A method for rapidly replacing filling layer mortar with low amount of raised track

Abstract

This invention discloses a method for rapid replacement of filling mortar with low rail lifting, comprising: lifting the rail and track slab at a low height; installing a series of cutting devices on the track slab, with the main body of the devices located between the track slab and the base; adjusting the height of the cutting mechanism through a positioning mechanism to control the mortar cutting thickness; operating the cutting trolley to cut the filling mortar laterally along the track; after one lateral cutting pass, moving the series of cutting devices longitudinally along the track; repeating the lateral cutting, longitudinal movement, and vertical height adjustment steps until the mortar under the entire track slab is cut; dismantling the series of cutting devices; cleaning the base surface; lowering the track slab for fine adjustment; injecting new filling mortar; and restoring the rail. This invention reduces the lifting height of the rail and track, reduces workload, alleviates the labor intensity of personnel, and improves construction efficiency; it is suitable for operation during maintenance windows on operating railway lines.

Description

Technical Field

[0001] This invention relates to the field of railway ballastless track maintenance technology, specifically to a method for rapid replacement of filling layer mortar with low rail lifting. Background Technology

[0002] CRTSⅡ type slab track, as one of the main track structures for high-speed railways in my country, boasts advantages such as high track smoothness, good stiffness uniformity, strong structural stability, good overall durability, and low maintenance workload. It consists of several parts, including a concrete base (support layer), a filling mortar layer, track slabs, fasteners, and rails. The filling mortar layer is a key technology of the CRTSⅡ type slab track. Its material is cement emulsified asphalt mortar, composed of cement, sand, emulsified asphalt, admixtures, aluminum powder, water, and other additives, mixed together. This mixture exhibits good workability, possesses certain strength and elasticity after hardening, and demonstrates good maintainability. The filling mortar layer is used between the track slab and the concrete base (support layer), serving to fill, support, and transmit force, while providing appropriate stiffness and toughness to the track. The performance of the filling mortar layer directly affects the track structure's smoothness, durability, operational safety, and passenger comfort.

[0003] CRTSⅡ type slab track is widely distributed in my country, with major application lines including the Beijing-Tianjin Intercity Railway, Beijing-Shanghai Railway, Beijing-Shijiazhuang-Wuhan Railway, Tianjin-Qinhuangdao Railway, Shanghai-Hangzhou Railway, Nanjing-Hangzhou Railway, Hangzhou-Changsha Railway, and Hefei-Bengbu High-Speed ​​Railway. Due to the complex and diverse environment, inherent deficiencies in some materials during construction, deviations in construction quality control, and the long-term effects of alternating train loads, certain sections or areas gradually exhibit deterioration defects such as cracking, spalling, peeling, separation, and mud pumping in the filling mortar. Because of the influence of the track slab above the filling mortar and its thin-layered structural characteristics, external repair work cannot guarantee its durability or the performance of the materials and structural layers. Therefore, when these defects develop to a certain extent, it is necessary to replace the deteriorated filling mortar to ensure the safety of high-speed railway operation and the stability and durability of the ballastless track structure. However, without affecting the normal operation of the high-speed railway, there are many difficulties in completing the replacement of the filling layer mortar during the limited maintenance window, such as the inability to use large equipment, limited working space, the impact of rails and track slabs on the operation, the difficulty in removing the filling layer mortar, and insufficient hardening time for the new materials.

[0004] Currently, research on the replacement technology of CRTSⅡ type slab track filling mortar in my country is still in its initial stage, and there is no mature international experience to draw upon. At present, my country uses two methods to replace the filling mortar of CRTSⅡ type slab track: The first method involves removing the rails and track slabs before replacing the filling mortar. This method requires cutting the rails before replacement, temporarily connecting them with short rail clamps during construction, and then re-welding the rails after construction. This results in a long construction period, complicated procedures, numerous coordinating departments and personnel, significant damage to the rails, and a substantial impact on the locking rail temperature and overall track integrity of seamless tracks. Therefore, this method not only has a long construction period, complicated procedures, and a large workload, but also significantly affects the track structure's stress system. The second method involves replacing the mortar filling layer with a high-lift rail. While this method doesn't require cutting the rail, it does require lifting the rail and track by 400mm to 600mm to create space for manual removal of the mortar filling layer beneath the track slab. The main problems with this method are: 1) The excessive lifting height leads to excessive workload in fastener assembly / disassembly, rail fine-tuning, and rail support limiting. Seamless rails also experience significant additional stress, posing risks of instability, high-temperature expansion, and low-temperature shrinkage in curved sections. Furthermore, extensive and repeated fastener disassembly and high-height rail lifting can damage the rail, track, and embedded sleeves. 2) The excessive lifting height of the track slab makes it prone to instability and overturning, especially in curved sections where the lifting and lowering time is long. 3) Manual removal is labor-intensive, incomplete, and inefficient, with limited working space and personnel needing to crawl under the slab, posing significant safety risks. 4) Lifting the rail is extremely difficult in special locations such as near turnout areas, making this method impractical.

[0005] Therefore, in order to ensure the normal service of my country's CRTSⅡ type slab track structure and the safe operation of my country's high-speed railway, it is urgent to develop a rapid replacement technology for the filling mortar that can meet the requirements of track maintenance window operations without cutting the rails and raising the rails and track slabs at a low height (less than 250mm).

[0006] The prior art (CN113756142B) provides a method for removing the mortar layer of ballastless track slabs with low clearance, comprising the following steps: chiseling away the wide joint concrete between the ballastless track slabs; using hydraulic jacks to lift the ballastless track slabs to separate them from the mortar layer on the base plate; transversely inserting two guide rails in the space between the ballastless track slabs and the base plate; slidably assembling at least one grooving mechanism on the guide rails, the grooving mechanism including a frame and several grooving machines installed side by side at intervals on the frame, the grooving machines including a motor, a grinding head and a transmission rod connected between the two; starting the motor of the grooving machine and pushing the grooving mechanism from the outside to the inside to grooving and cutting the mortar layer on the base plate until the mortar layer is completely removed by grooving. The above-mentioned method of removing mortar layers using trenching machines has the following drawbacks: First, the lifting height is relatively high (200mm~500mm); second, the method uses several electrically driven trenching machines installed side-by-side on a frame, which is limited by the size and power of the trenching machine motors, requiring them to be installed side-by-side at intervals. The width of the mortar layer cut by a single trenching machine is limited. Although the text does not specify the exact value, relevant equipment parameters indicate that it is between 20mm and 50mm. This means that the mortar layer can only be cut intermittently, leaving gaps after cutting. The equipment needs to be precisely moved and fixed before cutting again, which is difficult to operate and takes a long time to accurately move and fix. Third, the trenching machine method uses multiple small motors to drive the machine. Under this condition, the motors are prone to burnout due to prolonged high-power operation. Insufficient motor power reduces efficiency when the cutting depth is large. If a single motor fails, the entire equipment will stop operating, and the replacement and maintenance time will be long.

[0007] The existing technology "Research on Sectional Replacement Technology of CA Mortar Layer for Ballastless Track in High-Speed ​​Railway (Shanghai Railway Supplement, 2019, No. 1)" adopts the technique of replacing the filling mortar after removing the rails and track slabs, and its problems have been detailed above. The existing technology "Rapid Replacement Technology of Structural Components for Ballastless Track in High-Speed ​​Railway (Railway Technology Innovation, 2015, No. 2)" adopts the technique of replacing the filling mortar with a high rail lifting amount, and the application case is CRTSⅠ type slab ballastless track, in which the filling mortar is located in the injection bag and has almost no adhesion to the track slab and base, making manual removal relatively easy. The existing technology "Research on Rapid Replacement Technology of Mortar Layer for CRTSⅡ Type Slab Ballastless Track (Shanghai Railway Supplement, 2019, No. 2)" adopts the technique of replacing the filling mortar with a high rail lifting amount, and its problems have been detailed above. Summary of the Invention

[0008] To address the shortcomings of existing technologies, this invention provides a method for rapid replacement of filling mortar with low rail lifting volume.

[0009] This invention discloses a method for rapid replacement of filling mortar with low rail lifting amount, comprising:

[0010] Step 1: Remove the joints between the wide and narrow sections of the track, dismantle the tensioning locks and fasteners, and use jacks to lift the rails and track slabs at a low height;

[0011] Step 2: Install the tandem cutting equipment on the track slab. The track slab and the tandem cutting equipment are connected through a positioning mechanism. A hydraulic pump station is connected to the tandem cutting equipment to provide power.

[0012] Step 3: Adjust the height of the guide beam through the positioning mechanism, thereby driving the cutting carriage to move up and down to control the cutting thickness of the filling mortar.

[0013] Step 4: Start the cutting trolley and cut the filling mortar laterally along the track;

[0014] Step 5: After the cutting trolley completes one transverse pass of cutting the filling mortar, the cutting equipment is moved longitudinally along the track to the uncut area of ​​the filling mortar by the positioning mechanism.

[0015] Step 6: Repeat steps 3 to 5 until the cutting of the mortar filling layer under the entire track slab is completed;

[0016] Step 7: Dismantle the row of cutting equipment;

[0017] Step 8: Clean the surface of the base, control the track plate to fall using jacks, and then fine-tune the three-dimensional position of the track plate;

[0018] Step 9: After sealing and pressing the track slab, inject a new filling layer of mortar between the track slab and the base, and restore the rail.

[0019] As a further improvement of the present invention, the lifting height of the rail and track slab is 150mm to 250mm.

[0020] As a further improvement of the present invention, the combined cutting device includes: a cutting carriage, a guide beam, and a positioning mechanism;

[0021] The guide beam is equipped with positioning mechanisms at both ends and can be raised and lowered under the drive of the positioning mechanisms. The positioning mechanisms at both ends are straddling the two ends of the track plate in the transverse direction. The positioning mechanisms can move and position along the longitudinal direction of the track plate. The guide beam is located below the track plate.

[0022] The cutting trolley is mounted on the guide beam and is located above the filling mortar. The cutting trolley moves up and down with the guide beam to control the cutting thickness of the filling mortar. The cutting trolley can move laterally along the guide beam to complete the lateral cutting of the filling mortar.

[0023] As a further improvement of the present invention, the thickness of the filling mortar in a single transverse cutting of the cutting trolley is 10mm to 60mm, and the width of a single transverse cutting is 500mm to 1000mm.

[0024] As a further improvement of the present invention, the positioning mechanism includes a clamping body, an adjusting pressure plate, a guide shaft, an adjusting screw, an adjusting bracket, and longitudinal transfer wheels;

[0025] The lower part of the clamping body is provided with a clamping surface, and the adjusting pressure plate is installed on the clamping body and cooperates with the clamping surface to clamp and fix it on the track plate.

[0026] The adjusting bracket is located below the clamping body and is connected to the guide beam. A guide shaft and a height adjusting screw are installed on the clamping body and are connected to the adjusting bracket. Under the guidance of the guide shaft, the height of the adjusting bracket relative to the filling mortar is controlled by the height adjusting screw, thereby controlling the height of the guide beam and the cutting trolley relative to the filling mortar. After the adjusting pressure plate is released, the longitudinal transfer wheel is supported on the track plate and can move the row of cutting equipment longitudinally under the drive of external force.

[0027] As a further improvement of the present invention, the positioning mechanism is connected above the guide beam, and its height is adjusted by the positioning mechanism; the cutting carriage is connected below the guide beam, so that the cutting carriage is suspended above the base; the upper surface of the guide beam provides a lateral traveling surface along the track for the hanging and traveling mechanism of the cutting carriage, and transmits the vertical load of the cutting carriage; a rack is installed on the lower surface of the guide beam, and the rack meshes with the traveling motor of the cutting carriage to provide a lateral driving track for the cutting carriage along the track.

[0028] As a further improvement of the present invention, the cutting trolley includes a frame, a cutting motor, a traveling motor, a suspended traveling mechanism, a central cutting row of blades, and a side cutting row of blades. The suspended traveling mechanism is mounted on the frame and straddles the guide beam, suspending the cutting trolley above the base. The suspended traveling mechanism bears the load of the cutting trolley and moves on the guide beam via track wheels. The cutting motor is connected to a hydraulic pump station to provide power for the central and side cutting row of blades to cut the filling mortar. The traveling motor is connected to the hydraulic pump station and meshes with a rack mounted on the lower surface of the guide beam via gears to provide power for the trolley to move laterally along the track. The central and side cutting row of blades are connected to the cutting motor via gears to cut the filling mortar.

[0029] As a further improvement of the present invention, both the central cutting insert and the side cutting insert can be replaced with inserts with an outer diameter of 100mm to 200mm, and the insert gap can be adjusted between 1mm and 10mm.

[0030] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0031] This invention reduces the lifting height of rails and track slabs during mortar replacement, decreases the workload of disassembling and assembling fasteners and fine-tuning rails, and reduces the risk of damage to rails, fasteners, and embedded sleeves during operation, thus lowering operational safety risks. The modular cutting equipment used in this invention is a hydraulically driven, customized modular cutting device with modular blades tailored to the working conditions. The entire set of equipment can achieve a cutting width of 500mm to 1000mm in a single operation, greatly improving work efficiency, reducing equipment operation difficulty and time, improving equipment reliability, and increasing the cutting depth of the mortar filling layer. Attached Figure Description

[0032] Figure 1 This is an isometric view of the operating state of the tandem cutting equipment disclosed in this invention;

[0033] Figure 2 for Figure 1 A schematic diagram of the cross-section;

[0034] Figure 3 This is a schematic diagram of the structure of the parallel cutting device disclosed in this invention;

[0035] Figure 4 for Figure 3 Schematic diagram of the structure of the intermediate cutting carriage;

[0036] Figure 5 for Figure 3 A schematic diagram of the positioning mechanism;

[0037] Figure 6 This is a flowchart of the method for rapid replacement of filling mortar with low rail lifting volume disclosed in this invention.

[0038] In the picture:

[0039] 1. Steel rails;

[0040] 2. Track slab;

[0041] 3. Base;

[0042] 4. Filling layer mortar;

[0043] 5. Continuous cutting equipment;

[0044] 51. Cutting carriage; 511. Chassis; 512. Cutting motor; 513. Traveling motor; 514. Suspension and traveling mechanism; 515. Middle cutting row of inserts; 516. Side cutting row of inserts;

[0045] 52. Guide beam;

[0046] 53. Positioning mechanism; 531. Clamping body; 532. Adjusting pressure plate; 533. Guide shaft; 534. Height adjustment screw; 535. Adjusting bracket; 536. Longitudinal transfer wheel. Detailed Implementation

[0047] 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, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0048] 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. They are used only for the convenience of describing the invention and for 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. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0049] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" 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.

[0050] The present invention will now be described in further detail with reference to the accompanying drawings:

[0051] To address the following technical issues in the existing technology: (1) the large lifting height of the rails results in excessive workload for fastener assembly and disassembly, rail fine-tuning, and rail support limiting, and the seamless rails are subjected to greater additional stress. In curved sections, there is a risk of rail instability, high-temperature rail expansion, and low-temperature shrinkage that cannot be reset. In addition, large-scale repeated disassembly of fasteners and high-height rail lifting can easily cause damage to the rails, track, and pre-embedded sleeves; the large lifting height of the track slabs makes them prone to instability and overturning, especially in curved sections, where the lifting and lowering time of the track slabs is long; (3) manual chiseling is labor-intensive, incomplete, and inefficient, with limited working space and idle time. Personnel need to crawl under the slabs to chisel, posing a great safety risk; (4) lifting the rails is extremely difficult in special locations such as near turnout areas; etc., this invention provides a row of cutting equipment and a method for rapid replacement of filling mortar with low rail lifting volume.

[0052] Specifically:

[0053] like Figures 1-3 As shown, the present invention provides a series of cutting devices 5, which are used to cut the filling mortar 4 between the rail 1 and the track slab 2 and the base 3 after the rail 1 and the track slab 2 are lifted. The series of cutting devices 5 includes: a cutting trolley 51, a guide beam 52 and a positioning mechanism 53. The guide beam 52 is equipped with positioning mechanisms 53 at both ends and can be raised and lowered under the drive of the positioning mechanisms 53. The positioning mechanisms 53 are straddling the two ends of the track slab 2 in the transverse direction. The positioning mechanisms 53 can move and position along the longitudinal direction of the track slab 2. The guide beam 52 is located below the track slab 2. The cutting trolley 51 is installed on the guide beam 52 and is located above the filling mortar 4. The cutting trolley 51 is raised and lowered with the guide beam 52 to control the cutting thickness of the filling mortar 4. The cutting trolley 51 can move laterally along the guide beam 52 to complete the transverse cutting of the filling mortar 4.

[0054] Before using the tandem cutting device 5 to cut the filling mortar 4, the steel rail 1 and track slab 2 need to be lifted upwards by 150mm to 250mm using jacks.

[0055] The thickness of the filling mortar layer cut by the cutting carriage 51 of the present invention is 10mm to 60mm in a single transverse cutting, and the width of a single transverse cutting is 500mm to 1000mm.

[0056] like Figure 5As shown, the positioning mechanism 53 of the present invention includes a clamping body 531, an adjusting pressure plate 532, a guide shaft 533, an adjusting screw 534, an adjusting bracket 535, and a longitudinal transfer wheel 536. The lower part of the clamping body 531 is provided with a clamping surface. The adjusting pressure plate 532 is mounted on the clamping body 531 and, in conjunction with the clamping surface, can be clamped and fixed to the track plate 2. The adjusting bracket 535 is located below the clamping body 531 and is connected to the guide beam 52. A guide wheel 536 is mounted on the clamping body 531. The guide shaft 533 and the height adjustment screw 534 are connected to the adjusting bracket 535. Under the guidance of the guide shaft 533, the height of the adjusting bracket 535 relative to the filling mortar 4 is controlled by the height adjustment screw 534, thereby controlling the height of the guide beam 52 and the cutting trolley 51 relative to the filling mortar 4. After the adjusting pressure plate 532 is released, the longitudinal transfer wheel 536 is supported on the track plate 2, and the row of cutting equipment 5 can be moved longitudinally by manpower.

[0057] like Figure 3 As shown, a positioning mechanism 53 is connected above the guide beam 52 of the present invention, and its height is adjusted by the positioning mechanism 53; a cutting carriage 51 is connected below the guide beam 52, so that the cutting carriage 51 is suspended above the base 3; the upper surface of the guide beam 52 provides a lateral traveling surface along the track for the hanging and traveling mechanism 514 of the cutting carriage 51, and transmits the vertical load of the cutting carriage 51; a rack is installed on the lower surface of the guide beam 52, and the rack meshes with the traveling motor 513 of the cutting carriage 51, providing a lateral driving track for the cutting carriage 51 along the track. Furthermore, the guide beam 52 adopts a frame structure, is made of lightweight and high-strength materials, facilitates manual handling and disassembly during maintenance windows, and has a lateral length of 2500mm to 4000mm along the track.

[0058] like Figure 4As shown, the cutting carriage 51 of the present invention includes a frame 511, a cutting motor 512, a traveling motor 513, a suspension traveling mechanism 514, a central cutting row of inserts 515, and a side cutting row of inserts 516. The suspension traveling mechanism 514 is mounted on the frame 511 and straddles the guide beam 52, suspending the cutting carriage 51 above the base. The suspension traveling mechanism 514 bears the load of the cutting carriage 51 and moves on the guide beam 52 via track wheels. The cutting motor 512 is connected to a hydraulic pump station and provides power for the central cutting row of inserts 515 and the side cutting row of inserts 516. The row of cutting blades 516 provides power for cutting the filling mortar 4; the traveling motor 513 is connected to the hydraulic pump station and meshes with the rack mounted on the lower surface of the guide beam 52 via gears, providing power for the trolley 51 to move laterally along the track; the central cutting row of cutting blades 515 and the side cutting row of cutting blades 516 are connected to the cutting motor 512 via gears to cut the filling mortar 4; furthermore, both the central cutting row of cutting blades 515 and the side cutting row of cutting blades 516 can be replaced with blades with an outer diameter of 100mm to 200mm, and the blade gap can be adjusted between 1mm and 10mm. Furthermore, the frame 511 is made of lightweight, high-strength materials, facilitating manual handling and disassembly during maintenance windows.

[0059] The cutting depth of the cutting carriage 51 of the present invention is achieved by the height adjustment screw 534 of the positioning mechanism 53, and the cutting width is achieved by changing different models of the carriage 511, the middle cutting row of blades 515 and the side cutting row of blades 516.

[0060] like Figure 6 As shown, this invention provides a method for rapid replacement of filling mortar with low rail lifting, employing the aforementioned tandem cutting equipment, including:

[0061] S1. Remove the wide and narrow joints of the track, remove the tensioning locks and fasteners, and use jacks to lift the rails and track slabs upwards by 150mm to 250mm.

[0062] S2. Install a series of cutting devices on the track slab. The track slab and the series of cutting devices are connected through a positioning mechanism. A hydraulic pump station is connected to the series of cutting devices to provide power.

[0063] S3. Adjust the height of the guide beam through the positioning mechanism, thereby driving the cutting carriage to move up and down to control the cutting thickness of the filling mortar.

[0064] S4. Start the cutting trolley and cut the filling mortar layer laterally along the track;

[0065] S5. After the cutting trolley completes one transverse pass of cutting the filling mortar, the cutting equipment is moved longitudinally along the track to the uncut area of ​​the filling mortar by the positioning mechanism.

[0066] S6. Repeat steps S3 to S5 until the cutting of the mortar filling layer under the entire track slab is completed;

[0067] S7. Dismantle the row of cutting equipment;

[0068] S8. Clean the base surface, control the track plate to fall using jacks, and then fine-tune the three-dimensional position of the track plate;

[0069] S9. After sealing and pressing the track slab, inject a new filling layer of mortar between the track slab and the base, and restore the rail.

[0070] The main differences between the method of the parallel cutting equipment of the present invention and the trenching machine method of the prior art (CN113756142B) include:

[0071] 1. Different rail lifting heights: The rail slab lifting height of the grooving machine method is 200mm~500mm, while the rail slab lifting height of the row cutting equipment method is 150mm~250mm. This invention further reduces the lifting height of the rail and rail slab, further reduces the workload of disassembling and assembling fasteners and fine-tuning the rails, further reduces the risk of damage to the rails, fasteners, and embedded sleeves during operation, and further reduces the operational safety risks.

[0072] 2. The equipment used for cutting the filling mortar layer differs: The trenching machine method uses several electrically driven trenching machines installed side-by-side on a frame. Limited by the size and power of the trenching machine motors, this method requires spaced installation. The width of the filling mortar layer cut by a single trenching machine is limited; although not explicitly stated in the text, relevant equipment parameters indicate it is between 20mm and 50mm. This results in intermittent cutting of the mortar layer, leaving gaps that require precise repositioning and fixing before further cutting, making operation difficult and time-consuming. The combined cutting equipment method uses a hydraulically driven, customized combined cutting system with customized blades tailored to the specific working conditions. The entire system can cut a width of 500mm to 1000mm in a single operation, significantly improving efficiency and reducing operational difficulty and time. Furthermore, the trenching machine method uses multiple small motors, which, under these conditions, are prone to burnout due to prolonged high-power operation. Insufficient motor power leads to reduced efficiency at greater cutting depths, and a single motor failure can cause the entire system to shut down, resulting in lengthy replacement and maintenance times. The method of the parallel cutting equipment of the present invention is hydraulically driven, which ensures power and can achieve a maximum cutting depth of 60mm. The equipment has a low failure rate and the entire shaft can be quickly replaced after the blade wears out.

[0073] The above are merely preferred embodiments of the present invention and are not intended to limit the present 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 method for rapid replacement of filling layer mortar with low rail lifting volume, characterized in that, include: Step 1: Remove the wide and narrow joints of the track, remove the tensioning locks and fasteners, and use jacks to lift the rails and track slabs at a low height; wherein the lifting height of the rails and track slabs is 150mm~250mm. Step 2: Install a series of cutting devices on the track slab. The track slab and the series of cutting devices are connected by a positioning mechanism. A hydraulic pump station is connected to the series of cutting devices to provide power. The series of cutting devices includes a cutting trolley, a guide beam, and a positioning mechanism. The positioning mechanism is installed at both ends of the guide beam and can be raised and lowered under the action of the positioning mechanism. The positioning mechanism spans across both ends of the track slab laterally. The positioning mechanism can move and position itself along the longitudinal direction of the track slab. The guide beam is located below the track slab. The cutting trolley is installed on the guide beam and is positioned above the filling mortar. The cutting trolley rises and falls with the guide beam to control the cutting thickness of the filling mortar. The cutting trolley can move laterally along the guide beam to complete the lateral cutting of the filling mortar. Step 3: Adjust the height of the guide beam through the positioning mechanism, thereby driving the cutting carriage to move up and down to control the cutting thickness of the filling mortar. Step 4: Start the cutting trolley and cut the filling mortar laterally along the track; Step 5: After the cutting trolley completes one transverse pass of cutting the filling mortar, the cutting equipment is moved longitudinally along the track to the uncut area of ​​the filling mortar by the positioning mechanism. Step 6: Repeat steps 3 to 5 until the cutting of the mortar filling layer under the entire track slab is completed; Step 7: Dismantle the row of cutting equipment; Step 8: Clean the surface of the base, control the track plate to fall using jacks, and then fine-tune the three-dimensional position of the track plate; Step 9: After sealing and pressing the track slab, inject a new filling layer of mortar between the track slab and the base, and restore the rail.

2. The method for rapid replacement of filling mortar with low rail lifting volume as described in claim 1, characterized in that, The thickness of the filling mortar layer cut by the cutting trolley in a single transverse cut is 10mm~60mm, and the width of the single transverse cut is 500mm~1000mm.

3. The method for rapid replacement of filling mortar with low rail lifting volume as described in claim 1, characterized in that, The positioning mechanism includes a clamping body, an adjusting pressure plate, a guide shaft, an adjusting screw, an adjusting bracket, and longitudinal transfer wheels; The lower part of the clamping body is provided with a clamping surface, and the adjusting pressure plate is installed on the clamping body and cooperates with the clamping surface to clamp and fix it on the track plate. The adjusting bracket is located below the clamping body and is connected to the guide beam. A guide shaft and a height adjusting screw are installed on the clamping body and are connected to the adjusting bracket. Under the guidance of the guide shaft, the height of the adjusting bracket relative to the filling mortar is controlled by the height adjusting screw, thereby controlling the height of the guide beam and the cutting trolley relative to the filling mortar. After the adjusting pressure plate is released, the longitudinal transfer wheel is supported on the track plate and can move the row of cutting equipment longitudinally under the drive of external force.

4. The method for rapid replacement of filling mortar with low rail lifting volume as described in claim 1, characterized in that, The guide beam is connected to the positioning mechanism above, and its height is adjusted by the positioning mechanism; the guide beam is connected to the cutting carriage below, so that the cutting carriage is suspended above the base; the upper surface of the guide beam provides a lateral traveling surface along the track for the hanging and traveling mechanism of the cutting carriage, and transmits the vertical load of the cutting carriage; a rack is installed on the lower surface of the guide beam, and the rack meshes with the traveling motor of the cutting carriage to provide a lateral driving track for the cutting carriage along the track.

5. The method for rapid replacement of filling mortar with low rail lifting volume as described in claim 1, characterized in that, The cutting trolley includes a frame, a cutting motor, a traveling motor, a suspended traveling mechanism, a central cutting row of blades, and a side cutting row of blades. The suspended traveling mechanism is mounted on the frame and straddles the guide beam, suspending the cutting trolley above the base. The suspended traveling mechanism bears the load of the cutting trolley and moves on the guide beam via track wheels. The cutting motor is connected to a hydraulic pump station to provide power for the central and side cutting row of blades to cut the filling mortar. The traveling motor is connected to the hydraulic pump station and meshes with a rack mounted on the lower surface of the guide beam via gears to provide power for the trolley to move laterally along the track. The central and side cutting row of blades are connected to the cutting motor via gears to cut the filling mortar.

6. The method for rapid replacement of filling mortar with low rail lifting volume as described in claim 5, characterized in that, Both the central cutting insert and the side cutting insert can be replaced with inserts with an outer diameter of 100mm to 200mm, and the insert gap can be adjusted between 1mm and 10mm.

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