Turnout rail part replacement operation method

Abstract

The invention discloses a turnout rail piece replacement operation method. The method comprises the following steps that S1, vehicles are marshaled and run; s2) the vehicle marshalling is demarcated when arriving at a position near a fork area of an operation site; (S3) a third assembly of the old rail is dismantled; s4) deploying a gantry crane device; (S5) the second assembly of the new rail is unloaded, and the third assembly of the old rail is recycled; s6) replacing the second assembly of the new rail; (7) the second assembly of the old rail is recycled, and the first assembly and the third assembly of the new rail are unloaded; (S8) a first assembly of a new rail is replaced; (S9) a first assembly of the old rail is recycled; s10) recovering the gantry crane device; (S11) a third assembly of the old rail is replaced; and (S12) turnout rail piece replacement is completed. The technical problems that a turnout rail piece is long in size and large in weight, and an existing replacement operation method 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 relates to an operation method 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, composed of components such as switch points, switch rails, connecting rails, and stock rails. Their main characteristics are long dimensions and heavy weights, making manual replacement difficult, 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, easily causing long-distance wear of the rail lines. In particular, the turnout is subject to greater lateral forces and is more prone to wear and needs to be replaced. At the same time, the high-frequency passage of vehicles requires rapid repair after the rails are worn. To save time, the whole set of turnout rail components needs to be replaced simultaneously. Due to the limited operation area, 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 includes the following several types:

[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 scheme, large rail components are prone to large deformations 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 generating 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 consists 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 scheme 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 Engineering 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 China Railway Construction Heavy Industry 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 bearing platforms. A traveling mechanism is installed below the bearing platform, a bearing frame is installed above the bearing platform, the 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 horizontally based on the frame hinge beam. The 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 China Railway Construction Heavy Industry Co., Ltd. on August 15, 2016 and published on March 6, 2018, with the publication number CN107761486A. This invention discloses a rapid replacement method for large components of railway turnouts and its corresponding replacement equipment. The replacement equipment includes at least one set of bearing platforms. A bearing frame is installed above the bearing platform, the 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 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 parts in the prior art. There is an urgent need to propose a technical solution for replacing the entire set of turnout rail parts to solve the technical problems of high cost, long occupation of the overhead time, low operation efficiency, and low safety of the existing operation methods. Summary of the Invention

[0012] In view of this, the purpose of this application is to provide a method for replacing turnout rail parts to solve the technical problems of high cost, long occupation of the overhead time, low operation efficiency, and low safety of the existing turnout replacement operation methods.

[0013] To achieve the above-mentioned invention purpose, this application specifically provides a technical implementation solution for a method for replacing turnout rail parts, including the following steps:

[0014] S1) The vehicles are marshaled and run.

[0015] S2) The vehicles are unmarshaled when they reach near the turnout area of the operation site.

[0016] S3) Remove the third component of the old rail.

[0017] S4) Deploy the gantry crane device.

[0018] S5) Unload the second component of the new rail and recover the third component of the old rail.

[0019] S6) Replace the second component of the new rail.

[0020] S7) Recover the second component of the old rail and unload the first and third components of the new rail.

[0021] S8) Replace the first component of the new rail.

[0022] S9) Recover the first component of the old rail.

[0023] S10) Recover the gantry crane device.

[0024] S11) Replace the third component of the old rail.

[0025] S12) Complete the replacement of the turnout rail parts.

[0026] Further, the vehicle formation includes a first railcar, an equipment flatcar, a rail component flatcar, and a second railcar that are connected in sequence. The equipment flatcar is used to load a gantry crane device and a lifting platform, and the rail component flatcar is used to load turnout rail components.

[0027] Further, the step S2) includes the following process:

[0028] When the vehicle formation arrives near the turnout area, the vehicle formation is uncoupled from the rear of the equipment flatcar, and the first railcar is used to tow the equipment flatcar to place the gantry crane device, while the second railcar and the rail component flatcar stay on standby at the original position.

[0029] Further, the step S3) includes the following process:

[0030] Before placing the gantry crane device, first remove the third component of the old rail and transfer it to between the main line and the adjacent line through a simple gantry crane, then remove the simple gantry crane, and the first railcar and the equipment flatcar enter the turnout area to place the gantry crane device.

[0031] Further, the step S4) includes the following process:

[0032] The first railcar is used to push the equipment flatcar in, and the gantry crane device is placed sequentially along the main line by using the lifting platform.

[0033] Further, the step S5) includes the following process:

[0034] After the gantry crane device is placed, the second railcar is used to push the rail component flatcar into the turnout area. After the turnout rail components are aligned, the gantry crane device is used to lift and horizontally move the second component of the new rail from the rail component flatcar, and place it between the main line and the adjacent line and close to the leg of the gantry crane device. At the same time, the third component of the old rail is lifted onto the rail component flatcar, and the second railcar and the rail component flatcar withdraw.

[0035] Further, the step S6) includes the following process:

[0036] The gantry crane device is used to first lift out the second component of the old rail and place it between the main line and the adjacent line and close to the straight track side, then lift the second component of the new rail and insert it into the groove, and use a non-perforated fixture to fix the rail head.

[0037] Further, the step S7) includes the following process:

[0038] The gantry crane device is used to lift the second component of the old rail. The second railcar and the rail component flatcar are pushed in. After the second component of the old rail is placed on the rail component flatcar, the first component of the new rail is lifted and horizontally moved and unloaded, and the third component of the new rail is lifted and horizontally moved and placed between the main line and the adjacent line and close to the leg of the gantry crane device. The second railcar and the rail component flatcar withdraw.

[0039] Further, the step S8) includes the following process:

[0040] First, lift out the first component of the old rail and place it between the main line and the adjacent line and close to the straight side, then lift the first component of the new rail into the groove, and resume through traffic on the straight side.

[0041] Further, the step S9) includes the following process:

[0042] After lifting the first component of the old rail by the gantry crane device, push the rail flat car into the turnout 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.

[0043] Further, the step S10) includes the following process:

[0044] 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 main line, the vehicle formation withdraws, and aligns and inserts the third component of the new rail into the groove to complete the replacement.

[0045] Further, the step S11) includes the following process:

[0046] After the vehicle formation withdraws from the turnout area, transfer the third component of the new rail from between the main line and the adjacent line to the curved lower stock rail position through a simple gantry crane and complete the replacement.

[0047] Further, cut the turnout rail from the insulating joint to form the first component, the second component and the third component.

[0048] Further, the first component includes a straight stock rail and a curved switch rail.

[0049] Further, the second component includes a curved stock rail, a straight switch rail and a frog.

[0050] Further, the third component includes a curved lower stock rail and a guard rail.

[0051] Further, before the first component, the second component and the third component are transported to the operation site, they are welded into a whole by gas pressure welding or flash welding respectively at the base.

[0052] By implementing the technical solution of the turnout rail replacement operation method provided by the present application, the following beneficial effects are obtained:

[0053] (1) The turnout rail replacement operation method of the present application can realize on-site hoisting and replacement operation of the whole set of turnout rails. Using multiple sets of gantry crane operations can overcome the technical problems of large local deformation of the turnout rails, large hoisting swing amplitude, low operation efficiency, and long occupation time of the skylight;

[0054] (2) The switch rail component replacement operation method of the present application realizes the prefabrication or welding of the entire set of switch rail components in advance, cancels the thermite welding process in the turnout area, and greatly improves the welding quality and efficiency through welding and replacement in the base area, enhancing the turnout construction quality and the line operation safety.

[0055] (3) The switch rail component replacement operation method of the present application uses flatbed car formation to transport the entire set of switch rail components, well adapting to the loading and unloading operations of the entire set of switch rail components and the replacement turnout area environment, and systematically solving technical problems such as the transportation, hoisting, and laying and replacement of the entire set of switch rail components.

[0056] (4) The switch rail component replacement operation method of the present application uses multiple gantry cranes in cooperation with a wireless remote control method to hoist and replace the switch rail components, which is safe, reliable, simple in structure, and easy to operate. At the same time, the entire set of switch rail components is divided into two parts: the straight rail and the curved rail, facilitating the transportation and handling of the rail components on the flatbed car. BRIEF DESCRIPTION OF THE DRAWINGS

[0057] 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 use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, other embodiments can also be obtained based on these drawings without creative efforts.

[0058] Figure 1 It is a schematic structural diagram of the vehicle formation of a specific embodiment of the switch rail component replacement operation system based on the method of the present application;

[0059] Figure 2 It is a partial three-dimensional structural diagram of a specific embodiment of the switch rail component replacement operation system based on the method of the present application;

[0060] Figure 3 It is a partial side structural diagram of a specific embodiment of the switch rail component replacement operation system based on the method of the present application;

[0061] Figure 4 It is a three-dimensional structural diagram of the gantry crane device and the lifting platform in a specific embodiment of the switch rail component replacement operation system based on the method of the present application;

[0062] Figure 5 It is a three-dimensional structural diagram of the lifting platform in a specific embodiment of the switch rail component replacement operation system based on the method of the present application;

[0063] 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 switch rail component replacement operation system based on the method of the present application;

[0064] Figure 7It is a schematic structural diagram of turnout rail components in a specific embodiment of the turnout rail component replacement operation system based on the method of this application;

[0065] Figure 8 It is a schematic structural diagram of the first component in the turnout rail components in a specific embodiment of the turnout rail component replacement operation system based on the method of this application;

[0066] Figure 9 It is a schematic structural diagram of the second component in the turnout rail components in a specific embodiment of the turnout rail component replacement operation system based on the method of this application;

[0067] Figure 10 It is a schematic structural diagram of the third component in the turnout rail components in a specific embodiment of the turnout rail component replacement operation system based on the method of this application;

[0068] Figure 11 It is a schematic process diagram of vehicle formation and decomposition in a specific embodiment of the turnout rail component replacement operation method of this application;

[0069] Figure 12 It is a schematic operation process diagram of removing the third component of the old rail in a specific embodiment of the turnout rail component replacement operation method of this application;

[0070] Figure 13 It is a schematic operation process diagram of placing the gantry crane in a specific embodiment of the turnout rail component replacement operation method of this application;

[0071] Figure 14 It is a schematic operation process diagram of unloading the second component of the new rail in a specific embodiment of the turnout rail component replacement operation method of this application;

[0072] Figure 15 It is a schematic diagram after unloading the second component of the new rail is completed in a specific embodiment of the turnout rail component replacement operation method of this application;

[0073] Figure 16 It is a schematic operation process diagram of lifting out the second component of the old rail in a specific embodiment of the turnout rail component replacement operation method of this application;

[0074] Figure 17 It is a schematic operation process diagram of lifting the second component of the new rail into place in a specific embodiment of the turnout rail component replacement operation method of this application;

[0075] Figure 18 It is a schematic operation process diagram of recycling the second component of the old rail in a specific embodiment of the turnout rail component replacement operation method of this application;

[0076] Figure 19 It is a schematic operation process diagram of unloading the first and third components of the new rail in a specific embodiment of the turnout rail component replacement operation method of this application;

[0077] Figure 20It is a schematic diagram of the operation process for hoisting out the first component of the old rail, which is a specific embodiment of the switch rail component replacement operation method of this application;

[0078] Figure 21 It is a schematic diagram of the operation process for hoisting in the first component of the new rail, which is a specific embodiment of the switch rail component replacement operation method of this application;

[0079] Figure 22 It is a schematic diagram of the operation process for recycling the first component of the old rail, which is a specific embodiment of the switch rail component replacement operation method of this application;

[0080] Figure 23 It is a schematic diagram of the operation process for recycling the gantry crane, which is a specific embodiment of the switch rail component replacement operation method of this application;

[0081] Figure 24 It is a schematic diagram of the operation process for replacing the third component of the old rail, which is a specific embodiment of the switch rail component replacement operation method of this application;

[0082] Figure 25 It is a schematic diagram of the structure for completing the switch rail component replacement operation, which is a specific embodiment of the switch rail component replacement operation method of this application;

[0083] Figure 26 It is a schematic diagram of the partial structure composition of another specific embodiment of the switch rail component replacement operation system based on the method of this application;

[0084] In the figure: 1 - the first railcar, 2 - the equipment flatcar, 3 - the second railcar, 4 - the rail component flatcar, 5 - the gantry crane device, 6 - the lifting platform, 7 - the main line, 8 - the adjacent line, 9 - the simple gantry crane, 10 - the operation system, 11 - the insulated joint, 12 - the signal transmitter, 13 - the signal receiver, 20 - the switch rail component, 21 - the first component, 211 - the straight stock rail, 212 - the curved switch rail, 22 - the second component, 221 - the straight switch rail, 222 - the curved stock rail, 223 - the frog, 23 - the third component, 231 - the curved lower rail, 232 - the guard rail. Specific Embodiments

[0085] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of this application. Obviously, the described embodiments are only a part of the embodiments of this application, rather than all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the scope of protection of this application.

[0086] As shown in the attached Figure 1 to the attached Figure 26As shown, a specific embodiment of the turnout rail component replacement operation method of the present application is given. The present application will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0087] Embodiment 1

[0088] As shown in the Figures 11 to 25 accompanying drawings, an embodiment of the turnout rail component replacement operation method of the present application specifically includes the following steps:

[0089] S1) Vehicle formation and operation. The track vehicle (i.e., the first track vehicle 1 and the second track vehicle 3) transports the paving and replacement equipment flatbed vehicle (i.e., the equipment flatbed 2) and the rail transport flatbed vehicle (i.e., the rail component flatbed 4) to the turnout operation area.

[0090] S2) The vehicle formation is uncoupled when it arrives near the turnout area of the operation site.

[0091] Step S2) further includes the following process:

[0092] When the vehicle formation arrives near the turnout area, the vehicle formation is uncoupled from the rear of the equipment flatbed 2. The first track vehicle 1 pulls the equipment flatbed 2 to place the gantry crane device 5, and the second track vehicle 3 and the rail component flatbed 4 wait in place, as shown in the Figure 11 accompanying drawings.

[0093] S3) Remove the third component 23 of the old rail.

[0094] Step S3) further includes the following process:

[0095] Before placing the gantry crane device 5, first remove 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, and then remove the simple gantry crane 9. The first track vehicle 1 and the equipment flatbed 2 enter the turnout area to place the gantry crane device 5, as shown in the Figure 12 accompanying drawings.

[0096] S4) Deploy the gantry crane device 5. After the gantry crane devices 5 are placed one by one, the second track vehicle 3 pushes the rail component flatbed 4 under the relative line of the equipment flatbed 2.

[0097] Step S4) further includes the following process:

[0098] Push the equipment flatbed 2 in through the first track vehicle 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 Figure 13 accompanying drawings.

[0099] S5) Unload the second component 22 of the new rail and recycle the third component 23 of the old rail. Use the gantry crane device 5 for group lifting to unload the new turnout rail components beside the line for stacking, and then the equipment flatcar 2 withdraws; use the gantry crane device 5 to transfer the old turnout rail components beside the line. After the rail flatcar 4 is pushed in, place the old turnout rail components on the rail flatcar 4 to complete the loading.

[0100] Step S5) further includes the following process:

[0101] After the gantry crane device 5 is placed, use the second railcar 3 to push the rail flatcar 4 into the turnout area. 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 flatcar 4, and place it between the main line 7 and the adjacent line 8 and close to the leg of the gantry crane device 5. At the same time, lift the third component 23 of the old rail onto the rail flatcar 4, and then the second railcar 3 and the rail flatcar 4 withdraw, as shown in the appendix Figure 14 and 15 shown.

[0102] S6) Replace the second component 22 of the new rail.

[0103] Step S6) further includes the following process:

[0104] Use the gantry crane device 5 to 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, and then lift the second component 22 of the new rail into the groove and fix the rail head with a holeless fixture, as shown in the appendix Figure 16 and 17 shown.

[0105] S7) Recycle the second component 22 of the old rail and unload the first component 21 and the third component 23 of the new rail.

[0106] Step S7) further includes the following process:

[0107] Use the gantry crane device 5 to lift the second component 22 of the old rail. The second railcar 3 and the rail flatcar 4 are pushed in. 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 to unload it, and lift and horizontally move the third component 23 of the new rail and place it between the main line 7 and the adjacent line 8 and close to the leg of the gantry crane device 5. Then the second railcar 3 and the rail flatcar 4 withdraw, as shown in the appendix Figure 18 and 19 shown.

[0108] S8) Replace the first component 21 of the new rail.

[0109] Step S8) further includes the following process:

[0110] First, lift out the first component 21 of the old rail and place it between the present track 7 and the adjacent track 8, and place it close to the straight track side. Then, lift the first component 21 of the new rail and place it into the groove, and resume the through traffic on the straight track, as shown in the appendix Figure 20 and 21 shown

[0111] S9) Recover the first component 21 of the old rail. The turnout rail components 20 are hoisted onto the rail flatcar 4 by using the group hoisting method of the gantry crane device 5 and then loaded and reinforced for transportation.

[0112] Step S9) further includes the following process:

[0113] After lifting the first component 21 of the old rail by the gantry crane device 5, push the rail flatcar 4 into the turnout area by the second rail vehicle 3. 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, as shown in the appendix Figure 22 shown

[0114] S10) Recover the gantry crane device 5.

[0115] Step S10) further includes the following process:

[0116] The first rail vehicle 1 pushes the equipment flatcar 2 in, and uses the lifting platform 6 to recover the gantry crane device 5 along the present track 7 in the reverse order of 1, 2, 3, 4. The vehicle formation withdraws, and the third component 23 of the new rail is aligned and placed into the groove to complete the replacement, as shown in the appendix Figure 23 shown

[0117] S11) Replace the third component 23 of the old rail.

[0118] Step S11) further includes the following process:

[0119] After the vehicle formation withdraws from the turnout area, transfer the third component 23 of the new rail from between the present track 7 and the adjacent track 8 to the curved lower track position by the simple gantry crane 9 and complete the replacement, as shown in the appendix Figure 24 and 25 shown

[0120] S12) Complete the replacement of the turnout rail components 20. After the gantry crane device 5 is recovered one by one, align the two ends of the new turnout rail components, weld, grind, and finely adjust them, and then complete the hoisting and replacement construction of the entire set of turnout rail components 20.

[0121] The gantry crane device 5 uses the group hoisting method to lift out the old straight track side rail components and lift in the new straight track side rail components; then lift out the old curved track side rail components and lift in the new curved track side rail components to complete the hoisting and replacement of the entire turnout rail components 20.

[0122] The vehicle formation further includes a first railcar 1, an equipment flatcar 2, a rail flatcar 4, and a second railcar 3 that are connected in sequence. The equipment flatcar 2 is used to load a gantry crane device 5 and a lifting platform 6, and the rail flatcar 4 is used to load turnout rails 20.

[0123] The turnout rails 20 are cut at the insulating joint 11 to form a first component 21, a second component 22, and a third component 23.

[0124] The first component 21 further includes a straight stock rail 211 and a curved switch rail 212.

[0125] The second component 22 further includes a straight switch rail 221, a curved stock rail 222, and a frog 223.

[0126] The third component 23 further includes a curved outer rail 231 and a guard rail 232.

[0127] Before being transported to the operation site, the first component 21, the second component 22, and the third component 23 are welded into a whole at the base using gas pressure welding or flash welding respectively. The turnout rails 20 are pre-welded into two parts, namely the curved side rails and the straight side rails, at the base.

[0128] The turnout rail replacement operation method described in Embodiment 1 can realize the on-site hoisting and replacement operation of the whole set of turnout rails. The use of multiple gantry cranes can overcome the technical problems of large local deformation of the turnout rails, large hoisting swing amplitude, low operation efficiency, and long occupation time of the skylight. The turnout rail replacement process is safe and reliable; the whole set of operation systems can replace the whole set of turnout rails within one skylight time, compared with the existing technical solutions that require ≥4 skylights, greatly improving the operation efficiency. The turnout rail replacement operation system of the present application uses a flatcar formation to transport the whole set of turnout rails, well adapting to the loading and unloading operations of the whole set of turnout rails and the replacement turnout area environment, and systematically solving the technical problems of transportation, hoisting, laying and replacement of the whole set of turnout rails. The turnout rail replacement operation system of the present application hoists and replaces the turnout rails by using multiple gantry crane devices in cooperation with a wireless remote control method, which is safe, reliable, simple in structure, and easy to operate. At the same time, the whole set of turnout rails is divided into two parts, the straight side and the curved side, for hoisting and replacement respectively, which is convenient for the transportation and handling of the rail flatcars.

[0129] Embodiment 2

[0130] As shown in the Figure 1 accompanying drawings, an embodiment of the turnout rail replacement operation system based on the method described in Embodiment 1 specifically includes:

[0131] A vehicle formation;

[0132] The vehicle formation includes a first railcar 1, an equipment flatcar 2, a rail flatcar 4, and a second railcar 3 that are connected in sequence.

[0133] As shown in theFigure 2 to the attached Figure 6 As shown, the first rail vehicle 1 is used to tow the equipment flat car 2 (specifically, a 15.4m flat car can be used), and the equipment flat car 2 is used to load the gantry crane device 5 and the lifting platform 6 (in this embodiment, 4 sets of gantry crane devices 5 and 2 sets of lifting platforms 6 are introduced).

[0134] The second rail vehicle 3 is used to tow the rail component flat car 4, and the rail component flat car 4 is used to load the turnout rail components 20.

[0135] 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 flat car 2. As attached Figure 26 shown, the wireless remote controller further includes a signal transmitter 12 and signal receivers 13 disposed on the gantry crane device 5 and the lifting platform 6. Multiple sets of gantry crane devices 5 and lifting platforms 6 are all synchronously remotely controlled by the wireless remote controller. With this system, in-line operations can be realized. All the retracting and extending operations of the gantry crane devices 5 and the hoisting actions of the turnout rail components 20 can be wirelessly controlled by the remote controller. The hoisting operations are all carried out under the gantry crane device 5, which is safe, intelligent, and has no risk of touching the catenary. At the same time, according to the center of gravity of the rail components, multi-point lifting is configured, and the rail components have no permanent deformation, meeting the laying process requirements of the railway turnout 20; intelligent acceleration / deceleration control is carried out between the lifting points of multiple sets of gantry crane devices 5, with good synchronization, small shaking of the rail components, and they can quickly enter the groove, resulting in high operation efficiency.

[0136] When the vehicle formation runs to near the turnout area of the operation site, it is uncoupled. After removing the third component 23 of the old rail, the gantry crane 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, and 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 crane device 5 is recovered, and the third component 23 of the old rail is replaced to complete the replacement of the turnout rail components 20.

[0137] The operation system 10 described in this embodiment can complete the replacement of the entire set of No. 18 turnout rail components 20 on this line within a single skylight, and the turnout area situation is as attached Figure 7 shown. In order to realize hoisting, the turnout rail components 20 are cut into 3 large components from the insulated joint 11, namely the first component 21, the second component 22, and the third component 23.

[0138] As attached Figure 8 shown, the first component 21 further includes a straight stock rail 211 and a curved switch rail 212.

[0139] As attached Figure 9 shown, the second component 22 further includes a straight switch rail 221, a curved stock rail 222, and a frog 223.

[0140] As shown in the appendix Figure 10 As shown, the third component 23 further includes a curved lower strand 231 and a guard rail 232.

[0141] 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 using gas pressure welding or flash welding respectively. The thermite welding in the turnout area is cancelled. The turnout rail parts 20 are welded into a whole in advance at the base using highly reliable gas pressure welding or flash welding. By hoisting and replacing the turnout rail parts 20 as a whole on site, 8 thermite welding points in the turnout area can be effectively cancelled, 2 skylights required for turnout replacement can be saved, and more than 100 on-site operation personnel can be reduced.

[0142] The cross-section of the turnout assembly 20 is irregular and the space is limited. For the whole set of turnout rail parts 20 in the turnout rail part replacement operation system described in this embodiment, they can be prefabricated or welded and assembled at the base in advance, and the process of thermite welding in the turnout area is cancelled. By welding and replacing in the turnout area at the base, the welding quality and efficiency can be greatly improved. This not only improves the operation efficiency of the construction skylight, but also avoids the unqualified quality caused by short-time rapid welding of the on-site turnout rail parts 20, and improves the turnout construction quality and the line operation safety.

[0143] When the vehicle formation arrives near the turnout area, the vehicle formation is uncoupled from the rear of the equipment flat car 2, and the first railcar 1 is used to tow the equipment flat car 2 to place the gantry crane device 5, while the second railcar 3 and the rail part flat car 4 stay on standby in place.

[0144] Before placing the gantry crane device 5, first remove 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 remove the simple gantry crane 9, and the first railcar 1 and the equipment flat car 2 enter the turnout area to place the gantry crane device 5.

[0145] When deploying the gantry crane device 5, first push the equipment flat car 2 into place through the first railcar 1, and then use the lifting platform 6 to place the gantry crane device 5 in sequence along the main line.

[0146] After the gantry crane device 5 is placed, the second railcar 3 is used to push the rail part flat car 4 into the turnout area. After the turnout rail parts 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 part flat car 4, and place it between the main line 7 and the adjacent line 8 and close to the leg of the gantry crane device 5. At the same time, the third component 23 of the old rail is lifted onto the rail part flat car 4, and the second railcar 3 and the rail part flat car 4 withdraw.

[0147] When replacing the second component 22 of the new rail, 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 and close to the straight track side. Then, the second component 22 of the new rail is lifted into the groove and the rail head is fixed with a non-perforated fixture.

[0148] When recycling the second component 22 of the old rail, the second component 22 of the old rail is lifted by the gantry crane device 5, and the second rail car 3 and the rail flat car 4 are pushed in. After the second component 22 of the old rail is placed on the rail flat car 4, the first component 21 of the new rail is lifted, horizontally moved and unloaded. The third component 23 of the new rail is lifted and horizontally moved, and is placed between the main line 7 and the adjacent line 8 and close to the leg of the gantry crane device 5, and then the second rail car 3 and the rail flat car 4 withdraw.

[0149] 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 side, and then lift the first component 21 of the new rail into the groove to resume through traffic on the straight side.

[0150] 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 rail flat car 4 is pushed into the turnout area by the second rail car 3. After the first component 21 of the old rail is placed on the rail flat car 4, the second rail car 3 and the rail flat car 4 withdraw.

[0151] When recycling the gantry crane device 5, the first rail car 1 pushes the equipment flat car 2 in, and 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.

[0152] 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.

[0153] 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.

[0154] It should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "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, and 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, and therefore should not be construed as a limitation to the present application.

[0155] In addition, the terms "first" and "second" are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of such features. In the description of this application, "a plurality of" or "several" means two or more, unless otherwise specifically defined.

[0156] 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 familiar with this technology to understand and read, and are not used to limit the implementable conditions of this application. Therefore, they do not have substantial technical significance. Any modification of the structure, change of the proportional relationship, or adjustment of the size, without affecting the effects that this application can produce and the purposes that can be achieved, should still fall within the scope covered by the technical content disclosed in this application.

[0157] By implementing the technical solution of the switch rail component replacement operation method described in the specific embodiments of this application, the following technical effects can be achieved:

[0158] (1) The switch rail component replacement operation method described in the specific embodiments of this application can realize on-site hoisting and replacement operations of the entire set of switch rail components. Using multiple gantry cranes for operation can overcome the technical problems of large local deformation of switch rail components, large hoisting swing amplitude, low operation efficiency, and long occupation time of the skylight.

[0159] (2) The switch rail component replacement operation method described in the specific embodiments of this application realizes prefabrication or welding of the entire set of switch rail components in advance, cancels the thermite welding process in the turnout area, and greatly improves the welding quality and efficiency through base welding and turnout area replacement, enhancing the turnout construction quality and the safety of line operation.

[0160] (3) The switch rail component replacement operation method described in the specific embodiments of this application uses flatbed car formation to transport the entire set of switch rail components, well adapts to the loading and unloading operations of the entire set of switch rail components and the replacement turnout area environment, and systematically solves the technical problems of transportation, hoisting, laying and replacement of the entire set of switch rail components.

[0161] (4) The switch rail component replacement operation method described in the specific embodiments of this application hoists and replaces the switch rail components by using multiple gantry cranes in cooperation with a wireless remote control method, which is safe, reliable, simple in structure and easy to operate. At the same time, the entire set of switch rail components is divided into a straight rail and a curved rail for easy transportation and handling of the rail components on flatbed cars.

[0162] 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.

[0163] The above are only the preferred embodiments of the present application, and do not impose any formal restrictions on the present application. Although the present application has been disclosed above with the preferred embodiments, it is not intended to limit the present application. Any person skilled in the art can make many possible changes and modifications to the technical solution of the present application by using the methods and technical contents disclosed above, or modify it into equivalent embodiments with equivalent changes. Therefore, any simple modification, equivalent replacement, equivalent change and modification made to the above embodiments based on the technical essence of the present application without departing from the technical solution of the present application still fall within the scope of protection of the technical solution of the present application.

Claims

1. A method for replacing a turnout rail member, characterized in that: The following steps are involved: S1) Vehicle marshaling operation; S2) The vehicle group is disbanded when it arrives near the switch area at the operation site; S3) removing the third assembly of the old rail; S4) deploying the door crane; S5) unloading the second assembly of the new rail and recycling the third assembly of the old rail; S6) replacing the second assembly of the new rail; S7) Recovering the second component of the old rail, and unloading the first component and the third component of the new rail; S8) replacing the first assembly of the new rail; S9) Recycling the first assembly of the old rail; S10) Recovering the door hanging device; S11) replacing the third assembly of the old rail; S12) Complete the replacement of turnout rail parts.

2. The method for replacing a turnout rail member according to claim 1, characterized in that: The vehicle formation includes a first rail car, an equipment flat car, a rail flat car and a second rail car connected in sequence; the equipment flat car is used to load a door hanging device and a lifting platform, and the rail flat car is used to load a switch rail.

3. The turnout rail replacement method according to claim 2, characterized in that: The step S2) further The process includes: When the vehicle formation arrives near the switch area, the vehicle formation will be unmarshaled from the rear of the equipment flat car, and the equipment flat car will be towed by the first rail car to place the door hanging device, while the second rail car and the rail flat car will remain on standby.

4. The method for replacing a turnout rail member according to claim 3, characterized in that: The step S3) further The process includes: 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.

5. The method for replacing a turnout rail member according to claim 4, characterized in that: The step S4) further The process includes: The equipment flat car is pushed in by the first rail car, and the door hanging device is placed in sequence along the line using the lifting platform.

6. The method for replacing a turnout rail member according to claim 5, characterized in that: The step S5) further includes the following process: 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 second component of the new rail is lifted from the rail flatcar by the gantry crane device and moved 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.

7. The method for replacing a turnout rail member according to claim 6, characterized in that: The step S6) further includes the following process: The second assembly of the old rail is first lifted out by the gantry crane and placed between the current line and the adjacent line and close to the straight strand side. The second assembly of the new rail is then lifted into the groove and the rail head is fixed with a non-hole clamp.

8. The method for replacing a turnout rail member according to claim 7, characterized in that: The step S7) further includes the following process: 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. 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 legs of the gantry crane device. The second rail car and the rail flat car are withdrawn.

9. The method for replacing a turnout rail member according to claim 8, characterized in that: The step S8) further The process includes: First, the first assembly of the old rail is lifted out and placed between the line and the adjacent line and close to the straight side. Then the first assembly of the new rail is lifted into the groove to resume traffic on the straight line.

10. The method for replacing a turnout rail member according to claim 9, characterized in that: The step S9) further includes the following process: After the first component of the old rail is lifted by the door crane device, 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.

11. The method for replacing a turnout rail member according to claim 10, characterized in that: The step S10) further The process includes: The first rail car pushes the equipment flat car in, uses the lifting platform to retract the door 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.

12. The turnout rail replacement method according to claim 11, characterized in that: The step S11) further The process includes: 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 position below the curve through a simple gantry crane, and the replacement is completed.

13. The turnout rail replacement method according to any one of claims 1 to 12, characterized in that: The switch rail is cut off from the insulating joint to form a first component, a second component and a third component.

14. The method for replacing a turnout rail member according to claim 13, characterized in that: The first component includes a straight base rail and a curved tip rail.

15. The method for replacing a turnout rail member according to claim 14, characterized in that: The second component includes a curved base rail, a straight point rail and a switch rail.

16. The method for replacing a turnout rail member according to claim 15, characterized in that: The third component includes a curved lower leg and a guard rail.

17. The method for replacing a turnout rail member according to claim 1-12, 14, 15 or 16, 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.

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