Single turnout welding construction method based on air pressure welding

Abstract

The invention discloses a single turnout welding construction method based on air pressure welding, which relates to the technical field of railway welding, and comprises the following steps: S1, adopting an air pressure rail welding machine to realize accurate clamping of a welding joint in a narrow area in a turnout switch area; s2, the steel rail distribution length is calculated before welding, and it is ensured that a welded joint meets the geometric dimension standard; s3, the upsetting amount is accurately controlled in the welding process, and it is ensured that the length size of the welded steel rail meets the turnout size requirement; and S4, welding joint polishing and flaw detection are conducted after welding, and it is ensured that the welding quality meets the relevant standard. According to the method, an air pressure rail welding machine is used, welding joints in a plurality of narrow areas can be accurately clamped in a turnout area, the method is suitable for in-situ welding of new line turnouts, whole set replacement and maintenance welding of existing line turnouts and other scenes, and the method has the advantages of being high in welding precision, good in welding seam quality, high in applicability and the like; the device can be widely applied to railway turnout construction.

Description

Technical Field

[0001] The invention relates to the technical field of railway welding, and more specifically to the technical field of a single turnout welding construction method based on gas pressure welding. Background Art

[0002] The rail welding methods commonly used worldwide are flash welding, gas pressure welding and thermite welding.

[0003] The patent with the publication number CN118577914A and the patent name "A method for realizing seamless welding of the entire railway line" discloses the following content: The patent uses a flash welder to weld turnouts, and the method mainly lengthens the steel parts in the turnout area to meet the clamping space of the welder, so as to perform welding. However, the lengthening of the steel parts will increase the cost and make transportation difficult.

[0004] my country's railways mainly use thermite welding for welding. Small gas pressure welding machines were once used for turnout welding. However, due to the unstable welding quality and the difficulty in meeting the joint appearance standards, small gas pressure welding has been banned from use in various railway bureaus since 2012. At present, the welding joints in the turnout area of ​​railway turnouts are welded by thermite welding. However, according to the line damage statistics report of the whole railway bureau this year, the safety problems of the weld part are more prominent, among which thermite welding has the highest damage ratio and the situation is more serious. Therefore, it is very necessary and urgent to eliminate thermite welding joints in the turnout area, improve the joint quality, reduce the risk of broken rails, and ensure driving safety, which has important construction innovation significance and economic value. Summary of the invention

[0005] The purpose of the present invention is to solve the technical problems that the current railway turnout area adopts thermite welding, which results in the high proportion of thermite welding joints in the turnout area and the high proportion of line damage. The present invention provides a single-opening turnout welding construction method based on gas pressure welding.

[0006] In order to achieve the above-mentioned purpose, the present invention specifically adopts the following technical solutions:

[0007] The present invention provides a single turnout welding construction method based on gas pressure welding, comprising the following steps:

[0008] S1. Use pneumatic rail welding machine to achieve accurate clamping of welding joints in narrow areas of turnouts;

[0009] S2. Calculate the rail length before welding to ensure that the joint meets the geometric size standards after welding;

[0010] S3. During the welding process, the amount of upsetting is precisely controlled to ensure that the length of the rail after welding meets the size requirements of the turnout;

[0011] S4. After welding, the welding joints shall be polished and inspected to ensure that the welding quality meets the relevant standards.

[0012] Gas pressure welding can achieve precise control of the upset amount. After the turnout joint is welded, it can meet the line locking rail temperature requirements. The gas pressure rail welding machine used can weld the welding joints in the narrow area of ​​the turnout area, and the turnout steel parts can be welded without special lengthening.

[0013] In one embodiment, the turnout area includes a straight guide rail before the turnout, a curved guide rail before the turnout, a straight base rail, a curved base rail, a curved point rail, a straight point rail, an intermediate guide rail, a fork core, and four guide rails after the turnout; all of the above rails constitute four rails;

[0014] The first track includes the straight guide rails before the fork, the straight basic rails, the middle guide rails, the frog rails and the guide rails after the fork, which are arranged at intervals, and the intervals between the two are the No. 1 joint to be welded, the No. 3 joint to be welded, the No. 7 joint to be welded and the No. 11 joint to be welded respectively;

[0015] The second track includes a curved point rail, an intermediate guide rail, a fork core and a fork guide rail arranged at intervals, and the intervals between the two are No. 4 welding joint, No. 8 welding joint and No. 12 welding joint respectively;

[0016] The third track includes a straight point rail, an intermediate guide rail, a fork core and a fork guide rail arranged at intervals, and the intervals between each of them are No. 5 joint to be welded, No. 9 joint to be welded, and No. 13 joint to be welded respectively;

[0017] The third track includes the pre-fork curved guide rail, curved basic rail, middle guide rail, frog and post-fork guide rail, which are arranged at intervals. The intervals between each of them are No. 2 joint to be welded, No. 6 joint to be welded, No. 10 joint to be welded and No. 14 joint to be welded.

[0018] The curved point rail and the straight point rail are located between the straight basic rail and the curved basic rail. The curved point rail and the straight basic rail are replaced by a switching and withdrawing machine, and the straight point rail and the curved basic rail are replaced by a switching and withdrawing machine.

[0019] In one embodiment, the welded joint outside the turnout area includes a No. 1 welded joint and a No. 2 welded joint;

[0020] The welded joints in the narrow area of ​​the turnout area include No. 3 welded joint, No. 4 welded joint, No. 5 welded joint, No. 6 welded joint, No. 7 welded joint, No. 8 welded joint, No. 9 welded joint and No. 10 welded joint;

[0021] All welding joints are located at the corresponding joints to be welded; the welding equipment can adapt to the narrow welding area of ​​the turnout area.

[0022] Specifically, the pneumatic rail welding machine can clamp the No. 3 welding joint, No. 4 welding joint, No. 5 welding joint, No. 6 welding joint, No. 7 welding joint, No. 8 welding joint, No. 9 welding joint and No. 10 welding joint in the narrow area of ​​the turnout area, and can realize the welding of the joints in the entire fork area without special lengthening of the turnout steel parts (≤100mm).

[0023] In one embodiment, in step S1, the welding sequence includes first welding the base rail of the turnout, then sequentially welding the point rail and frog joint of the turnout, and finally completing the overall welding of the turnout.

[0024] In one embodiment, the welding equipment is capable of controlling the upset amount to ensure the strength and quality of the weld joint, and the upset amount control error is less than ±0.5 mm.

[0025] In one embodiment, the welding sequence includes:

[0026] S21, first weld the welding joints of the turnout stock rail, that is, first weld the No. 3 welding joint and the No. 6 welding joint in sequence;

[0027] S22, then welding the switch rail welding joints, welding the No. 4 welding joint and the No. 5 welding joint in sequence;

[0028] S23, then weld the outer welding joint of the frog part, and weld the seventh welding joint and the tenth welding joint in sequence;

[0029] S24. Finally, weld the inner welding joint of the frog part, and weld the No. 8 welding joint and the No. 9 welding joint in sequence.

[0030] Specifically, the welding operation sequence can be flexibly adjusted according to on-site construction conditions to ensure that the welding process is completed efficiently.

[0031] Due to the above-mentioned technical characteristics, various turnout welding construction operations can be realized by adjusting the construction operation sequence, including in-situ welding of turnout steel parts on new lines, replacement of entire groups of turnouts on existing lines, and in-situ replacement of turnout steel parts on existing lines.

[0032] In one embodiment, after welding is completed, all welded joints are subjected to ultrasonic flaw detection and appearance inspection to ensure that the welding quality meets the railway standard requirements.

[0033] In one embodiment, precise rail temperature control is used during the welding process to ensure that the welded joint is made at the rail locking rail temperature to avoid excessive internal stress in the rail after welding.

[0034] In one embodiment, the method for calculating the rail length before welding is:

[0035] L=X+a1+a2+u1+u2+4×b+2×d;

[0036] Among them, u1 and u2 represent the length of the mark, a1 and a2 represent the weld width, b represents the end milling amount of one end, and d represents the welding upsetting amount.

[0037] In one embodiment, the welding equipment is installed on a road-rail vehicle or a train flatbed with a single-arm crane, and can be flexibly moved on the construction site to adapt to different construction environments.

[0038] The beneficial effects of the present invention are as follows:

[0039] 1. The invention has a reasonable design and can complete the pneumatic welding of all joints in the turnout area, realizing the use of pneumatic welding instead of thermite welding in the turnout area. The pneumatic rail welding machine is used to weld all joints in the turnout area. The equipment can clamp and weld the turnout steel parts that are not specially lengthened. The welding method can significantly improve the welding quality of the turnout joints, reduce the failure rate, and has important innovation significance and economic value in engineering construction.

[0040] 2. The gas pressure welding of the present invention can realize accurate control of the upset amount. After the turnout joint is welded, the line locking rail temperature requirement can be met. The gas pressure rail welding machine used can weld the welding joints in the narrow area of ​​the turnout area, and the turnout steel parts can be welded without being specially lengthened.

[0041] 3. The welding operation sequence of the present invention can be flexibly adjusted according to the on-site construction conditions to ensure efficient completion of the welding process. Due to the above technical characteristics, by adjusting the construction operation sequence, various turnout welding operations can be achieved, including in-situ welding of new line turnout steel parts, replacement of existing line turnouts as a whole, and in-situ replacement of existing line turnout steel parts.

[0042] 4. The welding upsetting amount is precisely controlled. The straightness and geometric dimensions of the welded joints meet the requirements of "TB 10754-2018 High-speed Railway Track Engineering Construction Quality Acceptance Standard" and "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding". BRIEF DESCRIPTION OF THE DRAWINGS

[0043] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0044] Figure 1 It is a schematic diagram of the position of single turnout and welding joints.

[0045] Figure 2It is a schematic diagram for checking the track length marking.

[0046] Figure 3 It is the support diagram of straight and curved basic rails.

[0047] Figure 4 It is a schematic diagram of the straight and curved basic rail support pad.

[0048] Figure 5 It is a diagram of a combined frog pad.

[0049] Figure 6 This is a schematic diagram of the No. 3 welding joint rail and end milling to the position line.

[0050] Figure 7 This is a schematic diagram of the welding support pad for welding joint No. 3.

[0051] Figure 8 This is a schematic diagram of the No. 3 welding joint rail and end milling to the position line.

[0052] Fig. 9 This is a schematic diagram of the welding support pad for the No. 6 welding joint.

[0053] Fig.10 This is the schematic diagram of the No. 4 welding joint rail.

[0054] Fig.11 This is a schematic diagram of the rail support pad.

[0055] Fig.12 This is a schematic diagram of the No. 4 welded joint curved rail support pad.

[0056] Fig.13 This is a schematic diagram of the saw rail and end milling position line.

[0057] Fig.14 This is a schematic diagram of the No. 5 welding joint rail.

[0058] Figure 15(a) is a schematic diagram of the welding support pad of the No. 5 welding joint.

[0059] Figure 15(b) is a schematic diagram of the saw rail and end milling position line.

[0060] Fig.16 This is the schematic diagram of the No. 7 welding joint rail.

[0061] Fig.17 This is a schematic diagram of the No. 7 welded joint pad rail.

[0062] Fig.18 This is a schematic diagram of the No. 7 welding joint saw rail and end milling to the position line.

[0063] Fig.19 This is a schematic diagram of the No. 10 welding joint rail.

[0064] Fig. 20This is a schematic diagram of the welding support pad for the No. 10 welding joint.

[0065] Fig.21 This is a schematic diagram of the No. 8 welded joint frog end support pad.

[0066] Fig. 22 It is a schematic diagram of the No. 8 welded joint saw rail and end milling to the position line.

[0067] Fig.23 This is a schematic diagram of the No. 9 welded joint frog end support pad.

[0068] Fig.24 It is a schematic diagram of the No. 9 welded joint saw rail and end milling to the position line.

[0069] Fig.25 This is a schematic diagram of the alignment of the No. 1 and No. 2 welding joints and the end milling to the position line.

[0070] Fig.26 This is a schematic diagram of the rail matching and end milling to the position line.

[0071] Fig. 27 This is a welding diagram of No. 1 and No. 2 welding joints.

[0072] Fig.28 This is a welding diagram of No. 3, No. 4, No. 5, and No. 6 welding joints.

[0073] Fig.29 This is a welding diagram of No. 7, No. 8, No. 9 and No. 10 welding joints.

[0074] Fig.30 This is a welding diagram of No. 11, No. 12, No. 13, and No. 14 welding joints. DETAILED DESCRIPTION

[0075] In order to make the technical problems, technical solutions and technical effects of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0076] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0077] It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings. In addition, the terms "first", "second", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0078] In the description of the embodiments of the present invention, it should be noted that the terms "inside", "outside", "upper", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0079] The present invention provides a single turnout welding construction method based on gas pressure welding, comprising the following steps:

[0080] S1. Use pneumatic rail welding machine to achieve accurate clamping of welding joints in narrow areas of turnouts;

[0081] S2. Calculate the rail length before welding to ensure that the joint meets the geometric size standards after welding;

[0082] S3. During the welding process, the amount of upsetting is precisely controlled to ensure that the length of the rail after welding meets the size requirements of the turnout;

[0083] S4. After welding, the welding joints shall be polished and inspected to ensure that the welding quality meets the relevant standards.

[0084] Gas pressure welding can achieve precise control of the upset amount. After the turnout joint is welded, it can meet the line locking rail temperature requirements. The gas pressure rail welding machine used can weld the welding joints in the narrow area of ​​the turnout area, and the turnout steel parts can be welded without special lengthening.

[0085] In one embodiment, the turnout area includes a straight guide rail before the turnout, a curved guide rail before the turnout, a straight base rail, a curved base rail, a curved point rail, a straight point rail, an intermediate guide rail, two frogs, a fork core, and four guide rails after the turnout; all of the above rails constitute four rails;

[0086] The first track includes the straight guide rails before the fork, the straight basic rails, the middle guide rails, the frog rails and the guide rails after the fork, which are arranged at intervals, and the intervals between the two are the No. 1 joint to be welded, the No. 3 joint to be welded, the No. 7 joint to be welded and the No. 11 joint to be welded respectively;

[0087] The second track includes a curved point rail, an intermediate guide rail, a fork core and a fork guide rail arranged at intervals, and the intervals between the two are No. 4 welding joint, No. 8 welding joint and No. 12 welding joint respectively;

[0088] The third track includes a straight point rail, an intermediate guide rail, a fork core and a fork guide rail arranged at intervals, and the intervals between each of them are No. 5 joint to be welded, No. 9 joint to be welded, and No. 13 joint to be welded respectively;

[0089] The third track includes the pre-fork curved guide rail, curved basic rail, middle guide rail, frog and post-fork guide rail, which are arranged at intervals. The intervals between each of them are No. 2 joint to be welded, No. 6 joint to be welded, No. 10 joint to be welded and No. 14 joint to be welded.

[0090] The curved point rail and the straight point rail are located between the straight basic rail and the curved basic rail. The curved point rail and the straight basic rail are replaced by a switching and withdrawing machine, and the straight point rail and the curved basic rail are replaced by a switching and withdrawing machine.

[0091] In one embodiment, the welded joint outside the turnout area includes a No. 1 welded joint and a No. 2 welded joint;

[0092] The welded joints in the narrow area of ​​the turnout area include No. 3 welded joint, No. 4 welded joint, No. 5 welded joint, No. 6 welded joint, No. 7 welded joint, No. 8 welded joint, No. 9 welded joint and No. 10 welded joint;

[0093] All welding joints are located at the corresponding joints to be welded; the welding equipment can adapt to the narrow welding area of ​​the turnout area.

[0094] Specifically, the pneumatic rail welding machine can clamp the No. 3 welding joint, No. 4 welding joint, No. 5 welding joint, No. 6 welding joint, No. 7 welding joint, No. 8 welding joint, No. 9 welding joint and No. 10 welding joint in the narrow area of ​​the turnout area, and can realize the welding of the joints in the entire fork area without special lengthening of the turnout steel parts (≤100mm).

[0095] In one embodiment, in step S1, the welding sequence includes first welding the base rail of the turnout, then sequentially welding the point rail and frog joint of the turnout, and finally completing the overall welding of the turnout.

[0096] In one embodiment, the welding equipment is capable of controlling the upset amount to ensure the strength and quality of the weld joint, and the upset amount control error is less than ±0.5 mm.

[0097] In one embodiment, the welding sequence includes:

[0098] S21, first weld the welding joints of the turnout stock rail, that is, first weld the No. 3 welding joint and the No. 6 welding joint in sequence;

[0099] S22, then welding the switch rail welding joints, welding the No. 4 welding joint and the No. 5 welding joint in sequence;

[0100] S23, then weld the outer welding joints of the frog part, and weld the seventh welding joint and the tenth welding joint in sequence;

[0101] S24. Finally, weld the inner welding joint of the frog part, and weld the No. 8 welding joint and the No. 9 welding joint in sequence.

[0102] Specifically, the welding operation sequence can be flexibly adjusted according to on-site construction conditions to ensure that the welding process is completed efficiently.

[0103] Due to the above-mentioned technical characteristics, various turnout welding construction operations can be realized by adjusting the construction operation sequence, including in-situ welding of turnout steel parts on new lines, replacement of entire groups of turnouts on existing lines, and in-situ replacement of turnout steel parts on existing lines.

[0104] In one embodiment, after welding is completed, all welded joints are subjected to ultrasonic flaw detection and appearance inspection to ensure that the welding quality meets the railway standard requirements.

[0105] In one embodiment, precise rail temperature control is used during the welding process to ensure that the welded joint is made at the rail locking rail temperature to avoid excessive internal stress in the rail after welding.

[0106] In one embodiment, the method for calculating the rail length before welding is:

[0107] L=X+a1+a2+u1+u2+4×b+2×d;

[0108] Among them, u1 and u2 represent the length of the mark, a1 and a2 represent the weld width, b represents the end milling amount of one end, and d represents the welding upsetting amount.

[0109] In one embodiment, the welding equipment is installed on a road-rail vehicle or a train flatbed with a single-arm crane, and can be flexibly moved on the construction site to adapt to different construction environments.

[0110] In detail:

[0111] Welding methods for various welding joints in the fork area:

[0112] like Figure 1 As shown, a single set of turnouts has a total of 14 welding joints: welding joint No. 1, welding joint No. 2, welding joint No. 3, welding joint No. 4, welding joint No. 5, welding joint No. 6, welding joint No. 7, welding joint No. 8, welding joint No. 9, welding joint No. 10, welding joint No. 11, welding joint No. 12, welding joint No. 13, and welding joint No. 14.

[0113] The spacing between the No. 3, No. 4, No. 5 and No. 6 welding joints is narrow, so the straight and curved basic rails need to be pulled outwards by 100-200mm for clamping welding. The remaining welding joints are welded according to the requirements of gas pressure welding based on the on-site construction conditions.

[0114] Calculation method for rail matching before welding:

[0115] like Figure 2 As shown, the two middle rails (tool rails and matching rails) connecting the fork center need to be replaced. The length of the replacement rails is calculated according to the following formula:

[0116] L=X+a1+a2+u1+u2+4×b+2×d;

[0117] Among them, u1 and u2 represent the length of the mark, a1 and a2 represent the weld width, b represents the end milling amount of one end, and d represents the welding upsetting amount.

[0118] Rail support method before welding:

[0119] (1) Straight and curved basic rails

[0120] 1) Before removing the fasteners, mark the relative positions between the point rail and the sleeper, and the relative positions between the straight and curved base rails and the point rails;

[0121] 2) Loosen the 10m rail iron plate bolts between the end face to be welded and the point rail end, and keep the remaining length of the steel parts in their original state; loosen the rail fasteners at the fork end as a whole and keep them free;

[0122] 3) Remove the iron plates at both ends of the welded joint and Figure 3 As shown, inter-pillar support is performed on both sides of the welded joint.

[0123] (2) Straight and curved rails

[0124] 1) Remove the 6 fasteners from the end face of the pointed rail to be welded to the end of the pointed rail, and remove the 3 lateral limit wheels of the pointed rail;

[0125] 2) Move the straight and curved rails inwards by 230 mm. Figure 4 The support rail shown has a rail bottom higher than the top surface of the fastener seat and is aligned with the new rail to be connected;

[0126] 3) Both sides of the welding joint are supported outward from the end surface.

[0127] (3) Combined frog

[0128] 1) Before removing the iron plate bolts, mark the relative position between the frog center and the sleeper;

[0129] 2) Loosen the 9m rail iron plate bolts at the end of the fork core to be welded, and loosen the fasteners of the two middle rails (tool rails and matching rails) connecting the fork core as a whole;

[0130] 3) Remove the first iron plate at both ends of the welded joint and follow Figure 5 Support rails;

[0131] Welding methods for various welding joints:

[0132] The welding method of No. 3 welding joint is as follows:

[0133] ① Track matching: According to the factory-extended size of the turnout steel parts of 100mm, the rear end of the saw rail is milled to the position line (the straight basic rail reserve D = 4mm (aluminum thermite weld) + 16mm (1 / 2 of the top forging amount of 32mm) = 20mm) Figure 6 As shown;

[0134] ② Loosen the bolts: loosen the 9m iron plate bolts (15 pieces) at the end of the straight basic rail to be welded, and remove the first iron plate at the end of the welding joint to facilitate the lowering of the welding machine;

[0135] ③ Rail support pad:

[0136] Loosen all fasteners of the middle rail (tool rail) of the fork-removal connection, support the rail, and remove the first iron pad at the end of the welded joint; move the point rail 230mm to the center of the track to facilitate rail welding and clamping; support the rail in the following way: Figure 7 shown.

[0137] ④ Saw rail marking: leave a line on the saw rail 76mm away from the end face, and the verticality of the saw rail is less than 2mm;

[0138] ⑤ End milling position line: 80mm away from the end face is the end milling position line (such as Figure 7 As shown), the design value of top forging consumption is 32mm.

[0139] End milling error <0.1mm;

[0140] ⑥ End surface treatment and welding: The results must meet the requirements of "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding";

[0141] ⑦ Fill in the welding record sheet for welding joint No. 3.

[0142] The welding method of No. 6 welding joint is as follows:

[0143] ① Track matching: According to the factory-extended size of the turnout steel parts of 100mm, the rear end of the saw rail is milled to the position line (the straight basic rail reserve D = 4mm (aluminum thermite weld) + 16mm (1 / 2 of the top forging amount of 32mm) = 20mm). Figure 8 As shown;

[0144] ② Loosen the bolts: loosen the 9m iron plate bolts (15 pieces) at the end of the straight basic rail to be welded, and remove the first iron plate at the end of the welding joint to facilitate the lowering of the welding machine;

[0145] ③ Rail shifting and support: loosen all fasteners of the middle rail (tool rail) of the fork-removal connection, support the rail, and remove the first iron pad at the end of the welded joint; shift the point rail 230mm to the center of the track to facilitate rail welding and clamping; support methods such as Fig. 9 shown.

[0146] ④ Saw rail marking: leave a line on the saw rail 76mm away from the end face, and the verticality of the saw rail is less than 2mm;

[0147] ⑤ End milling position line: 80mm away from the end face is the end milling position line (such as Fig. 9 As shown), the design value of top forging consumption is 32mm.

[0148] End milling error <0.1mm;

[0149] ⑥ End surface treatment and welding: The results must meet the requirements of "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding";

[0150] ⑦ Fill in the welding record sheet for welding joint No. 6.

[0151] The welding method of No. 4 welding joint is as follows:

[0152] ① Rail matching: AT rail is lengthened by 600mm, the rail tip end is not lengthened, and the rail is marked 560mm from the end face when sawing the rail (D = upsetting amount 32mm + 8mm aluminum thermite weld); Fig.10 As shown;

[0153] ② Loosen bolts: loosen the 6 rail fasteners at the end of the curved point rail to be welded (leave the loosened fasteners in place), and remove the 3 point rail limit wheels;

[0154] ③ Rail support pad:

[0155] Loosen the rail fastener, leave a 50mm spacer at the weld of the rail point rail end to smooth it, remove the first iron pad at the end of the welded joint, and place the pad as shown in the figure. Fig.11 As shown;

[0156] The support pads at the six points of the pointed rail are spaced 3m apart, with a height of 165mm, and are moved inwards 150-230mm to be aligned with the connecting rail; Fig.12 As shown;

[0157] ④ Rail sawing and marking: AT rails are not sawn, the rails are marked 556mm from the end face, and the verticality of the sawed rails is less than 2mm;

[0158] ⑤ End milling position line: 2mm from the end face of the AT track gauge is the end milling position line (such as Fig.13 As shown), the end face of the gauge is 558mm, which is the end milling position line (as shown Fig.13 As shown), the design value of upsetting consumption is 32mm. End milling error is less than 0.1mm;

[0159] ⑥ End surface treatment and welding: The results must meet "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding";

[0160] ⑦ Fill in the welding record sheet for welding joint No. 4.

[0161] The welding method of No. 5 welding joint is as follows:

[0162] ① Rail: AT rail is lengthened by 600mm, the rail tip end is not lengthened, and the rail is marked 560mm from the end face when sawing the rail (D = upsetting amount 32mm + 8mm aluminum thermite weld). Fig.14 As shown;

[0163] ② Loosen bolts: loosen the 6 rail fasteners at the end of the curved point rail to be welded (leave the loosened fasteners in place), and remove the 3 point rail limit wheels;

[0164] ③ Rail support pad:

[0165] Loosen the rail fastener, leave a 50mm spacer at the rail point end weld to make it smooth, and remove the first iron pad at the end of the rail fork core of the welded joint;

[0166] The six points of the support rail are spaced 3m apart, with a height of 165mm, and are moved inwards by 150-230mm to be aligned with the connecting rail;

[0167] The support diagram is shown in Figure 15(a).

[0168] ④ Rail sawing and marking: AT rails are not sawn, the rails are marked 556mm from the end face, and the verticality of the sawed rails is less than 2mm;

[0169] ⑤ End milling position line: 2mm at the AT gauge end face is the end milling position line (as shown in Figure 15(b)), and 558mm at the matching gauge end face is the end milling position line (as shown in Figure 15(b)). The design value of the top forging consumption is 32mm. The end milling error is less than 0.1mm.

[0170] ⑥ End surface treatment and welding: The results must meet "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding"

[0171] ⑦ Fill in the welding record sheet for No. 5 welding joint.

[0172] The welding method of No. 7 welding joint is as follows:

[0173] ① Track matching: According to the factory-extended size of the turnout steel parts of 100mm, the rear end of the saw rail is milled to the position line (the straight basic rail reserve D = 4mm (aluminum thermite weld) + 16mm (1 / 2 of the top forging amount of 32mm) = 20mm). Fig.16 As shown;

[0174] ② Loosen the bolts: loosen the rail 3-7 fasteners, reserve 50mm spacing at the weld to make it smooth, and remove the first iron pad on the end face of the welded joint to facilitate the lowering of the welding machine;

[0175] ③ Rail support pad:

[0176] Loosen all rail fasteners and support rails;

[0177] Smoothly weld the rail supports at both ends of the welded joint;

[0178] Support method such as Fig.17 shown.

[0179] ④ Saw rail marking: leave a line on the saw rail 76mm away from the end face, and the verticality of the saw rail is less than 2mm;

[0180] ⑤ End milling position line: 80mm away from the end face is the end milling position line (such as Fig.18 As shown), the design value of top forging consumption is 32mm.

[0181] End milling error <0.1mm;

[0182] ⑥ End surface treatment and welding: The results must meet "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding".

[0183] ⑦ Fill in the welding record sheet for welding joint No. 7.

[0184] The welding method of No. 10 welding joint is as follows:

[0185] ① Track matching: According to the factory-extended size of the turnout steel parts of 100mm, the rear end of the saw rail is milled to the position line (the straight basic rail reserve D = 4mm (aluminum thermite weld) + 16mm (1 / 2 of the top forging amount of 32mm) = 20mm); Fig.19 As shown;

[0186] ② Loosen the bolts: loosen the rail fasteners, reserve 50mm spacing at the weld to make it smooth, and remove the first iron pad on the end face of the welded joint to facilitate the lowering of the welding machine;

[0187] ③ Rail support pad:

[0188] Loosen all rail fasteners and support rails;

[0189] Smoothly weld the rail supports at both ends of the welded joint;

[0190] Support method such as Fig. 20 shown.

[0191] ④ Saw rail marking: leave a line on the saw rail 76mm away from the end face, and the verticality of the saw rail is less than 2mm;

[0192] ⑤ End milling position line: 80mm away from the end face is the end milling position line (such as Fig.19 As shown), the design value of top forging consumption is 32mm.

[0193] End milling error <0.1mm;

[0194] ⑥ End surface treatment and welding: The results must meet "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding".

[0195] ⑦ Fill in the welding record sheet for welding joint No. 10.

[0196] The welding method of No. 8 welding joint is as follows:

[0197] ① Track matching: restore the track with the matching rail and the point rail according to the gauge size and the stopper size requirements; leave 12m of fasteners unlocked from the end face, and when the design locked rail temperature is 34° (±2), the length of the track matching is calculated by overlapping the steel parts at both ends of the welded joint. The frog center end is first sawn and milled flat as the starting line (80mm from the end face is the end milling position line), and the matching length is the reserved amount D = 32mm for the sawn rail rear end milling position line;

[0198] ② Loosen the bolts: Loosen the 9m iron pad from the frog core fastener and remove the first iron pad at the end of the welded joint;

[0199] ③ Rail support pad:

[0200] Loosen all the fasteners at the end of the point rail and push the 80mm support rail straight toward the point rail;

[0201] Pad the frog end ties 100mm apart and make the rail pads between the point rails straight;

[0202] Support diagram Fig.21 As shown;

[0203] ④ Saw rail marking: leave a saw rail at 76mm from the end face of the frog center, and the verticality of the saw rail is less than 2mm; leave a saw rail at 36mm from the end milling precision point to the frog center. The verticality of the saw rail is less than 2mm;

[0204] ⑤ End milling position line: The end milling position line is 80mm from the frog center end to the end face (such as Fig. 22 The end of the rail is 32mm away from the end face, which is the end milling position line (as shown in Fig. 22 As shown), the design value of upsetting consumption is 32mm. End milling error is less than 0.1mm;

[0205] ⑥ End surface treatment and welding: The results must meet the requirements of "TB / T 1632.4-2014 Rail Welding Part 4 Gas Pressure Welding".

[0206] ⑦ Fill in the welding record sheet for No. 8 welding joint.

[0207] The welding method of No. 9 welding joint is as follows:

[0208] ① Track matching: restore the track with the matching rail and the point rail according to the gauge size and the stopper size requirements; leave 12m of fasteners unlocked from the end face, and when the design locked rail temperature is 34° (±2), the length of the track matching is calculated by overlapping the steel parts at both ends of the welded joint. The frog center end is first sawn and milled flat as the starting line (80mm from the end face is the end milling position line), and the matching length is the reserved amount D = 32mm for the sawn rail rear end milling position line;

[0209] ② Loosen bolts: Loosen the 9m iron pad of the frog core fastener, remove the first iron pad at the end of the welded joint; loosen all fasteners at the end of the point rail and push the 80mm pad rail toward the point rail to make it straight;

[0210] ③ Rail support pad:

[0211] Loosen all the fasteners at the end of the point rail and push the 80mm support rail straight toward the point rail;

[0212] The pads between the frog end sleepers are 100mm apart, and the pads between the point rails are straightened;

[0213] Support diagram Fig.23 As shown;

[0214] ④ Saw rail marking: leave a saw rail at 76mm from the end face of the frog center, and the verticality of the saw rail is less than 2mm; leave a saw rail at 36mm from the end milling precision point to the frog center. The verticality of the saw rail is less than 2mm;

[0215] ⑤ End milling position line: The end milling position line is 80mm from the frog center end to the end face (such as Fig.24 As shown), the end of the rail is 32mm away from the end face, which is the end milling position line (as shown Fig.24 As shown). The design value of upsetting consumption is 32mm. End milling error is <0.1mm;

[0216] ⑥ End surface treatment and welding: The results must meet "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding".

[0217] ⑦ Fill in the welding record sheet for welding joint No. 9.

[0218] The welding method for No. 1 and No. 2 welding joints is as follows:

[0219] ① Track matching: According to the factory-extended size of the turnout steel parts of 100mm, the rear end of the saw rail is milled to the position line (reserved amount D = 4mm (aluminum thermite weld) + 16mm (1 / 2 of the top forging amount of 32mm) = 20mm). Fig.25 As shown;

[0220] ② Loosen the bolts: loosen the 6m iron plate bolts (10 in number) at the end of the straight and curved basic rail to be welded, and remove the first iron plate at the end of the welding joint to facilitate the lowering of the welding machine;

[0221] ③ Rail support: remove all fasteners of the steel parts to be welded, and support 3-4 places at 3m intervals to keep the rails straight;

[0222] ④ Saw rail marking: leave a line on the saw rail 76mm away from the end face, and the verticality of the saw rail is less than 2mm;

[0223] ⑤ End milling position line: 80mm away from the end face is the end milling position line (such as Fig.25 As shown), the design value of top forging consumption is 32mm.

[0224] End milling error <0.1mm;

[0225] ⑥ End surface treatment and welding: The results must meet the requirements of "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding";

[0226] ⑦Fill in the record form.

[0227] The welding method for No. 11 to No. 14 welding joints is as follows:

[0228] ① Track matching: According to the factory-extended size of the turnout steel parts of 100mm, the rear end of the saw rail is milled to the position line (reserved amount D = 4mm (aluminum thermite weld) + 16mm (1 / 2 of the top forging amount of 32mm) = 20mm). Fig.26 As shown;

[0229] ② Loosen the bolts: loosen the static end support 9m of the fastener bolts of the end face to be welded, and remove the first iron pad at the end of the welding joint to facilitate the lowering of the welding machine;

[0230] ③ Rail support: remove all fasteners of the steel parts to be welded, and support 3-4 places at 3m intervals to keep the rails straight; when the transition steel parts are closed, weld them according to the on-site rail matching requirements;

[0231] ④ Saw rail marking: leave a line on the saw rail 76mm away from the end face, and the verticality of the saw rail is less than 2mm;

[0232] ⑤ End milling position line: 80mm away from the end face is the end milling position line (such as Fig.26 As shown), the design value of top forging consumption is 32mm.

[0233] End milling error <0.1mm;

[0234] ⑥ End surface treatment and welding: The results must meet the requirements of "TB / T 1632.4-2014 Rail Welding Part 4: Gas Pressure Welding";

[0235] ⑦Fill in the welding record form.

[0236] According to the method of the present invention, the technical scheme of the present invention is specifically described below through specific embodiments 1 to 3, wherein numbers 1-14 correspond to 14 welding joints of a single set of turnouts: welding joint No. 1, welding joint No. 2, welding joint No. 3, welding joint No. 4, welding joint No. 5, welding joint No. 6, welding joint No. 7, welding joint No. 8, welding joint No. 9, welding joint No. 10, welding joint No. 11, welding joint No. 12, welding joint No. 13, and welding joint No. 14.

[0237] Example 1

[0238] like Figures 26 to 30 As shown, the entire set of turnouts on the new line is pre-laid, and each tool steel part is replaced one by one on the line: the tool rail is used to pre-lay the entire set of turnouts according to the technical standards, and then the steel parts of the turnouts are combined one by one using the above method to replace all the rails of the turnouts. The specific steps are:

[0239] S1. Operation preparation;

[0240] S11, Track matching: According to the requirements of gas pressure welding technology, the turnout steel parts are extended during processing to reserve the consumption of welding upsetting;

[0241] S12, marking;

[0242] S121, marking of straight and curved base rails and point rails: before loosening the fasteners, use a fine drawing needle to mark the relative positions of the straight base rail, curved point rail, curved base rail and straight point rail; the marking positions are: the starting point of the root end of the point rail, the guide surface of the straight and curved base rail, and the top surface of the rail at the center of the limit device;

[0243] S122, frog center mark: before loosening the iron pad bolts, use a fine drawing pin to mark the relative position of the frog center rail surface; the marking position is the tip rail surface of the movable frog and the top rail surface of the combined frog tail end;

[0244] S2. Welding: The welding sequence is to first weld 3-6-4-5 (or 6-3-5-4, 3-6-5-4, 6-3-4-5), then weld 7-10-9-8 (or 10-7-9-8, 7-10-8-9, 10-7-8-9); the remaining welded joints are welded in the order of 1-2-11-12-13-14 (or any combination of the order);

[0245] S3. Grind and inspect all weld joints after welding;

[0246] S4. Inspection of turnout geometric dimensions.

[0247] Example 2

[0248] like Figures 26 to 30 As shown, the entire set of turnouts is assembled on the line and each joint is welded in situ one by one.

[0249] That is, on the main line of the railway, the steel parts of the turnout are assembled on the turnout track bed according to the technical standards. During the assembly process, the weld seams of the steel parts are welded one by one to finally form the entire turnout. Specific steps:

[0250] S1. Operation preparation;

[0251] S11. Track matching: According to the technical requirements of pneumatic welding, the turnout steel parts are extended during processing to reserve the consumption of welding upsetting.

[0252] S12. Welding: The welding sequence is to weld 6-5-4-3 (or 3-4-5-6) first, then 7-8-10-9 (9 is welded last, and the rest can be welded in any combination); the remaining welded joints can be welded in the order of 1-2-11-12-13-14 (can also be welded in any combination);

[0253] S3. Grind and inspect all weld joints after welding;

[0254] S4. Inspection of turnout geometric dimensions.

[0255] Example 3

[0256] like Figures 26 to 30 As shown, the entire set of turnouts are assembled and welded offline, and after welding is completed, the turnouts are replaced as a whole.

[0257] That is, when repairing and replacing turnouts on existing railway lines, there is a problem of short window time. Therefore, pre-replacement turnout assembly and welding are carried out offline (outside the main line turnout) in advance, and then the overall horizontal shift turnout is replaced, which can save a lot of construction time. The specific steps are as follows:

[0258] S1. Preparation:

[0259] S11, Track matching: According to the technical requirements of gas pressure welding, the turnout steel parts are extended during processing to reserve the consumption of welding upsetting;

[0260] S12, Welding: The welding sequence is to first weld 6-5-4-3 (or 3-4-5-6), then weld 7-8-10-9 (9 is welded last, and the rest can be any combination);

[0261] S2. Grind and inspect all welded joints after welding;

[0262] S3. Inspection of geometric dimensions of new turnouts;

[0263] S4, overall replacement of turnout;

[0264] Cut off the old turnouts from positions 1, 2, 11, 12, 13, and 14 and move them offline. Then move the newly assembled and welded turnout rails as a whole to the main line, and complete the welding of the welding joints 1-2-11-12-13-14 (any combination order is also possible) in sequence.

[0265] S6. Inspection of turnout geometric dimensions.

Claims

1. A single-opening turnout welding construction method based on gas pressure welding, characterized in that: The following steps are involved: S1. Use pneumatic rail welding machine to achieve accurate clamping of welding joints in narrow areas of turnouts; S2. Calculate the rail length before welding to ensure that the joint meets the geometric size standards after welding; S3. During the welding process, the amount of upsetting is precisely controlled to ensure that the length of the rail after welding meets the size requirements of the turnout; S4. After welding, the welding joints shall be polished and inspected to ensure that the welding quality meets the relevant standards.

2. The single-turnout welding construction method based on gas pressure welding according to claim 1 is characterized in that: The turnout area includes a straight guide rail in front of the turnout, a curved guide rail in front of the turnout, a straight basic rail, a curved basic rail, a curved point rail, a straight point rail, an intermediate guide rail, two frogs, a fork removal center and four guide rails after the turnout; all the above rails constitute four rails; The first track includes the straight guide rails before the fork, the straight basic rails, the middle guide rails, the frog rails and the guide rails after the fork, which are arranged at intervals, and the intervals between the two are the No. 1 joint to be welded, the No. 3 joint to be welded, the No. 7 joint to be welded and the No. 11 joint to be welded respectively; The second track includes a curved point rail, an intermediate guide rail, a fork core and a fork guide rail arranged at intervals, and the intervals between the two are No. 4 welding joint, No. 8 welding joint and No. 12 welding joint respectively; The third track includes a straight point rail, an intermediate guide rail, a fork core and a fork guide rail arranged at intervals, and the intervals between each of them are No. 5 joint to be welded, No. 9 joint to be welded, and No. 13 joint to be welded respectively; The third track includes the pre-fork curved guide rail, curved basic rail, middle guide rail, frog and post-fork guide rail, which are arranged at intervals. The intervals between each of them are No. 2 joint to be welded, No. 6 joint to be welded, No. 10 joint to be welded and No. 14 joint to be welded. The curved point rail and the straight point rail are located between the straight basic rail and the curved basic rail. The curved point rail and the straight basic rail are replaced by a switching and withdrawing machine, and the straight point rail and the curved basic rail are replaced by a switching and withdrawing machine.

3. The single-opening turnout welding construction method based on gas pressure welding according to claim 2 is characterized in that: The welding joints outside the turnout area include welding joint No. 1 and welding joint No. 2; The welded joints in the narrow area of ​​the turnout area include No. 3 welded joint, No. 4 welded joint, No. 5 welded joint, No. 6 welded joint, No. 7 welded joint, No. 8 welded joint, No. 9 welded joint and No. 10 welded joint; All welding joints are located at the corresponding joints to be welded; the welding equipment can adapt to the narrow welding area of ​​the turnout area.

4. The single-opening turnout welding construction method based on gas pressure welding according to claim 3 is characterized in that: In step S1, the welding sequence includes first welding the base rail of the turnout, then sequentially welding the point rail and frog joint of the turnout, and finally completing the overall welding of the turnout.

5. The single-turnout welding construction method based on gas pressure welding according to claim 1 or 2, characterized in that: The welding equipment can control the upset amount to ensure the strength and quality of the welded joint, and the upset amount control error is less than ±0.5mm.

6. The single-turnout welding construction method based on gas pressure welding according to claim 4 is characterized in that: The welding sequence includes: S21, first weld the welding joints of the turnout stock rail, that is, first weld the No. 3 welding joint and the No. 6 welding joint in sequence; S22, then welding the switch rail welding joints, welding the No. 4 welding joint and the No. 5 welding joint in sequence; S23, then weld the outer welding joint of the frog part, and weld the seventh welding joint and the tenth welding joint in sequence; S24. Finally, weld the inner welding joint of the frog part, and weld the No. 8 welding joint and the No. 9 welding joint in sequence.

7. The single turnout welding construction method based on gas pressure welding according to claim 1 is characterized in that: After welding is completed, all welded joints are subjected to ultrasonic testing and appearance inspection to ensure that the welding quality meets railway standard requirements.

8. The single turnout welding construction method based on gas pressure welding according to claim 1 is characterized in that: Precise rail temperature control is used during the welding process to ensure that the welding joint is carried out at the rail locking temperature to avoid excessive internal stress in the rail after welding.

9. The single-turnout welding construction method based on gas pressure welding according to claim 4 is characterized in that: The calculation method of the rail length before welding is: L=X+a1+a2+u1+u2+4×b+2×d; Among them, u1 and u2 represent the length of the mark, a1 and a2 represent the weld width, b represents the end milling amount of one end, and d represents the welding upsetting amount.

10. The single turnout welding construction method based on gas pressure welding according to claim 1 is characterized in that: The welding equipment is mounted on a road-rail vehicle or a train flatbed with a single-arm crane.

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