A sleeper cast-in-place mold and a mounting and positioning method thereof

Abstract

The present application relates to the technical field of ballastless track, and particularly relates to a sleeper cast-in-place mold and a mounting and positioning method thereof, which comprises a fastener mounting plate and a mold shell, the mold shell has an inner cavity with the same shape and size as an existing sleeper block, a rail bearing groove part is arranged on the top surface of the mold shell, the fastener mounting plate is mounted in the rail bearing groove part, and the fastener mounting plate is matched with the fastener system of the existing sleeper block. The sleeper cast-in-place mold has simple structure, the inner cavity of the mold shell is designed according to the size of the existing sleeper block, one-time casting forming of a special complex high-precision special-shaped concrete structure can be realized, the fastener mounting plate is matched with the existing fastener system, the elevation and plane adjustment functions of the fastener system can be fully utilized to realize rapid mounting and positioning of the sleeper cast-in-place mold, rapid and accurate mounting and positioning and casting forming of the sleeper cast-in-place mold can be realized on the existing operating line, and then rapid repair of damaged sleepers and rapid treatment of deformed ballastless tracks can be realized.

Description

Technical Field

[0001] The present invention relates to the technical field of ballastless track, and in particular to a cast-in-situ sleeper mould and an installation and positioning method thereof, which are suitable for the maintenance of ballastless tracks in high-speed railways, passenger dedicated lines and urban rail transit projects. Background Art

[0002] During railway operations, ballastless track can be damaged and deformed due to various environmental conditions and human activities. When deformation or displacement of the ballastless track structure exceeds the adjustment limits of existing fasteners, this can affect the smoothness of the track, adversely impacting the smoothness, comfort, and safety of train operation, the lifespan of vehicles and track components, and environmental noise. In these cases, the damaged and deformed ballastless track requires repair.

[0003] High-speed railways can operate safely and smoothly at high speeds thanks to the high smoothness of ballastless track lines. As the direct foundation of the rails, sleepers are adjusted and controlled by a fastener system to ensure that the rail's geometric dimensions, height, and stress state meet the requirements of high-speed train operation. When the deformation of the ballastless track exceeds the adjustment amount of the fasteners, the existing sleepers can be removed and cast in place. Ballastless track sleepers are usually prefabricated in factories, requiring high geometric dimensions and precision control. The current technical challenges are how to achieve accurate and rapid installation and positioning of cast sleepers and the on-site casting of complex and special-shaped components. Summary of the Invention

[0004] In order to solve the above technical difficulties, the technical solution of the present invention is a cast-in-place mold for sleepers, including a fastener mounting plate and a mold shell, the mold shell has an inner cavity with the same shape and size as the existing sleeper block, the top surface of the mold shell is provided with a rail supporting groove part, the fastener mounting plate is installed in the rail supporting groove part, and the fastener mounting plate matches the fastener system of the existing sleeper block.

[0005] Furthermore, two sleeve holes are provided on the bottom surface of the rail support groove portion and the fastener mounting plate. The rail support groove portion corresponds one to one with the sleeve holes of the fastener mounting plate, and sleeves are installed in the corresponding sleeve holes above and below.

[0006] Furthermore, the mold shell is provided with a plurality of exhaust holes, and the diameter of the exhaust holes is 2 to 10 mm.

[0007] Furthermore, the top surface of the mold shell is also provided with two shoulder portions, and the two shoulder portions are respectively located on both sides of the support rail groove portion.

[0008] Furthermore, a pouring gate is provided on the shoulder portion.

[0009] The application further provides a positioning method for the sleeper cast-in-place mold.

[0010] S1, measuring and determining the vertical displacement and plane offset of the existing sleeper block corresponding to the ballastless track;

[0011] S2, marking the longitudinal position of the steel rail corresponding to the existing sleeper block, and chiseling the existing sleeper block;

[0012] S3, loosening the fastener system in the front and rear ranges of the construction area, lifting the steel rail to a certain height, and installing the sleeper cast-in-place mold into the space under the steel rail;

[0013] S4, installing and fixing the sleeper cast-in-place mold at the longitudinal position of the steel rail marked in step S2 by using the existing fastener system, taking the steel rail as the reference standard for the installation of the sleeper cast-in-place mold, and adjusting the vertical position and plane position of the sleeper cast-in-place mold relative to the steel rail according to the vertical displacement and plane offset measured in step S1;

[0014] S5, tightening the anchor bolts of the existing fastener system, fixing the sleeper cast-in-place mold on the steel rail, lowering the steel rail, and tightening the fastener system in the front and rear ranges of the construction area.

[0015] Further, in step S4, the vertical position of the sleeper cast-in-place mold relative to the steel rail is adjusted by adjusting the type and number of the rail micro-adjusting pad and the height-adjusting pad under the iron pad in the fastener system.

[0016] Further, in step S4, the plane position of the sleeper cast-in-place mold relative to the steel rail is adjusted by adjusting the type of the gauge baffle and the insulating block in the fastener system.

[0017] Further, in step S4, the height to which the steel rail is lifted is greater than the height of the sleeper cast-in-place mold.

[0018] Further, the vertical position and plane position of the steel rail should be measured and confirmed before formal pouring, and if changes occur, the pouring should be carried out after adjustment.

[0019] Compared with the prior art, the application has the following beneficial effects:

[0020] (1) The present application has simple structure, and the inner cavity of the formwork is designed according to the size of the existing sleeper block, so that the special complex high-precision special-shaped concrete structure can be formed by one-time pouring, the fastener mounting plate matches the existing fastener system, the sleeper cast-in-place formwork can be fixed relative to the rail by installing the existing fastener system, the elevation and plane adjustment functions of the fastener system can be fully utilized to realize the rapid installation and positioning of the sleeper cast-in-place formwork, the rapid and accurate installation and positioning of the sleeper cast-in-place formwork can be realized on the existing operating line, and then the rapid repair of the damaged sleeper and the rapid treatment of the deformed ballastless track can be realized.

[0021] (2) The installation and positioning method of the present application can quickly install and position the sleeper cast-in-place formwork, is convenient to install, simple to position, high in positioning accuracy, high in construction efficiency, and has little influence on the existing line operation. BRIEF DESCRIPTION OF DRAWINGS

[0022] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description only some embodiments of the present application, and for those skilled in the art, other drawings can be obtained without creative labor on the basis of these drawings.

[0023] Figure 1 The structure diagram of the sleeper cast-in-place formwork provided by the embodiments of the present application is shown in the figure.

[0024] In the figure: 1, fastener mounting plate; 2, formwork; 3, pouring port; 4, sleeve; 5, exhaust hole. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be described clearly and completely in the following with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0026] In the description of the present application, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore it cannot be understood as a limitation of the present application.

[0027] The terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, features specified as "first" or "second" may explicitly or implicitly include one or more of such features; and in the description of the present invention, unless otherwise specified, "plurality" means two or more.

[0028] Example 1

[0029] like Figure 1 As shown, this embodiment provides a cast-in-place mold for sleepers, comprising a fastener mounting plate 1 and a mold shell 2. The mold shell 2 has an inner cavity with the same shape and size as the existing sleeper block. The top surface of the mold shell 2 is provided with a rail-bearing groove portion. The fastener mounting plate 1 is installed in the rail-bearing groove portion, and the fastener mounting plate 1 matches the fastener system of the existing sleeper block. The cast-in-place mold for sleepers of this embodiment has a simple structure. The inner cavity of the mold shell 2 is designed according to the specifications and dimensions of the existing sleeper block, and can achieve one-time casting and molding of special, complex, high-precision special-shaped concrete structures. The fastener mounting plate 1 matches the existing fastener system, and can fix the cast-in-place mold for sleepers relative to the rails by installing the existing fastener system. At the same time, the elevation and plane adjustment functions of the fastener system can be fully utilized to achieve rapid installation and positioning of the cast-in-place mold for sleepers, and can achieve rapid and accurate installation, positioning and casting of the cast-in-place mold for sleepers on existing operating lines, thereby achieving rapid repair of damaged sleepers and rapid improvement of deformed ballastless tracks.

[0030] This embodiment allows for the selection or fabrication of a matching formwork 2 and fastener mounting plate 1 based on existing sleepers and fastener systems. Both the fastener mounting plate 1 and formwork 2 are constructed from high-strength mold steel or other materials and reinforced to withstand external forces during construction without deformation, ensuring excellent dimensional and structural stability. Specifically, the fastener mounting plate 1 and formwork 2 can be connected by welding or other fixed means.

[0031] Furthermore, two sleeve holes are provided on the bottom surface of the rail supporting groove part and the fastener mounting plate 1. The rail supporting groove part corresponds one-to-one to the sleeve holes of the fastener mounting plate 1, and sleeves 4 are installed in the corresponding sleeve holes above and below. The anchor bolts of the fastener system on both sides of the rail are respectively installed in the two sleeves 4.

[0032] Furthermore, the mold shell 2 is provided with a plurality of vent holes 5, each having a diameter of 2 to 10 mm. The specific number of vent holes 5 can be set as needed. Optimally, a plurality of vent holes 5 can be provided at intervals on the side of the mold shell 2 near the bottom of the support rail groove portion, a plurality of vent holes 5 can be provided at intervals on the top of the shoulder portion, and a plurality of vent holes 5 can be provided at intervals on the top surface of the end of the mold shell 2.

[0033] Further, the top surface of the formwork 2 is further provided with two shoulder portions, and the two shoulder portions are respectively located on the two sides of the rail groove portion. Further, the shoulder portion is provided with a pouring gate 3. Specifically, two ends of the formwork 2 can be provided with 2-3 pouring gates 3.

[0034] Specifically, the fastener mounting plate 1 includes a bottom plate provided on the bottom surface of the rail groove portion, and the bottom plate is bent downward at both ends to form a groove, and the side wall corresponding to the shoulder portion is bent upward to extend, and the sleeve hole is arranged on the bottom plate, and the bottom plate is thicker than other positions.

[0035] Embodiment two

[0036] The embodiment provides a mounting and positioning method of the sleeper cast-in-place form of the embodiment one, and the method comprises the following steps:

[0037] S1, measuring and determining the vertical displacement and plane offset of the existing sleeper block corresponding to the ballastless track;

[0038] S2, marking the longitudinal position of the rail corresponding to the existing sleeper block, and chiseling the existing sleeper block;

[0039] S3, loosening the fastener system in the front and rear ranges of the construction area, lifting the rail to a certain height, and loading the sleeper cast-in-place form into the space below the rail;

[0040] S4, installing and fixing the sleeper cast-in-place form at the longitudinal position of the rail marked in the step S2 by using the existing fastener system, fixing the two anchor bolts of the fastener system in the two sleeve pipes 4 of the sleeper cast-in-place form, and taking the rail as a reference standard for the installation of the sleeper cast-in-place form, adjusting the vertical position and plane position of the sleeper cast-in-place form relative to the rail according to the vertical displacement and plane offset measured in the step S1, so that the sleeper block formed by using the sleeper cast-in-place form meets the requirements of high-speed train operation and ensures the smoothness of the track line;

[0041] S5, after the vertical position and plane position of the sleeper cast-in-place form are determined, the anchor bolts of the existing fastener system are tightened by using a special torque wrench with a torque of 60kN, so that the sleeper cast-in-place form is firmly fixed on the rail, the rail is lowered back, and the fastener system in the front and rear ranges of the construction area is tightened, so that the vertical position and plane position of the rail remain unchanged.

[0042] The installation positioning method of the embodiment can quickly reposition the position of the sleeper cast-in-place mold according to the existing ballastless track deformation, is convenient to install, simple to position, high in positioning accuracy, high in construction efficiency, small in influence on the existing line operation, realizes high-precision and rapid casting of the double-block sleeper, solves the key technical problems of sleeper casting, can be applied to rapid repair of ballastless track deformation and sleeper damage, and can also be applied to repair construction of the CRTS II and III plate-type ballastless track track plate damage support platform.

[0043] Further, in step S4, the vertical position of the sleeper cast-in-place mold relative to the steel rail is quickly adjusted by adjusting the type and number of the rail-down fine adjustment pad and the iron pad height-down pad in the fastener system.

[0044] Further, in step S4, the planar position of the sleeper cast-in-place mold relative to the steel rail is quickly adjusted by adjusting the type of the gauge baffle and the insulating block in the fastener system.

[0045] Further, in step S4, the height of the steel rail is lifted to be greater than the height of the sleeper cast-in-place mold, and the specific height is accurate to ensure that the sleeper cast-in-place mold can pass through the rail-down gap and be installed under the steel rail, and the lifting height is generally about 10-15 cm.

[0046] Further, the vertical position and the planar position of the steel rail should be measured and confirmed before formal casting, and if changes occur, the fastener system needs to be adjusted in time before casting. Specifically, polymer mortar, concrete or epoxy mortar can be used for casting.

[0047] The above only describes the preferred embodiments of the present application and is not intended to limit the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application.

Claims

1. A method for installing and positioning a cast-in-place sleeper mold, characterized in that: The cast-in-place sleeper mold includes a fastener mounting plate and a mold shell. The mold shell has an inner cavity with the same shape and size as the existing sleeper block. The top surface of the mold shell is provided with a rail-bearing groove portion. The fastener mounting plate is installed in the rail-bearing groove portion, and the fastener mounting plate matches the fastener system of the existing sleeper block. The method includes the following steps: S1. Measure and determine the vertical displacement and plane offset of the ballastless track corresponding to the existing sleeper blocks; S2. Mark the longitudinal position of the rail corresponding to the existing sleeper block and chisel out the existing sleeper block; S3. Loosen the fastener systems in front and behind the construction area, raise the rails to a certain height, and install the cast-in-place sleeper molds under the rails through the gap under the rails; S4. Using the existing fastener system, fix the cast-in-place mold for the sleeper at the longitudinal position of the rail marked in step S2. At the same time, use the rail as a reference standard for the installation of the cast-in-place mold for the sleeper. According to the vertical displacement and planar offset measured in step S1, adjust the vertical position and planar position of the cast-in-place mold for the sleeper relative to the rail. S5. Tighten the anchor bolts of the existing fastener system, fix the cast-in-place mold of the sleeper on the rail, lower the rail, and tighten the fastener system in the front and rear areas of the construction area.

2. The installation and positioning method according to claim 1, wherein: Two sleeve holes are provided on the bottom surface of the rail supporting groove part and the fastener mounting plate. The rail supporting groove part corresponds to the sleeve holes of the fastener mounting plate one by one, and sleeves are installed in the corresponding sleeve holes above and below.

3. The installation and positioning method according to claim 1, wherein: The mold shell is provided with a plurality of exhaust holes, and the aperture of the exhaust holes is 2-10 mm.

4. The installation and positioning method according to claim 1, wherein: The top surface of the mold shell is further provided with two shoulder portions, and the two shoulder portions are respectively located on both sides of the support rail groove portion.

5. The installation and positioning method according to claim 4, wherein: A pouring port is provided on the shoulder portion.

6. The installation and positioning method according to claim 1, wherein: In step S4, the vertical position of the cast-in-place mold for the sleeper relative to the rail is adjusted by adjusting the type and quantity of the under-rail fine-tuning pads and the iron pad lower height adjustment pads in the fastener system.

7. The installation and positioning method according to claim 1, wherein: In step S4, the planar position of the cast-in-place sleeper mould relative to the rail is adjusted by adjusting the types of the gauge baffle and the insulating block in the fastener system.

8. The installation and positioning method according to claim 1, wherein: In step S4, the rail is raised to a height greater than the height of the cast-in-place mold for the sleeper.

9. The installation and positioning method according to claim 1, wherein: Before formal pouring, the vertical and horizontal positions of the rails should be measured to confirm whether they have changed. If so, adjustments need to be made before pouring.

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