Operation equipment and operation method for replacing ballastless track bed sleeper

Abstract

According to the operation equipment and method for replacing the ballastless track bed sleepers, the operation equipment for replacing the ballastless track bed sleepers comprises a vehicle frame and a foundation pit digging system, a walking device is arranged at the bottom of the vehicle frame and can drive the vehicle frame to walk on steel rails, the foundation pit digging system is used for breaking and dismantling old sleepers, and the foundation pit digging system is used for digging the old sleepers; the device comprises an abrasive drilling tool, a coring tool and a milling tool which are sequentially arranged from front to back, and the abrasive drilling tool is used for drilling and grinding a sleeper ballast bed surface; the coring tool is used for breaking and taking out a concrete core column; the milling tool is used for removing the pillow block; through the operation equipment for replacing the ballastless track bed sleeper, the construction efficiency is greatly improved, and the personnel investment is reduced; the construction quality is improved, the foundation pit digging quality is improved, the consistency of the digging depth is good, the galling quality of the contact surface is good, and the crushing influence area is small.

Description

Technical Field

[0001] The present application relates to the technical field of track maintenance, and in particular to an operating device and an operating method for replacing sleepers on a ballastless track bed. Background Art

[0002] As the subway lines have been used for a long time, the sleepers have experienced varying degrees of wear and aging. Some sleepers have cracks and damage, making it difficult to accurately maintain the track gauge, affecting the stability of train travel; some sleepers have frequent sinking or displacement problems due to long-term uneven force, posing potential risks to driving safety.

[0003] At present, common construction has many shortcomings. For example, the efficiency of manual sleeper replacement is low. Each process relies on manual labor and small machines are used for manual operation. The construction is time-consuming. According to preliminary research, it takes an average of 60 to 90 minutes for a skilled construction team to replace a sleeper. The labor intensity is high. Sleeper materials and operating tools need to be manually carried, and small machines are used for operations such as digging foundation pits, mixing mortar, and building new sleepers. Concrete sleepers are difficult to break and are broken by manual handheld electric picks, which is inefficient. There is serious noise and dust pollution during the operation. The noise generated by manual electric picks when breaking concrete sleepers is as high as 100 to 120dB (A). The operating dust affects the health of personnel and pollutes track equipment and electrical lines. The overall economic benefits of the construction are poor, and labor costs account for a large proportion. The level of construction automation is low and mainly relies on manual organization. Summary of the invention

[0004] The embodiments of the present application provide an operating device and an operating method for replacing track sleepers on a ballastless track bed, so as to solve the problems that the existing track sleeper replacement process mostly relies on manual labor, has a low level of automation and poor operating quality.

[0005] In order to achieve the above objectives, this application provides the following technical solutions:

[0006] An operating device for replacing sleepers on a ballastless track bed, comprising:

[0007] The frame has a running device at the bottom to drive the frame to move on the rails;

[0008] The foundation pit excavation system is located below the frame and is used for dismantling old sleepers; the foundation pit excavation system includes a grinding and drilling tool, a coring tool and a milling tool which are arranged in sequence from front to back; the grinding and drilling tool is used for drilling and grinding the sleeper bed surface; the coring tool is used for breaking and removing the concrete core column; and the milling tool is used for removing the sleeper block.

[0009] Optionally, the drill grinding tool comprises:

[0010] A guide frame, used to be connected to the frame and capable of reciprocating longitudinally relative to the frame;

[0011] A base, located on the guiding frame and capable of reciprocatingly moving horizontally relative to the vehicle frame;

[0012] A water mill drill device, located on the base and used for drilling and grinding old sleepers; the water mill drill device can reciprocatingly move vertically.

[0013] Optionally, the water mill drill device includes:

[0014] A drill barrel, used for drilling and grinding the roadbed surface of the old sleeper;

[0015] A power assembly, connected to the drill barrel and driving the drill barrel to rotate;

[0016] A drill barrel lifting assembly, vertically fixed on the base and used for driving the drill barrel to reciprocatingly move vertically.

[0017] Optionally, the drill barrel lifting assembly includes:

[0018] A drill barrel lifting driving member, a water mill drill mounting seat, a vertical guide rail and a vertical guide sleeve. The water mill drill mounting seat is fixed on the base, and the vertical guide rail is vertically fixed on the water mill drill mounting seat; the vertical guide sleeve is sleeved with the vertical guide rail and slides on the vertical guide rail;

[0019] The vertical guide sleeve is fixed to the power assembly.

[0020] Optionally, the core sampling tooling includes:

[0021] A framework;

[0022] A core sampling longitudinal movement assembly, with a fixed end fixed to the vehicle frame and a movable end fixedly connected to the framework, and used for driving the framework to reciprocatingly move longitudinally;

[0023] A core sampling transverse movement assembly, located on the framework and capable of reciprocatingly moving horizontally along the framework;

[0024] A core sampling assembly, located on the core sampling transverse movement assembly, and the core sampling assembly can reciprocatingly move vertically to break and take out the core column.

[0025] Optionally, the milling tooling includes:

[0026] A base;

[0027] A milling transverse movement assembly, including a milling transverse movement slide rail and a milling transverse movement slide block. The milling transverse movement slide rail is fixed on the vehicle frame, the milling transverse movement slide block slides on the milling transverse movement slide rail, and the base is fixed to the milling transverse movement slide block;

[0028] The milling lifting assembly includes a milling lifting slide rail and a milling lifting slider. The milling lifting slide rail is arranged vertically along the base, and the milling lifting slider slides on the milling lifting slide rail.

[0029] The milling assembly is located on the milling lifting slider and is used for milling the sleeper blocks.

[0030] Optionally, the milling assembly includes:

[0031] A milling cutter head;

[0032] A milling power member, which is connected to the milling cutter head and drives the milling cutter head to rotate;

[0033] A dust suction assembly for sucking debris and sleeper residues.

[0034] Optionally, it further includes:

[0035] A concrete integral pouring device, which is located on the vehicle frame and is used for the preparation and pouring of new sleeper mortar;

[0036] And / or, a vehicle-mounted hoisting device, which is located on the vehicle frame and is used for the loading and unloading transfer of materials and tools.

[0037] Optionally, it further includes:

[0038] A driver's cab, which is located above the vehicle frame;

[0039] A cabinet and a battery pack, which are located above the vehicle frame and are used to supply power to the driver's cab, the foundation pit excavation system, the concrete integral pouring device and the vehicle-mounted hoisting device;

[0040] An auxiliary generator set, which is located above the vehicle frame and is used to supply auxiliary power to the foundation pit excavation system, the concrete integral pouring device and the vehicle-mounted hoisting device.

[0041] This application provides a method for replacing ballastless track sleepers of a ballastless track sleeper replacement operation device. The method includes:

[0042] Removing the fasteners at intervals along the construction line and installing gauge tie bars and rail support blocks;

[0043] Demolishing the old sleeper concrete blocks, taking out the concrete core columns, and milling the old sleeper concrete;

[0044] Installing the new sleeper module;

[0045] Injecting glue and implanting steel bars for the sleeper;

[0046] Pouring self-compacting mortar;

[0047] Maintaining the ballast bed;

[0048] Remove the gauge tie rod and the rail support block.

[0049] Optionally, the working equipment for replacing the ballastless track sleeper includes a vehicle frame with a traveling device at the bottom to drive the vehicle frame to travel on the rail; a foundation pit excavation system located below the vehicle frame for demolishing the old sleeper; the foundation pit excavation system includes a grinding and drilling tooling, a core sampling tooling, and a milling tooling arranged in sequence from front to back;

[0050] Demolish the concrete block of the old sleeper, take out the concrete core column, and mill the concrete of the old sleeper, which specifically includes:

[0051] Drill the concrete block of the old sleeper through the grinding and drilling tooling, take out the drilled concrete core column through the core sampling tooling, and mill the concrete of the old sleeper through the milling tooling.

[0052] Optionally, before demolishing the concrete block of the old sleeper, taking out the concrete core column, and milling the concrete of the old sleeper, the method further includes:

[0053] The working equipment for replacing the ballastless track sleeper travels to the working position through the traveling device.

[0054] Optionally, drilling the concrete block of the old sleeper through the grinding and drilling tooling, taking out the drilled concrete core column through the core sampling tooling, and milling the concrete of the old sleeper through the milling tooling specifically includes:

[0055] The grinding and drilling tooling moves down to drill the current concrete block of the old sleeper, and the milling tooling waits.

[0056] After the grinding and drilling tooling finishes drilling, it retracts and moves forward, and the core sampling tooling takes out the drilled concrete core column;

[0057] The working equipment for replacing the ballastless track sleeper travels forward to the next target sleeper, and the milling tooling synchronously mills the current old sleeper.

[0058] Adopting the working equipment and working method for replacing the ballastless track sleeper provided in the embodiment of the present application, compared with the prior art, has the following technical effects:

[0059] The working equipment for replacing the ballastless track sleeper of the present application includes a vehicle frame and a foundation pit excavation system. The bottom of the vehicle frame is provided with a traveling device that can drive the vehicle frame to travel on the rail. The foundation pit excavation system demolishes the old sleeper. It includes a grinding and drilling tooling, a core sampling tooling, and a milling tooling arranged in sequence from front to back. The grinding and drilling tooling is used for drilling and grinding the sleeper ballast bed surface; the core sampling tooling is used for breaking and taking out the concrete core column; the milling tooling is used for removing the sleeper block; the construction efficiency is greatly improved by the working equipment for replacing the ballastless track sleeper, and the personnel input is reduced; the construction quality is improved, including the quality of the foundation pit excavation, with good consistency of the cutting depth, good quality of the contact surface roughening, and small broken influence area. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The drawings described herein are used to provide a further understanding of the present application and constitute a part of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0061] Figure 1 A schematic diagram of the structure of an operating device for replacing sleepers on a ballastless track provided in an embodiment of the present application;

[0062] Figure 2 A schematic diagram of the structure of a drill grinding tool provided in an embodiment of the present application;

[0063] Figure 3 A schematic diagram of the structure of a water-grinding drill device provided in an embodiment of the present application;

[0064] Figure 4 A schematic diagram of the structure of the coring tool provided in the embodiment of the present application;

[0065] Figure 5 A schematic diagram of the structure of the milling tool provided in an embodiment of the present application.

[0066] The following are marked in the accompanying drawings:

[0067] Driver's cab 1, frame 2, running device 3, cabinet and battery pack 4, auxiliary generator set 5, vehicle hoisting device 6, integrated concrete pouring device 7, grinding and drilling tool 8, coring tool 9, milling tool 10;

[0068] Guide frame 81, water-grinding drill device 82, base 83, drill barrel 821, power assembly 822, drill barrel lifting assembly 823, frame 91, coring longitudinal movement assembly 92, coring transverse movement assembly 93, coring assembly 94, milling transverse movement assembly 101, base 102, milling lifting assembly 103, milling cutter head 104, dust suction assembly 105, milling power part 106. DETAILED DESCRIPTION

[0069] The embodiment of the present invention discloses an operation device and an operation method for replacing rail sleepers on a ballastless track bed, so as to solve the problems that the existing rail sleeper replacement process of the ballastless track bed mostly relies on manual labor, has a low automation level and poor operation quality.

[0070] In order to make the technical solutions and advantages in the embodiments of the present application more clearly understood, the exemplary embodiments of the present application are further described in detail below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than an exhaustive list of all the embodiments. It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict.

[0071] Please refer to Figures 1-5 , Figure 1 which is a schematic structural diagram of an operating device for replacing ballastless track sleepers provided by an embodiment of the present application; Figure 2 which is a schematic structural diagram of a grinding and drilling tooling provided by an embodiment of the present application; Figure 3 which is a schematic structural diagram of a water jet drilling device provided by an embodiment of the present application; Figure 4 which is a schematic structural diagram of a core extraction tooling provided by an embodiment of the present application; Figure 5 which is a schematic structural diagram of a milling tooling provided by an embodiment of the present application.

[0072] In a specific embodiment, the operating device for replacing ballastless track sleepers provided by the present application includes a vehicle frame 2 and a foundation pit excavation system; the foundation pit excavation system is located on the vehicle frame 2 and is used for demolishing the old sleepers. The foundation pit excavation system includes a grinding and drilling tooling 8, a core extraction tooling 9, and a milling tooling 10 arranged in sequence from front to back; wherein, the grinding and drilling tooling 8 is used for drilling and grinding the sleeper ballast surface; the core extraction tooling 9 is used for breaking and removing the concrete core column; the milling tooling 10 is used for removing the sleeper blocks.

[0073] The grinding and drilling tooling 8 drills and grinds the sleeper ballast surface. The grinding and drilling tooling 8 includes a guiding frame 81, a base 83, and a water jet drilling device 82; the guiding frame 81 is used for connecting with the vehicle frame 2 and can reciprocate longitudinally relative to the vehicle frame 2; the base 83 is located on the guiding frame 81 and can reciprocate transversely relative to the vehicle frame 2; the water jet drilling device 82 is located on the base 83 and is used for drilling and grinding the old sleepers; the water jet drilling device 82 can reciprocate vertically.

[0074] Among them, the guiding frame 81 is preferably a rectangular frame to provide a stable supporting force. The base 83 is arranged on the guiding frame 81, preferably on the cross bar of the guiding frame 81, and the base 83 moves transversely relative to the vehicle frame 2. The movement can be realized by setting a slide rail and slider mechanism and cylinders, oil cylinders, and hydraulic cylinders. Through longitudinal, transverse, and vertical adjustments, it is ensured that the water jet drilling device 82 can be accurately positioned and drilled, improving the accuracy of drilling and grinding. The water jet drilling device 82 is arranged on the base 83 and can drill and grind the old sleepers. The water jet drilling device 82 can reciprocate vertically, providing the ability to adjust the height and ensuring the drilling and grinding accuracy. It can be understood that the vertical reciprocating movement of the water jet drilling device 82 can also be realized by combining a slide rail and slider mechanism with a cylinder.

[0075] Among them, the water jet drilling device 82 includes:

[0076] a drill barrel 821, which is used for drilling and grinding the ballast surface of the old sleeper;

[0077] a power assembly 822, which is connected with the drill barrel 821 and drives the drill barrel 821 to rotate;

[0078] The drill barrel lifting assembly 823 is fixedly arranged on the base 83 along the vertical direction and is used to drive the drill barrel 821 to reciprocate vertically.

[0079] The drill barrel 821 drills and grinds the ballast surface of the old sleeper to remove the surface material and prepare for subsequent operations. The power assembly 822 is connected to the drill barrel 821 to provide rotational power and drive the drill barrel 821 to rotate. The drill barrel 821 is usually made of high-strength wear-resistant materials to cope with long-term high-load work. The drill barrel 821 is provided with special tooth shapes or cutting edges to more effectively cut concrete or other hard materials; the power assembly 822 includes an electric motor or a hydraulic motor to provide rotational power and drive the drill barrel 821 to rotate at high speed, so as to effectively drill and grind the ballast surface of the sleeper. The power assembly 822 should have sufficient torque and rotational speed to ensure that the drill barrel 821 can work normally under various working conditions.

[0080] Preferably, the drill barrel lifting assembly 823 includes a guide rail, a slider and a driving mechanism (such as a hydraulic cylinder or an electric push rod) to ensure that the drill barrel 821 can move smoothly along the vertical direction. The drill barrel lifting assembly 823 drives the drill barrel 821 to reciprocate vertically, enabling the drill barrel 821 to adjust its height according to actual needs, ensuring the accuracy and efficiency during the drilling and grinding process, and having good stability and precise control ability to avoid shaking or deviation during the operation.

[0081] In this embodiment, the drill barrel lifting assembly 823 includes a drill barrel 821 lifting driving member, a water mill drill mounting seat, a vertical guide rail and a vertical guide sleeve. The water mill drill mounting seat is fixed on the base 83, and the vertical guide rail is fixed on the water mill drill mounting seat along the vertical direction; the vertical guide sleeve is sleeved on the vertical guide rail and slides on the vertical guide rail; the vertical guide sleeve is fixed to the power assembly 822.

[0082] The drill barrel 821 lifting driving member can be an electric push rod, a hydraulic cylinder or other types of linear actuators, specifically depending on the overall design and power requirements of the equipment, to provide driving force and drive the vertical guide sleeve (and the components fixed thereto) to move up and down along the vertical guide rail to realize the height adjustment of the drill barrel 821. The water mill drill mounting seat is fixed on the base 83 to provide a stable basic support for the entire drill barrel lifting assembly 823. As a connection point, the vertical guide rail is fixed thereon to ensure the stable position of the guide rail, thereby ensuring the accuracy and stability during the lifting process of the drill barrel 821. The vertical guide rail is fixed on the water mill drill mounting seat along the vertical direction to provide a guiding path to ensure that the vertical guide sleeve can slide smoothly on the guide rail. The vertical guide sleeve is sleeved on the vertical guide rail and slides on the vertical guide rail to ensure that the drill barrel 821 can move smoothly along the vertical direction; the vertical guide sleeve is fixed to the power assembly 822 and drives the power assembly 822 (including the drill barrel 821) to reciprocate vertically through cooperation with the vertical guide rail. The guide sleeve needs to have good sliding performance and wear resistance to ensure that there is no jamming or excessive wear during long-term use.

[0083] The lifting drive member of the drill pipe 821 can accurately adjust the height of the drill pipe 821 as needed, ensuring consistent drilling depth and improving the accuracy of drilling; the design of the vertical guide rail and vertical guide sleeve provides stable support, preventing the drill pipe 821 from shaking or shifting during operation and further improving the drilling quality.

[0084] The lifting drive member of the drill pipe 821 works in coordination with the control system, reducing manual intervention and enhancing the operation speed and efficiency. The drill pipe 821 is reasonably designed and can continuously work for a long time, reducing the time for tool replacement or maintenance and improving the overall work efficiency.

[0085] In this embodiment, the core sampling tooling 9 includes:

[0086] A framework 91;

[0087] A core sampling longitudinal translation assembly 92, with a fixed end fixed to the vehicle frame 2 and a movable end fixedly connected to the framework 91, for driving the framework 91 to reciprocate longitudinally;

[0088] A core sampling transverse translation assembly 93, located on the framework 91 and capable of reciprocating transversely along the framework 91;

[0089] A core sampling assembly 94, located on the core sampling transverse translation assembly 93, and the core sampling assembly 94 can reciprocate vertically to break and extract the core column.

[0090] The framework 91 serves as a basic support structure, providing an installation platform for other components and ensuring the stability of the entire core sampling tooling 9. The fixed end of the core sampling longitudinal translation assembly 92 is fixed to the vehicle frame 2, providing a stable connection point; the movable end of the core sampling longitudinal translation assembly 92 is fixedly connected to the framework 91, driving the framework 91 to reciprocate longitudinally (in the track direction) to achieve position adjustment; the core sampling longitudinal translation assembly 92 drives the framework 91 to move longitudinally through a driving mechanism (such as an electric push rod, hydraulic cylinder, etc.). The core sampling longitudinal translation assembly 92 realizes precise longitudinal position adjustment of the framework 91, ensuring that the core sampling tooling 9 can accurately reach the target position for operation. The longitudinal translation assembly should have good control accuracy and response speed to adapt to different operation requirements.

[0091] The core sampling traversing assembly 93 is located on the framework 91 and can reciprocate in the transverse direction (perpendicular to the track direction) of the framework 91 to further adjust the position of the core sampling assembly 94, ensuring that the core sampling assembly 94 can accurately align with the core column to be processed; the core sampling assembly 94 is located on the core sampling traversing assembly 93 and can reciprocate in the vertical direction (perpendicular to the ground direction) to perform the operations of breaking and removing the core column. It usually includes a power device (such as a hydraulic motor or an electric motor), a cutting tool (such as a saw blade or a drill bit), etc., to perform the operations of breaking and removing the core column, ensuring that the old sleeper is completely removed. The core sampling assembly 94 should have sufficient power and cutting ability to handle different types of core column materials and sizes. Through the longitudinal movement assembly, the transverse movement assembly and the vertical movement, precise positioning in the three-dimensional space can be achieved, ensuring that the core sampling assembly 94 can accurately align with and process the core column.

[0092] Through the longitudinal movement assembly, the transverse movement assembly and the vertical movement, precise positioning in the three-dimensional space can be achieved, ensuring that the core sampling assembly 94 can accurately align with and process the core column; the design of the framework 91 and each movement assembly provides stable support, avoiding the equipment from shaking or shifting during the operation process, and further improving the operation quality.

[0093] In another embodiment, the milling tooling 10 includes:

[0094] A base 102;

[0095] A milling traversing assembly 101, including a milling traversing slide rail and a milling traversing slider. The milling traversing slide rail is fixed on the vehicle frame 2, and the milling traversing slider slides on the milling traversing slide rail. The base 102 is fixed to the milling traversing slider;

[0096] A milling lifting assembly 103, including a milling lifting slide rail and a milling lifting slider. The milling lifting slide rail is arranged along the vertical direction of the base 102, and the milling lifting slider slides on the milling lifting slide rail;

[0097] A milling assembly, located on the milling lifting slider, for milling the sleeper blocks.

[0098] The base 102 provides installation interfaces for other components (such as the milling traversing assembly 101, the milling lifting assembly 103 and the milling assembly). It is usually made of high-strength steel or other strong materials to ensure sufficient strength and rigidity in a high-load working environment. The base 102 provides stable basic support to ensure that the milling tooling 10 will not shake or shift during the operation process.

[0099] The milling transverse translation slide rail is fixed on the vehicle frame 2, providing a guiding path for transverse movement to ensure the smooth sliding of the slider. The milling transverse translation slider slides on the milling transverse translation slide rail, driving the base 102 to move transversely to achieve position adjustment and accurate transverse position adjustment of the base 102, ensuring that the milling component can accurately reach the target position for operation.

[0100] The milling lifting slide rail is arranged vertically along the base 102, providing a guiding path for vertical movement to ensure the smooth sliding of the slider. The milling lifting slider slides on the milling lifting slide rail, driving the milling component to move vertically to achieve height adjustment. The milling lifting component 103 realizes the accurate vertical height adjustment of the milling component, ensuring consistent milling depth, improving the milling accuracy, having good stability and precise control ability, and avoiding shaking or deviation during operation.

[0101] The milling component is installed on the milling lifting slider and can move reciprocally vertically. It generally includes a power device (such as an electric motor or a hydraulic motor), a cutting tool (such as a milling cutter), etc., for milling the sleeper blocks to ensure that the old sleepers are completely removed. The milling component should have sufficient power and cutting ability to handle different types of sleeper block materials and sizes.

[0102] The milling tooling 10 can achieve precise positioning in a two-dimensional space through the transverse movement component and the lifting component, ensuring that the milling component can accurately align with and process the sleeper blocks. The design of the base 102 and each moving component provides stable support, avoiding shaking or deviation of the equipment during operation and further improving the operation quality.

[0103] Specifically, the milling component includes:

[0104] The milling cutter head 104;

[0105] The milling power component 106, which is connected to the milling cutter head 104 and drives the milling cutter head 104 to rotate;

[0106] The dust suction component 105, which is used to suck up debris and sleeper residues.

[0107] The milling cutter head 104 is usually made of high-strength wear-resistant materials, with special cutting edges or tooth profiles on its surface to improve cutting efficiency and durability, and to perform efficient and precise cutting and milling on the sleeper blocks, ensuring that the old railway sleepers are completely removed. The milling power unit 106 provides rotational power to drive the milling cutter head 104 to rotate at high speed, thereby achieving effective cutting and milling of the sleeper blocks. The milling power unit 106 should have sufficient torque and rotational speed to ensure that the milling cutter head 104 can work properly under various working conditions. It includes a dust suction pipeline, a dust suction port, and a dust suction device (such as a vacuum pump or a blower) to ensure effective suction of the debris and residues generated during the operation. The dust suction assembly 105 sucks the debris and sleeper residues generated during the milling process, keeps the working area clean, and reduces the impact of dust and debris on the equipment and the environment. The dust suction assembly 105 should have good suction and filtering capabilities to ensure effective operation in a long-term high-load working environment. The design of the milling cutter head 104 enables it to cut and mill the sleeper blocks efficiently and precisely, improving the operation quality.

[0108] Optionally, the above-mentioned operating equipment for replacing ballastless track sleepers further includes:

[0109] A concrete integral pouring device 7, located on the vehicle frame 2, for the preparation and pouring of new sleeper mortar;

[0110] And / or, a vehicle-mounted lifting device 6, located on the vehicle frame 2, for the transfer of materials and tools on and off the vehicle

[0111] The concrete integral pouring device 7 includes a mixing system, a conveying system, and a pouring system; the mixing system is responsible for mixing cement, sand, gravel, and water in proportion to make uniform new sleeper mortar; the conveying system transports the mixed mortar to the designated position, usually by pumping or pipeline conveying. The pouring system precisely pours the mortar into the foundation pit under the new railway sleeper to ensure the pouring volume and stability of the new railway sleeper.

[0112] The vehicle-mounted lifting device 6 includes a boom, a hook, a hydraulic system, and a control system; the boom of the vehicle-mounted lifting device 6 can be telescoped and rotated to adapt to the lifting requirements at different heights and distances, the hook is used to hang and lift materials and tools, the hydraulic system provides power to drive the telescoping and rotating actions of the boom, and the control system precisely controls the lifting process to ensure the safety and accuracy of the operation.

[0113] The on-vehicle hoisting device 6 improves the construction quality. The automated mixing and pouring system ensures the uniformity and consistency of the mortar, enhancing the installation quality and stability of the new sleepers; saves time and labor: the integrated equipment reduces the time for manual handling and manual mixing, improving the overall construction efficiency; flexibly adapts to different working conditions: the mixing system can adjust the mortar ratio according to actual needs to adapt to different track conditions and environmental requirements. The on-vehicle hoisting device 6 can quickly complete the loading and unloading transfer of materials and tools, reducing the time and labor intensity of manual handling. The telescopic and rotatable boom design enables it to adapt to different hoisting requirements, improving the versatility and adaptability of the equipment. The precise control system ensures the safety and accuracy of the hoisting process, reducing the risk of accidents.

[0114] The operating equipment for ballastless track sleeper replacement further includes:

[0115] The driver's cab 1, located above the vehicle frame 2;

[0116] The cabinet and battery pack 4, located above the vehicle frame 2, are used to supply power to the driver's cab 1, the foundation pit excavation system, the concrete integral pouring device 7, and the on-vehicle hoisting device 6;

[0117] The auxiliary generator set 5, located above the vehicle frame 2, is used to supply power to the foundation pit excavation system, the concrete integral pouring device 7, and the on-vehicle hoisting device 6.

[0118] Among them, the driver's cab 1 includes an operation console, a seat, a display screen, a control panel, etc., providing a centralized control operation platform where operators can monitor and control all key equipment.

[0119] The cabinet contains a distribution box, a controller, and other electrical components for managing and distributing power. The battery pack provides the main power supply to ensure the operation of key systems. The cabinet and battery pack 4 provide a stable power supply to the driver's cab 1, the foundation pit excavation system, the concrete integral pouring device 7, and the on-vehicle hoisting device 6. It has functions such as overload protection and short-circuit protection to ensure electrical safety.

[0120] The auxiliary generator set 5 includes a generator, an engine, a cooling system, and an exhaust system; in the case of insufficient power supply from the battery pack, it provides additional power support to ensure the normal operation of each system, and has the function of automatically adjusting voltage and frequency to ensure the stability and reliability of the output power.

[0121] The centralized control system of the driver's cab 1 makes the operation more convenient, improves work efficiency, and enhances safety: operators can work in a safe and comfortable environment, reducing the impact of the external environment on the operation.

[0122] The cabinet and battery pack 4 ensure that each system can obtain a stable power supply under different working conditions. It avoids exhaust emissions, effectively ensures the cleanliness of the air in the working space, and ensures the breathing safety of construction workers. At the same time, it avoids the low-frequency vibration and high-decibel noise generated by the operation of the diesel engine, which not only protects the hearing health of the workers, but also significantly improves the acoustic environment of the working space.

[0123] The auxiliary generator set 5 meets the needs of emergency or charging the battery pack: it can maintain the operation of key systems when the main power supply fails, improving the reliability and emergency response capabilities of the equipment. At the same time, it improves independence: it reduces dependence on the external power grid, allowing the equipment to work normally in remote areas or areas with inconvenient power supply.

[0124] Based on the above embodiments, the present application further provides a ballastless track sleeper replacement operation method using an operation device for replacing a ballastless track sleeper, the method comprising:

[0125] S11: Remove the fasteners according to the construction line intervals and install the gauge rods and rail support blocks;

[0126] According to the scheduled construction line interval, such as 1 in 4, remove the existing rail fasteners to facilitate subsequent operations; after removing the fasteners, install the gauge tie rods and rail support blocks. When removing the old sleepers, the track structure can still remain stable to prevent track deformation or deviation due to construction, so as to maintain the stability of the track and the consistency of the gauge;

[0127] S12: breaking and dismantling the old sleeper concrete blocks, taking out the concrete core column, and milling the old sleeper concrete;

[0128] Use the grinding and drilling tool 8, coring tool 9 and milling tool 10 in the foundation pit excavation system to break the old sleepers and remove the surface concrete. Remove the concrete core column: Use the coring tool 9 to break and remove the concrete core column in the old sleeper. Mill the old sleeper concrete: Use the milling tool 10 to further clean the remaining old sleeper concrete to ensure that the foundation pit is flat.

[0129] S13: New pillow module installation;

[0130] The prefabricated new sleeper modules are hoisted into place and their positions are precisely adjusted to ensure that the new sleepers are seamlessly connected to the original track structure, thus ensuring the overall smoothness and stability of the track.

[0131] S14: sleeper glue injection and reinforcement;

[0132] Special glue is injected into the preset holes of the new sleepers, and steel bars (embedded bars) are inserted to enhance the bonding strength between the new sleepers and the surrounding concrete, improve the connection strength between the new sleepers and the base bed, and ensure their long-term stability and load-bearing capacity.

[0133] S15: self-compacting mortar pouring;

[0134] Use the integral concrete pouring device 7 to prepare and pour self-compacting mortar to fill the gap between the new sleeper and the subgrade, ensuring that the new sleeper is firmly fixed in place. By filling with self-compacting mortar, the gap is eliminated, and the stability and integrity of the new sleeper are improved.

[0135] S16: Ballast bed maintenance;

[0136] Maintain the poured mortar to ensure that the mortar is fully hardened to reach the design strength, avoid early damage or crack formation, and extend the service life of the ballast bed.

[0137] S17: Remove the gauge tie rod and rail support block.

[0138] After the ballast bed maintenance is completed, remove the previously installed gauge tie rod and rail support block, restore the normal state of the track, complete the entire replacement process, and ensure the safe passage of trains.

[0139] Step S12: Specifically includes:

[0140] Drill the old sleeper concrete block through the grinding and drilling tooling 8, take out the drilled concrete core column through the core sampling tooling 9, and mill the old sleeper concrete through the milling tooling 10.

[0141] Before step S12, the method further includes:

[0142] The working equipment for ballastless track sleeper replacement travels to the working position through the traveling device 3.

[0143] In another embodiment, drilling the old sleeper concrete block through the grinding and drilling tooling 8, taking out the drilled concrete core column through the core sampling tooling 9, and milling the old sleeper concrete through the milling tooling 10 specifically includes:

[0144] The grinding and drilling tooling 8 moves down to drill the current old sleeper concrete block, and the milling tooling 10 waits.

[0145] After the grinding and drilling tooling 8 finishes drilling, it retracts and moves forward, and the core sampling tooling 9 takes out the drilled concrete core column.

[0146] The working equipment for ballastless track sleeper replacement travels forward to the next target sleeper, and the milling tooling 10 synchronously mills the current old sleeper.

[0147] After the excavation of the first sleeper foundation pit is completed, the working vehicle steps forward and enters the next working cycle.

[0148] The construction adopts the assembly line construction method, with the group as the construction unit, reasonably arranges the personnel division of labor. The starting operation fastener disassembly and assembly personnel disassemble the fasteners and install the tie rods, and the personnel working with the vehicle carry out the demolition of the old sleepers, replacement and pouring of the new sleepers, giving full play to the efficiency of manual organization and the utilization rate of machines and tools, and can greatly improve the construction efficiency and operation quality.

[0149] It can greatly improve the construction efficiency, shorten the existing foundation pit excavation time from 1.5 hours to 20 minutes, and significantly improve the overall sleeper replacement efficiency. For example, the maximum efficiency of 5 people on a single vehicle is to replace 15 sleepers in 180 minutes, and the efficiency can be further improved if multiple vehicles operate simultaneously. The personnel input is reduced, and the number of construction workers in a single skylight operation can be reduced from the original 35 - 40 people to 5 - 10 people. It has good environmental protection performance. The use of water mill drills in construction suppresses dust, and the use of non-impact picks reduces noise, making the construction process more environmentally friendly. The construction quality is improved, including the quality of foundation pit excavation (good cutting depth, good quality of surface roughening, small broken influence area) and the quality of concrete mixing (good mixing uniformity, stable construction time limit, high pouring quality).

[0150] Although the preferred embodiments of the present application have been described, those skilled in the art can make additional changes and modifications to these embodiments once they know the basic creative concept. Therefore, the appended claims are intended to be construed as including the preferred embodiments and all changes and modifications falling within the scope of the present application.

[0151] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalent technologies, the present application is also intended to include these modifications and variations.

Claims

1. An operating device for replacing sleeper of ballastless track bed, characterized in that, Comprising: A frame with a running device at the bottom to drive the frame to move on the rail. A foundation pit excavation system located below the frame for demolishing old sleepers. The foundation pit excavation system includes a grinding and drilling tooling, a core extraction tooling, and a milling tooling arranged in sequence from front to back. The grinding and drilling tooling is used for drilling and grinding the ballastless track surface of the sleeper. The core extraction tooling is used for breaking and removing the concrete core column. The milling tooling is used for removing the sleeper blocks.

2. The working equipment for replacing sleeper of ballastless track bed according to claim 1, characterized in that, The grinding and drilling tooling includes: A guiding frame for connecting with the frame and capable of reciprocating longitudinally relative to the frame. A base located on the guiding frame and capable of reciprocating transversely relative to the frame. A water-cooled diamond drilling device located on the base for drilling and grinding the old sleeper. The water-cooled diamond drilling device can reciprocate vertically.

3. The working equipment for replacing the sleeper of the ballastless track bed according to claim 2, characterized in that, The water-cooled diamond drilling device includes: A drill barrel for drilling and grinding the ballastless track surface of the old sleeper. A power component connected to the drill barrel to drive the drill barrel to rotate. A drill barrel lifting component vertically fixed on the base for driving the drill barrel to reciprocate vertically.

4. The working equipment for replacing sleeper of ballastless track bed according to claim 1, characterized in that, The drill barrel lifting component includes: A drill barrel lifting driving part, a water-cooled diamond drilling mounting seat, a vertical guide rail, and a vertical guide sleeve. The water-cooled diamond drilling mounting seat is fixed on the base, and the vertical guide rail is vertically fixed on the water-cooled diamond drilling mounting seat. The vertical guide sleeve is sleeved on the vertical guide rail and slides on the vertical guide rail. The vertical guide sleeve is fixed to the power component.

5. The working equipment for replacing sleeper of ballastless track bed according to claim 1, characterized in that, The core extraction tooling includes: A framework. A core extraction longitudinal movement component with a fixed end fixed to the frame and a movable end fixedly connected to the framework for driving the framework to reciprocate longitudinally. A core extraction transverse movement component located on the framework and capable of reciprocating transversely along the framework. A core extraction component located on the core extraction transverse movement component. The core extraction component can reciprocate vertically to break and remove the core column.

6. The working equipment for replacing sleeper of ballastless track bed according to claim 1, characterized in that, The milling tooling includes: A base. A milling transverse movement component including a milling transverse movement slide rail and a milling transverse movement slide block. The milling transverse movement slide rail is fixed to the frame, the milling transverse movement slide block slides on the milling transverse movement slide rail, and the base is fixed to the milling transverse movement slide block. A milling lifting component including a milling lifting slide rail and a milling lifting slide block. The milling lifting slide rail is arranged vertically along the base, and the milling lifting slide block slides on the milling lifting slide rail. A milling component located on the milling lifting slide block for milling the sleeper blocks.

7. The working equipment for replacing the sleeper of the ballastless track bed according to claim 6, characterized in that, The milling component includes: A milling cutter head. A milling power part connected to the milling cutter head to drive the milling cutter head to rotate. A dust suction component for sucking debris and sleeper residues.

8. The working equipment for replacing the sleeper of the ballastless track bed according to claim 1, characterized in that, It further includes: A concrete integral pouring device located on the frame for preparing and pouring new sleeper mortar. And / or a vehicle-mounted hoisting device located on the frame for transferring materials and tools on and off the vehicle.

9. The working equipment for replacing the sleeper of the ballastless track bed according to claim 8, characterized in that, It further includes: A driver's cab located above the frame. A cabinet and a battery pack located above the frame for supplying power to the driver's cab, the foundation pit excavation system, the concrete integral pouring device, and the vehicle-mounted hoisting device. The auxiliary generating set is located above the vehicle frame and is used to supply auxiliary power to the foundation pit excavation system, the concrete one-piece pouring device, and the vehicle-mounted hoisting device.

10. A method for replacing sleepers of an operating device for replacing sleepers of a ballastless track bed, characterized in that, The method includes: S1: Remove the fasteners at intervals along the construction line, and install gauge tie rods and rail support blocks; S2: Demolish the concrete blocks of the old sleepers, take out the concrete core columns, and mill the concrete of the old sleepers; S3: Install the new sleeper modules; S4: Inject glue and implant steel bars into the sleepers; S5: Pour self-compacting mortar; S6: Maintain the ballastless track bed; S7: Remove the gauge tie rods and the rail support blocks.

11. The method for replacing sleeper in ballastless track bed according to claim 10, characterized in that, The operating equipment for replacing ballastless track bed sleepers includes a vehicle frame with a traveling device at the bottom to drive the vehicle frame to travel on the rails; a foundation pit excavation system located below the vehicle frame for demolishing old sleepers; the foundation pit excavation system includes a grinding and drilling tool, a core extraction tool, and a milling tool arranged in sequence from front to back; Demolishing the concrete blocks of the old sleepers, taking out the concrete core columns, and milling the concrete of the old sleepers specifically includes: Drilling the concrete blocks of the old sleepers through the grinding and drilling tool, taking out the drilled concrete core columns through the core extraction tool, and milling the concrete of the old sleepers through the milling tool.

12. The method for replacing sleeper of ballastless track bed according to claim 10, characterized in that, Before demolishing the concrete blocks of the old sleepers, taking out the concrete core columns, and milling the concrete of the old sleepers, the method further includes: The operating equipment for replacing ballastless track bed sleepers travels to the position to be operated through the traveling device.

13. The method for replacing sleeper of ballastless track bed according to claim 11, characterized in that, Drilling the concrete blocks of the old sleepers through the grinding and drilling tool, taking out the drilled concrete core columns through the core extraction tool, and milling the concrete of the old sleepers through the milling tool specifically includes: The grinding and drilling tool moves down to drill the current concrete block of the old sleeper, and the milling tool waits; After the grinding and drilling tool finishes drilling, it retracts and moves forward, and the core extraction tool takes out the drilled concrete core column; The operating equipment for replacing ballastless track bed sleepers travels forward to the next target sleeper, and the milling tool synchronously mills the current old sleeper.

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