A positioning inspection method and device for high-speed railway ballastless track sleepers and fasteners

Abstract

The application discloses a positioning inspection method and a detection device for high-speed rail ballastless track sleepers and fasteners, and the device comprises a control frame of a four-wheel track vehicle structure, and a power transmission unit and an electric control inspection unit are arranged in the control frame. The power transmission unit comprises a servo motor, a driving shaft and walking wheels, wherein the servo motor is fixedly arranged in the control frame and provides rotating power for the driving shaft; the driving shaft is rotatably connected to the bottom of the control frame, and the walking wheels are coaxially fixedly arranged at the two ends of the driving shaft. The electric control inspection unit comprises a laser ranging sensor, an encoder, a travel switch and a controller which is provided with a display screen and internally carries a data acquisition system; the application can replace manual inspection of fasteners under the track one by one, improve the inspection efficiency, reduce the missed inspection probability, avoid single sleeper empty lifting and protrusion and other diseases caused by improper installation of fasteners in the later period, improve the precision and timeliness of fastener inspection, and improve the economic benefits.

Description

Technical Field

[0001] The invention relates to the field of track construction technology, and in particular to a positioning inspection method and testing device for sleepers and fasteners of high-speed railway ballastless track. Background Technology

[0002] Currently, during the installation of double-block ballastless track fasteners, assembly quality issues such as missing fasteners, foreign objects on the rail base, loose fasteners, and poor adhesion between the rail base and the rubber pad are prone to occur. These issues can lead to error transmission after concrete pouring, resulting in uneven track surfaces.

[0003] Although technicians are required to inspect each sleeper after the track panel frame is assembled, such problems still arise frequently, making it difficult to fine-tune the long rails of the ballastless track later.

[0004] In the double-block track panel assembly process, two methods are used: manual sleeper disassembly, on-site track panel assembly, and assembly platform assembly. The sleeper spacing is prone to deviations exceeding limits and cumulative errors. After the sleeper disassembly is completed, the sleeper spacing needs to be checked, which is a large workload and prone to omissions.

[0005] Therefore, how to solve the above problems and ensure the quality of pillow spacing and fastener installation has become a technical problem that urgently needs to be solved by those in this field. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies by proposing a positioning inspection method and testing device for sleepers and fasteners on high-speed railway ballastless tracks. This device allows for rapid on-track movement, intelligent detection of the sleeper center position via limit switches, and displays the measured distance between the centers of two sleepers on the controller. This distance is then calculated against the pre-set sleeper spacing. Simultaneously, a laser sensor activates, ensuring efficient operation while effectively and accurately detecting assembly quality issues such as fastener tightness and missing fasteners, even in low-light conditions. This replaces manual inspection of each rail base fastener, improving inspection efficiency, reducing the chance of missed inspections, and preventing defects such as loose or bulging sleepers due to improper fastener installation. This enhances the accuracy and timeliness of fastener inspection and improves economic benefits.

[0007] A method for positioning inspection of sleepers and fasteners for high-speed railway ballastless track includes the following steps:

[0008] S100: Before sleeper assembly, a crane is used in conjunction with sleeper lifting equipment to unload the sleepers and place them in the middle of the track.

[0009] S200: Use a gantry crane and sleeper lifting equipment to lift the sleepers to the site for manual distribution. After distribution, check the sleeper spacing. The sleeper spacing is 650mm, and the spacing deviation is ≤5mm. Before installation, clean the sleeper support platform and check the protective grease inside the pre-embedded sleeve.

[0010] S300: Install the elastic pad under the iron pad, iron pad, rail pad, gauge baffle, insulating gauge block, spring clip and spiral spike in sequence, and tighten the spiral spike with an electric torque wrench to a torque of 160 N·m.

[0011] S400: Place the control frame on the assembled track panel, align the laser sensor with the center of the first sleeper, set the standard value of the laser sensor to the sleeper shoulder to be 290mm, and start the servo motor.

[0012] S500: The control frame moves at a constant speed on the rails of the track panel. The limit switch controls the trolley to stop accurately at the center position of the sleeper. The measured sleeper spacing data is fed back to the controller. The difference between the measured sleeper distance and the designed sleeper distance is judged. If the difference exceeds the limit, an alarm is triggered, the movement stops, and the operator confirms on site. If the difference is within the normal range, the trolley stops for 5 seconds and the laser ranging function is executed.

[0013] S600: The data acquisition system collects the actual distance between the laser sensor and the sleeper. It analyzes and judges the data according to the judgment rules set in advance in the data acquisition system. When the laser shines on the ground or other invalid positions such as the track beam during distance measurement, the data acquisition system outputs invalid data on the display screen. When the fastener is installed correctly, the data acquisition system displays that the installation is normal, waits for 5 seconds, and then moves to the next sleeper for testing.

[0014] S700: When a fastener is missing due to a lack of rubber pads during on-site fastener installation, the display screen will show an out-of-limit deviation value and indicate that a pad is missing, and an alarm will be triggered; when a fastener is not tightened properly or there are foreign objects on the rail base, the display screen will show an out-of-limit deviation value and indicate that the fastener is not tightened, and an alarm will be triggered; at the same time, the servo motor will stop working, and the operator will need to confirm the situation on-site.

[0015] S800: If the fastener in the problematic area is indeed installed incorrectly, notify the construction personnel to rectify it immediately. After rectification, restart the servo motor and repeat the above steps S500-600 until all fasteners on site have been inspected.

[0016] The inspection device used in the positioning inspection method of high-speed railway ballastless track sleepers and fasteners includes a control frame of a four-wheeled railcar structure, which is equipped with a power transmission unit and an electrical control inspection unit.

[0017] Preferably, the power transmission unit includes a servo motor, a drive shaft, and wheels, wherein the servo motor is fixed inside the control frame and provides rotational power to the drive shaft; the drive shaft is rotatably connected to the bottom of the control frame, and wheels are coaxially fixed at both ends of the drive shaft.

[0018] Preferably, the electronic control testing unit includes: a laser rangefinder, an encoder, a limit switch, and a controller with a display screen and an internal data acquisition system;

[0019] Laser rangefinders are fixed on both sides of the bottom surface of the control frame. These laser rangefinders vertically detect the vertical distance between the top surface of the sleeper and the bottom surface of the control frame.

[0020] The encoder is fixed on the rotating drive shaft and moves relative to the control frame to measure the number of rotations of the drive shaft in order to determine the distance traveled by the wheels.

[0021] The limit switch is radially fixed at one end of the drive shaft. The trigger condition is that the limit switch contacts the top of the fastener to determine the start and stop inspection position of the positioning control frame.

[0022] The controller receives detection signals from the laser rangefinder, encoder, and limit switch, and feeds back to control the servo motor. The test results are displayed on the controller's screen.

[0023] The advantages and technical effects of this invention are as follows:

[0024] This invention discloses a positioning inspection method and testing device for high-speed railway ballastless track sleepers and fasteners. It features rapid movement on the track, simple assembly, lightweight design, high intelligence, and high accuracy. Using the track panel rails as the running track, the control frame can move freely on the rails via a servo motor. Laser distance sensors are installed at both ends of the control frame's crossbeam and can be adjusted within a certain range along the crossbeam direction, allowing for compatibility with all fastener systems of various specifications. A display mounted on the upper surface of the control frame shows the real-time distance between the left and right laser probes and the double-block sleepers. A remote control handle activates the servo motor. The servo motor allows for quick and convenient movement, while the limit switch intelligently detects the center position of the sleepers. The controller displays the measured distance between the centers of two sleepers and calculates it against the pre-set sleeper spacing. Simultaneously, the laser sensor activates, effectively and accurately detecting assembly quality issues such as whether fasteners are tight or missing, even in low-light conditions. This replaces manual inspection of each rail base fastener, improving inspection efficiency, reducing the chance of missed inspections, and preventing defects such as loose or bulging sleepers caused by improper fastener installation. This enhances the accuracy and timeliness of fastener inspection, thereby improving economic benefits. Attached Figure Description

[0025] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0026] Figure 2 This is a side view (partial cross-sectional view) of the present invention;

[0027] Figure 3 This is a side perspective view of the present invention;

[0028] Figure 4 This is a top view of the present invention.

[0029] In the diagram: 1 - Control frame; 2 - Walking wheel; 3 - Drive shaft; 4 - Servo motor; 5 - Encoder; 6 - Limit switch; 7 - Laser rangefinder; 8 - Controller; 9 - Display. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit the scope of this application; that is, the described embodiments are only a portion of, and not all, of the embodiments described herein.

[0031] This invention provides a positioning inspection method and testing device for sleepers and fasteners of high-speed railway ballastless track, such as... Figure 1 As shown, the walking system consists of a control frame 1, walking wheels 2, drive shaft 3, servo motor 4, encoder 5, and limit switch 6; the data acquisition system consists of a laser rangefinder sensor 7, controller 8, and display 9. This invention is applicable to the detection of CRTSⅠ type double-block ballastless track bed slabs and SK-2 type double-block sleepers. The fasteners consist of spiral track spikes, flat washers, elastic strips, insulated gauge blocks, gauge baffles, under-rail rubber pads, iron pads, and elastic pads under the iron pads. Using a gantry crane and sleeper lifting equipment, the sleepers are hoisted to the site for manual distribution. After distribution, the sleeper spacing is checked; the spacing is 650mm, with a deviation of ≤5mm. The following components are then installed in sequence: elastic pad under the iron pad, iron pad, under-rail rubber pad, gauge baffle, insulated gauge block, elastic clip, and spiral spikes (flat washers). The bolt holes of the elastic pad and iron pad must be aligned with the center of the pre-embedded sleeve. The flange of the under-rail pad must engage with the iron pad, and the edge lug of the insulated gauge block must engage with the shoulder of the iron pad. The spiral spikes are tightened to 160 N·m using an electric torque wrench. A limit switch controls the trolley to accurately stop at the center of the sleeper, and the measured sleeper data is fed back to the controller. The difference between the measured sleeper distance and the designed sleeper distance is checked, and an alarm is triggered if the difference exceeds the limit. Using the designed distance between the sensor and the sleeper as a benchmark, the difference between the measured distance and the designed distance is checked to quickly detect defects such as missing fasteners or unsupported rails.

[0032] Four wheels are mounted on the control frame, and servo motors are mounted on the two front wheels. The control frame is made of two parallel stainless steel square tubes with a cross-section of 50mm×50mm and a length of 2300mm, welded to two flanges. The distance between the two stainless steel square tubes is 392mm, the distance between the two flanges is 1340mm, the flange is 600mm long and 140mm wide, and the distance between the inner edges of the wheels is 1435mm. The wireless remote control handle can control the servo motor switch. The trolley moves at a constant speed on the track. The limit switch controls the trolley to stop accurately at the center position of the sleeper. The measured sleeper spacing data is fed back to the controller. The difference between the measured sleeper distance and the designed sleeper distance is judged and displayed on the controller. If the difference exceeds the limit, an alarm is triggered and the movement stops. If the difference is within the normal range, the movement stops for 5 seconds and the laser ranging function is executed. The servo motor is powered by a 24V DC battery.

[0033] The traveling wheels 2 are double-sided insulated nylon wheels with a diameter of 100mm. Each traveling wheel is equipped with a flange plate that matches the flange plate on the control frame 1. Two traveling wheels 2 are installed on each flange on the control frame 1.

[0034] Preferably, two laser ranging sensors are installed at both ends of the control frame crossbeam, with a distance of 1880mm between the two sensors. The display is installed in the middle of the trolley and connected to the two laser sensors via a data cable. The sensors are TOF laser sensors with a ranging accuracy of 1mm, short response time (millisecond level), and a detection angle of 19°. The display is a 230mm*460mm LED display. The left side of the display shows the relevant information of the left probe, and the right side shows the relevant information of the right probe, without interfering with each other.

[0035] Preferably, the servo motor controller can read data from the display. When the laser sensor detects a problem with the fastener installation, the servo motor stops working, the display shows the actual problem with the fastener installation, the operator checks the fastener on-site, and after confirming that there is no problem, the fastener installation is rectified. After the rectification is completed, the servo motor switch is restarted, and the automatic fastener inspection continues.

[0036] Based on the structure of the above embodiments, the detection method of the present invention is as follows:

[0037] S100: Before sleeper assembly, a crane is used in conjunction with sleeper lifting equipment to unload the sleepers and place them in the middle of the track.

[0038] S200: The sleepers are manually distributed on-site using a gantry crane and sleeper lifting equipment. After distribution, the sleeper spacing is checked. The sleeper spacing is 650mm, and the spacing deviation is ≤5mm. Before installation, the sleeper support platform is cleaned, and the protective grease inside the pre-embedded sleeve is checked.

[0039] S300: Install the elastic pad under the iron pad, iron pad, rail pad, gauge baffle, insulating gauge block, spring strip and spiral spike (flat washer) in sequence and accurately. Tighten the spiral spike with an electric torque wrench to a torque of 160 N·m.

[0040] S400: Place the control frame on the assembled track panel, align the laser sensor with the center of the first sleeper, set the standard value from the sensor to the sleeper shoulder to be 290mm, and start the servo motor.

[0041] S500: The trolley moves at a constant speed on the rail. The limit switch controls the trolley to stop accurately at the center position of the sleeper. The measured sleeper spacing data is fed back to the controller. The difference between the measured sleeper distance and the designed sleeper distance is judged. If the difference exceeds the limit, an alarm is triggered and the trolley stops moving. The operator confirms on site. If it is within the normal range, it stays for 5 seconds and executes the laser ranging function.

[0042] S600: The data acquisition system collects the actual distance between the laser sensor and the sleeper. It analyzes and judges the data using pre-set rules. If the distance measurement hits the ground or other invalid locations such as the track beam, invalid data is displayed on the screen. When the fastener is installed correctly, the screen displays "Installation Normal," waits 5 seconds, and then moves to the next sleeper for testing.

[0043] S700: When fastener installation on site is found to be incomplete, such as lacking rubber pads, the display screen will show an out-of-limit deviation value and indicate that a pad is missing, triggering an alarm. When fastener installation on site is found to be incomplete, such as loose bolts or foreign objects on the rail base, the display screen will show an out-of-limit deviation value and indicate that the fastener is not tight, triggering an alarm. Simultaneously, the servo motor will stop working, and operators will need to verify the situation on site.

[0044] S800: If the fastener in the problematic area is indeed installed incorrectly, notify the construction personnel to rectify it immediately. After rectification, restart the servo motor and repeat the above steps S500-600 until all fasteners on site have been inspected.

[0045] In addition, preferably, the controller is connected to a display 9 to send real-time monitoring data to the display for display.

[0046] Finally, any parts of the invention not fully described herein utilize existing mature products and technologies.

[0047] In the description of this specification, references to the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example that are included in the embodiment or example of the invention.

[0048] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A positioning inspection method for high-speed railway ballastless track sleeper and fastener, characterized in that, The method comprises the following steps: S100: Before the sleeper assembly construction, the sleepers are unloaded by a crane cooperating with a sleeper lifting tool, and the sleepers are placed in the middle of the line; S200: The sleepers are lifted to the site by a gantry crane and a sleeper lifting tool for manual sleeper scattering, the sleeper spacing is rechecked after the sleeper scattering is completed, the sleeper spacing is 650mm, and the spacing deviation is ≯5mm; the rail support platform of the sleeper is cleaned before installation, and the protective grease in the embedded sleeve is checked; S300: The elastic pad under the iron pad, the iron pad, the rail pad, the gauge baffle, the insulating gauge block, the elastic strip and the spiral spike are sequentially installed, and the spiral spike is tightened by using an electric torque wrench according to the torque of 160N·m; S400: The control frame is placed on the assembled rail, the laser sensor is aligned with the center of the first sleeper, the standard value of the laser sensor to the sleeper shoulder is set to 290mm, and the servo motor is started; S500: The control frame walks at a constant speed on the rail of the rail track, the travel switch controls the trolley to accurately stop at the center position of the sleeper, the actual sleeper spacing data is fed back to the controller, the difference between the actual sleeper distance and the designed sleeper distance is judged, when the limit is exceeded, the walking is stopped, and the on-site confirmation is performed by the worker; when it is within the normal range, it is stopped for 5 seconds, and the laser ranging function is executed; S600: The data acquisition system collects the actual distance between the laser sensor and the sleeper, analyzes and judges the data through the judgment rules set in the data acquisition system in advance, when the laser irradiation reaches the invalid position including the ground or the rail track beam during the ranging, the data acquisition system outputs and displays invalid data through the display screen; when the fastener is installed correctly, the data acquisition system displays the installation on the display screen, waits for 5 seconds, and moves to the next sleeper for detection; S700: When the fastener is missing due to the lack of rubber pad, the display screen displays the deviation value exceeding the limit value and the lack of pad, and an alarm is prompted; when the bolt is not tightened and there is foreign matter at the rail bottom, the display screen displays the deviation value exceeding the limit value and the fastener is not tightened, and an alarm is prompted; at the same time, the servo motor stops working, and the on-site confirmation is performed by the worker; S800: When the fastener at the problem position is indeed installed incorrectly, the construction personnel are informed to immediately correct, after the correction is completed, the servo motor is restarted, and the steps S500-S600 are repeated until the detection of all fasteners on the site is completed.

2. The positioning inspection method for the high-speed railway ballastless track sleeper and fastener according to claim 1, characterized in that: The inspection device used in the inspection method comprises a control frame in the structure of a four-wheel rail car, and a power transmission unit and an electric control inspection unit are arranged in the control frame.

3. The positioning inspection method of the high-speed railway ballastless track sleeper and fastener according to claim 2, characterized in that: The power transmission unit comprises a servo motor, a driving shaft and walking wheels, wherein the servo motor is fixedly arranged in the control frame and provides rotary power for the driving shaft; the driving shaft is rotatably connected to the bottom of the control frame, and walking wheels are fixedly arranged on the two ends of the driving shaft.

4. The positioning inspection method for the high-speed railway ballastless track sleeper and fastener according to claim 3, characterized in that: The electric control inspection unit comprises a laser ranging sensor, an encoder, a travel switch and a controller with a display screen and a data acquisition system arranged therein; The laser ranging sensor is fixedly arranged on the two sides of the bottom surface of the control frame, and the laser ranging sensor vertically detects the vertical distance between the top surface of the sleeper and the bottom surface of the control frame. The encoder is fixed on the rotating drive shaft and measures the number of rotations of the drive shaft relative to the control frame to obtain the running distance of the running wheel; The travel switch is radially fixed on one end of the drive shaft, and the trigger condition is that the travel switch contacts the top of the fastener to locate the start-stop inspection position of the control frame; The controller receives the detection signals of the laser ranging sensor, the encoder and the travel switch, and feeds back the control servo motor, and the inspection results are shown on the display screen on the controller.

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