Construction method for replacing elastic base plate of ballastless track of high-speed railway

Abstract

The invention discloses a construction method for replacing an elastic base plate of a ballastless track of a high-speed railway, which belongs to the technical field of tracks and comprises the following specific steps of: 1, preparing construction, 2, marking and acquiring original data, 3, mounting a lifting appliance, and connecting a portal crane with the lifting appliance through a steel wire rope, 4, lifting a track plate and separating the track plate from a base plate. 6, replacing an elastic cushion layer; 7, carrying out auxiliary fine adjustment falling and mounting; 8, carrying out track bed slab reset measurement; and 9, starting the next work construction until the construction of the whole rectification and replacement section is completed. The problems that in the prior art, the replacement construction efficiency of the ballastless track elastic base plate is low, the precision is difficult to guarantee, and the construction difficulty is large under the complex working condition are solved, operation is easy and convenient, and practicability is high.

Description

Technical Field

[0001] The invention relates to the field of track technology, and in particular to a construction method for replacing an elastic pad of a ballastless track of a high-speed railway. Background Art

[0002] Ballastless track has the characteristics of high stability, good uniformity of rigidity, strong structural durability, small maintenance workload and relatively mature technology, and is widely used in my country's high-speed railways. As an important part of the track structure, the elastic pad of the ballastless track of high-speed railways is mainly used to buffer train loads, reduce vibration and noise, and adjust track rigidity. Its performance directly affects the stability of the track and driving safety.

[0003] However, in the long-term operation process, the elastic pads will gradually harden, crack, deform or lose elasticity due to material aging, fatigue damage, environmental factors (such as temperature and humidity changes) and repeated effects of train dynamic loads, leading to their functional failure. In addition, factors such as construction defects, foreign body intrusion or foundation settlement may also accelerate the performance degradation of the elastic pads. In order to ensure the safety, comfort and durability of high-speed railways, elastic pads with degraded or damaged performance need to be replaced in a timely manner.

[0004] The existing ballastless track elastic pad replacement method has many problems in practical application, mainly including low construction efficiency and difficulty in ensuring accuracy, and the construction is difficult under complex working conditions, such as bridges and tunnel sections. Summary of the invention

[0005] The purpose of the present invention is to provide a construction method for replacing elastic pads of ballastless tracks of high-speed railways, so as to solve the problems of low construction efficiency and difficulty in ensuring precision of elastic pads of ballastless tracks in the prior art, and great construction difficulty under complex working conditions.

[0006] To achieve the above object, the present invention provides the following technical solution: a construction method for replacing an elastic pad of a ballastless track of a high-speed railway, wherein the specific steps of the construction method are as follows:

[0007] Step 1: Construction preparation, safety technology briefing, preparation of machinery and equipment, raw materials entering the site and completing inspection, calibration of measuring instruments, and gantry crane in place;

[0008] Step 2: Marking and original data collection. Vertical through-marking lines are made on the sides of the track slab and base plate. Four marks are made on the side of each slab and numbered as centering marks for the slab in-situ installation. Line marks are drawn on the center lines of the top surfaces of adjacent slabs and base plates. Eight horizontal markings of the top center lines and sides of adjacent slabs and base plates are collected, and the original data of level and height difference are recorded. The re-measurement of the rail support platform uses a re-measurement tool, a total station and a special measurement notebook to measure the original data, and collect the plane position and height of the second rail sleeper rail support platform at both ends of each slab and base plate.

[0009] Step 3: Install the spreader. The gantry crane is connected to the spreader through a wire rope.

[0010] Step 4: Lift the track plate and separate it from the base plate. When lifting, set the lifting point on the rail directly below the gantry crane beam, corresponding to the position of the rail lifting hole. Ensure that the track plate and the base plate are parallel during the lifting process. Lift to 10-30mm and then check by hovering to ensure that all four sides of the track plate are separated from the base plate, the plate seams are consistent, and there is no plane shaking of the track plate before continuing to lift.

[0011] Step 5: Place the horse stool. Before lifting the ballast plate, place the supporting horse stool in advance according to the size of the ballast plate and the position of the boss. The horse stool is placed on the beam surface between the two lines, corresponding to the ballast plate horizontally.

[0012] Step 6: Replace the elastic cushion layer. Use cleaning tools to remove and clean the elastic cushion layer in the upper limit groove of the base plate, and inspect, repair and clean the geotextile of the ballast plate boss. After cleaning, assemble the elastic cushion layer and foam board and stick them together with tape on one side. Apply adhesive universal glue evenly on the contact surface between the elastic cushion layer and the concrete, and stick the elastic cushion plate around the groove to ensure accurate position and dense sticking.

[0013] Step 7: Assist fine-tuning the fall and installation. Move the gantry crane horizontally to move the roadbed plate to the corresponding position of the base plate, lower the roadbed plate to a position 11-15cm away from the base plate, and adjust the hoisting position of the roadbed plate by observing the vertical and horizontal markings;

[0014] Step 8: Track bed slab reset measurement, through vertical and horizontal markings alignment check, use ruler to check the height difference and center line between adjacent track bed slabs, re-measure the second rail sleeper support platform at both ends of the track bed slab, compare and analyze the measurement data before lifting and after reset;

[0015] Step 9: Start construction of the next work until the construction of the entire rectification and replacement section is completed.

[0016] As a preferred technical solution of the present invention: two gantry cranes are arranged as a group, the two gantry cranes are rigidly connected, and synchronizers are installed on the gantry cranes to ensure synchronous walking and hoisting operations of the two gantry cranes.

[0017] As the preferred technical solution of the present invention: the lifting device adopts a double-piece channel steel shoulder pole beam, with fine-rolled threaded steel bars at both ends. The lower part of the threaded steel bars is lifted by steel plate perforated pins, and the two ends are fixed with special nuts for fine-rolled threaded steel bars, and the wire rope is inclined to the horizontal plane.

[0018] As a preferred technical solution of the present invention: the hanger adopts a rail rack, the rail rack uses two long rails, and the rails and the roadbed plate are connected by WJ-8B type constant resistance fasteners.

[0019] As the preferred technical solution of the present invention: the crossbeam of the horse stool is made of double-piece I10 steel, the small longitudinal beam is made of single I10 steel, the legs and the transverse connections of the legs are made of square steel, there are steel plates under the legs, and all components are connected by full-weld corner welds.

[0020] As a preferred technical solution of the present invention: the gantry crane is equipped with a frequency converter, and the traveling motor of the gantry crane has an electromagnetic braking function.

[0021] As a preferred technical solution of the present invention: the gantry crane is assembled under the bridge and the crane is hoisted into place as a whole.

[0022] As a preferred technical solution of the present invention: flanges are provided on both gantry cranes, and a connecting rod with adjustable length is installed between the two flanges.

[0023] By adopting the above technical solution, the beneficial effects of the present invention are:

[0024] 1. The present application discloses a construction method for replacing elastic pads for ballastless tracks of high-speed railways. Compared with traditional construction methods, the method has the effect of improving construction efficiency and shortening construction period. The method adopts a modular design to pre-assemble elastic pads, machinery and equipment and other components into modules, which greatly reduces on-site operation time. At the same time, professional mechanical equipment is introduced and used to realize mechanized disassembly and assembly, thereby reducing manual labor intensity.

[0025] 2. The use of high-precision measuring instruments and positioning devices, combined with clever and simple marking methods, ensures the accuracy of the installation position of the elastic pad, ensures that the track geometry meets the design requirements, and promotes the advancement of high-speed railway ballastless track maintenance technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 The present invention is a process flow chart of a construction method for replacing an elastic pad of a high-speed railway ballastless track;

[0027] Figure 2 It is a schematic diagram of the rigid connection of the gantry crane in the present invention;

[0028] Figure 3 It is a schematic diagram of the structure of the supporting horse stool in the present invention;

[0029] Figure 4 It is a structural schematic diagram of the sling in the present invention;

[0030] Figure 5 It is a schematic diagram of the track bed plate marking line in the present invention.

[0031] In the figure: 1. gantry crane; 2. flange; 3. connecting rod; 4. cross beam; 5. small longitudinal beam; 6. outrigger; 7. steel plate; 8. double-jointed channel steel; 9. high-rolled rebar; 10. track bed plate; 11. base plate. DETAILED DESCRIPTION

[0032] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and cannot be understood as limiting the present invention. In the description of the present invention, it should be understood that the orientation or position relationship indicated by the terms "upper", "lower", "front", "upper surface", etc. is based on the orientation or position relationship shown in the accompanying drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying 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 limiting the present invention. In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral body; it can be a mechanical connection, an electrical connection, or can communicate with each other; it can be directly connected, or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0033] See also Figure 1-5 The present invention provides an embodiment: a construction method for replacing an elastic pad of a high-speed railway ballastless track, and the specific steps of the construction method are as follows:

[0034] Step 1: Construction preparation, safety technical disclosure, preparation of machinery and equipment, including lifting equipment, ropes, rail racks, horse stools, etc. Raw materials are brought in and inspected, and measuring instruments such as total stations, prisms, and frames are calibrated, and gantry crane 1 is in place.

[0035] Step 2: Marking and original data collection. Vertical through-marking lines are made on the sides of the track bed plate 10 and the base plate 11. Four marks are made on the side of each track bed plate 10 and numbered as centering marks for the in-situ installation of the track bed plate 10, 20 cm away from the edge.

[0036] Draw a line mark at the center line position of the top surface of the adjacent track bed plate 10 and the base plate 11, 15 cm away from the top surface; use a ruler to assist the pencil to draw lines, collect eight locations of the top surface center line and side horizontal markings of the adjacent track bed plate 10 and the base plate 11, and record the original data of level and height difference;

[0037] The re-survey of the track support platform uses a re-survey tool, a total station and a special measuring notebook to measure the original data and collect the plane position and height of the second rail sleeper track support platform at both ends of each track bed plate 10 and base plate 11.

[0038] The third step: installation of the sling. The gantry crane 1 is connected to the sling through a wire rope. The gantry crane 1 adopts a 24-diameter equal-length wire rope and a double-piece channel steel 8 shoulder beam. High-quality rolled threaded steel 9 is set at both ends. The lower part of the threaded steel is lifted by a steel plate 7 through-hole pin. The two ends are fixed with special nuts for high-quality rolled threaded steel 9. The angle between the wire rope and the horizontal plane is not less than 60 degrees to ensure that the roadbed plate 10 is parallel to the base plate 11 during the lifting process to avoid damage to the corners of the roadbed plate 10 and the base plate 11 due to the non-parallel roadbed and base plate 11 during the lifting process.

[0039] The sling is installed in place and checked to ensure that the sling and the lifting point are in vertical correspondence under natural conditions before lifting.

[0040] Step 4: The track plate is lifted and separated from the base plate 11. During lifting, the lifting point is set on the rail directly below the crossbeam 4 of the gantry crane 1, corresponding to the position of the rail lifting hole. By controlling the position of the fine-rolled threaded steel 9 bolts and adjusting the length of the screw, ensure that the track plate 10 and the base plate 11 are in a parallel state during the lifting process. Lift to 10-30mm and hover to check to ensure that the four sides of the track plate 10 are separated from the base plate 11, the plate seams are consistent, and the track plate 10 has no plane shaking before continuing to lift.

[0041] Step 5: Placement of horse stools. Before lifting the ballast plate 10, place supporting horse stools in advance according to the size of the ballast plate 10 and the position of the bosses. The horse stools are placed on the beam surface between the two lines, corresponding to the ballast plate 10 horizontally, to avoid longitudinal misalignment that causes displacement of the gantry crane 1.

[0042] The lifting height of the roadbed plate 10 is 1.2m from the beam surface. It is placed on the upper part of the supporting saddle by means of horizontal sliding of an electric hoist. The saddle is ensured to be in a stressed state through measures such as artificial shaking. At the same time, the wire rope of the gantry crane 1 is in a taut state before the bottom construction work can be carried out.

[0043] A 5-10mm thick rubber pad is laid on the top of the horse stool in the straight section, and a support pad is provided at the bottom of the roadbed plate 10 in the curved section to ensure that the roadbed plate 10 is evenly stressed during the falling process, and a 5-10mm thick rubber pad is fully provided on the upper surface of the square wood of the track. Before the roadbed plate 10 is horizontally moved and placed on the horse stool, it is necessary to check the uniform stress of the horse stool legs 6, and the suspended legs 6 need to be plugged with support pads to ensure stability.

[0044] Step 6: Replace the elastic cushion layer, use cleaning tools to remove and clean the elastic cushion layer in the upper limit groove of the base plate 11, inspect, repair and clean the geotextile on the ballast plate 10 boss, and use a manual handheld hair dryer for comprehensive cleaning.

[0045] After cleaning, assemble the elastic cushion and foam board and use single-sided tape to form a whole. Apply universal adhesive evenly on the contact surface between the elastic cushion and the concrete, and stick the elastic cushion around the groove to ensure accurate positioning and dense adhesion.

[0046] After the elastic cushion layer is installed, the top of the foam board that protrudes beyond the concrete surface of the base plate 11 is cut with a special tool. When cutting, ensure that the foam board is 1-2mm lower than the top of the base plate 11. At the same time, ensure that the top cut of the foam board is an inclined surface to facilitate the downward sliding of the roadbed plate 10 to reduce the impact on the elastic cushion layer. Use tape to press and paste the outer side of the elastic cushion layer from top to bottom to prevent the tape from peeling off during the falling installation process.

[0047] Check the integrity of the geotextile around the top and bottom of the limiting boss at the bottom of the roadbed slab 10, remove the surface tape and debris around the detached parts, use glue to stick them together, cut the part that exceeds the boss, and replace the damaged part.

[0048] During the replacement of the elastic cushion layer, after the roadbed plate 10 has been safely placed on the horse stool, after inspection and confirmation by the on-site safety personnel, the boss is quickly cleaned from both sides at the same time.

[0049] Step 7: Assisted fine-tuning of the fall and installation. The gantry crane 1 moves the roadbed plate 10 to the corresponding position of the base plate 11 horizontally, and lowers the roadbed plate 10 to a position 11-15cm away from the base plate. By observing the vertical and horizontal markings, adjust the hoisting position of the roadbed plate 10. When the alignment is correct, it can be lowered. When the roadbed plate 10 is 112cm away from the base plate, stop falling, check the alignment of the markings again, and fall into place when the alignment is correct. If necessary, use a guide auxiliary device.

[0050] Before placing the ballast plate 10, the bonding condition of the elastic cushion in the groove, the flatness of the geotextile at the bottom of the ballast plate 10, and the base surfaces of the ballast plate 10 and the base plate 11 are comprehensively inspected and cleaned.

[0051] Step 8: Reset and measure the ballast plate 10, check the alignment of vertical and horizontal markings, use a ruler to verify the height difference and center line between adjacent ballast plates 10, re-measure the second rail sleeper support platform at both ends of the ballast plate 10, and compare and analyze the measurement data before lifting and after resetting.

[0052] Step 9: Start construction of the next work until the construction of the entire rectification and replacement section is completed.

[0053] Two gantry cranes 1 are arranged as a group, and the two gantry cranes 1 are rigidly connected, mainly by installing flanges 2 on the two gantry cranes 1, and a length-adjustable connecting rod 3 is installed between the two flanges 2. A synchronizer is installed on the gantry crane 1 to ensure the synchronous walking and hoisting of the two gantry cranes 1. The gantry crane 1 is equipped with a frequency converter to ensure the smooth lifting and lowering process; the traveling motor of the gantry crane 1 has an electromagnetic braking function, and the iron shoes are installed in time before and after the gantry crane 1 is lifted, and the rail clamp is locked to prevent the gantry crane 1 from slipping. The gantry crane 1 is assembled under the bridge, and the crane is hoisted into place as a whole.

[0054] The crossbeam 4 of the horse stool is made of double-piece I10 steel, the small longitudinal beam 5 is made of single I10 steel, the legs 6 and the horizontal connection of the legs 6 are made of square steel, and the legs 6 are padded with steel plates 7. All components are connected by full welding with fillet welds, and all components are made of Q345 steel.

[0055] Another embodiment provided by the present invention is that the hanger adopts a rail rack, the rail rack uses two long rails, and the rails are connected to the roadbed plate 10 using WJ-8B type constant resistance fasteners. The rail rack is placed in the center, and when the length of the roadbed plate 10 exceeds 6m, the outermost sleepers of the roadbed plate 10 do not need to be connected to the rails.

[0056] The track frame has two sections as lifting points. Each section is lifted by two steel wire ropes. One end of the steel wire rope is connected to the track frame with a shackle, and the other end is directly put on the main hook of the gantry crane. The angle between the steel wire rope and the horizontal plane is not less than 60°.

[0057] During hoisting, first use a jack to separate the roadbed plate 10 from the base plate 11, and then use a gantry crane to hoist the roadbed plate 10 to the horse stool.

[0058] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments. For those skilled in the art, various changes, modifications, substitutions and variations of these embodiments are made without departing from the principles and spirit of the present invention, and still fall within the scope of protection of the present invention.

Claims

1. A construction method for replacing an elastic pad of a high-speed railway ballastless track, characterized in that: The specific steps of the construction method are as follows: Step 1: Construction preparation, safety technology briefing, preparation of machinery and equipment, raw materials entering the site and completing inspection, calibration of measuring instruments, and gantry crane in place; Step 2: Marking and original data collection. Vertical through-marking lines are made on the sides of the track slab and base plate. Four marks are made on the side of each slab and numbered as centering marks for the slab in-situ installation. Line marks are drawn on the center lines of the top surfaces of adjacent slabs and base plates. Eight horizontal markings of the top center lines and sides of adjacent slabs and base plates are collected, and the original data of level and height difference are recorded. The re-measurement of the rail support platform uses a re-measurement tool, a total station and a special measurement notebook to measure the original data, and collect the plane position and height of the second rail sleeper rail support platform at both ends of each slab and base plate. Step 3: Install the spreader. The gantry crane is connected to the spreader through a wire rope. Step 4: Lift the track plate and separate it from the base plate. When lifting, set the lifting point on the rail directly below the gantry crane beam, corresponding to the position of the rail lifting hole. Ensure that the track plate and the base plate are parallel during the lifting process. Lift to 10-30mm and then check by hovering to ensure that all four sides of the track plate are separated from the base plate, the plate seams are consistent, and there is no plane shaking of the track plate before continuing to lift. Step 5: Place the horse stool. Before lifting the ballast plate, place the supporting horse stool in advance according to the size of the ballast plate and the position of the boss. The horse stool is placed on the beam surface between the two lines, corresponding to the ballast plate horizontally. Step 6: Replace the elastic cushion layer. Use cleaning tools to remove and clean the elastic cushion layer in the upper limit groove of the base plate, and inspect, repair and clean the geotextile of the ballast plate boss. After cleaning, assemble the elastic cushion layer and foam board and stick them together with tape on one side. Apply adhesive universal glue evenly on the contact surface between the elastic cushion layer and the concrete, and stick the elastic cushion plate around the groove to ensure accurate position and dense sticking. Step 7: Assist fine-tuning the fall and installation. Move the gantry crane horizontally to move the roadbed plate to the corresponding position of the base plate, lower the roadbed plate to a position 11-15cm away from the base plate, and adjust the hoisting position of the roadbed plate by observing the vertical and horizontal markings; Step 8: Track bed slab reset measurement, through vertical and horizontal markings alignment check, use ruler to check the height difference and center line between adjacent track bed slabs, re-measure the second rail sleeper support platform at both ends of the track bed slab, compare and analyze the measurement data before lifting and after reset; Step 9: Start construction of the next work until the construction of the entire rectification and replacement section is completed.

2. The construction method for replacing the elastic pad of a high-speed railway ballastless track according to claim 1 is characterized in that: Two gantry cranes are set as a group. The two gantry cranes are rigidly connected and synchronizers are installed on the gantry cranes to ensure synchronous walking and hoisting operations of the two gantry cranes.

3. The construction method for replacing the elastic pad of a high-speed railway ballastless track according to claim 1 is characterized in that: The lifting equipment uses a double-piece channel steel shoulder beam with high-quality rolled threaded steel bars at both ends. The lower part of the threaded steel bars is lifted by steel plate perforated pins, and the two ends are fixed with special nuts for high-quality rolled threaded steel bars. The wire rope is inclined to the horizontal plane.

4. The construction method for replacing the elastic pad of a high-speed railway ballastless track according to claim 1 is characterized in that: The hoist adopts a rail rack, which uses two long rails. The rails and the trackbed plate are connected with WJ-8B constant resistance fasteners.

5. The construction method for replacing the elastic pad of a high-speed railway ballastless track according to claim 1 is characterized in that: The crossbeam of the horse stool is made of double-piece I10 steel, the small longitudinal beam of the horse stool is made of single I10 steel, the legs and the horizontal connection of the legs are made of square steel, and there are steel plates under the legs. All components are connected by full welding with fillet welds.

6. The construction method for replacing the elastic pad of a high-speed railway ballastless track according to claim 2 is characterized in that: The gantry crane is equipped with a frequency converter, and the gantry crane's traveling motor has an electromagnetic braking function.

7. The construction method for replacing the elastic pad of the high-speed railway ballastless track according to claim 6 is characterized by: The gantry crane is assembled under the bridge and the crane is hoisted into place as a whole.

8. The construction method for replacing the elastic pad of a high-speed railway ballastless track according to claim 2 is characterized in that: Both gantry cranes are provided with flanges, and a connecting rod with adjustable length is installed between the two flanges.

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