding means comprising:
           at least one guiding shaft,   at least one guiding wheel connected to said guiding shaft, said guiding wheel comprising a first and a second half-wheel, each half-wheel being free to rotate relative to the other and free to rotate about said guiding shaft;   
           at least one guiding wheel is designed and dimensioned such that during rail guiding, each first half-wheel contacts the rail on the feet and second half-wheel on the web to maintain the rail in a predefined position;   at least two of said guiding wheels are located in a plane perpendicular to the path of the rail;   each guiding wheels is chosen between two kinds of wheels only;   the system comprises means for reversibly rotating at least one guiding shaft and the corresponding guiding wheel between a working position wherein said guiding wheel is able to contact the rail to be thermally treated and a non-working position wherein said guiding wheel is not anymore able to contact the rail.       

    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       Other objectives, features and advantages of the present invention will be now described in greater details with reference to the drawings, wherein: 
         FIG. 1  is a 3D view of a thermal treatment system according to an embodiment of the invention, 
         FIG. 2  is a transversal and partial cross section of  FIG. 1  showing the cooling means in a first working position, 
         FIG. 3  is a transversal cross section of  FIG. 1  showing the cooling means in a second working position, 
         FIG. 4  is a transversal cross section of  FIG. 1  showing the cooling means in a non-working position, 
         FIG. 5  are 2D and 3D view of an embodiment of the means guiding the rails during the thermal treatment, 
         FIG. 6  is a view similar to  FIG. 2  showing further details of the system according to the invention, 
         FIG. 7  are cross sections of guiding means according to the invention; 
         FIG. 8  is a cross section showing different kinds of cooling means used in the system according to the invention. 
     
    
    
     DESCRIPTION OF THE INVENTION 
     In the figures, like reference numerals depict like elements. 
       FIG. 1  shows a 3D view of a system  2  for thermal treatment of rails according to a possible embodiment of the invention. In this embodiment, the system comprises a plurality of cooling means  4  defining a cooling path through which a rail  6  is moved forward. 
     In operation, and as can be seen on  FIGS. 1-3,6 and 8 , the cooling means are spraying a cooling medium  8  onto the rail for cooling a specific part of the rail, head or feet for example. 
     Each cooling means  4  is secured to a cooling support or ramp  10 . In the embodiment of  FIG. 1 , each cooling support has a C shape and carries three cooling means angularly spaced apart, for example by 90°. Each cooling support  10  and its respective cooling means form what it called a cooling module  5 . In the embodiment of the figures, a cooling module  5  comprises three cooling means  4  located in such a way to spray the cooling medium  8  on the top of the rail head and on each side of said head. 
     Furthermore, in the embodiment shown in  FIG. 1 , the system according to the invention comprises four cooling modules, but the number of cooling modules can be adapted depending on the rail to be treated. 
     It has also to be noted that for sake of clarity references have been added on  FIG. 1  mainly only in relation with one cooling module, on the right hand side of the figure. Of course a reference used for one given element of this cooling module also applies for any similar element of any other three cooling modules shown in  FIG. 1 . 
     In the working position shown in  FIG. 1 , the system according to the invention comprises a plurality of cooling modules  5  aligned longitudinally to form the cooling path through which the rail is conducted. Each cooling module  5  overlooks the cooling path the rail is intended to follow. 
     Each cooling support or ramp  10  also supports feeding pipes  12  to which the cooling means are connected. For this purpose, a plurality of maintaining flanges  14  (see  FIGS. 2-4 ) defining passages receiving said pipes  12  are secured to each cooling support  10  by means of blocking flanges  16  screwed in said cooling supports or ramps  10 . 
     The assembly comprising all feeding pipes linking the cooling modules  5  and the cooling modules themselves forms an integral cooling block  3 . As will be explained latter, such a cooling block as above defined is rigid enough to be replaced at once by another cooling block able to spray a different cooling medium onto the rail, and this without using additional lifting tool. 
     The system according to the invention also comprises conveying means to displace the rail to be treated within the cooling path. In the embodiment shown in the figures, the conveying means comprise a plurality of rollers  7  on which rail  6  lies. Each roller has its rotation axis perpendicular to the rail cooling path. The rollers  7  can be driven by one or a plurality of motors. 
     The system according to the invention further comprises means to displace vertically each cooling means  4  and each cooling support  10 , and in a preferred embodiment only the cooling means located above the cooling path or above the conveying means during operation of the system. These displacing means comprise a plurality of supporting arms  18 . Each supporting arm  18  is releasably secured to a cooling support  10  by means of securing means. In the embodiment of the figures, the securing means comprise securing screws  19  received in passages defined in each supporting arm  18  and in each cooling support  10 . Each supporting arm  18  comprises at one of its extremities a flange  25  receiving a horizontal linking shaft  20 . This means that each supporting arm  18  is fixedly secured to said linking shaft. Furthermore, said liking shaft  20  extends parallel to the rail cooling path and connect the supporting arms  18  ones to the others. 
     The displacing means also comprise two horizontally spaced apart deformable parallelograms  22 ,  22 ′. One side  22   a ,  22   a ′ of each parallelogram being fixedly secured to a supporting structure  24 . Each deformable parallelogram  22 , 22 ′ extends in a plane perpendicular to the rail cooling path. Two linking beams  26  extend horizontally between mobile vertical sides  22   b  and  22   b ′ (parallel to fix sides  22   a  and  22   b ) of each deformable parallelogram in order to fixedly secured them together. Each mobile vertical side  22   b , 22   b ′ is fixedly secured to a bearing  32  (called parallelogram&#39;s bearing for sake of clarity) which also receives linking shaft  20 . 
     The vertical displacing means also comprise a driving actuator intended to displace the parallelograms. In one embodiment, this driving actuator is a screw jack  28  driven by a motor  30 . The screw jack  28  is secured to one of the horizontal linking beam  26 . 
     Actuation of the screw jack  28  provokes a vertical translation of mobile parallelogram vertical sides  22   b  and  22   b ′ of each deformable parallelogram  22  and  22 ′, which in turn vertically translate horizontal linking shaft  20 , supporting arms  18  and cooling supports or ramps  10  with the cooling means  4  and the feeding pipes  12 . 
       FIG. 2  shows a situation wherein the system according to the invention is in a raised working position to treat a first type of rail  6 . 
       FIG. 3  is view similar to  FIG. 2  wherein the system according to the invention is in a lowered working position to treat a second different type of rail  6 . Two types of rail  6  with different height are represented in this figure to illustrate difference of vertical level that can be achieved with the invention. As an example, the system of the invention can vertically translate the cooling means by at least 75 mm 
     The system according to the invention also comprises optional means to retract the cooling means  4 . These retracted means may comprise a horizontal retracting jack or cylinder  34 . Cylinder  34  is secured to the horizontal linking shaft  20  by means of a retracting arm  36  fixedly secured to the horizontal linking shaft  20  by means of a flange. Said cylinder  34  is carried by and secured to a platform  38 , said platform being in turn secured the upper linking beam  26 . 
     When actuated, the retracting cylinder  34  pulls retracting arm  36  which in turn rotates the horizontal linking shaft  20 . The horizontal shaft  20  rotates in and relative to parallelogram&#39;s bearing  32 . This rotation also drives supporting arms  18 , and all the cooling modules  5 . 
     The retracting means can reversibly rotate the cooling modules  5  from a working position shown in  FIGS. 2 and 3 , wherein the cooling means  4  are located above the conveying means  7 , to a non-working position or tilted position shown in  FIG. 4  wherein each cooling means is located beside the conveying means, thus allowing an easy access to the cooling means  4  for maintenance operators. 
     As previously mentioned, different type of cooling means can be used in the system  2  according to the invention, depending of the type of rails to be treated and the expected results. For example, the cooling means of a cooling block can be nozzles spraying water and air or can be air blades. More precisely and as can be seen on  FIG. 8 , a cooling block can comprise a plurality of cooling supports  10  supporting nozzles  8  spraying water and air or a plurality of cooling support  10 ′ supporting air blades  8 ′ spraying only air. 
     The system according to the invention is therefore designed such that a complete cooling block as above defined can be quickly (substitution can be made in ¼ of hour) exchanged with another type of block. For this purpose, the connection of each cooling block are standardised to correspond to the connection point with the supporting arms  18  and the distance between the cooling support  10  of each type of cooling block is the same than the distance between the supporting arms  18 . 
     The system  2  according to the invention also comprises a cables chain  40  (see  FIG. 6 ) which hosts, guide and supports the flexible hoses  12  feeding each cooling block. In the context of this description a cables chain is an assembly comprising a guide/support for flexible hoses. The system according to the invention is provided in one embodiment with two sorts of feeding pipes  12 , water and air, both are fed by the same cables chain. 
     Both types of above mentioned cooling blocks have the same kind of connections with the cables chain  40  and with the supporting arms  18 . This allows easy and quick interchanges between cooling blocks, which in turn allows an improved flexibility as rail with different steel grades and different metallurgical characteristics can thus be obtained. 
     The pipe chain  40  is designed in order to accommodate both pipes necessary for air/water type cooling blocks and air blade type cooling blocks in order to allow fast change of the cooling support from water/air type to air blade type and vice versa. The use of flexible feeding pipes allows the vertical adjustment and the tilting of the cooling blocks. This can be seen in  FIG. 6  where two different positions of the cables chain  40  are shown, one position in continuous line, and the other one in dotted line. The pipes for these two types of cooling blocks  3  are different, but their connection means with the pipe chain  40  are similar. When the feeding pipes of the air blade type cooling block are connected to the pipe chain  40 , the air pipes are used at a low percentage of their capacity, given the section of the pipe. 
     The standardised connection between the different types of cooling blocks and the rest of the system allows a substitution in for example ¼ of hours. This also allows complete flexibility of the system. 
     The system according to the invention also comprises means to guide the rail during the thermal treatment. These guiding means comprise a plurality of guiding shaft, each shaft receiving a guiding wheel. Each guiding shaft is further secured to a cylinder. Actuation of the cylinder provokes the rotation of the guiding shaft which in turns rotates its corresponding guiding wheel toward or away from the rail. 
     In the embodiment shown in  FIGS. 5 a  and 5 b   , guiding shaft  42  is linked to its corresponding cylinder  46 , 46 ′ by means of a lever  45 , 45 ′. Each lever  45   45 ′ has a C shape and is angled at 45° relative to a horizontal plane. Each lever  45 , 45 ′ is received in a bearing  47  fixedly secured to the supporting structure  24 . Actuation of cylinder  46 , 46 ′ provokes rotation of lever  45 , 45 ′ which in turn rotates guiding shaft  42 , 42 ′ and guiding wheel  44  around the inclined axis of the bearing  47 . Furthermore, rotation of the lever  45 , 45 ′ about said inclined axis, also allows the opening of the guiding means in case of a severally bended rail without damaging to the system according to the invention (both the guiding means and the cooling system). 
     Each guiding wheel  44  is idler (free to rotate about shaft  42 , 42 ′) and is divided in a first  44   a ,  44   a ′ and a second  44   b , 44   b ′ half-wheel. Each half-wheel  44   a ,  44   a ′, 44   b , 44   b ′ is free to rotate relative to its other corresponding half-wheel and free to rotate about its guiding shaft  42 ,  42 ′. 
     Each guiding wheel  44 ,  44 ′ has a profile designed such that to be in contact with the upper part of the foot and with the web which are the less critical parts of the rails. Furthermore, during the thermal treatment, the rail has a constant speed, therefore the two points of contact of the rail and each wheel  44 ,  44 ′ have the same tangential speed but may be located at a different distance from the centre of the corresponding wheel. This means a different radius and therefore different angular speed for the two wheels  44 , 44 ′, and therefore undesirable friction points. This difference of speed problem is solved by the fact that each half wheel  44   a , 44   b , 44   a ′, 44   b  is free to rotate one relative to the other about the axis of the guiding wheel. 
     Cylinder  46 , 46 ′ is provided to adapt the position of each guiding wheel  44 ,  44 ′ to different rail profiles by rotating said wheel  44 ,  44 ′ such that they contact the rail. In this manner, guiding wheels  44 ,  44 ′ guide the rail vertically and horizontally, via the contacting points between the guiding wheel and the rail. 
     Furthermore, the fact that each guiding wheel contacts the rail on the upper part of the foot avoid any deviation of the rail in the vertical direction and the fact that the each guiding wheel contact the rail at the web avoid any deviation of the rail in the horizontal. In this manner the rail is guided and kept in correct position during the thermal treatment and all kinds of bending are prevented. 
     As can be seen in  FIG. 5 a    a pairs of assembly each comprising a wheel  44 ,  44 ′ a guiding shaft  42 , 42 ′ and a cylinder  46 , 46 ′ can be located in a plane perpendicular to the rail path. In a preferred embodiment, in operation, and in case of symmetrical rail, each assembly is symmetrically located relative to the other and relative to the vertical median plane of the rail. 
       FIGS. 7 a -7 f    show the type of guiding wheels  44 , 44 ′, 44 ″ and  44 ′″ used for rails of different shapes. As this can be seen on  FIGS. 7 a  to 7 d    the same type of guiding wheels or rolls are used on both sides of the rail when the rail is symmetrical. In case of an asymmetrical rail, as this is represented on  FIGS. 7 e  and 7 f   , the geometry of the guiding wheels is such that each guiding wheel is in contact with the lowest critical parts of the rails, the upper part of the foot and the web. In the latter situation different kinds of guiding wheels with different geometries are used on each side of the rail. 
     It has to be noted that even though the guiding means are presented in the present description in relation with rail technology, they can be used in all kinds of application where guiding with different angular speeds is needed. 
     Furthermore, the system according to the invention is equipped with a suction means comprising an overall movable hood  48  (see  FIGS. 1 and 8 ) for reduction of pollution in the area. The hood  48  is tiltable by means of cylinder  50  in order to allow the tilting of the cooling supports  10 . 
     As above shown, the vertical translation implemented via the parallelograms  22 ,  22 ′ allows a pure vertical movement of the cooling support that will always correctly fit the horizontal distance of the spray system from the head of the rail thus allowing a uniform and symmetrical cooling of the head of the rail for each type of rail (different standards, symmetrical/asymmetrical). 
     The introduction of completely compatible water/air type ramp and air type ramp allows a reliable and flexible system that can easily fit the different needs of different production lots and different customers. 
     The rail guiding means are in contact with the rail at the less important portions of the rail and are capable of restraining the rail both vertically (against rail bending) and horizontally (against asymmetrical rail bending and rail fluctuation on the conveying means). 
     The rail guiding means also keep the head of the rail in the predefined position to maximize the uniformity of the hardening treatment. 
     The guiding means are adaptable to each type of rail (different standards, symmetrical/asymmetrical) with two profiles only of guiding rolls or wheels (thus allowing low changing operation time and few spares parts). Only for the asymmetrical rail the change of guiding wheel is needed. 
     The rail guiding system is mechanically self-centring the head of symmetrical rails in the predefined position; therefore no manual or electronic regulation is needed. 
     The oblique wheels of the rail guiding means are divided into two halves that can rotate independently in order to avoid friction due to the difference of tangential speed of the contact points. 
     The tilting of the cooling means is designed in order to position the spraying system (both water/air nozzle and air blades) at a height easily accessible by maintenance operators. 
     All the operations (vertical regulation of the ramps, opening/closing of the tilting system for the ramps, opening/closing of the overhead hood) are automatically operated in order to achieve the fastest and more reliable operation and the lowest possible manual intervention by Operation &amp; Maintenance operators.