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US 7,253,380 B2Granted
Induction heating of rail welds
AssigneeHolland Company
InventorRichard Miller
Life of this patent
Estimating the term…
Abstract
An apparatus (10) and method for preheating welds uses a centered induction plate (12) having preferably a plurality of induction coils (30, 32) to impart the generation of heat in the materials to be welded (14), being interactively controlled by at least a temperature sensor (90, 92) and power supply control loop (16) so that even preheating can be obtained for a selected length of time given the parameters of the weld desired.
Claims31
A self contained system for preheating and welding a gap in a railroad rail comprising:
- a weld delivery apparatus and power supply;
- a tool having first and second opposing sides, and disposed in a gap defined by first and second facing ends of the gap in the railroad rail, the tool further including mechanical centering assemblies disposed adjacent the facing ends of the gap in the railroad rail, wherein the mechanical centering assemblies position the tool longitudinally with respect to the railroad rails for proper proximity to the gap in the railroad rail;
- a first induction heating element affixed to the first side of the tool and disposed proximate the first and second railroad rails;
- a first heating zone defined by a first temperature sensor positioned proximate the first end of the gap in the railroad rail and the first heating element;
- a second induction heating element affixed to the second side of the tool and disposed proximate the first and second ends;
- a second heating zone defined by a second temperature sensor positioned proximate the second end of the gap in the railroad rail and the second heating element;
- a controller coupled to the first and second temperature sensors, the controller activating the first and second heating elements independently to achieve a preheating welding temperature in both first and second heating zones, said preheating temperature being controlled to be less than the melting point of the rail;
- and
- welding means for welding the railroad rails by filling the gap with weld material;
- said welding means comprising arc welding in which the energy used in welding can be sensed thereby providing feedback to said controller;
- said controller using said feedback to adjust said first temperature and said second temperature;
- said power supply providing energy for continuous operation of said first and second heating elements and welding means.
9 more elements
A system for preheating and welding first and second railroad rails to be welded together comprising:
- a tool disposed in a gap defined by facing ends of the railroad rails, the tool further including mechanical centering assemblies disposed adjacent the facing ends of the railroad rails, wherein the mechanical centering assemblies position the tool longitudinally with respect to the railroad rails for proper proximity to the railroad rails;
- an induction heating element affixed to the tool and disposed proximate the first and second railroad rails;
- a heating zone defined by a temperature sensor positioned proximate the first railroad rail and the heating element;
- a controller coupled to the temperature sensor, the controller activating the heating element to achieve a preheating welding temperature in the heating zone;
- and
- at least one of an arc welding means or thermite welding means for welding the railroad rails by filling the gap between the railroad rails with weld material;
- said controller working in conjunction with feedback transmitted between said temperature sensor and said at least one of the arc welding means and the thermite welding means.
4 more elements
A system for preheating and welding first and second railroad rails to be welded together comprising:
- a tool disposed in a gap defined by facing ends of the railroad rails, the tool further including mechanical centering assemblies disposed adjacent the facing ends of the railroad rails, wherein the mechanical centering assemblies position the tool longitudinally with respect to the railroad rails for proper proximity to the railroad rails;
- a plurality of induction heating elements affixed to the tool and disposed proximate the first and second railroad rails;
- as plurality of heating zones defined by multiple temperature sensors positioned proximate the first railroad rail and the heating elements;
- a controller coupled to the temperature sensors, the controller activating the heating elements to achieve a preheating welding temperature in the heating zones;
- and
- a welder providing weld material filling the gap between the railroad rails;
- said preheating welding temperature being below the melting point of said rails;
- said controller processing feedback between said sensors and welder.
5 more elements
A system for preheating and welding first and second railroad rails to be welded together comprising:
- mounting means having first and second opposing sides, and disposed in a gap defined by facing ends of the railroad rails, wherein the mounting means further includes mechanical centering assemblies disposed adjacent the facing ends of the railroad rails, wherein the mechanical centering assemblies position the mounting means longitudinally with respect to the railroad rails for proper proximity to the railroad rails;
- a first induction heating means affixed to the first side of the mounting means and disposed proximate the first and second railroad rails;
- a first heating zone defined by a first temperature sensing means positioned proximate the first railroad rail and the first heating means;
- a second induction heating means affixed to the second side of the mounting means and disposed proximate the first and second railroad rails;
- a second heating zone defined by a second temperature sensing means positioned proximate the first railroad rail and the second heating means;
- a controller means coupled to the first and second temperature sensing means, the controller means activating the first and second heating means independently to achieve a preheating welding temperature in both first and second heating zones;
- and
- a welder providing weld material filling the gap between the railroad rails to weld the rails;
- said welder and heating means being transported and powered by a self contained vehicle;
- said heating means being controlled by said controller means in conjunction with the operation of said welder.
7 more elements
A method for preheating and welding a railroad rail, the method comprising the steps of:
- (a) disposing, within a gap defined by first and second faces of at least a portion of a railroad rails, mounting means having first and second opposing sides;
- (b) providing mechanical centering assemblies disposed adjacent the first and second faces, wherein the mechanical centering assemblies position the mounting means longitudinally with respect to the railroad rails for proper proximity to the gap;
- (c) disposing a first induction heating means affixed to the first side of the mounting means proximate the first face;
- (d) defining a first heating zone by positioning a first temperature sensing means proximate the first face and the first heating means;
- (e) disposing a second induction heating means affixed to the second side of the mounting means proximate the first and second faces;
- (f) defining a second heating zone by positioning a second temperature sensing means proximate the second face and the second heating means;
- (g) activating the first and second heating means independently to achieve a predetermined preheat temperature in both first and second heating zones;
- and
- (h) welding the railroad rails by applying non-induction welding heat to the weld area;
- (i) providing weld material filling the gap between the faces to weld the rail;
- (j) providing power for both said non-induction welding heat and said first and second heating means being transported and powered by a self contained vehicle;
- (k) controlling said first and second heating means in conjunction with the operation of said non-induction welding heat.
9 more elements
Dependencies are inferred from the claim text.