Turnout rail part replacement operation system

Abstract

The invention discloses a turnout rail piece replacement operation system. The system comprises a vehicle group; the vehicle marshalling comprises a first rail car, an equipment flat car, a rail piece flat car and a second rail car which are connected in sequence. The first rail car is used for dragging the equipment flatcar, and the equipment flatcar is used for loading the gantry crane device and the lifting platform. The second rail car is used for dragging the rail piece flatcar, and the rail piece flatcar is used for loading turnout rail pieces. And the vehicle marshalling is demarcated when the vehicle marshalling arrives near the operation site turnout area. And after the third assembly of the old rail is dismantled, a gantry crane device is deployed, the second assembly of the new rail is unloaded, the third assembly of the old rail is recycled, and the second assembly of the new rail is replaced. And the second assembly of the old rail is recycled, the first assembly and the third assembly of the new rail are unloaded, the first assembly of the new rail is replaced, and the first assembly of the old rail is recycled. And the gantry crane device is recycled, the third assembly of the old rail is replaced, and turnout rail piece replacement is completed. The technical problems that an existing replacement operation system is high in cost, long in occupied skylight, low in operation efficiency and low in safety can be solved.

Description

Technical Field

[0001] This application relates to the technical field of railway construction machinery, and particularly to an operation system applied to the replacement of a whole set of turnout rail components. Background Art

[0002] Turnout rail components mainly refer to the whole set of rail components above the sleepers, which are composed of components such as frog, switch rail, connecting rail, stock rail, etc. Their main characteristics are long size and heavy weight, making it difficult to replace manually, and existing equipment is difficult to meet the requirements. With the multiple speed increases of railways, vehicles pass quickly, and the wheels impact and roll, which easily causes long-distance wear of the rail line. Especially, the turnout is subjected to a large lateral force and is more prone to wear and needs to be replaced. At the same time, the high-frequency passage of vehicles requires that the rails be repaired quickly after wear. To save time, the whole set of turnout rail components needs to be replaced simultaneously. Due to the limited operation area and the long, large, and heavy rail components, existing equipment such as rail replacement vehicles and 25-ton rail cranes cannot meet the requirements. Therefore, replacing the whole set of turnout rail components is a very difficult task and urgently needs to be improved.

[0003] In the prior art, the replacement of turnout components mainly has the following several methods:

[0004] The first method is to use 2 - 3 25T lifting rail vehicles from the adjacent line to lift the large rail components of the track. However, in the operation process of this solution, the large rail components are prone to large deformation and damage, and due to the poor synchronization of the operations of the drivers of multiple lifting rail vehicles, large swings are likely to occur, thus causing potential safety hazards and other problems.

[0005] The second method is to use a large turnout large-component emergency replacement vehicle group for construction, which is composed of 2 lifting rail flat cars and 1 - 2 rail flat cars. During the construction operation, two groups of lifting rail vehicles are used to replace the rail components. This solution is limited by the number of lifting points and usually cannot meet the operation requirements of long and large rail components. Moreover, the equipment is huge, expensive, the operation is complex, the operation preparation time is long, and the operation efficiency is difficult to meet the increasing demand for the replacement of turnout rail components.

[0006] In the prior art, the following documents are mainly related to this application:

[0007] Document 1 is a Chinese invention application filed by CRRC Times Construction Machinery Co., Ltd. in Baoji on February 1, 2018 and published on March 1, 2019, with the publication number CN109403161A. This invention discloses a construction process for replacing turnouts of large-tonnage crane rail cars, and the specific steps are as follows: First, before the new turnout is installed on the roadbed, it is first assembled integrally in sections by the pre-laying and moving method; Second, before installing the new turnout, a crane rail car is used as the main turnout disassembly equipment to remove the old turnout and clean the roadbed; Third, after the new turnout is assembled, a crane rail car is used as the main turnout transfer equipment to transfer the new turnout to the vicinity of the installation position; Fourth, after the new turnout is transferred to the vicinity of the installation position, a crane rail car is used as the main turnout installation equipment to accurately install it at the corresponding position of the roadbed.

[0008] Document 2 is a Chinese utility model patent filed by CRRC High-Tech Equipment Co., Ltd. on August 15, 2016 and announced on June 6, 2017, with the announcement number CN206219916U. This utility model discloses a rapid replacement device for large components of railway turnouts, which includes at least one set of load-bearing platforms. A traveling mechanism is installed below the load-bearing platform, a load-bearing frame is installed above the load-bearing platform, the load-bearing frame is connected to a telescopic beam, the telescopic beam is connected to a sliding hoisting mechanism, a driving mechanism is also installed on the telescopic beam, one end of the telescopic beam is connected to a frame hinge beam and can rotate or move laterally based on the frame hinge beam. The load-bearing platform is also connected to at least one set of stable support devices, and the front end of the telescopic beam is connected to at least one set of front support devices.

[0009] Document 3 is a Chinese invention application filed by CRRC High-Tech Equipment Co., Ltd. on August 15, 2016 and published on March 6, 2018, with the publication number CN107761486A. This invention discloses a construction method for rapidly replacing large components of railway turnouts and its corresponding replacement equipment. The replacement equipment includes at least one set of load-bearing platforms. A load-bearing frame is installed above the load-bearing platform, the load-bearing frame is connected to a telescopic beam, the telescopic beam is connected to a sliding hoisting mechanism, a driving mechanism is also installed on the telescopic beam, one end of the telescopic beam is connected to a frame hinge beam, and a Z-direction flipping auxiliary adjustment mechanism is installed on the load-bearing frame.

[0010] Document 4 is a Chinese invention application filed by China Railway Heavy Industry Co., Ltd. and China Railway Science & Industry Corporation on January 5, 2013 and published on May 1, 2013, with the publication number CN103074829A. This invention discloses a construction method for replacing and laying railway turnouts and a railway turnout track laying machine set. The track laying machine set includes three main parts: a main machine, an auxiliary machine, and a hydraulic replacement rack. The main machine includes a main machine flat car, a machine arm, a front column gantry structure, a rear column gantry structure, a lifting trolley, a hoisting mechanism, and a traveling mechanism. The auxiliary machine includes at least an auxiliary machine flat car. The hydraulic replacement rack includes a first replacement rack, a second replacement rack, and a replacement sling.

[0011] In summary, there is no technical solution for replacing the entire set of turnout rail components in the prior art. There is an urgent need to propose a technical solution for replacing the entire set of turnout rail components to solve the technical problems of high cost, long occupation of the skylight, low operation efficiency, and low safety in the existing operation methods. Summary of the Invention

[0012] In view of this, the purpose of this application is to provide a turnout rail component replacement operation system to solve the technical problems of high cost, long occupation of the skylight, low operation efficiency, and low safety in the existing turnout replacement operation methods.

[0013] To achieve the above invention purpose, this application specifically provides a technical implementation solution for a turnout rail component replacement operation system, including:

[0014] Vehicle formation;

[0015] The vehicle formation includes a first railcar, an equipment flat car, a rail component flat car, and a second railcar connected in sequence.

[0016] The first railcar is used to tow the equipment flat car, and the equipment flat car is used to load the gantry crane device and the lifting platform.

[0017] The second railcar is used to tow the rail component flat car, and the rail component flat car is used to load the turnout rail components.

[0018] When the vehicle formation runs to near the turnout area of the operation site, it is uncoupled. After removing the third component of the old rail, deploy the gantry crane device, unload the second component of the new rail, recover the third component of the old rail, and replace the second component of the new rail. Recover the second component of the old rail, unload the first and third components of the new rail, replace the first component of the new rail, and recover the first component of the old rail. Recover the gantry crane device, replace the third component of the old rail, and complete the replacement of the turnout rail components.

[0019] Further, the turnout rail components are cut into a first component, a second component, and a third component at the insulated joint.

[0020] Further, the first component includes a straight stock rail and a curved switch rail.

[0021] Furthermore, the second component includes a straight point rail, a curved base rail and a switch core.

[0022] Furthermore, the third component includes a curved lower leg and a guard rail.

[0023] Furthermore, the first component, the second component and the third component are welded into a whole at the base by gas pressure welding or flash welding before being transported to the work site.

[0024] Furthermore, when the vehicle set arrives near the switch area, the vehicle set is uncoupled from the rear of the equipment flat car, and the equipment flat car is towed by the first rail car to place the door hanging device, while the second rail car and the rail flat car remain on standby.

[0025] Furthermore, before placing the gantry crane device, the third component of the old track is first removed and transferred between the line and the adjacent line through a simple gantry crane, and then the simple gantry crane is removed, and the first rail car and the equipment flat car enter the switch area to place the gantry crane device.

[0026] Furthermore, when deploying the gantry crane device, the equipment flat car is first pushed in by the first rail car, and then the gantry crane device is placed in sequence along the line using the lifting platform.

[0027] Furthermore, after the gantry crane device is placed, the rail flat car is pushed into the switch area by the second rail car. After the switch rail is aligned, the gantry crane device is used to lift and move the second component of the new rail from the rail flat car, and place it between the current line and the adjacent line and close to the support legs of the gantry crane device. At the same time, the third component of the old rail is lifted onto the rail flat car, and the second rail car and rail flat car withdraw.

[0028] Furthermore, when replacing the second component of the new rail, the second component of the old rail is first lifted out by the door lifting device and placed between the current line and the adjacent line and close to the straight side. The second component of the new rail is then lifted into the groove and the rail head is fixed with a hole-free clamp.

[0029] Furthermore, when the second component of the old rail is recovered, the second component of the old rail is lifted by the gantry crane device, and the second rail car and the rail flat car are pushed in. After the second component of the old rail is placed on the rail flat car, the first component of the new rail is lifted and moved horizontally and unloaded, and the third component of the new rail is lifted and moved horizontally and placed between the current line and the adjacent line and close to the support legs of the gantry crane device, and the second rail car and the rail flat car withdraw.

[0030] Furthermore, when replacing the first assembly of the new rail, the first assembly of the old rail is first lifted out and placed between the line and the adjacent line and close to the straight strand side, and then the first assembly of the new rail is lifted into the groove to restore traffic on the straight strand.

[0031] Further, when recycling the first component of the new rail, after lifting the first component of the old rail by the gantry crane device, the second rail car is used to push the rail flat car into the turnout area. After the first component of the old rail is placed on the rail flat car, the second rail car and the rail flat car withdraw.

[0032] Further, when recycling the gantry crane device, the first rail car pushes the equipment flat car in. The gantry crane device is recycled in reverse order along the line by using the lifting platform. The vehicle formation withdraws, and the third component of the new rail is aligned and inserted into the groove to complete the replacement.

[0033] Further, when recycling the gantry crane device, after the vehicle formation withdraws from the turnout area, the third component of the new rail is transferred from between the main line and the adjacent line to the curved lower rail position by a simple gantry crane and the replacement is completed.

[0034] By implementing the technical solution of the turnout rail component replacement operation system provided by the present application, the following beneficial effects are achieved:

[0035] (1) The turnout rail component replacement operation system of the present application can realize the on-site hoisting and replacement operation of the whole set of turnout rail components. The use of multiple gantry cranes can overcome the technical problems of large local deformation of the turnout rail components, large hoisting swing amplitude, low operation efficiency, and long occupation time of the skylight.

[0036] (2) The turnout rail component replacement operation system of the present application realizes the prefabrication or welding of the whole set of turnout rail components in advance, cancels the thermite welding process in the turnout area, and greatly improves the welding quality and efficiency by welding and replacing in the base area, thus improving the turnout construction quality and the line operation safety.

[0037] (3) The turnout rail component replacement operation system of the present application uses a flat car formation to transport the whole set of turnout rail components, which well adapts to the loading and unloading operations of the whole set of turnout rail components and the replacement turnout area environment, and systematically solves the technical problems of transportation, hoisting, laying and replacement of the whole set of turnout rail components.

[0038] (4) The turnout rail component replacement operation system of the present application hoists and replaces the turnout rail components by using multiple gantry cranes in cooperation with the wireless remote control method, which is safe, reliable, simple in structure and easy to operate. At the same time, the whole set of turnout rail components is divided into two parts: the straight rail and the curved rail, which is convenient for the transportation and handling of the rail flat car. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present application, and those of ordinary skill in the art can also obtain other embodiments according to these drawings without creative efforts.

[0040] Figure 1It is a schematic structural diagram of the vehicle formation in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0041] Figure 2 It is a partial three-dimensional structural diagram of a specific embodiment of the turnout rail component replacement operation system of the present application;

[0042] Figure 3 It is a partial side structural diagram of a specific embodiment of the turnout rail component replacement operation system of the present application;

[0043] Figure 4 It is a three-dimensional structural diagram of the gantry crane device and the lifting platform in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0044] Figure 5 It is a three-dimensional structural diagram of the lifting platform in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0045] Figure 6 It is a schematic diagram of the operation process of deploying the gantry crane device on the lifting platform in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0046] Figure 7 It is a schematic structural diagram of the turnout rail components in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0047] Figure 8 It is a schematic structural diagram of the first component in the turnout rail components of a specific embodiment of the turnout rail component replacement operation system of the present application;

[0048] Figure 9 It is a schematic structural diagram of the second component in the turnout rail components of a specific embodiment of the turnout rail component replacement operation system of the present application;

[0049] Figure 10 It is a schematic structural diagram of the third component in the turnout rail components of a specific embodiment of the turnout rail component replacement operation system of the present application;

[0050] Figure 11 It is a schematic diagram of the process of vehicle formation and decomposition in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0051] Figure 12 It is a schematic diagram of the operation process of removing the third component of the old rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0052] Figure 13 It is a schematic diagram of the operation process of placing the gantry crane in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0053] Figure 14It is a schematic diagram of the operation process of unloading the second component of the new rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0054] Figure 15 It is a schematic diagram after the unloading of the second component of the new rail in a specific embodiment of the turnout rail component replacement operation system of the present application is completed;

[0055] Figure 16 It is a schematic diagram of the operation process of hoisting out the second component of the old rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0056] Figure 17 It is a schematic diagram of the operation process of hoisting the second component of the new rail into place in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0057] Figure 18 It is a schematic diagram of the operation process of recycling the second component of the old rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0058] Figure 19 It is a schematic diagram of the operation process of unloading the first and third components of the new rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0059] Figure 20 It is a schematic diagram of the operation process of hoisting out the first component of the old rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0060] Figure 21 It is a schematic diagram of the operation process of hoisting the first component of the new rail into place in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0061] Figure 22 It is a schematic diagram of the operation process of recycling the first component of the old rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0062] Figure 23 It is a schematic diagram of the operation process of recycling the gantry crane in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0063] Figure 24 It is a schematic diagram of the operation process of replacing the third component of the old rail in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0064] Figure 25 It is a schematic diagram of the structure after completing the turnout rail component replacement operation in a specific embodiment of the turnout rail component replacement operation system of the present application;

[0065] Figure 26 It is a schematic diagram of the partial structure composition of another specific embodiment of the turnout rail component replacement operation system of the present application;

[0066] In the figure: 1 - First railcar, 2 - Equipment flatcar, 3 - Second railcar, 4 - Rail component flatcar, 5 - Gantry crane device, 6 - Lifting platform, 7 - This line, 8 - Adjacent line, 9 - Simple gantry crane, 10 - Operation system, 11 - Insulating joint, 12 - Signal transmitter, 13 - Signal receiver, 20 - Turnout rail component, 21 - First component, 211 - Straight stock rail, 212 - Curved switch rail, 22 - Second component, 221 - Straight switch rail, 222 - Curved stock rail, 223 - Frog, 23 - Third component, 231 - Curved lower rail, 232 - Guard rail. Detailed implementation manners

[0067] To make the objectives, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application. Apparently, the described embodiments are only a part rather than all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present application.

[0068] As shown in the attached Figure 1 to the attached Figure 26 figures, specific embodiments of the turnout rail component replacement operation system of the present application are given. The present application will be further described below with reference to the accompanying drawings and specific embodiments.

[0069] Embodiment 1

[0070] As shown in the attached Figure 1 figures, an embodiment of the turnout rail component replacement operation system of the present application specifically includes:

[0071] Vehicle formation;

[0072] The vehicle formation includes a first railcar 1, an equipment flatcar 2, a rail component flatcar 4 and a second railcar 3 that are connected in sequence.

[0073] As shown in the attached Figure 2 to the attached Figure 6 figures, the first railcar 1 is used to tow the equipment flatcar 2 (a 15.4m flatcar can be specifically adopted), and the equipment flatcar 2 is used to load the gantry crane device 5 and the lifting platform 6 (4 sets of gantry crane devices 5 and 2 sets of lifting platforms 6 are introduced in this embodiment).

[0074] The second railcar 3 is used to tow the rail component flatcar 4, and the rail component flatcar 4 is used to load the turnout rail component 20.

[0075] As a preferred specific embodiment of the present application, the operation system 10 further includes a set of power device and a set of wireless remote controller disposed on the equipment flatcar 2. As shown in the attached Figure 26As shown in the figure, the wireless remote controller further includes a signal transmitter 12 and signal receivers 13 disposed on the gantry device 5 and the lifting platform 6. Multiple sets of gantry devices 5 and lifting platforms 6 are all synchronously remotely controlled by the wireless remote controller. With this system, in-line operation can be achieved. All the retracting and extending actions of the gantry devices 5 and the hoisting actions of the turnout rail members 20 can be wirelessly controlled by the remote controller. The hoisting operations are all carried out under the gantry devices 5, which is safe, intelligent, and has no risk of touching the overhead catenary. At the same time, multiple-point lifting is configured according to the center of gravity of the rail members, and the rail members have no permanent deformation, meeting the laying process requirements of the railway turnout 20. The intelligent acceleration / deceleration control between the lifting points of multiple sets of gantry devices 5 has good synchronism, small shaking of the rail members, can quickly enter the slot, and has high operation efficiency.

[0076] When the vehicle formation runs to the vicinity of the turnout area at the arrival operation site, it is uncoupled. After removing the third component 23 of the old rail, the gantry device 5 is deployed, the second component 22 of the new rail is unloaded, the third component 23 of the old rail is recovered, and the second component 22 of the new rail is replaced. The second component 22 of the old rail is recovered, the first component 21 and the third component 23 of the new rail are unloaded, the first component 21 of the new rail is replaced, and the first component 21 of the old rail is recovered. The gantry device 5 is recovered, the third component 23 of the old rail is replaced, and the replacement of the turnout rail member 20 is completed.

[0077] The operation system 10 described in this embodiment can complete the replacement of the entire set of No. 18 turnout rail members 20 on the same line within a single skylight period. The turnout area situation is as shown in the appendix. Figure 7 As shown in the figure, in order to realize hoisting, the turnout rail member 20 is cut into three large components from the insulated joint 11, namely the first component 21, the second component 22, and the third component 23.

[0078] As shown in the appendix Figure 8 The first component 21 further includes a straight stock rail 211 and a curved switch rail 212.

[0079] As shown in the appendix Figure 9 The second component 22 further includes a straight switch rail 221, a curved stock rail 222, and a frog 223.

[0080] As shown in the appendix Figure 10 The third component 23 further includes a curved lower rail 231 and a guard rail 232.

[0081] Before the first component 21, the second component 22, and the third component 23 are transported to the operation site, they are welded into a whole at the base by gas pressure welding or flash welding respectively. Canceling the thermite welding in the turnout area, the turnout rail member 20 is welded into a whole at the base in advance by highly reliable gas pressure welding or flash welding. The whole turnout rail member 20 is hoisted and replaced on-site, which can effectively cancel 8 thermite welding points in the turnout area, save 2 skylights required for turnout replacement, and reduce more than 100 on-site operation personnel.

[0082] The turnout assembly 20 has an irregular cross-section and limited space. For the turnout rail replacement operation system described in this embodiment, the entire set of turnout rails 20 can be prefabricated or welded and assembled in the base in advance, eliminating the thermite welding process in the turnout area. By welding and replacing in the base in the turnout area, the welding quality and efficiency can be greatly improved. This not only improves the operation efficiency of the construction skylight operation, but also avoids the quality problems caused by short-time rapid welding of the on-site turnout rails 20, improving the turnout construction quality and the line operation safety.

[0083] When the vehicle formation arrives near the turnout area, the vehicle formation is uncoupled from the rear of the equipment flatcar 2, and the first railcar 1 is used to tow the equipment flatcar 2 to place the gantry device 5, while the second railcar 3 and the rail flatcar 4 stay on standby in place.

[0084] Before placing the gantry device 5, first remove the third component 23 of the old rail and transfer it to between the main line 7 and the adjacent line 8 through the simple gantry 9, then remove the simple gantry 9, and the first railcar 1 and the equipment flatcar 2 enter the turnout area to place the gantry device 5.

[0085] When deploying the gantry device 5, first push the equipment flatcar 2 into place through the first railcar 1, and then use the lifting platform 6 to place the gantry device 5 in sequence along the main line.

[0086] After the gantry device 5 is placed, the second railcar 3 is used to push the rail flatcar 4 into the turnout area. After the turnout rails 20 are aligned, use the gantry device 5 to lift and horizontally move the second component 22 of the new rail from the rail flatcar 4, place it between the main line 7 and the adjacent line 8 and close to the leg of the gantry device 5. At the same time, lift the third component 23 of the old rail onto the rail flatcar 4, and the second railcar 3 and the rail flatcar 4 withdraw.

[0087] When replacing the second component 22 of the new rail, first lift out the second component 22 of the old rail and place it between the main line 7 and the adjacent line 8 and close to the straight track side, then lift the second component 22 of the new rail into the groove and fix the rail head with a non-perforated clamp.

[0088] When recovering the second component 22 of the old rail, lift the second component 22 of the old rail through the gantry device 5, and push in the second railcar 3 and the rail flatcar 4. After the second component 22 of the old rail is placed on the rail flatcar 4, lift and horizontally move the first component 21 of the new rail and unload it from the vehicle, lift and horizontally move the third component 23 of the new rail, place it between the main line 7 and the adjacent line 8 and close to the leg of the gantry device 5, and the second railcar 3 and the rail flatcar 4 withdraw.

[0089] When replacing the first component 21 of the new rail, first lift out the first component 21 of the old rail and place it between the main line 7 and the adjacent line 8 and close to the straight track side, then lift the first component 21 of the new rail into the groove and resume the through traffic on the straight track.

[0090] When recycling the first component 21 of the new rail, after lifting the first component 21 of the old rail by the gantry crane device 5, the second rail vehicle 3 is used to push the rail flatcar 4 into the turnout area. After the first component 21 of the old rail is placed on the rail flatcar 4, the second rail vehicle 3 and the rail flatcar 4 withdraw.

[0091] When recycling the gantry crane device 5, the first rail vehicle 1 pushes the equipment flatcar 2 in. The gantry crane device 5 is recycled in reverse order along the main line 7 by using the lifting platform 6. The vehicle formation withdraws, and the third component 23 of the new rail is aligned and inserted into the groove to complete the replacement.

[0092] When recycling the gantry crane device 5, after the vehicle formation withdraws from the turnout area, the third component 23 of the new rail is transferred from between the main line 7 and the adjacent line 8 to the curved lower rail position by the simple gantry crane 9 and the replacement is completed.

[0093] The turnout rail component replacement operation system described in Embodiment 1 can realize the on-site hoisting and replacement operation of the entire set of turnout rail components. The use of multiple sets of gantry crane operations can overcome the technical problems of large local deformation of the turnout rail components, large hoisting swing amplitude, low operation efficiency, and long occupation time of the skylight. The process of replacing the turnout rail components is safe and reliable; the entire set of operation systems can replace the entire set of turnout rail components within one skylight time, compared with the existing technical solutions that require ≥4 skylights, greatly improving the operation efficiency. The turnout rail component replacement operation system of this application uses a flatcar formation to transport the entire set of turnout rail components, which well adapts to the loading and unloading operations of the entire set of turnout rail components and the replacement turnout area environment, and systematically solves the technical problems of transportation, hoisting, and laying and replacement of the entire set of turnout rail components. The turnout rail component replacement operation system of this application uses multiple sets of gantry crane devices in cooperation with a wireless remote control method to hoist and replace the turnout rail components, which is safe and reliable, has a simple structure, and is easy to operate. At the same time, the entire set of turnout rail components is divided into two parts, the straight rail side and the curved rail side, for hoisting and replacement respectively, which is convenient for the transportation and handling of the rail flatcar.

[0094] Embodiment 2

[0095] As shown in the attached Figure 9 An embodiment of a turnout rail component replacement operation method based on the system described in Embodiment 1 specifically includes the following steps:

[0096] S1) Vehicle formation operation. The track vehicles (i.e., the first rail vehicle 1 and the second rail vehicle 3) are used to transport the paving and replacement equipment flatcar (i.e., the equipment flatcar 2) and the rail transport flatcar (i.e., the rail flatcar 4) to the operation turnout area.

[0097] S2) The vehicle formation is uncoupled when it arrives near the turnout area of the operation site.

[0098] Step S2) further includes the following process:

[0099] When the vehicle formation arrives near the turnout area, the vehicle formation is uncoupled from the rear of the equipment flatcar 2, and the first railcar 1 is used to tow the equipment flatcar 2 to place the gantry crane device 5. The second railcar 3 and the rail component flatcar 4 stay on standby at the original place, as shown in the appendix Figure 11 as shown.

[0100] S3) Demolish the third component 23 of the old rail.

[0101] Step S3) further includes the following process:

[0102] Before placing the gantry crane device 5, first demolish the third component 23 of the old rail and transfer it between the main line 7 and the adjacent line 8 through the simple gantry crane 9, then demolish the simple gantry crane 9. The first railcar 1 and the equipment flatcar 2 enter the turnout area to place the gantry crane device 5, as shown in the appendix Figure 12 as shown.

[0103] S4) Deploy the gantry crane device 5. After each gantry crane device 5 is placed, the second railcar 3 pushes the rail component flatcar 4 under the opposite line of the equipment flatcar 2.

[0104] Step S4) further includes the following process:

[0105] Push the equipment flatcar 2 in through the first railcar 1, and use the lifting platform 6 to place the gantry crane devices 5 in the order of 4, 3, 2, 1 from right to left along the main line, as shown in the appendix Figure 13 as shown.

[0106] S5) Unload the second component 22 of the new rail and recover the third component 23 of the old rail. Use the group lifting method of the gantry crane device 5 to unload the new turnout rail components and stack them beside the line, and the equipment flatcar 2 withdraws; and use the gantry crane device 5 to transfer the old turnout rail components to beside the line. After the rail component flatcar 4 is pushed in, place the old turnout rail components on the rail component flatcar 4 to complete the loading.

[0107] Step S5) further includes the following process:

[0108] After the gantry crane device 5 is placed, push the rail component flatcar 4 into the turnout area through the second railcar 3. After the turnout rail components 20 are aligned, use the gantry crane device 5 to lift and horizontally move the second component 22 of the new rail from the rail component flatcar 4, and place it between the main line 7 and the adjacent line 8 and close to the legs of the gantry crane device 5. At the same time, lift the third component 23 of the old rail onto the rail component flatcar 4, and the second railcar 3 and the rail component flatcar 4 withdraw, as shown in the appendix Figure 14 and 15 as shown.

[0109] S6) Replace the second component 22 of the new rail.

[0110] Step S6) further includes the following process:

[0111] First, use the gantry crane device 5 to lift out the second component 22 of the old rail and place it between the main line 7 and the adjacent line 8, close to the straight side, and then lift the second component 22 of the new rail and place it into the groove. Fix the rail head with a holeless fixture, as shown in the appendix Figure 16 and 17 shown

[0112] S7) Recover the second component 22 of the old rail, and unload the first component 21 and the third component 23 of the new rail.

[0113] Step S7) further includes the following process:

[0114] Use the gantry crane device 5 to lift the second component 22 of the old rail, push in the second rail car 3 and the rail component flat car 4. After the second component 22 of the old rail is placed on the rail component flat car 4, lift and horizontally move the first component 21 of the new rail and unload it from the car, lift and horizontally move the third component 23 of the new rail, place it between the main line 7 and the adjacent line 8, close to the leg of the gantry crane device 5, and then the second rail car 3 and the rail component flat car 4 withdraw, as shown in the appendix Figure 18 and 19 shown

[0115] S8) Replace the first component 21 of the new rail.

[0116] Step S8) further includes the following process:

[0117] First, lift out the first component 21 of the old rail and place it between the main line 7 and the adjacent line 8, close to the straight side, and then lift the first component 21 of the new rail and place it into the groove, and resume through traffic on the straight side, as shown in the appendix Figure 20 and 21 shown

[0118] S9) Recover the first component 21 of the old rail. The turnout rail components 20 are lifted and loaded onto the rail component flat car 4 by using the gantry crane device 5 in a group lifting method for reinforcement and transportation.

[0119] Step S9) further includes the following process:

[0120] After lifting the first component 21 of the old rail by the gantry crane device 5, use the second rail car 3 to push the rail component flat car 4 into the turnout area. After the first component 21 of the old rail is placed on the rail component flat car 4, the second rail car 3 and the rail component flat car 4 withdraw, as shown in the appendix Figure 22 shown

[0121] S10) Recover the gantry crane device 5.

[0122] Step S10) further includes the following process:

[0123] The first rail car 1 pushes the equipment flat car 2 in, uses the lifting platform 6 to recover the gantry crane device 5 along the main line 7 in the reverse order of 1, 2, 3, 4, the vehicle formation withdraws, and straightens the third component 23 of the new rail into the groove to complete the replacement, as shown in the appendixFigure 23 as shown

[0124] S11) Replace the third component 23 of the old rail.

[0125] Step S11) further includes the following process:

[0126] After the vehicle formation withdraws from the turnout area, the third component 23 of the new rail is transferred from between the main line 7 and the adjacent line 8 to the curved lower rail position by the simple gantry crane 9, and the replacement is completed, as shown in the appendix Figure 24 and 25 as shown

[0127] S12) Complete the replacement of the turnout rail components 20. After the gantry crane device 5 retrieves each one, align the two ends of the new turnout rail components, then weld, grind, and finely adjust them, thus completing the hoisting and replacement construction of the entire set of turnout rail components 20.

[0128] The gantry crane device 5 uses the group hoisting method to hoist out the old straight side rail components and hoist in the new straight side rail components; then hoist out the old curved side rail components and hoist in the new curved side rail components to complete the hoisting and replacement of the entire turnout rail components 20.

[0129] The vehicle formation further includes a first railcar 1, an equipment flatcar 2, a rail component flatcar 4, and a second railcar 3 connected in sequence. The equipment flatcar 2 is used to load the gantry crane device 5 and the lifting platform 6, and the rail component flatcar 4 is used to load the turnout rail components 20.

[0130] The turnout rail components 20 are cut at the insulating joint 11 to form a first component 21, a second component 22, and a third component 23.

[0131] The first component 21 further includes a straight stock rail 211 and a curved switch rail 212.

[0132] The second component 22 further includes a straight switch rail 221, a curved stock rail 222, and a frog 223.

[0133] The third component 23 further includes a curved lower rail 231 and a guard rail 232.

[0134] Before the first component 21, the second component 22, and the third component 23 are transported to the operation site, they are welded into a whole respectively by gas pressure welding or flash welding at the base. The turnout rail components 20 are pre-welded into two parts, namely the curved side rail components and the straight side rail components, at the base.

[0135] In the description of the present application, it should be noted that when an element is referred to as "fixed to" or "disposed on" another element, it can be directly disposed on the other element or indirectly disposed on the other element. When an element is referred to as "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element.

[0136] It should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application 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. Therefore, it should not be construed as a limitation to the present application.

[0137] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of the present application, the meaning of "a plurality" and "several" is two or more, unless otherwise specifically defined.

[0138] It should be noted that the structures, ratios, sizes, etc. shown in the drawings of this specification are only used to cooperate with the content disclosed in the specification for those skilled in the art to understand and read, and are not used to limit the implementation conditions of the present application. Therefore, they do not have a substantial technical meaning. Any modification of the structure, change of the proportional relationship or adjustment of the size, without affecting the efficacy and the purpose that the present application can achieve, should still fall within the scope that the technical content disclosed in the present application can cover.

[0139] By implementing the technical solutions of the turnout rail component replacement operation system described in the specific embodiments of the present application, the following technical effects can be achieved:

[0140] (1) The turnout rail component replacement operation system described in the specific embodiments of the present application can realize the on-site hoisting and replacement operation of the whole set of turnout rail components. Using multiple gantry cranes for operation can overcome the technical problems of large local deformation of the turnout rail components, large hoisting swing amplitude, low operation efficiency, and long occupation time of the skylight.

[0141] (2) The turnout rail component replacement operation system described in the specific embodiments of the present application realizes the prefabrication or welding of the whole set of turnout rail components in advance, cancels the thermite welding process in the turnout area, and greatly improves the welding quality and efficiency by welding and replacing in the base area, thus improving the turnout construction quality and the safety of line operation.

[0142] (3) The turnout rail component replacement operation system described in the specific embodiments of the present application uses flatbed car formation to transport the whole set of turnout rail components, well adapts to the loading and unloading operations of the whole set of turnout rail components and the replacement turnout area environment, and systematically solves the technical problems of transportation, hoisting, laying and replacement of the whole set of turnout rail components.

[0143] (4) The switch rail replacement operation system described in the specific embodiments of this application uses multiple gantry cranes in cooperation with a wireless remote control method to lift and replace the switch rails. It is safe, reliable, simple in structure, and easy to operate. At the same time, the entire set of switch rails is divided into a straight rail part and a curved rail part, which is convenient for transporting and handling the rail flat cars.

[0144] The various embodiments in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments. For the same or similar parts among the various embodiments, reference can be made to each other.

[0145] As mentioned above, it is only the preferred embodiment of this application, and there is no limitation to this application in any form. Although this application has been disclosed as above with the preferred embodiment, it is not intended to limit this application. Any person skilled in the art can make many possible changes and modifications to the technical solution of this application by using the methods and technical content disclosed above, or modify it into an equivalent embodiment with equivalent changes. Therefore, any simple modification, equivalent replacement, equivalent change, and modification made to the above embodiments based on the technical essence of this application without departing from the technical solution of this application still fall within the scope of protection of the technical solution of this application.

Claims

1. A turnout rail replacement system, characterized in that: include: Vehicle marshaling; The vehicle formation comprises a first rail car, an equipment flat car, a rail flat car and a second rail car connected in sequence; The first rail car is used to tow the equipment flat car, and the equipment flat car is used to load the door hanging device and the lifting platform; The second rail car is used to pull the rail flat car, and the rail flat car is used to load the turnout rails; The vehicle marshaling is disassembled when it arrives near the switch area at the operation site; after the third component of the old track is removed, the gantry crane device is deployed, the second component of the new track is unloaded, the third component of the old track is recovered, and the second component of the new track is replaced; the second component of the old track is recovered, and the first component and the third component of the new track are unloaded, the first component of the new track is replaced, and the first component of the old track is recovered; the gantry crane device is recovered, the third component of the old track is replaced, and the switch rail replacement is completed.

2. The turnout rail replacement system according to claim 1, characterized in that: The switch rail is cut into a first component, a second component and a third component from an insulating joint.

3. The switch rail replacement system according to claim 2, characterized in that: The first component includes a straight base rail and a curved tip rail.

4. The switch rail replacement system according to claim 3, characterized in that: The second component includes a straight point rail, a curved base rail and a switch core.

5. The switch rail replacement system according to claim 4, characterized in that: The third component includes a curved lower leg and a guard rail.

6. The turnout rail replacement system according to any one of claims 2 to 5, characterized in that: The first component, the second component and the third component are welded into a whole at the base by gas pressure welding or flash welding before being transported to the operation site.

7. The switch rail replacement system according to claim 2, characterized in that: When the vehicle formation arrives near the switch area, the vehicle formation is unmarshaled from the rear of the equipment flat car, and the equipment flat car is towed by the first rail car to place the door hanging device, while the second rail car and the rail flat car remain on standby.

8. The switch rail replacement system according to claim 3, characterized in that: Before placing the gantry crane device, first remove the third component of the old track and transfer it between the line and the adjacent line through a simple gantry crane, then remove the simple gantry crane, and the first rail car and equipment flat car enter the switch area to place the gantry crane device.

9. The switch rail replacement system according to claim 4, characterized in that: When deploying the gantry crane device, first push the equipment flat car through the first rail car, and then use the lifting platform to place the gantry crane device in sequence along the line.

10. The switch rail replacement system according to claim 5, characterized in that: After the gantry crane device is placed, the rail flatcar is pushed into the switch area by the second rail car. After the switch rail is aligned, the gantry crane device is used to lift the second component of the new rail from the rail flatcar and move it horizontally. It is placed between the current line and the adjacent line and close to the legs of the gantry crane device. At the same time, the third component of the old rail is lifted onto the rail flatcar, and the second rail car and rail flatcar withdraw.

11. The switch rail replacement system according to claim 6, characterized in that: When replacing the second component of the new rail, first use the door crane device to lift the second component of the old rail and place it between the current line and the adjacent line and close to the straight side. Then lift the second component of the new rail into the groove and fix the rail head with a hole-free clamp.

12. The switch rail replacement system according to claim 7, characterized in that: When the second component of the old rail is recovered, the second component of the old rail is lifted by the gantry crane device, and the second rail car and the rail flat car are pushed in. After the second component of the old rail is placed on the rail flat car, the first component of the new rail is lifted and moved horizontally and unloaded, and the third component of the new rail is lifted and moved horizontally, placed between the current line and the adjacent line and close to the support legs of the gantry crane device, and the second rail car and the rail flat car withdraw.

13. The switch rail replacement system according to claim 8, characterized in that: When replacing the first assembly of the new rail, first lift out the first assembly of the old rail and place it between the line and the adjacent line and close to the straight side, then lift the first assembly of the new rail into the groove and resume traffic on the straight line.

14. The switch rail replacement system according to claim 9, characterized in that: When the first component of the new rail is recovered, the first component of the old rail is lifted by the door crane device, and the rail flat car is pushed into the switch area by the second rail car. After the first component of the old rail is placed on the rail flat car, the second rail car and the rail flat car withdraw.

15. The switch rail replacement system according to claim 10, characterized in that: When the gantry crane device is recovered, the first rail car pushes the equipment flat car in, uses the lifting platform to recover the gantry crane device in reverse order along the line, the vehicle formation is evacuated, and the third component of the new rail is placed in the groove to complete the replacement.

16. The switch rail replacement system according to claim 11, characterized in that: When the gantry crane device is recovered, after the vehicle formation withdraws from the switch area, the third component of the new rail is transferred from between the main line and the adjacent line to the lower section of the curve through a simple gantry crane, and the replacement is completed.

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