A method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation

Abstract

This invention discloses a method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation, belonging to the field of rail transit technology. The method includes: acquiring track data; determining the spatial position adjustment amount of the track slab based on the track data; releasing the limiting device of the track slab; lifting the track slab to separate it from the filling layer on the base; removing a portion of the filling layer on both sides of the base; spraying an interface agent onto the remaining unremoved filling layer on the base; inserting a mesh between the base and the track slab, covering the unremoved filling layer; adjusting the height of the track slab according to the spatial position adjustment amount; sealing the edges of the track slab; and injecting grouting material between the base and the track slab. This invention eliminates the need to completely remove the existing filling layer; it only requires removing a certain range of mortar on both sides of the existing filling layer, then sealing and injecting grouting material to completely encapsulate the existing filling layer, forming a unified whole that shares the load.

Description

Technical Field

[0001] This invention relates to the field of rail transit, specifically to a method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation. Background Technology

[0002] Slab track structures are the main structural form used in high-speed railway construction, primarily including CRTS I, II, and III types. From bottom to top, they consist of a concrete base slab, a filler layer, precast track slabs, fasteners, and rails. The filler layer is a crucial structural layer, bearing functions such as adjustment, support, and force transmission; its performance directly affects the overall track structure performance. However, changes in the substructure can cause track irregularities, or the filler layer itself can deteriorate, necessitating replacement to adjust track smoothness or to replace severely deteriorated fillers.

[0003] Because high-speed railway maintenance can only be carried out during designated maintenance windows (generally only 4 hours), and due to limited track access conditions (only small access doors are allowed, preventing large equipment from being used), and because most high-speed railways are elevated, reaching maintenance work sites requires access via regularly spaced access doors and stairs. The large number of tools involved further wastes time traveling to and from the work site and moving various tools, impacting the efficiency of maintenance work on operating high-speed railways. Given the limited maintenance windows, current maintenance techniques involve raising the track slab, removing the entire filling layer, and then re-filling it. This process is complex, difficult, and labor-intensive. Therefore, finding a way to quickly and safely adjust and maintain the filling layer of slab track within maintenance windows is a pressing issue that needs to be addressed.

[0004] The existing technical means and methods are as follows:

[0005] (1) The invention patent "A method for quick replacement of slab track plates for ballastless track (CN106948228B)" involves lifting the rails on the track plate to be replaced to a certain height, using a jack to lift the track plate, then using a track plate translation device to move the track plate out of the rail range and place it on a pallet. A hoisting device is then used to remove the track plate to be replaced, and a new track plate is placed on the pallet and moved into place in the original track plate position. Finally, the track plate's limiting position and the bonding between the track plate and the filling layer are restored. However, the process involved is very complex. The mortar layer needs to be completely removed, which cannot be completed within a single track window, especially when train operation schedules result in less than 4 hours of available track window time, making it impossible to complete the entire process. Furthermore, no reliable transition plan is provided to ensure that the track can be temporarily restored if the process is not completed, thus not affecting the punctual operation of trains the following day.

[0006] (2) The invention patent “A Repair Method for CRTSⅡ Type Slab Track Base Plate” (CN106436492A) mainly includes the following steps: track plate reinforcement and anchoring, rail sawing, wide joint cutting, track plate removal, removal of filling layer mortar, laying transition sleepers, base plate defect repair, track plate laying, filling layer mortar injection, track plate longitudinal bonding, wide joint injection, rail welding fine adjustment, and track restoration. However, it also requires cutting the rails, which increases the number of procedures and causes damage to the rails during subsequent rail welding. In addition, the patent also requires the complete removal of the filling layer, which is complex and cannot be completed within one track window. Furthermore, it does not provide a reliable transition plan for when the track is not completed, so as to ensure that the line can still be opened the next day. Summary of the Invention

[0007] The purpose of this invention is to provide a method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railways, which can complete the maintenance without completely removing the entire existing filling layer.

[0008] To solve the above-mentioned technical problems, the present invention provides a method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation, comprising the following steps:

[0009] Acquire orbital data;

[0010] Based on the track data, the spatial position adjustment amount of the track slab is obtained;

[0011] Release the limiting device on the track slab;

[0012] Lift the track slab to separate it from the filling layer on the base;

[0013] A portion of the filling layer on each side of the base was removed.

[0014] Spray an interface agent onto the remaining unremoved fill layer on the base;

[0015] Insert a mesh between the base and the track plate, and cover the unremoved filling layer;

[0016] Adjust the height of the track slab according to the spatial position adjustment amount;

[0017] The two sides of the track slab are sealed, and grouting material is injected between the base and the track slab. After the grouting material cures, it is bonded to the base, track slab, unremoved filling layer and mesh as a whole.

[0018] Restore the limit device of the track slab.

[0019] Preferably, the spatial position adjustment amount of the track slab is obtained based on the track data, specifically including the following steps:

[0020] Based on the track data and preset positions, the spatial position adjustment amount of the track slab is calculated.

[0021] Preferably, the spatial position adjustment of the track slab includes a height adjustment and a horizontal adjustment.

[0022] Preferably, a mesh is inserted between the base and the track plate, covering the unremoved filling layer, specifically including the following steps:

[0023] Insert a mesh between the base and the track plate, with the mesh directly above the unremoved filling layer. Raise the mesh by pads to a height of more than 5mm above the unremoved filling layer, and then bend both sides of the mesh downwards into a hook shape.

[0024] Preferably, the bending length on both sides of the mesh is not less than 3cm and the bending angle is not less than 90 degrees;

[0025] The mesh size of the mesh sheet is not less than 5mm; the diameter of the mesh sheet is not less than 1mm; the length of the mesh sheet is the same as that of the track slab, and the width is not less than the width of the track slab.

[0026] The surface of the mesh may be provided with spikes;

[0027] The mesh is woven or welded.

[0028] Preferably, the track slab is lifted to separate it from the filling layer on the base, specifically including the following steps:

[0029] The track slab is lifted by the steel rails on the track slab, so that the track slab is separated from the filling layer on the base, and the lifting height does not exceed 10cm.

[0030] Preferably, the grouting material is polymer mortar or a high molecular polymer material.

[0031] Preferably, the grouting material has an expansion of not less than 260 mm, a setting time of not more than 40 min, and a bonding strength of not less than 1 MPa.

[0032] Preferably, the interface agent is a polymer emulsion or epoxy, and the dosage is not less than 200 g / m³. 2 .

[0033] Preferably, the width of the chiseling range on both sides of the filling layer on the base is not more than 130cm and not less than 3cm, and the strength of the mortar chiseled on the outer side is not less than 1MPa and there are no cracks.

[0034] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0035] (1) It is not necessary to completely remove the entire existing filling layer. Only a certain range of local mortar on both sides of the existing filling layer needs to be removed, and then the edges are sealed and grouted to wrap the existing filling layer as a whole, forming a whole and bearing the load together.

[0036] (2) By laying mesh and applying interface material, the adhesion between the new grouting material and the existing filling layer is enhanced. This not only reduces the workload and greatly improves the efficiency and quality of adjustment and maintenance of the filling layer of the slab track of high-speed railway, but also ensures that the line can be opened on time when the maintenance window ends. Attached Figure Description

[0037] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0038] Figure 1 This is a flowchart illustrating a method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to the present invention.

[0039] Figure 2 It is a schematic diagram of the plan of removing the existing filling layer within a certain range on both sides;

[0040] Figure 3 It is a schematic diagram of the cross-section of the existing filling layer within a certain range on both sides after it has been removed;

[0041] Figure 4 This is a diagram illustrating how the two sides of the mesh are folded into hook shapes;

[0042] Figure 5 This is a schematic diagram showing the newly poured material being consolidated into a single unit with the existing filling layer and mesh.

[0043] Figure 6 This is a schematic diagram of the mesh.

[0044] Figure 7 This is a schematic diagram of the barbed wire mesh.

[0045] in:

[0046] 1. Rail; 2. Track slab; 3. Unremoved filling layer; 4. Base; 5. Removed filling layer; 6. Mesh; 7. Spikes. Detailed Implementation

[0047] Numerous specific details are set forth in the following description to provide a full understanding of the invention. However, the invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0048] The terminology used in one or more embodiments of this specification is for the purpose of describing particular embodiments only and is not intended to be limiting of the one or more embodiments of this specification. The singular forms “a,” “described,” and “the” as used in one or more embodiments of this specification and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in one or more embodiments of this specification refers to and includes any or all possible combinations of one or more associated listed items.

[0049] It should be understood that although the terms first, second, etc., may be used to describe various information in one or more embodiments of this specification, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, first may also be referred to as second without departing from the scope of one or more embodiments of this specification, and similarly, second may also be referred to as first. Depending on the context, the word "if" as used herein may be interpreted as "when," "when," or "in response to a determination."

[0050] The following is in conjunction with the appendix Figure 1-7 The present invention will be described in further detail as follows:

[0051] like Figure 1 As shown, the present invention provides a method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation, comprising the following steps:

[0052] Acquire orbital data;

[0053] Based on the track data, the spatial position adjustment amount of track slab 2 is obtained;

[0054] Release the limiting device of track slab 2;

[0055] Lift the track plate 2 to separate the track plate 2 from the filling layer on the base 4;

[0056] A portion of the filling layer on both sides of the base 4 was removed.

[0057] Spray an interface agent onto the remaining unremoved filling layer 3 on the base 4;

[0058] A mesh 6 is inserted between the base 4 and the track plate 2, and the mesh 6 covers the unremoved filling layer 3.

[0059] Adjust the height of track 2 according to the spatial position adjustment amount;

[0060] Seal the edges of both sides of the track slab 2, and inject grouting material between the base 4 and the track slab 2; after the grouting material has cured, it is solidified into a whole with the base 4, the track slab 2, the unremoved filling layer 3 and the mesh 6.

[0061] Preferably, the spatial position adjustment amount of track slab 2 is obtained based on track data; specifically, this includes the following steps:

[0062] Based on the track data and preset position, the spatial position adjustment amount of track slab 2 is calculated.

[0063] Preferably, a mesh 6 is inserted between the base 4 and the track plate 2, and the mesh 6 covers the filling layer, specifically including the following steps:

[0064] Insert the mesh 6 between the base 4 and the track plate 2. The mesh 6 is located directly above the unremoved filling layer 3. The mesh 6 is raised by the pad block to be more than 5mm higher than the unremoved filling layer 3. Then, bend the two sides of the mesh 6 downward into a hook shape.

[0065] Preferably, the bending length on both sides of the mesh 6 is not less than 3cm, and the bending angle is not less than 90 degrees.

[0066] Preferably, the mesh size of the mesh 6 is not less than 5mm, the diameter is not less than 1mm, the length is the same as that of the track plate 2, and the width is not less than the width of the track plate 2.

[0067] Preferably, the surface of the mesh 6 may be provided with spikes 7 or raised dots.

[0068] Preferably, the mesh 6 is woven or welded.

[0069] Preferably, lifting the track plate 2 to separate the track plate 2 from the filling layer on the base 4 specifically includes the following steps:

[0070] The track slab 2 is lifted by the steel rail 1 on the track slab 2, so that the track slab 2 is separated from the filling layer on the base 4, and the lifting height does not exceed 10cm.

[0071] Preferably, the grouting material is polymer mortar or a high molecular polymer material.

[0072] Preferably, the grouting material has an expansion of not less than 260 mm, a setting time of not more than 40 min, a strength of 1 MPa in 1 hour, a bond strength of not less than 1 MPa, an elastic modulus close to that of the original filling layer and a strength more than 1 MPa higher than that of the original filling layer.

[0073] Preferably, the spatial position adjustment of the track slab 2 includes a height adjustment and a horizontal adjustment.

[0074] Preferably, the interface agent is a polymer emulsion or epoxy, and the dosage is not less than 200 g / m³. 2 .

[0075] Preferably, the width of the chiseling range on both sides of the filling layer on the base 4 is not more than 130cm and not less than 3cm, and the strength of the chiseled mortar on the outer side is not less than 1MPa and there are no cracks.

[0076] This invention eliminates the need to completely remove the existing filling layer, requiring only the removal of local mortar within a certain range on both sides. This significantly reduces workload and greatly improves the efficiency and quality of adjusting and maintaining the filling layer of high-speed rail slab track. By laying mesh 6, applying interface agent, and then sealing the edges before grouting, the unremoved filling layer 3 is completely wrapped, ensuring the adhesion between the grouting material and the unremoved filling layer 3, which is conducive to forming a whole and sharing the load.

[0077] To better illustrate the technical effects of the present invention, the present invention provides the following specific embodiments to illustrate the above technical process:

[0078] Example 1:

[0079] A high-speed railway line has experienced subsidence exceeding the adjustment range of the fastening system, necessitating the raising of the CRTSⅡ type track slab 2 filling layer 3. Figure 2 As shown. The construction process for rapid adjustment and repair of the filling layer using this invention is as follows: Figure 1 As shown, the specific steps include:

[0080] (1) Location data collection, determine the spatial position adjustment of track slab 2, elevation +3cm, plane shift 1cm to the left.

[0081] (2) Remove the structural limiting devices such as lateral blocks, wide joints, and existing rebars that affect the lifting of track slab 2.

[0082] (3) Raise rail 1 and lift track slab 2 to a certain height:

[0083] Loosen the track slab 2 corresponding to the filling layer 3 to be replaced and the fasteners within a certain range before and after it. The loosening length of the fasteners should be determined in combination with the construction temperature, the locking temperature of the rail 1 and the maximum lifting height. Use a track lifter to lift the track slab 2 and separate it from the existing filling layer, forming a 5cm high construction space under the slab, which is convenient for cleaning the existing filling layer under the slab.

[0084] (4) Remove a certain area on both sides of the existing filling layer: After the track slab 2 is lifted and fixed, use tools such as electric picks, blowers, grinders, and milling machines to remove 50cm on each side of the filling layer under the track slab 2, forming an unremoved filling layer 3 and a removed filling layer 5, and clean up dust, debris, etc. Figure 3 As shown;

[0085] (5) Spraying interface agent: Spray the interface agent evenly on the surface of the filling layer 3 that has not been removed by inserting the nozzle.

[0086] (6) Prepare in advance 6 pieces of woven or welded wire mesh with a mesh size of 5cm, a diameter of 3mm, a total length of 645cm, and a width of 255cm-5cm-5cm+5cm+5cm. Figure 6 As shown; the mesh 6 has barbs 7, each barb 5mm long and 2mm in diameter, spaced 3cm apart, arranged in a plum blossom pattern, with the tips being 5mm in diameter spheres. The barbs 7 on the mesh 6 are arranged alternately with their orientations alternating upwards and downwards, meaning adjacent barbs 7 face opposite directions. Figure 7 As shown; the mesh 6 is inserted between the track slab 2 and the existing unremoved filling layer 3. Using spacers, the mesh 6 is raised to 15mm higher than the existing filling layer 3. The mesh 6 is then bent into hooks 5cm on each side to strengthen the connection between the newly poured material and the existing unremoved filling layer 3, ensuring they share the load and preventing the newly poured material from breaking and leaking out. Figure 4 As shown; the track plate 2 is finely adjusted and pressed to the limit simultaneously according to the spatial position adjustment amount of the track plate 2.

[0087] The mesh 6 is made of metal or plastic, and its surface is provided with spikes 7 or raised dots to enhance the adhesion between the mesh 6 and the newly poured material.

[0088] (7) Seal the edges of both sides of the track plate 2 and leave vent holes. Pour in grouting material that cures quickly. The grouting material is polymer mortar or high molecular polymer material with an expansion of not less than 260 mm, a setting time of not more than 40 min, and a strength of 1 MPa in 1 hour. The bonding strength is not less than 1 MPa, the elastic modulus is close to that of the original filling layer and the strength is more than 1 MPa higher than that of the original filling layer.

[0089] (8) The grouting material solidifies rapidly, and the newly poured material, together with the unremoved filling layer 3 and mesh 6, forms a unified whole, such as Figure 5 As shown, the old and new materials share the load.

[0090] In the several embodiments provided by this invention, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For instance, the division of modules, units, or units is merely a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units, modules, or components may be combined or integrated into another device, or some features may be ignored or not executed.

[0091] The units may or may not be physically separate. The components shown as units can be one or more physical units, meaning they can be located in one place or distributed in multiple different locations. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0092] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions within the technical scope disclosed in the present invention should be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation, characterized in that, Includes the following steps: Acquire orbital data; Based on the track data, the spatial position adjustment amount of the track slab is obtained; Release the limiting device on the track slab; Lift the track slab to separate it from the filling layer on the base; A portion of the filling layer on each side of the base was removed. Spray an interface agent onto the remaining unremoved fill layer on the base; Insert a mesh between the base and the track plate. The mesh is located directly above the unremoved filling layer. The mesh is raised by pads to be more than 5mm higher than the unremoved filling layer. Then, bend the mesh downwards on both sides to cover the unremoved filling layer. Adjust the height of the track slab according to the spatial position adjustment amount; The two sides of the track slab are sealed, and grouting material is injected between the base and the track slab. After the grouting material cures, it is bonded to the base, track slab, unremoved filling layer and mesh as a whole. Restore the limit device of the track slab; The grouting material has an expansion of not less than 260 mm, a setting time of not more than 40 min, and a bonding strength of not less than 1 MPa.

2. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 1, characterized in that, Based on the position data of the track slab, the spatial position adjustment amount of the track slab is obtained; specifically, the following steps are included: Based on the track data and preset positions, the spatial position adjustment amount of the track slab is calculated.

3. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 2, characterized in that: The spatial position adjustment of the track slab includes height adjustment and horizontal adjustment.

4. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 3, characterized in that: The bending length on both sides of the mesh is not less than 3cm, and the bending angle is not less than 90 degrees; The mesh size of the mesh sheet is not less than 5mm; the diameter of the mesh sheet is not less than 1mm; the length of the mesh sheet is the same as that of the track slab, and the width is not less than the width of the track slab. The surface of the mesh is provided with spikes; The mesh is woven or welded.

5. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 1, characterized in that, Lifting the track slab to separate it from the filling layer on the base involves the following steps: The track slab is lifted by the steel rails on the track slab, so that the track slab is separated from the filling layer on the base, and the lifting height does not exceed 10cm.

6. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 1, characterized in that: The grouting material is polymer mortar or high molecular polymer material.

7. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 1, characterized in that: The interface agent is a polymer emulsion or epoxy, and the dosage is not less than 200 g / m³. 2 .

8. The method for rapid adjustment and maintenance of the filling layer of slab track for high-speed railway operation according to claim 1, characterized in that: The width of the removal area on both sides of the filling layer on the base shall not exceed 130cm and shall not be less than 3cm.

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