Process for manufacturing bonded insulated joints in a rail mill

Abstract

The application provides a steel rail in-plant bonding insulation joint preparation process and relates to the technical field of track manufacturing. The process comprises preparing a clamp plate, the clamp plate having a first clamping surface, the first clamping surface comprising an arc-shaped top surface, an intermediate side surface and an arc-shaped bottom surface connected in sequence, the included angle between the arc-shaped top surface and the intermediate side surface being alpha, and the included angle between the arc-shaped bottom surface and the intermediate side surface being beta. Two steel rail bodies to be butt-jointed are arranged between two clamp plates, and an insulation plate is arranged between the first clamping surface of each clamp plate and the two steel rail bodies to be butt-jointed. The steel rail body has a second clamping surface capable of being attached to the insulation plate, the second clamping surface comprising a rail top bottom surface, a rail waist side surface and a rail bottom top surface connected in sequence, the included angle between the rail top bottom surface and the rail waist side surface being gamma, the included angle between the rail bottom top surface and the rail waist side surface being delta, alpha>gamma and beta>delta. The clamp plate, the insulation plate and the steel rail body are fixed by bolts to form an insulation joint assembly. The insulation joint assembly is bonded. The process can improve the fatigue performance of the insulation joint.

Description

Technical Field

[0001] This invention relates to the field of rail manufacturing technology, and more specifically, to a process for preparing adhesive-bonded insulating joints in a rail factory. Background Technology

[0002] Rail adhesive-bonded insulated joints are structures that integrate fully contact clamps, insulating components, and rails using high-strength bolts. With the widespread application of seamless railway tracks, rail adhesive-bonded insulated joint technology has received increasing attention as a key technology for laying seamless tracks across sections. Rail insulated joints serve both electrical and mechanical functions. Firstly, they divide track circuit sections, ensuring insulation between adjacent rails and providing technical support for train operation, scheduling, and monitoring. Secondly, they must withstand the impact force generated when trains pass over the joint, requiring sufficient strength to ensure its safety and reliability. Currently, two adhesive bonding processes exist for rail adhesive-bonded insulated joints used on Chinese railways: one is room-temperature curing adhesive, used for on-site bonding; the other is hot-applied adhesive, used in the factory. Factory bonding, due to its favorable construction environment and hot-applied bonding process, results in superior mechanical properties compared to room-temperature bonding joints. The fatigue performance of the insulated joint is a crucial indicator of bonding quality.

[0003] The inventors discovered through research that existing in-house glued insulating joints have at least the following drawbacks:

[0004] It has poor fatigue performance, short lifespan, and high cost. Summary of the Invention

[0005] The purpose of this invention is to provide a process for preparing in-plant adhesive-bonded insulating joints for rails, which can improve fatigue performance, extend service life, reduce costs, and improve safety and reliability during service.

[0006] The embodiments of the present invention are implemented as follows:

[0007] In a first aspect, the present invention provides a process for preparing adhesive-bonded insulating joints in a rail factory, comprising the following steps:

[0008] Step s100: Prepare a clamping plate, the clamping plate having a first clamping surface, the first clamping surface including an arc-shaped top surface, a middle side surface and an arc-shaped bottom surface connected in sequence, the angle between the arc-shaped top surface and the middle side surface is α, and the angle between the arc-shaped bottom surface and the middle side surface is β;

[0009] Step s200: Arrange two rail bodies to be connected between the two clamping plates, and arrange an insulating plate between the first clamping surface of each clamping plate and the two rail bodies to be connected; the rail body has a second clamping surface that can fit with the insulating plate, the second clamping surface includes a rail top bottom surface, a rail web side surface and a rail bottom top surface connected in sequence, the angle between the rail top bottom surface and the rail web side surface is γ, the angle between the rail bottom top surface and the rail web side surface is δ, α>γ, β>δ, so that the distance between the arc-shaped top surface and the rail top bottom surface and the distance between the arc-shaped bottom surface and the rail bottom top surface are both smaller than the distance between the middle side surface and the rail web side surface;

[0010] Step s300: Secure the clamping plate, the insulating plate, and the rail body with bolts to form an insulating joint assembly;

[0011] Step s400: Bond the insulating joint assembly.

[0012] In an optional embodiment, in step s100, the clamping plate further includes a first outer side surface opposite to the first clamping surface, and the first outer side surface is connected to the arc-shaped bottom surface by an inclined surface; after the insulating joint assembly is glued, the first outer side surface is flush with the second outer side surface of the rail bottom of the rail body, and the top surface of the rail bottom and the inclined surface cooperate to define an avoidance space.

[0013] Based on the above solution, by making the first outer side of the clamp plate flush with the second outer side of the rail base of the rail body, the thickness of the clamp plate can be increased, thereby improving its strength and further enhancing the fatigue performance of the insulation joint. Simultaneously, due to the inclined surface design of the clamp plate, a clearance space is created at the inclined surface while increasing the clamp plate thickness. When the rail body is fixed using mounting fasteners, the position of the fasteners corresponds to the clearance space, preventing interference between the clamp plate and the fasteners. In other words, existing clamp plates, because they need to provide installation space for rail fasteners, require thinning the clamp plate, exposing a portion of the top surface of the rail base on the outer side of the clamp plate. The rail fasteners then contact the exposed top surface of the rail base, resulting in reduced clamp plate structural strength. However, in this embodiment, while increasing the clamp plate thickness to improve the strength of the clamp plate body, the clearance space design does not affect the fit between the rail fasteners and the top surface of the rail base, thus improving both structural strength and assembly quality.

[0014] In an optional embodiment, in step s100, a rib is provided on the side of the clamping plate opposite to the first clamping surface. The rib protrudes from the clamping plate by 20mm-30mm and is located at the joint of the two rail bodies to be connected.

[0015] Based on the above solution, by adding ribs to the joint of the two main rails on the clamping plate, the structural strength at the joint of the two main rails is improved, thereby enhancing the fatigue performance of the overall structure. Furthermore, the protrusion size of the ribs is set between 20-30mm, and the protrusion distance is reasonably controlled to reduce costs while ensuring strength. It should be understood that the protrusion size of the ribs can be 20mm, 25mm, or 30mm, etc.

[0016] In an optional implementation, in step s200, the distance between the arc-shaped top surface and the bottom surface of the rail top is (0.5-0.8) mm, the distance between the arc-shaped bottom surface and the top surface of the rail bottom is (0.5-0.8) mm, and the distance between the middle side surface and the side surface of the rail waist is (1.0-1.5) mm.

[0017] Based on the above scheme, the final thickness of the insulation plate is determined by controlling the distance between the clamping plate and the rail body. This ensures insulation performance while maximizing the tightness of the connection between the clamping plate and the rail body, thereby improving fatigue performance. It should be understood that the distance between the curved top surface and the bottom surface of the rail top can be 0.5mm, 0.6mm, 0.7mm, or 0.8mm, etc. The distance between the curved bottom surface and the top surface of the rail bottom can be 0.5mm, 0.65mm, or 0.8mm, etc. The distance between the middle side and the side of the rail web can be 1.0mm, 1.25mm, or 1.5mm, etc.

[0018] In an optional embodiment, in step s300, the clamping plate, the insulating plate, and the rail body are fastened using multiple bolts arranged side by side along the length of the clamping plate.

[0019] Based on the above scheme, multiple bolts are used to clamp the clamping plate. The bolts are distributed along the length of the clamping plate, which makes the locking force acting on the clamping plate and the rail body evenly distributed, thus improving the firmness of the connection between the clamping plate and the rail body.

[0020] In an optional implementation, in step s400, the insulating joint assembly is heated multiple times using a step-by-step heating method, and the tightening force of the bolt is adjusted after each heating is completed.

[0021] Based on the above solution, the step-by-step heating insulation joint assembly can adjust the screw tightening force after heating, and the insulation plate is not easily damaged during adjustment, thus ensuring both connection strength and insulation performance.

[0022] In an optional embodiment, in the step of heating the insulating joint assembly multiple times using a step heating method, the insulating joint assembly is heated for the first time at a temperature of 235-245°C for 30-35 minutes. Heating is stopped after the temperature of the clamping plate and the main body of the rail reaches 90-110°C. The tightening force of the bolt is adjusted, and the torque of the bolt is set to 800-900 N·m.

[0023] Based on the above scheme, this process can ensure that the insulation layer reaches the designed thickness, improve the ability of the insulation joint assembly to resist vertical impact, and optimize the fatigue resistance of the joint.

[0024] In an optional embodiment, after the first adjustment of the bolt's tightening force, the insulating joint assembly is heated a second time. The heating temperature is set to 235-245°C, and the heating time is set to 50-60 minutes. Heating is stopped after the temperature of the clamp and the rail body reaches 155-160°C.

[0025] Based on the above scheme, under this process, the insulation board has good insulation performance, can achieve ideal bonding strength, and the joint position is not easily pulled apart during service, ensuring safe and reliable operation.

[0026] In an optional embodiment, after step s400, excess insulating material overflowing from the clamping plate on both sides in the height direction of the rail body is removed, so that the insulating plate is flush with the clamping plate; excess insulating material overflowing from the clamping plate on both sides in the length direction of the rail body is trimmed, so that the insulating plate protrudes (8-10) mm from the clamping plate in the length direction of the rail body.

[0027] Based on the above solution, by removing the excess insulation material from the top and bottom sides of the clamp, making the insulation plate flush with the top and bottom edges of the clamp, the long-term retention of rainwater at the residual adhesive area during the service life of the insulation joint can be avoided, thus preventing the joint's insulation performance from deteriorating and improving its safety and reliability during service. Furthermore, reserving 8-10mm of insulation material on both sides along the length of the clamp increases the surface area of ​​the insulation material, improving the insulation performance of the insulation plate. Since the reserved insulation material on both sides along the length of the clamp is located at the rail web, the excess extends vertically (the height of the rail body) rather than horizontally (the length of the rail body). Therefore, this location is less affected, or even virtually unaffected, by the long-term retention of rainwater that could lead to insulation performance deterioration.

[0028] In an optional embodiment, after the insulating board is cut and the temperature of the insulating joint assembly drops below 60°C, the bolt is finally tightened, and the torque of the bolt is set to 1000-1100 N·m.

[0029] Based on the above scheme, after cooling, the insulation plate is shaped and the bolts are tightened to ensure that the clamping plate, insulation plate and rail body are tightly fitted, resulting in high overall structural strength, good insulation performance and safe and reliable service.

[0030] The beneficial effects of the embodiments of the present invention are:

[0031] In summary, the in-plant adhesive bonding insulation joint preparation process for rails provided in this embodiment utilizes a clamp to abut the insulation plate against the outer side of the rail body. Since the distance between the arc-shaped top surface of the clamp and the bottom surface of the rail body is less than the distance between the middle side surface of the clamp and the side surface of the rail web, and the distance between the arc-shaped bottom surface of the clamp and the top surface of the rail bottom is less than the distance between the middle side surface of the clamp and the side surface of the rail web, after determining the distance between the bottom and top surfaces of the rail body, reducing the thickness of the insulation plate between these surfaces increases the height of the clamp between them. This increased height enhances the stiffness of the clamp in the height direction of the rail body, thereby increasing its resistance to vertical impact loads and improving fatigue performance.

[0032] Simultaneously, when the clamping plates, insulating plates, and rail body are tightened with bolts, the clamping plates and rail body work together to compress the insulating plates, causing the insulation plates to gradually thin. Furthermore, during the compression process, the insulation plates gradually thin, and the material overflowing from the insulating plates moves from the center outwards. The center of the insulating plate mainly corresponds to the central area defined by the middle side and the rail web side, while the perimeter mainly corresponds to the side areas defined by the curved top surface and the bottom surface of the rail top, as well as the side areas defined by the curved bottom surface and the top surface of the rail bottom. The thickness of both side areas is greater than that of the center area. The mating structures of the curved top surface and the bottom surface of the rail top, and the curved bottom surface and the top surface of the rail bottom, help to slow down the deformation as the material overflowing from the center moves outwards during the compression process. This ensures that the insulating plates can fully fill the central area defined by the middle side and the rail web side, guaranteeing uniform deformation and preventing cracking. Furthermore, when the overflowing insulating material moves to the side areas defined by the arc-shaped top surface and the bottom surface of the rail, as well as the side areas defined by the arc-shaped bottom surface and the top surface of the rail, the deformation rate slows down and the deformation is hindered, resulting in high density of the insulating plates in the two side areas and good insulation performance at the edge positions. Attached Figure Description

[0033] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is an exploded structural diagram of the insulating joint assembly according to an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the assembly structure of the insulating joint assembly according to an embodiment of the present invention;

[0036] Figure 3 This is a schematic diagram illustrating the fit between the rail body and the clamping plate in an embodiment of the present invention.

[0037] Figure 4 This is an exploded structural diagram of the rail body, insulation plate, and clamping plate according to an embodiment of the present invention.

[0038] icon:

[0039] 001 - Central area; 002 - Side area; 003 - Clearance space; 100 - Clamping plate; 110 - First clamping surface; 111 - Arc-shaped top surface; 112 - Middle side surface; 113 - Arc-shaped bottom surface; 120 - First outer side surface; 130 - Inclined surface; 200 - Rail body; 210 - Second clamping surface; 211 - Rail top bottom surface; 212 - Rail web side surface; 213 - Rail bottom top surface; 214 - Second outer side surface; 300 - Insulation plate; 400 - Bolt; 500 - Rib plate. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0041] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0042] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0043] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this invention is in use. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. In addition, the terms "first," "second," "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0044] Furthermore, terms such as "horizontal" and "vertical" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0045] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0046] Please combine Figures 1-4 In this embodiment, the process for preparing adhesive-bonded insulating joints in the rail factory includes the following steps:

[0047] Please combine Figure 4 Step s100: Prepare clamping plate 100. Clamping plate 100 has a first clamping surface 110. The first clamping surface 110 includes an arc-shaped top surface 111, a middle side surface 112 and an arc-shaped bottom surface 113 connected in sequence. The angle between the arc-shaped top surface 111 and the middle side surface 112 is α, and the angle between the arc-shaped bottom surface 113 and the middle side surface 112 is β. Wherein, α and β are both obtuse angles, and the specific angles are not limited in this embodiment.

[0048] Step s200: Arrange two rail bodies 200 to be connected between two clamping plates 100. An insulating plate 300 is arranged between the first clamping surface 110 of each clamping plate 100 and the two rail bodies 200 to be connected. The rail body 200 has a second clamping surface 210 that can fit against the insulating plate 300. The second clamping surface 210 includes a rail top bottom surface 211, a rail web side surface 212, and a rail bottom top surface 213 connected in sequence. The angle between the rail top bottom surface 211 and the rail web side surface 212 is γ, and the angle between the rail bottom top surface 213 and the rail web side surface 212 is δ, where α > γ and β > δ, so that the distance between the arc-shaped top surface 111 and the rail top bottom surface 211, and the distance between the arc-shaped bottom surface 113 and the rail bottom top surface 213, are both smaller than the distance between the middle side surface 112 and the rail web side surface 212. Here, γ and δ are both obtuse angles, and the specific angles are not limited in this embodiment.

[0049] Step s300: Fix the clamping plate 100, the insulating plate 300 and the rail body 200 with bolts 400 to form an insulating joint assembly.

[0050] Step s400: Bond the insulating joint assembly.

[0051] As described above, in the rail factory bonding insulation joint preparation process provided in this embodiment, when the insulating plate 300 is abutted against the outside of the rail body 200 using the clamping plate 100, the distance between the arc-shaped top surface 111 of the clamping plate 100 and the bottom surface 211 of the rail top of the rail body 200 is less than the distance between the middle side surface 112 of the clamping plate 100 and the side surface 212 of the rail web of the rail body 200. Furthermore, the distance between the arc-shaped bottom surface 113 of the clamping plate 100 and the top surface 213 of the rail bottom of the rail body 200 is less than the distance between the middle side surface 112 of the clamping plate 100 and the bottom surface 213 of the rail web of the rail body 200. The distance between the rail web sides 212 of the rail body 200, that is, after the distance between the top surface 211 and the bottom surface 213 of the rail body 200 is determined, by reducing the thickness of the insulating plate 300 between the top surface 211 and the bottom surface 213, the height of the clamping plate 100 between the top surface 211 and the bottom surface 213 can be increased. By increasing the height of the clamping plate 100, the stiffness of the clamping plate 100 in the height direction of the rail body 200 is improved, thereby increasing the ability to resist vertical impact loads and improving fatigue performance.

[0052] Please combine Figure 3Simultaneously, when the clamping plate 100, insulating plate 300, and rail body 200 are locked with bolts 400, the clamping plate 100 and rail body 200 cooperate to compress the insulating plate 300, causing the thickness of the insulating plate 300 to gradually decrease. Furthermore, during the compression process, the thickness of the insulating plate 300 gradually decreases, and the material overflowing from the insulating plate 300 during compression gradually moves from the center outwards. The center position of the insulating plate 300 mainly corresponds to the central region 001 defined by the middle side 112 and the rail web side 212, while the surrounding positions of the insulating plate 300 mainly correspond to the side regions 002 defined by the arc-shaped top surface 111 and the rail top bottom surface 211, and the side regions 002 defined by the arc-shaped bottom surface 113 and the rail bottom top surface 213. The thickness of each side region 002 is greater than that of the central region 001. The mating structure of the arc-shaped top surface 111 and the rail top bottom surface 211, as well as the mating structure of the arc-shaped bottom surface 113 and the rail bottom top surface 213, can slow down the deformation of the material overflowing from the center to the surrounding areas during the extrusion of the insulation plate 300. This ensures that the insulation plate 300 can fully fill the central region 001 defined by the middle side surface 112 and the rail web side surface 212, ensuring uniform deformation of the insulation plate 300 and preventing cracking. Furthermore, when the overflowing insulating material moves to the side regions 002 defined by the arc-shaped top surface 111 and the rail top bottom surface 211, and the side regions 002 defined by the arc-shaped bottom surface 113 and the rail bottom top surface 213, the deformation rate slows down and the deformation is hindered, resulting in high density of the insulation plate 300 in the two side regions 002 and good insulation performance at the edges.

[0053] It should be noted that the two side regions 002 can be set symmetrically.

[0054] The following details the process for preparing in-plant adhesive-bonded insulating joints for rails provided in this application, illustrated by examples.

[0055] It is worth noting that an insulating plate 300 and a clamping plate 100 are respectively provided on both sides of the rail body 200. The rail body 200 cooperates with the two clamping plates 100 to clamp the two insulating plates 300. Taking the rail body 200 as a reference, the structure formed by the insulating plates 300 and the clamping plates 100 on both sides can be set accordingly. In this embodiment, in order to avoid repetition and redundancy, the description is based on the cooperation of the insulating plate 300, the clamping plate 100 and the rail body 200 on one side.

[0056] In this embodiment, optionally, before step s100, the materials of components such as the rail body 200, the clamping plate 100, the bolts 400, and the insulating plate 300 for bonding can be screened and tested to ensure that they meet industry standards.

[0057] In this embodiment, optionally, in step s100, the clamping plate 100 is made of 42CrMo, which has higher comprehensive mechanical properties than 55#. Simultaneously, the clamping plate 100 also includes a first outer surface 120 opposite to the first clamping surface 110, and the first outer surface 120 is connected to the arc-shaped bottom surface 113 via an inclined surface 130. After the insulating joint assembly is glued, the first outer surface 120 is flush with the second outer surface 214 of the rail base of the rail body 200, and the top surface 213 of the rail base and the inclined surface 130 cooperate to define a clearance space 003. The design principle of the clearance space 003 is primarily to avoid interfering with the installation of the fasteners. Taking the 50 clamping plate 100 as an example, the thickness direction of the clamping plate 100 is milled by 15-25mm, and the height direction of the clamping plate 100 is milled by 25-35mm.

[0058] It should be understood that by making the first outer surface 120 of the clamping plate 100 flush with the second outer surface 214 of the rail base of the rail body 200, the thickness of the clamping plate 100 can be increased, thereby improving the strength of the clamping plate 100 and further improving the fatigue performance of the insulating joint. Simultaneously, due to the structural design of the inclined surface 130 on the clamping plate 100, a clearance space 003 is formed at the position of the inclined surface 130 while increasing the thickness of the clamping plate 100. When the rail body 200 is fixed using mounting fasteners, the position of the fasteners corresponds to the clearance space 003, preventing interference between the clamping plate 100 and the fasteners. In other words, in the prior art, the clamping plate 100, because it needs to provide installation space for the rail fasteners, has its thickness reduced, exposing a portion of the top surface 213 of the rail base on its outer surface. The rail fasteners contact the exposed top surface 213 of the rail base. Due to the reduced thickness of the clamping plate 100, the structural strength of the clamping plate 100 is decreased. In this embodiment, while increasing the thickness of the clamping plate 100 to improve the strength of the main body of the clamping plate 100, the structural design of the clearance space 003 will not affect the fit between the rail fastener and the top surface 213 of the rail base, thus improving the structural strength and ensuring the assembly quality.

[0059] In this embodiment, optionally, a rib 500 is further provided on the first outer side 120 of the clamping plate 100 opposite to the first clamping surface 110. The rib 500 protrudes from the clamping plate 100 by a height of 20mm-30mm, and the rib 500 is located at the joint of the two rail bodies 200 to be joined. By adding a rib 500 at the joint of the clamping plate 100 corresponding to the joint of the two rail bodies 200, the structural strength at the joint of the two rail bodies 200 is improved, thereby improving the fatigue performance of the overall structure. Furthermore, the protrusion of the rib 500 is set between 20-30mm, reasonably controlling the protrusion distance to reduce costs while ensuring strength. It should be understood that the protrusion of the rib 500 can be 20mm, 25mm, or 30mm, etc.

[0060] In this embodiment, optionally, in step s200, the distance between the arc-shaped top surface 111 and the rail top bottom surface 211 is (0.5-0.8) mm, the distance between the arc-shaped bottom surface 113 and the rail bottom top surface 213 is (0.5-0.8) mm, and the distance between the middle side surface 112 and the rail web side surface 212 is (1.0-1.5) mm. This design, by controlling the distance between the clamping plate 100 and the rail body 200, determines the final thickness of the insulation plate 300, ensuring insulation performance while maximizing the tightness of the connection between the clamping plate 100 and the rail body 200, thus improving fatigue performance. It should be understood that the distance between the arc-shaped top surface 111 and the rail top bottom surface 211 can be 0.5 mm, 0.6 mm, 0.7 mm, or 0.8 mm, etc. The distance between the arc-shaped bottom surface 113 and the rail bottom top surface 213 can be 0.5 mm, 0.65 mm, or 0.8 mm, etc. The distance between the middle side 112 and the rail web side 212 can be 1.0mm, 1.25mm or 1.5mm, etc.

[0061] In this embodiment, in step s300, multiple bolts 400 arranged side-by-side along the length of the clamping plate 100 are used to fasten the clamping plate 100, the insulating plate 300, and the rail body 200. For example, in this embodiment, there are six bolts 400, and all six bolts 400 are high-strength bolts 400. The six bolts 400 are arranged at intervals along the length of the clamping plate 100. Three bolts 400 are used to connect one of the two rail bodies 200 to be connected, and another set of three bolts 400 is used to connect the other rail body 200 to be connected. Furthermore, the six bolts 400 are numbered 1, 2, 3, 4, 5, and 6 along the length of the clamping plate 100. When tightening the bolts 400, they are tightened symmetrically, for example, in the order of 162534 or 342516.

[0062] In this embodiment, optionally, in step s400, the insulating joint assembly is heated multiple times using a step-by-step heating method, and the tightening force of the bolt 400 is adjusted after each heating. This embodiment uses a two-stage heating of the insulating joint assembly as an example. During heating, the insulating joint assembly is placed in a heating chamber. Specifically, during the first heating of the insulating joint assembly, the heating temperature of the heating chamber is set to 235-245℃, and the heating time is set to 30-35 minutes. Heating is stopped after the temperature of the clamping plate 100 and the rail body 200 reaches 90-110℃, and the tightening force of the bolt 400 is adjusted, with the torque of the bolt 400 set to 800-900 N·m. This process ensures that the insulation layer reaches the designed thickness, improves the insulating joint assembly's resistance to vertical impact, and optimizes the joint's fatigue resistance.

[0063] Simultaneously, after the initial adjustment of the tightening force of bolt 400, a second heating process is performed. During the second heating, the heating chamber temperature is set to 235-245℃, and the heating time is set to 50-60 minutes. Heating is stopped once the temperatures of the clamping plate 100 and the rail body 200 reach 155-160℃. Under this process, the insulation plate 300 exhibits good insulation performance, achieving ideal bonding strength. During service, the joint is not easily pulled apart, ensuring safe and reliable operation.

[0064] It should be noted that after the second heating of the insulating joint assembly and before the tightening force of the adjusting bolt 400, the excess residual adhesive around the clamping plate 100 is also treated. For example, excess insulating material overflowing from the clamping plate 100 on both sides in the height direction of the rail body 200 is removed, making the insulating plate 300 flush with the clamping plate 100. Excess insulating material overflowing from the clamping plate 100 on both sides in the length direction of the rail body 200 is trimmed, making the insulating plate 300 protrude (8-10) mm from the clamping plate 100 in the length direction of the rail body 200. By removing the excess insulating material overflowing from the upper and lower sides of the clamping plate 100, and making the insulating plate 300 flush with the upper and lower edges of the clamping plate 100, the insulation performance of the joint can be prevented from being affected by rainwater remaining at the residual adhesive during service, thus reducing the risk of insulation performance deterioration and improving safety and reliability during service. On both sides of the length of the clamping plate 100, 8-10mm of insulating material is reserved, which increases the surface area of ​​the insulating material and improves the insulation performance of the insulating plate 300. Furthermore, the insulating material reserved on both sides of the length of the clamping plate 100 is located at the web of the rail, and the overflow part extends in the vertical direction, that is, the height direction of the rail body 200, rather than in the horizontal direction, that is, the length direction of the rail body 200. Therefore, this position is less affected or even basically unaffected by the long-term retention of rainwater that leads to the deterioration of insulation performance.

[0065] It should be understood that the dimension of the insulating plate 300 protruding in the length direction of the clamping plate 100 can be 8mm, 9mm or 10mm, etc.

[0066] After removing excess adhesive around the clamp plate 100, and waiting for the temperature of the insulating joint assembly to drop to 60°C, tighten bolt 400. The torque of bolt 400 is set to 1000-1100 N·m.

[0067] It should be noted that during the production process, the differences in ambient temperature in different seasons should be fully considered, and the heating temperature and holding time should be adjusted in a timely manner to ensure that the actual temperature of the insulation board 300 reaches the process temperature.

[0068] The table below compares the fatigue performance of the insulating joint assembly prepared using the process of this embodiment with that of the comparative insulating joint assembly prepared using the prior art.

[0069]

[0070] In the examples, the data in the horizontal row are all less than 1.1, while in the comparative examples, the ratio gradually increases and becomes greater than 1.1 as the number of tests increases. Therefore, as can be seen from the table above, the preparation process of this example can significantly improve the fatigue performance of the rail adhesive-bonded insulation joint, extend the service life of the joint, and improve the smoothness and safety of track operation.

[0071] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A process for the production of a bonded insulated joint in a rail mill, characterized in that, The method comprises the following steps: Step s100, preparing a clamp plate, the clamp plate having a first clamping surface, the first clamping surface comprising an arc-shaped top surface, an intermediate side surface and an arc-shaped bottom surface connected in sequence, the arc-shaped top surface and the intermediate side surface forming an angle α, the arc-shaped bottom surface and the intermediate side surface forming an angle β; Step s200, arranging two steel rail bodies to be coupled between two clamp plates, and arranging an insulating plate between the first clamping surface of each clamp plate and the two steel rail bodies to be coupled; the steel rail body having a second clamping surface capable of being attached to the insulating plate, the second clamping surface comprising a rail top bottom surface, a rail waist side surface and a rail bottom top surface connected in sequence, the rail top bottom surface and the rail waist side surface forming an angle γ, the rail bottom top surface and the rail waist side surface forming an angle δ, α>γ, β>δ, so that the distance between the arc-shaped top surface and the rail top bottom surface and the distance between the arc-shaped bottom surface and the rail bottom top surface are both smaller than the distance between the intermediate side surface and the rail waist side surface; Step s300, fastening the clamp plate, the insulating plate and the steel rail body by means of bolts to make an insulating joint assembly; Step s400, gluing the insulating joint assembly; In the step s100, the clamp plate further comprises a first outer side surface opposite to the first clamping surface, the first outer side surface being connected to the arc-shaped bottom surface by means of an inclined surface; after the gluing of the insulating joint assembly is completed, the first outer side surface is flush with a second outer side surface of a rail bottom of the steel rail body, and the rail bottom top surface and the inclined surface cooperatively define an avoiding space; In the step s100, a rib plate is arranged on a side of the clamp plate away from the first clamping surface, the rib plate protruding from the clamp plate by a height of 20-30 mm, and the rib plate is located at a joint of the two steel rail bodies to be coupled; In the step s200, the distance between the arc-shaped top surface and the rail top bottom surface is 0.5-0.8 mm, the distance between the arc-shaped bottom surface and the rail bottom top surface is 0.5-0.8 mm, and the distance between the intermediate side surface and the rail waist side surface is 1.0-1.5 mm; In the step s300, a plurality of bolts arranged side by side in the length direction of the clamp plate are used to fasten the clamp plate, the insulating plate and the steel rail body; In the step s400, the insulating joint assembly is heated multiple times by means of a step-by-step heating mode, and the locking force of the bolts is adjusted after each heating is completed; After the step s400, the excess insulating material on both sides of the clamp plate in the height direction of the steel rail body is removed so that the insulating plate is flush with the clamp plate; the excess insulating material on both sides of the clamp plate in the length direction of the steel rail body is cut so that the insulating plate protrudes from the clamp plate by 8-10 mm in the length direction of the steel rail body.

2. The method according to claim 1, wherein In the step of heating the insulated joint assembly multiple times by using the step heating method, the insulated joint assembly is heated for the first time at a temperature of 235-245 DEG C for 30-35 minutes, and the heating is stopped when the temperature of the clamp plate and the rail body reaches 90-110 DEG C, the locking force of the bolt is adjusted, and the torque of the bolt is set to 800-900 N*m. 3.The rail in-plant glued insulated joint preparation process of claim 2, wherein: After the step of adjusting the locking force of the bolt for the first time, the insulated joint assembly is heated for the second time at a temperature of 235-245 DEG C for 50-60 minutes, and the heating is stopped when the temperature of the clamp plate and the rail body reaches 155-160 DEG C. 4.The rail in-plant glued insulated joint preparation process of claim 1, wherein: After the step of cutting the insulated plate and the temperature of the insulated joint assembly is reduced to below 60 DEG C, the bolt is finally tightened, and the torque of the bolt is set to 1000-1100 N*m.

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