Construction method of monitoring unit of turnout broken rail monitoring device

Abstract

The application provides a construction method for a monitoring unit of a turnout broken rail monitoring device, and has the characteristics that the method comprises the following steps: step 1, polishing pretreatment of a turnout surface; step 2, cleaning treatment of the turnout surface; step 3, pasting of a lead tape and a protective tape; step 4, reliability test of the lead tape; after the lead tape is pasted, circuit on-off test and rail piece insulation test are carried out; step 5, circuit connection; and step 6, reliability test of the monitoring unit. Through the design of an automatic pasting device and a set of monitoring unit construction method combined with the service status of existing turnout rail pieces and actual site conditions, the required personnel, materials and time in each link in the construction process such as rail surface rust removal and cleaning, tape pasting and tape reliability test are accurately calculated, so that the purpose of efficiently and high-quality completing the installation of the monitoring unit is achieved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of railway track detection, and relates to a construction method for a monitoring unit of a turnout broken rail monitoring device. BACKGROUND

[0002] Turnouts are weak links in railway lines and are the key to affecting the stability and safety of train operation. At present, there are five kinds of real-time broken rail monitoring technologies at home and abroad, including real-time broken rail monitoring based on track circuit principle, optical fiber real-time broken rail monitoring, conductive coating real-time broken rail monitoring, ultrasonic real-time broken rail monitoring, and acoustic emission real-time broken rail monitoring. However, due to the fact that there are many research directions for turnout broken rail monitoring at home and abroad, and various technologies are involved, but affected by factors such as false alarm rate, functional stability, equipment safety, etc., fewer turnout broken rail monitoring devices are actually applied.

[0003] The monitoring units in the existing broken rail monitoring devices at home have different degrees of construction difficulties or problems. For example, it is difficult to install and maintain the monitoring unit using optical fiber, which is sensitive to the environment, and the optical fiber has poor ductility and is easy to break, so it is easy to be damaged during construction, and the installation is difficult. Therefore, the broken rail monitoring device using optical fiber as the monitoring unit has the problems of high construction difficulty, poor maintenance, easy breakage under the action of large external force vibration or bending, and non-normal alarm. When the conductive coating is used as the monitoring unit, due to the complex structure of the turnout and the difficulty of installation operation, and the conductive coating is easy to be damaged by external force and foreign matter, the practicability and popularization of this technology are poor. The ultrasonic and acoustic emission monitoring devices use sound signals as the monitoring unit, and due to the limitations of the turnout rail and the actual situation of the line, they cannot accurately monitor the broken rail, and have problems such as false alarm and missed alarm. If the construction method is not reasonable during the actual installation of the monitoring unit based on the conductive tape, there will also be problems such as installation difficulty, poor installation effect, and low reliability.

[0004] The installation of the monitoring system on the existing turnout rail requires very strict construction time. Because the installation of the monitoring unit needs to be completed within a specific window point. The window point time of general railways is very limited, generally about 120 minutes, and sometimes it is set at night. At the same time, outdoor work may encounter high temperature in summer, low temperature in winter, or rain and snow environment and other bad weather. Under this construction condition, it is required that the construction method must be designed to be reasonable, efficient, economical and convenient, which is also a difficulty in the installation of the monitoring system.

[0005] Therefore, based on the above technical deficiencies, the present application provides a construction method for a monitoring unit of a turnout broken rail monitoring device, which designs an automatic pasting device and a set of monitoring unit construction method combined with the service status and actual site conditions of the existing turnout rail. SUMMARY

[0006] In order to overcome the defects of the prior art, the application provides a construction method for a monitoring unit of a turnout broken rail monitoring device.

[0007] A construction method for a monitoring unit of a turnout broken rail monitoring device, comprising

[0008] Step 1. Turnout surface polishing pretreatment: for the oil sludge serious area, the oil sludge on the surface of the rail is removed by using an oil sludge shovel;

[0009] Step 2. Turnout surface cleaning treatment: after the polishing pretreatment is completed, the surface of the pretreatment is sprayed with water by using a lithium battery cleaning water gun, so as to remove the dust and dirt remaining on the surface after polishing;

[0010] Step 3. Paste of lead wire adhesive tape and protective adhesive tape: the paste of the lead wire adhesive tape and the protective adhesive tape is completed by using an automatic paste equipment;

[0011] Step 4. Lead wire adhesive tape reliability test: after the lead wire paste is completed, the circuit on-off test and the rail insulation test are performed;

[0012] Step 5. Circuit connection: after the paste of the protective adhesive tape is completed, each lead wire adhesive tape on the rail is connected by brazing, so as to become a complete rail monitoring unit;

[0013] Step 6. Monitoring unit reliability test: after the installation of the monitoring unit is completed, the content in step 4 is repeated, the circuit on-off and the rail insulation of the entire rail monitoring unit are tested, and the installation stability and reliability of the monitoring unit are ensured.

[0014] In step 3, the automatic paste equipment comprises an automatic walking unit, an automatic glue injection unit and an automatic paste unit, wherein the automatic glue injection unit is arranged on the upper portion of the automatic walking unit, and the automatic glue injection unit is arranged on one side of the automatic walking unit.

[0015] The automatic walking unit mainly comprises a control cabinet, a walking device and a storage battery, a driving motor is arranged in the control cabinet, the walking device is driven to walk on the steel rail through the motor, the storage battery provides power for the driving motor, the walking speed and the walking time can be adjusted through the control panel on the control cabinet, and the length of the paste is controlled;

[0016] The automatic glue injection unit mainly comprises an air pump, a pressure control system and a glue injection device, the air pump is provided with power by the storage battery, the air pump provides pressure for the glue injection device, the glue flow rate is controlled through the pressure control system,

[0017] The glue injection device is provided with a glue applicator, when the glue flow rate and the contact pressure between the glue applicator and the rail surface are set, the oily original glue can be evenly and flatly applied in the paste area of the rail surface along with the start of the automatic paste equipment;

[0018] The automatic sticking unit comprises a tape sticking device, wherein the lower end of the height telescopic adjusting rod is connected with the tape sticking device, a given pressure value is set through the pressure control system to control the pressure of the tape sticking device when it is stuck to the surface of the rail, the tape sticking device adjusts the position of the tape sticking device through the height telescopic adjusting rod, two spoolers are arranged in front of and behind the tape sticking device to place the conductor tape and the protective tape respectively, and the protective tape sticking device is arranged in parallel with the conductor tape sticking device.

[0019] In the step 3, the automatic sticking device completes the steps of sticking the conductor tape and the protective tape, opens the power supply of the control cabinet, fills the oil-based original glue in the glue injection device for use, sets the walking speed and walking time on the control cabinet panel, sets the pressure values of the glue injection device, the glue applicator and the tape sticking device on the pressure control system, adjusts the telescopic rod through the buttons on the pressure control system to determine the sticking position, and starts the device by pressing the start button on the control cabinet after all the parameters of the device are set, so that the device automatically completes the processes of rail surface glue coating, conductor tape sticking and protective tape sticking.

[0020] In the step 3, the automatic sticking device completes the steps of sticking the conductor tape and the protective tape, opens the power supply of the control cabinet, fills the oil-based original glue in the glue injection device for use, sets the walking speed and walking time on the control cabinet panel, sets the pressure values of the glue injection device, the glue applicator and the tape sticking device on the pressure control system, adjusts the telescopic rod through the buttons on the pressure control system to determine the sticking position, and starts the device by pressing the start button on the control cabinet after all the parameters of the device are set, so that the device automatically completes the processes of rail surface glue coating, conductor tape sticking and protective tape sticking.

[0021] In the step 4, the circuit on-off test: after the conductor tape is stuck, one end of the conductor is closed, and the resistance of the conductor is detected by connecting the two leads of the conductor with the red and black ends of the multimeter at the other end of the conductor; and the rail piece insulation test: one end of the multimeter is connected with the lead of the conductor, and the other end contacts the surface of the rail with metallic luster.

[0022] In the step 5, after the protective tape is stuck, each section of the conductor tape on the rail piece is connected by brazing, the conductor tape needs to be cut when it needs to be turned or the sticking position is changed, and the two ends of the conductor tape are connected by using an electric soldering iron or a two-hole connector and wrapped with insulating tape for insulation protection, so that the monitoring unit has a flexible function and becomes a complete rail piece monitoring unit.

[0023] The application designs an automatic sticking device, and designs a monitoring unit construction method combining the service status of existing turnout rail pieces and actual site conditions, so as to achieve the purpose of high-efficiency and high-quality completion of monitoring unit installation by accurately calculating the personnel, materials and time required in each link in the construction process such as rail surface rust cleaning, adhesive tape sticking and adhesive tape reliability test. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 It is a schematic diagram of the operation steps of the construction method for the monitoring unit of the turnout broken rail monitoring device.

[0025] Figure 2 It is a schematic diagram of the automatic sticking device.

[0026] Figure 3 It is a schematic diagram of the automatic sticking device components.

[0027] Figure 4 It is a schematic diagram of the adhesive tape sticking device. DETAILED DESCRIPTION

[0028] The construction method for the monitoring unit of the turnout broken rail monitoring device provided by the application will be described in detail below in combination with the drawings and specific embodiments.

[0029] ATTACHED Figures 1-4 As shown in the drawings, a construction method for the monitoring unit of the turnout broken rail monitoring device includes

[0030] Step 1. Turnout surface polishing pretreatment: for the oil sludge serious area, the oil sludge on the surface of the rail piece is removed by using an oil sludge shovel;

[0031] Step 2. Turnout surface cleaning treatment: after the polishing pretreatment is completed, the surface of the pretreatment is sprayed with water by using a lithium battery cleaning water gun, so as to remove the dust and dirt remaining on the surface after polishing;

[0032] Step 3. Sticking of the lead wire adhesive tape and the protective adhesive tape: the sticking of the lead wire adhesive tape and the protective adhesive tape is completed by using the automatic sticking device;

[0033] Step 4. Lead wire adhesive tape reliability test: after the lead wire sticking is completed, the circuit on-off test and the rail piece insulation test are performed;

[0034] Step 5. Circuit connection: after the protective adhesive tape sticking is completed, each section of the lead wire adhesive tape on the rail piece is connected by brazing, so as to become a complete rail piece monitoring unit;

[0035] Step 6. Monitoring unit reliability test: after the monitoring unit installation is completed, the content in step 4 is repeated, and the circuit on-off and rail piece insulation of the entire rail piece monitoring unit are tested, so as to ensure that the installation of the monitoring unit is stable and reliable.

[0036] The automatic sticking device in step 3 comprises an automatic walking unit, an automatic glue injection unit and an automatic sticking unit, wherein the automatic glue injection unit is arranged on the upper part of the automatic walking unit, and the automatic glue injection unit is arranged on one side of the automatic walking unit.

[0037] The automatic walking unit mainly comprises a control cabinet 1, a walking device 2 and a storage battery 3, a driving motor is arranged in the control cabinet 1, the walking device 2 is driven to walk on the steel rail through the motor, the storage battery 3 provides power for the driving motor, the walking speed and the walking time can be adjusted through the control panel on the control cabinet to control the length of sticking;

[0038] The automatic glue injection unit mainly comprises a gas pump 4, a pressure control system 5 and a glue injection device 6, the gas pump 4 is provided with power by the storage battery 3, the gas pump 4 provides pressure for the glue injection device, the glue injection speed is controlled through the pressure control system 5,

[0039] The glue injection device 6 is provided with a glue applicator 61, when the glue injection speed and the contact pressure between the glue applicator 61 and the rail surface are set, the oily original glue can be evenly and flatly applied in the sticking area of the rail surface with the start of the automatic sticking device;

[0040] The automatic sticking unit comprises a glue tape sticking device 7, in the glue tape sticking device 7, the lower end of the height telescopic adjusting rod 74 is connected with the glue tape sticking device 71, the pressure when the glue tape sticking device 71 is stuck to the surface of the steel rail is controlled by setting a given pressure value through the pressure control system, the position of the glue tape sticking device 71 adhering to the rail surface is adjusted through the height telescopic adjusting rod 74, two spoolers are arranged in front of and behind the glue tape sticking device, and a lead wire glue tape sticking device 72 and a protective glue tape sticking device 73 are respectively arranged in the two spoolers, wherein the protective glue tape sticking device 73 is arranged in parallel with the lead wire glue tape sticking device 72.

[0041] The step of completing the sticking of the lead wire glue tape and the protective glue tape by the automatic sticking device in step 3 is as follows: the power supply of the control cabinet is turned on, the glue injection device 6 is filled with the oily original glue for use, the walking speed and the walking time are set on the control panel of the control cabinet, the pressure values of the glue injection, the glue applicator and the glue tape sticking device are respectively set on the pressure control system, the telescopic rod is adjusted through the button on the pressure control system, the sticking position is determined, and after all the parameters of the device are set, the device is started by pressing the start button on the control cabinet, and the device will automatically complete the glue application on the rail surface, the sticking of the lead wire glue tape and the protective glue tape.

[0042] A 0.5m interval distance is arranged between the glue tape sticking device 71 and the lead wire glue tape sticking device 72, and a 0.2m interval distance is arranged between the lead wire glue tape sticking device 72 and the protective glue tape sticking device 73, and the glue tape sticking device 71, the lead wire glue tape sticking device 72 and the protective glue tape sticking device 73 work simultaneously during the walking process of the device, and the work of the glue tape sticking is completed at one time.

[0043] In step 4, the circuit on-off test: after the completion of the wire sticking, one end of the wire is closed, and at the other end of the wire, the red and black ends of the multimeter are connected to the two leads of the wire, and the resistance of the wire is detected; the resistivity of the wire is about 3Ω / M (double-stranded), and the resistance of the wire can be calculated according to the length. For example, if the total length of the wire is 10 meters, the resistance should be 30Ω. If the resistance measured by the multimeter is 30Ω, it indicates that the full length of the wire is in a pass state; if the wire resistance is infinite or the resistance is in the order of megaohm, the wire is in an open circuit, indicating that there is a broken wire in the wire.

[0044] Rail insulation test: using a multimeter with red and black ends, one end is connected to the lead of the wire, and the other end is in contact with the surface of the steel rail with a metallic luster. If the resistance is infinite (the multimeter shows an open circuit) or the resistance is >1000Ω, it indicates that the wire and the rail are well insulated; if the multimeter shows a certain resistance (single digit to hundred digits), it indicates that the insulation between the wire and the rail is damaged.

[0045] In step 5, after the completion of the protective tape sticking, each section of the wire tape on the rail is connected by brazing. When the wire tape needs to turn or change the sticking position due to obstacles, the wire tape needs to be cut. When connecting two sections of the wire tape, there needs to be some overlap to achieve complete coverage and avoid missing monitoring points. The overlapping part of the wire is connected by a copper lead to ensure that the monitoring is continuous. An electric soldering iron or a two-hole connector is used to connect the leads at both ends of the wire tape, and insulating tape is used to wrap it for insulation protection, so that the monitoring unit can be flexible and become a complete rail monitoring unit.

[0046] The present application adopts the most practical and economical construction method and method, which can realize the rapid and effective installation of the monitoring unit based on the wire tape on the existing turnout rail under the limitation of various complex conditions in the actual field (narrow space, poor rail surface conditions, limited skylight time, etc.). The construction method has low cost, simple method and high installation efficiency. The method can realize the automatic sticking process of the wire tape, which can save manpower and maintain the stability of the sticking process. It has the characteristics of repeatability, high operability, high implementation efficiency and low cost.

[0047] The reliability test in the construction method can ensure that the monitoring unit achieves long-term stable monitoring effect. The circuit connection in the construction method can make the wire tape in the monitoring unit realize the function of flexible turning and bypassing obstacles.

[0048] Finally, it should be noted that the above examples are only used to describe the technical solutions of the present application and not to limit the technical method. The present application can be extended to other modifications, changes, applications and embodiments, and therefore all such modifications, changes, applications, embodiments are considered to be within the spirit and teachings of the present application.

Claims

1. A construction method for a monitoring unit of a turnout rail breakage monitoring device, characterized in that, Methods include Step 1. Pre-treatment of turnout surface grinding: For areas with severe sludge, use a sludge scraper to remove the sludge from the surface of the rail components; Step 2. Turnout surface cleaning treatment: After the grinding pretreatment is completed, use a lithium battery cleaning water gun to spray water onto the pretreated surface to remove the dust and dirt remaining on the surface after grinding. Step 3. Applying wire tape and protective tape: Use an automatic application device to apply the wire tape and protective tape. Step 4. Reliability test of the wire tape: After the wires are pasted, conduct circuit continuity tests and rail insulation tests; Step 5. Circuit connection: After the protective tape is applied, connect each section of wire tape on the rail component by brazing to form a complete rail component monitoring unit; Step 6. Reliability test of monitoring unit: After the monitoring unit is installed, repeat the steps in step 4 to test the continuity of the monitoring unit circuit and the insulation of the rail component to ensure that the monitoring unit is installed stably and reliably.

2. The construction method for a monitoring unit of a turnout rail breakage monitoring device according to claim 1, characterized in that, In step 3, the automatic pasting device includes an automatic traveling unit, an automatic glue dispensing unit, and an automatic pasting unit, wherein the automatic glue dispensing unit is located on the upper part of the automatic traveling unit and on one side of the automatic traveling unit.

3. A construction method for a monitoring unit of a turnout rail breakage monitoring device according to claim 1 or 2, characterized in that, The steps for the automatic pasting equipment to complete the pasting of wire tape and protective tape in step 3 are as follows: turn on the power of the control cabinet, fill the glue injection device (6) with oily raw glue for use, set the travel speed and travel time on the control cabinet panel, set the pressure values ​​of the glue injection, glue applicator and tape pasting device on the pressure control system respectively, adjust the telescopic rod by operating the button on the pressure control system, determine the pasting position, after all the parameters of the equipment are set, press the start button on the control cabinet to start the equipment, and the equipment will automatically complete the process of applying glue to the rail surface, pasting wire tape and protective tape.

4. The construction method for a monitoring unit of a turnout rail breakage monitoring device according to claim 1, characterized in that, In step 4, the circuit continuity test is performed: after the wire is pasted, one end of the wire is closed. At the other end of the wire, the two leads of the wire are connected to the red and black ends of a multimeter to test the resistance of the wire. The rail insulation test is performed: the red and black ends of a multimeter are connected to the leads of the wire at one end and the other end is in contact with the surface of the rail with a metallic luster.

5. A construction method for a monitoring unit of a turnout rail breakage monitoring device according to claim 1, characterized in that, In step 5, after the protective tape is applied, each section of conductor tape on the rail component is connected by brazing. When the conductor tape encounters an obstacle and needs to turn or change its position, it needs to be cut. When connecting two sections of conductor tape, there needs to be some overlap to achieve complete coverage and avoid missing any monitoring points. The overlapping conductors are connected by copper leads to ensure uninterrupted monitoring along the entire length. The leads at both ends of the conductor tape are connected using a soldering iron or a two-hole connector and wrapped with insulating tape for insulation protection, enabling the monitoring unit to function flexibly and become a complete rail component monitoring unit.

6. The automatic pasting device for the construction method of the monitoring unit of the turnout rail breakage monitoring device according to claim 2, characterized in that, The automatic walking unit mainly consists of a control cabinet (1), a walking device (2) and a storage battery (3). The control cabinet (1) is equipped with a drive motor, which drives the walking device (2) to walk on the rail. The storage battery (3) provides power to the drive motor. The walking speed and walking time can be adjusted by operating the control panel on the control cabinet to control the length of the pasting. The automatic glue dispensing unit mainly consists of an air pump (4), a pressure control system (5), and a glue dispensing device (6). The air pump (4) is powered by a battery (3) and provides pressure to the glue dispensing device. The pressure control system (5) controls the glue flow rate. The glue injection device (6) is equipped with a glue applicator (61). When the glue flow rate and the contact pressure between the glue applicator (61) and the rail surface are set, the oily raw glue can be evenly and straightly applied to the adhesive area of ​​the rail surface as the automatic pasting equipment is started. The automatic pasting unit includes a tape pasting device (7). In the tape pasting device (7), the lower end of the height telescopic adjustment rod (74) is connected to the tape paster (71). The pressure control system sets a given pressure value to control the pressure when the tape paster (71) is pasted onto the rail surface. The tape paster (71) adjusts its position against the rail surface through the height telescopic adjustment rod (74). Two rollers are set in front and behind the tape paster to hold the conductor tape paster (72) and the protective tape paster (73) respectively. The protective tape paster (73) is set parallel to the conductor tape paster (72).

7. The automatic pasting device according to claim 6, characterized in that, The tape applicator (71) and the wire tape applicator (72) are spaced 0.5m apart, and the wire tape applicator (72) and the protective tape applicator (73) are spaced 0.2m apart. During the movement of the equipment, the tape applicator (71), the wire tape applicator (72) and the protective tape applicator (73) work simultaneously to complete the tape applicating work in one go.

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